This work proposes an improved multi-objective slime mould algorithm, called IBMSMA, for solving the multi-objective truss optimization problem. In IBMSMA, the chaotic grouping mechanism and dynamic regrouping strateg...This work proposes an improved multi-objective slime mould algorithm, called IBMSMA, for solving the multi-objective truss optimization problem. In IBMSMA, the chaotic grouping mechanism and dynamic regrouping strategy are employed to improve population diversity;the shift density estimation is used to assess the superiority of search agents and to provide selection pressure for population evolution;and the Pareto external archive is utilized to maintain the convergence and distribution of the non-dominated solution set. To evaluate the performance of IBMSMA, it is applied to eight multi-objective truss optimization problems. The results obtained by IBMSMA are compared with other 14 well-known optimization algorithms on hypervolume, inverted generational distance and spacing-to-extent indicators. The Wilcoxon statistical test and Friedman ranking are used for statistical analysis. The results of this study reveal that IBMSMA can find the Pareto front with better convergence and diversity in less time than state-of-the-art algorithms, demonstrating its capability in tackling large-scale engineering design problems.展开更多
The Swarm intelligence algorithm is a very prevalent field in which some scholars have made outstanding achievements.As a representative,Slime mould algorithm(SMA)is widely used because of its superior initial perform...The Swarm intelligence algorithm is a very prevalent field in which some scholars have made outstanding achievements.As a representative,Slime mould algorithm(SMA)is widely used because of its superior initial performance.Therefore,this paper focuses on the improvement of the SMA and the mitigation of its stagnation problems.For this aim,the structure of SMA is adjusted to develop the efficiency of the original method.As a stochastic optimizer,SMA mainly stimulates the behavior of slime mold in nature.For the harmony of the exploration and exploitation of SMA,the paper proposed an enhanced algorithm of SMA called ECSMA,in which two mechanisms are embedded into the structure:elite strategy,and chaotic stochastic strategy.The details of the original SMA and the two introduced strategies are given in this paper.Then,the advantages of the improved SMA through mechanism comparison,balance-diversity analysis,and contrasts with other counterparts are validated.The experimental results demonstrate that both mechanisms have a significant enhancing effect on SMA.Also,SMA is applied to four structural design issues of the welded beam design problem,PV design problem,I-beam design problem,and cantilever beam design problem with excellent results.展开更多
Reducing pollutant emissions from electricity production in the power system positively impacts the control of greenhouse gas emissions.Boosting kernel search optimizer(BKSO)is introduced in this research to solve the...Reducing pollutant emissions from electricity production in the power system positively impacts the control of greenhouse gas emissions.Boosting kernel search optimizer(BKSO)is introduced in this research to solve the combined economic emission dispatch(CEED)problem.Inspired by the foraging behavior in the slime mould algorithm(SMA),the kernel matrix of the kernel search optimizer(KSO)is intensified.The proposed BKSO is superior to the standard KSO in terms of exploitation ability,robustness,and convergence rate.The CEC2013 test function is used to assess the improved KSO's performance and compared to 11 well-known optimization algorithms.BKSO performs better in statistical results and convergence curves.At the same time,BKSO achieves better fuel costs and fewer pollution emissions by testing with four real CEED cases,and the Pareto solution obtained is also better than other MAs.Based on the experimental results,BKSO has better performance than other comparable MAs and can provide more economical,robust,and cleaner solutions to CEED problems.展开更多
The relative performance of coatings for furan resin sand moulds [P-toluol sulphonic acid(PTSA) as hardener] [FRS-PTSA moulds], was compared by analyzing the surface layer for degenerated graphite in Mg treated iron w...The relative performance of coatings for furan resin sand moulds [P-toluol sulphonic acid(PTSA) as hardener] [FRS-PTSA moulds], was compared by analyzing the surface layer for degenerated graphite in Mg treated iron with 0.020 wt.% to 0.054 wt.% Mgres. It was found that the iron nodularising potential(Mg, Ce, La content) and whether the mould coatings contained S, or were capable of desulphurizing were important factors. These moulds have S in the PTSA binder, which aggravates graphite degeneration in the surface layer, depending strongly on the Mgres with lower Mgres increasing the layer thickness. The application of a mould coating strongly influenced graphite deterioration in the surface layer of castings. It either promoted graphite degeneration to less compact morphologies when using S-bearing coatings, or conversely, limited the surface layer thickness using desulphurization type coatings. Independently of the S-source at the metal – mould interface, the presence of sulphur had an adverse effect on graphite quality at the surface of Mg-treated irons, but its negative effect could also reach the graphite phase within the casting section. If the coatings employed desulphurization materials, such as Mg O, or a mixture(Ca O + Mg O + Talc) or Mgbearing Fe Si, they protected the graphite shape, improving graphite nodularity, at the metal – mould interface, and so decreased the average layer thickness in FRS-PTSA moulds. Fe Si Mg was highly efficient in minimizing the casting skin by improving graphite nodularity. It is presumed that the Mg O or(Mg O + Ca O + Talc) based coatings acted to remove any S released by the mould media. The Mg-Fe Si coatings also reacted with S from the mould but additionally supplemented the Mg nodularising potential prior to solidification. This dual activity is achievable with coatings containing active magnesium derived from fine Mg-Fe Si materials.展开更多
Digital patternless freeze-casting technology is a new approach for obtaining frozen sand moulds using digital milling technology. The change law of tensile strength and air permeability of frozen sand moulds (100-mes...Digital patternless freeze-casting technology is a new approach for obtaining frozen sand moulds using digital milling technology. The change law of tensile strength and air permeability of frozen sand moulds (100-mesh and 200-mesh silica sand, and zircon sand moulds) under different freezing temperatures and water contents was studied. Results show that with the decrease of freezing temperature and the increase of water contents, the tensile strength and air permeability of the sand moulds are gradually improved. Meanwhile, computed tomography technology was used to characterize the shape and size of the water film between the sand particles mixed with 4wt.% water. The results show that in silica sand moulds, the form of water film is lumpy, and 200-mesh silica sand moulds have more water films and higher proportion of small-sized water films than 100-mesh silica sand moulds, while in zircon sand moulds, the form of water film is membranous. At the same freezing temperature and water content, the tensile strength of zircon sand mould is the highest, and 100-mesh silica sand mould is the lowest. A comparative solidification experiment of A356 aluminum alloy was carried out in frozen sand mould and resin sand mould. The results show that the primary α-Al phase appears in the form of equiaxed and eutectic silicon phase is needle-like in freezing sand mould casting, but the primary α-Al phase grows in the form of dendrites, and the eutectic silicon phase is coarse needle-like in the resin sand mould casting. The difference of microstructure is caused by the different cooling rate. The cooling rate of A356 aluminum alloy in frozen sand mould is higher than that in resin sand mould.展开更多
In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t...In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t runner systems are being applied in the moulding industry to save material and decrease the losses of injection pressure. Heat transfer from hot runner system from the fixed half which is secured in the fix machine platen could transmit s o much heat that it may cause high temperature differential between the machine fix platen and moving platen. This will cause the tie bar to become unparallel. Part quality will be compromised and the wear of the tie bar will be excessive. Overhaul of the tie bar may be necessary after a short period of time which is c ostly. This raises the need to analyze the heat transfer from the hot runner sys tem to the machine fix platen and the methods of isolating or minimizing the hea t transfer. In this case study, a photo lens article mould was used. The mould w as built with a direct hot runner nozzle system. Heat conduction from hot runner and machine screw to machine fix platen were studied based on either using high temperature heat insulating plate put in placed between the mould and the mould ing machine fix platen or drill cooling channels in the front mould clamping pla te. The high temperature insulator is very costly as it is made out of glass re inforced polymer composite material. Experimental results were obtained and anal yzed to find the best method to minimize the unwanted heat transfer using the ch eapest and most effective method.展开更多
In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h...In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h research on the mould cooling analysis and cooling design optimization has bee n focused on the core and the cavity, excluding other systems of injection mould s. However, the runner system introduces a considerable amount of heat into the mould. In recent years, more and more hot runner systems are being applied in th e moulding industry to save material and decrease losses of injection pressure. This raises the need to include the hot runner system in the cooling analysis. I n this paper, a photo frame part was studied. The mould was built with a hot run ner system. Two thermal sensors were installed: one measures the temperature of lateral surface of hot runner nozzle; the other measures the plastic temperature from the core side. A pressure sensor was also installed to measure the pressur e of the core impression. Cooling analysis was performed using ABAQUS, ananalysi s software based on the Finite Element Method (FEM). The assembly including core , cavity and plastic part was modeled. Heat conduction from hot runner to cavity and from polymer melt to the mould and force convection on the cooling channel surfaces were studied. The natural convection between the ambient air and the ex terior mould surface was ignored. The simulations were adjusted with the experim ental results to find out the heat input from hot runner and its influence on mo uld cooling. Finally, the optimal cooling design and optimal injection condition were obtained.展开更多
Seamless bra cup moulding is an important manufacturing technique for the apparel industry,and in particular,for bra production.Polyurethane(PU)foams and/or fabric-foam laminated sheets are moulded into a desirable cu...Seamless bra cup moulding is an important manufacturing technique for the apparel industry,and in particular,for bra production.Polyurethane(PU)foams and/or fabric-foam laminated sheets are moulded into a desirable cup shape in order to fit the three-dimensional(3D)breast contour.Such foam cups not only provide a wide range of designs combined with different levels of softness and support,but also reduce production costs with minimum cutting and sewing of seams.In this study,two selected PU foam and fabric materials typically used for bra cup moulding were examined.Their respective performance behaviour in relation to different moulding temperatures and time changes were recorded and analyzed.The results reveal that cup heights are greatly affected by the use of foam and/or fabric-foam laminated materials.High moulding temperatures and/or prolonged dwell time could be required when deforming laminated materials and setting large cup sizes.Nevertheless,cup height cannot be taken as the only criteria to determine the optimal moulding conditions,and this is especially the case for large cup sizes.The design of mould heads is a major factor that affects the dimension changes of foam cups.In this respect,to control the foam moulding process,it is suggested that bra manufacturers examine the fabric/foam material properties to determine the optimal moulding condition,and quantify the shape of foam cups to enhance the design and development process of aluminum mould heads.展开更多
The solvent debinding of water soluble binder in powder injection moulding (MIM) was investigated systematically, including the effects of solvent types, temperature and the thickness of green parts on the solvent deb...The solvent debinding of water soluble binder in powder injection moulding (MIM) was investigated systematically, including the effects of solvent types, temperature and the thickness of green parts on the solvent debinding rate. After studying the debinding of a green part with a thickness of 4.26 mm, it was found that, the debinding rate of polyethylene glycol(PEG) in water and alcohol was high initially, and then decreased; however, it would increase with temperature increasing. At room temperature, the dissolution rate of PEG in water was higher than that in alcohol, but the latter would be much faster with temperature increasing because the debinding activation energy in alcohol was 51.44 kJ·mol -1 ·K -1 , much higher than 24.23 kJ·mol -1 ·K -1 in water. With a green part thickness larger than 4.26 mm, the debinding was controlled by diffusion; but with that smaller than 2.36 mm, the debinding was controlled by both dissolution and diffusion.展开更多
Failure of rock mass that is subjected to compressive loads occurs from initiation, propagation, and linkage of new cracks from preexisting fissures. Our research investigates the cracking behaviour and coalescence pr...Failure of rock mass that is subjected to compressive loads occurs from initiation, propagation, and linkage of new cracks from preexisting fissures. Our research investigates the cracking behaviour and coalescence process in a brittle material with two non-parallel overlapping flaws using a high-speed camera. The coalescence tensile crack and tensile wing cracks were the first cracks to occur from the preexisting flaws. The initiation stresses of the primary cracks at the two tips of each flaw were simultaneous and decreased with reduced flaw inclination angle. The following types of coalescence cracks were identified between the flaws: primary tensile coalescence crack, tensile crack linkage, shear crack linkage, mixed tensile-shear crack, and indirect crack coalescence. Coalescence through tensile linkage occurred mostly at pre-peak stress. In contrast, coalescence through shear or mixed tensile-shear cracks occurred at higher stress.Overall, this study indicates that the geometry of preexisting flaws affect crack initiation and coalescence behaviour.展开更多
A kind of Cu base composite reinforced by 0 1μm Al 2O 3 particles were prepared by hot pressing and sintering process for steel continuous casting mould. The microstructure and properties were studied. The results sh...A kind of Cu base composite reinforced by 0 1μm Al 2O 3 particles were prepared by hot pressing and sintering process for steel continuous casting mould. The microstructure and properties were studied. The results show that the Al 2O 3 particle distribution is uniform, and the particles refine the grain size. The tensile fracture is a mixture of quasi cleavage and dimple due to the moderate interface strength. As a result, the composite has better soft resistance and wear resistance than those of Cu and Cu alloy. With increase in super fine Al 2O 3, the density and electric conductivity of the composite decrease, but hardness and strength increase.展开更多
Further development of the technology for making moulding and core sands will be strictly limited by tough requirements due to protection of the natural environment. These tendencies are becoming more and more tense, ...Further development of the technology for making moulding and core sands will be strictly limited by tough requirements due to protection of the natural environment. These tendencies are becoming more and more tense, so that we will reach a point when even processes, that from technological point of view fulfill high requirements of the foundry industry, must be replaced by more ecologically-friendly solutions. Hence, technologies using synthetic resins as binding materials will be limited. This paper presents some predictable development tendencies of moulding and core sands. The increasing role of inorganic substances will be noticed, including silicate binders with significantly improved properties, such as improved knock-out property or higher reclamation strength. Other interesting solutions might also be moulding sands bonded by geo-polymers and phosphate binders or salts and also binders based on degradable biopolymers. These tendencies and the usefulness of these binders are put forward in this paper.展开更多
The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achiev...The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achieving cost and durability performance somewhere between that of cast and machined from solid(MFS) aluminium alloy wheels.Experimental results show SSM material has a superior microstructure and mechanical properties over cast and comparable to MFS materials.Component testing including durability testing,using accelerated speed cycle tests,proves SSM compressor wheels emerge as being significantly more durable than cast equivalents and approaching that of MFS impellers.Further challenges for semi-solid processing in manufacture of other complex components and other materials in automotive industry in terms of both cost and durability are also discussed.展开更多
Coupling the quasi 3D numerical simulation of electromagnetic field and the experiments with some metals such as tin, aluminum, copper and steel, the electromagnetic characteristics of continuous casting with soft con...Coupling the quasi 3D numerical simulation of electromagnetic field and the experiments with some metals such as tin, aluminum, copper and steel, the electromagnetic characteristics of continuous casting with soft contacted mould, especially the influences of power frequency, the mould structure, and the inductor position, size and current on the electromagnetic force and pressure on the billet, were analyzed. The result shows that, in continuous casting with soft contacted mould, the electromagnetic pressure on the surface of billet increases with the rising of the power frequency as a logarithmically parabolic function and, with that of inductor current as a parabolic function. The design principle of the soft contacted mould is that 1) the mould structure should be ‘more segments and thin slits’; 2) the topside of inductor should be at the same location with the meniscus of molten metal; 3) the inductor should cover the initial solidifying shell of billet.展开更多
The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtaine...The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtained. It is found that the stress distribution is very uneven, and the stress convergence is rather severe in the bridge of the aluminum profile extrusion mould. The optimum height of the mould is 70.527 mm, and the optimum radius of dividing holes are 70.182 mm and 80.663 mm. Increasing the height of the mould in the range of 61.282 mm to 70.422 mm can prolong its longevity, but when the height is over 70.422 mm, its longevity reduces.展开更多
This study proposes an innovative precast shear wall system, called an EVE precast hollow shear wall structure (EVE-PHSW). Precast panels in EVE-PHSW are simultaneously precast with vertical and horizontal holes. Nonc...This study proposes an innovative precast shear wall system, called an EVE precast hollow shear wall structure (EVE-PHSW). Precast panels in EVE-PHSW are simultaneously precast with vertical and horizontal holes. Noncontact lap splices of rebars are used in vertical joints connecting adjacent precast panels for automated prefabrication and easy in situ erection. The seismic behavior of EVE walls was examined through a series of tests on six wall specimens with aspect ratios of 1.0~1.3. Test results showed that EVE wall specimens with inside cast-in situ concrete achieved the desired “strong bending and weak shear” and failed in shear mode. Common main diagonal cracks and brittle shear failure in squat cast-in situ walls were prevented. Inside cast-in situ concrete could signifi cantly improve the shear strength and stiff ness of EVE walls. The details of boundary elements (cast-in situ or prefabricated) and vertical joints (contiguous or spaced) had little eff ect on the global behavior of EVE walls. Noncontact lap splices in vertical joints could enable EVE walls to exhibit stable load-carrying capacity through extensive deformations. Evaluation on design codes revealed that both JGJ 3-2010 and ACI 318-14 provide conservative estimation of shear strength of EVE walls, and EVE walls achieved shear strength reserves comparative to cast-in situ walls. The recommended eff ective stiff ness for cast-in situ walls in ASCE 41-17 appeared to be appropriate for EVE walls.展开更多
High pressure squeeze is the most popular moulding process applied in modern moulding machines.Because of the unique characters of moulding sand and nonlinearity of squeezing process,the mechanical model is of key imp...High pressure squeeze is the most popular moulding process applied in modern moulding machines.Because of the unique characters of moulding sand and nonlinearity of squeezing process,the mechanical model is of key importance for computer simulation.Drucker-Prager/Cap is a typical soil mechanical theory model and it was used to simulate the squeezing process in this study,while ABAQUS software is used to simulate dynamic stress/strain evolution during the process.The simulation agrees well with the experimental results.We conclude that Drucker-Prager/Cap is an appropriate model for the squeezing compaction of moulding sand,and that the associated nonlinearity can be solved well with ABAQUS software.展开更多
The paper presents the research results of using an innovative method to reclaim the waste moulding sands containing water glass. Two of the examined processes are connected with "dry" or "wet" act...The paper presents the research results of using an innovative method to reclaim the waste moulding sands containing water glass. Two of the examined processes are connected with "dry" or "wet" activation of inorganic binder in waste moulding sand mixtures physically hardened by microwave radiation. The sand mixtures consisting of high-silica sand and water-glass with average molar module 2.5, were subjected to the following cyclical process: mixing the components, compacting, microwave heating, cooling-down, thermally loading the mould to 800 °C, cooling-down to ambient temperature, and knocking-out. After being knocked-out, the waste moulding sands were subjected to either dry or wet activation of the binder. To activate thermally treated inorganic binder, each of the examined processes employed the surface phenomenon usually associated to mechanical reclamation. The study also covered possible use of some elements of wet reclamation to rehydrate waste binder. To evaluate the effectiveness of the two proposed methods of waste binder activation, selected strength and technological parameters were measured. After each subsequent processing cycle, the permeability, tensile strength and bending strength were determined. In addition, the surface of activated sand grains was examined with a scanning electron microscope. Analysis of the results indicates that it is possible to re-activate the used binder such as sodium silicate, and to stabilize the strength parameters in both activation processes. Permeability of the refreshed moulding sands strongly depends on the surface condition of high-silica grains. The wet activation process by wetting and buffering knocked-out moulding sands in closed humid environment makes it possible to reduce the content of refreshing additive in water-glass. The moulding sands cyclically prepared in both processes do not require the addition of fresh high-silica sand. The relatively high quality achieved in the refreshed moulding sands allows them to be reused for manufacture of next moulds. Thus, the two proposed methods for cyclically processing used moulding sands containing sodium silicate, subject to microwave hardening, are suitable for economic and ecological circulation moulding mixtures.展开更多
The study on the fluid flow, meniscus oscillation, slag entrapment in continuous casting mould was conducted mathematically and experimentally. The results show that the injection of argon into submerged nozzle enhanc...The study on the fluid flow, meniscus oscillation, slag entrapment in continuous casting mould was conducted mathematically and experimentally. The results show that the injection of argon into submerged nozzle enhances the meniscus oscillation, thus increases the probability of slag entrapment, and the critical argon blowing flow rate, which will give rise to slag entrapment, is around 10l/min. The trajectory of bubble is affected by the bubble diameter and the molten steel flow, and the bubble diameter is dominant. The bubble with diameter 1.4mm floats fastest with 0.47m/s terminal velocity.展开更多
基金supported by the National Science Foundation of China under Grant No.U21A20464,62066005Innovation Project of Guangxi University for Nationalities Graduate Education under Grant gxun-chxs2021058.
文摘This work proposes an improved multi-objective slime mould algorithm, called IBMSMA, for solving the multi-objective truss optimization problem. In IBMSMA, the chaotic grouping mechanism and dynamic regrouping strategy are employed to improve population diversity;the shift density estimation is used to assess the superiority of search agents and to provide selection pressure for population evolution;and the Pareto external archive is utilized to maintain the convergence and distribution of the non-dominated solution set. To evaluate the performance of IBMSMA, it is applied to eight multi-objective truss optimization problems. The results obtained by IBMSMA are compared with other 14 well-known optimization algorithms on hypervolume, inverted generational distance and spacing-to-extent indicators. The Wilcoxon statistical test and Friedman ranking are used for statistical analysis. The results of this study reveal that IBMSMA can find the Pareto front with better convergence and diversity in less time than state-of-the-art algorithms, demonstrating its capability in tackling large-scale engineering design problems.
基金supported in part by the National Natural Science Foundation of China(J2124006,62076185)。
文摘The Swarm intelligence algorithm is a very prevalent field in which some scholars have made outstanding achievements.As a representative,Slime mould algorithm(SMA)is widely used because of its superior initial performance.Therefore,this paper focuses on the improvement of the SMA and the mitigation of its stagnation problems.For this aim,the structure of SMA is adjusted to develop the efficiency of the original method.As a stochastic optimizer,SMA mainly stimulates the behavior of slime mold in nature.For the harmony of the exploration and exploitation of SMA,the paper proposed an enhanced algorithm of SMA called ECSMA,in which two mechanisms are embedded into the structure:elite strategy,and chaotic stochastic strategy.The details of the original SMA and the two introduced strategies are given in this paper.Then,the advantages of the improved SMA through mechanism comparison,balance-diversity analysis,and contrasts with other counterparts are validated.The experimental results demonstrate that both mechanisms have a significant enhancing effect on SMA.Also,SMA is applied to four structural design issues of the welded beam design problem,PV design problem,I-beam design problem,and cantilever beam design problem with excellent results.
基金This research was supported by the Science&Technology Development Project of Jilin Province,China(YDZJ202201ZYTS555)the Science&Technology Research Project of the Education Department of Jilin Province,China(JJKH20220244KJ)。
文摘Reducing pollutant emissions from electricity production in the power system positively impacts the control of greenhouse gas emissions.Boosting kernel search optimizer(BKSO)is introduced in this research to solve the combined economic emission dispatch(CEED)problem.Inspired by the foraging behavior in the slime mould algorithm(SMA),the kernel matrix of the kernel search optimizer(KSO)is intensified.The proposed BKSO is superior to the standard KSO in terms of exploitation ability,robustness,and convergence rate.The CEC2013 test function is used to assess the improved KSO's performance and compared to 11 well-known optimization algorithms.BKSO performs better in statistical results and convergence curves.At the same time,BKSO achieves better fuel costs and fewer pollution emissions by testing with four real CEED cases,and the Pareto solution obtained is also better than other MAs.Based on the experimental results,BKSO has better performance than other comparable MAs and can provide more economical,robust,and cleaner solutions to CEED problems.
基金funded by the Sectoral Operational Programme Human Resources Development 2007-2013 of the Romanian Ministry of Labour,Family and Social Protection through the Financial Agreement POSDRU/6/1.5/S/19
文摘The relative performance of coatings for furan resin sand moulds [P-toluol sulphonic acid(PTSA) as hardener] [FRS-PTSA moulds], was compared by analyzing the surface layer for degenerated graphite in Mg treated iron with 0.020 wt.% to 0.054 wt.% Mgres. It was found that the iron nodularising potential(Mg, Ce, La content) and whether the mould coatings contained S, or were capable of desulphurizing were important factors. These moulds have S in the PTSA binder, which aggravates graphite degeneration in the surface layer, depending strongly on the Mgres with lower Mgres increasing the layer thickness. The application of a mould coating strongly influenced graphite deterioration in the surface layer of castings. It either promoted graphite degeneration to less compact morphologies when using S-bearing coatings, or conversely, limited the surface layer thickness using desulphurization type coatings. Independently of the S-source at the metal – mould interface, the presence of sulphur had an adverse effect on graphite quality at the surface of Mg-treated irons, but its negative effect could also reach the graphite phase within the casting section. If the coatings employed desulphurization materials, such as Mg O, or a mixture(Ca O + Mg O + Talc) or Mgbearing Fe Si, they protected the graphite shape, improving graphite nodularity, at the metal – mould interface, and so decreased the average layer thickness in FRS-PTSA moulds. Fe Si Mg was highly efficient in minimizing the casting skin by improving graphite nodularity. It is presumed that the Mg O or(Mg O + Ca O + Talc) based coatings acted to remove any S released by the mould media. The Mg-Fe Si coatings also reacted with S from the mould but additionally supplemented the Mg nodularising potential prior to solidification. This dual activity is achievable with coatings containing active magnesium derived from fine Mg-Fe Si materials.
基金This work was financially supported by the National Science Found for Distinguished Young Scholars(No.51525503).
文摘Digital patternless freeze-casting technology is a new approach for obtaining frozen sand moulds using digital milling technology. The change law of tensile strength and air permeability of frozen sand moulds (100-mesh and 200-mesh silica sand, and zircon sand moulds) under different freezing temperatures and water contents was studied. Results show that with the decrease of freezing temperature and the increase of water contents, the tensile strength and air permeability of the sand moulds are gradually improved. Meanwhile, computed tomography technology was used to characterize the shape and size of the water film between the sand particles mixed with 4wt.% water. The results show that in silica sand moulds, the form of water film is lumpy, and 200-mesh silica sand moulds have more water films and higher proportion of small-sized water films than 100-mesh silica sand moulds, while in zircon sand moulds, the form of water film is membranous. At the same freezing temperature and water content, the tensile strength of zircon sand mould is the highest, and 100-mesh silica sand mould is the lowest. A comparative solidification experiment of A356 aluminum alloy was carried out in frozen sand mould and resin sand mould. The results show that the primary α-Al phase appears in the form of equiaxed and eutectic silicon phase is needle-like in freezing sand mould casting, but the primary α-Al phase grows in the form of dendrites, and the eutectic silicon phase is coarse needle-like in the resin sand mould casting. The difference of microstructure is caused by the different cooling rate. The cooling rate of A356 aluminum alloy in frozen sand mould is higher than that in resin sand mould.
文摘In an injection moulding process, the parallelism b et ween the tie bars of the injection moulding machine is very important as it will affect the mould closing and clamping system. In recent years, more and more ho t runner systems are being applied in the moulding industry to save material and decrease the losses of injection pressure. Heat transfer from hot runner system from the fixed half which is secured in the fix machine platen could transmit s o much heat that it may cause high temperature differential between the machine fix platen and moving platen. This will cause the tie bar to become unparallel. Part quality will be compromised and the wear of the tie bar will be excessive. Overhaul of the tie bar may be necessary after a short period of time which is c ostly. This raises the need to analyze the heat transfer from the hot runner sys tem to the machine fix platen and the methods of isolating or minimizing the hea t transfer. In this case study, a photo lens article mould was used. The mould w as built with a direct hot runner nozzle system. Heat conduction from hot runner and machine screw to machine fix platen were studied based on either using high temperature heat insulating plate put in placed between the mould and the mould ing machine fix platen or drill cooling channels in the front mould clamping pla te. The high temperature insulator is very costly as it is made out of glass re inforced polymer composite material. Experimental results were obtained and anal yzed to find the best method to minimize the unwanted heat transfer using the ch eapest and most effective method.
文摘In an injection moulding process, the mould cooling s ystem is very important as an efficient and uniform cooling effect can improve b oth the productivity and part quality. Due to the complexity of the process, muc h research on the mould cooling analysis and cooling design optimization has bee n focused on the core and the cavity, excluding other systems of injection mould s. However, the runner system introduces a considerable amount of heat into the mould. In recent years, more and more hot runner systems are being applied in th e moulding industry to save material and decrease losses of injection pressure. This raises the need to include the hot runner system in the cooling analysis. I n this paper, a photo frame part was studied. The mould was built with a hot run ner system. Two thermal sensors were installed: one measures the temperature of lateral surface of hot runner nozzle; the other measures the plastic temperature from the core side. A pressure sensor was also installed to measure the pressur e of the core impression. Cooling analysis was performed using ABAQUS, ananalysi s software based on the Finite Element Method (FEM). The assembly including core , cavity and plastic part was modeled. Heat conduction from hot runner to cavity and from polymer melt to the mould and force convection on the cooling channel surfaces were studied. The natural convection between the ambient air and the ex terior mould surface was ignored. The simulations were adjusted with the experim ental results to find out the heat input from hot runner and its influence on mo uld cooling. Finally, the optimal cooling design and optimal injection condition were obtained.
基金Research Grants Council of the Hong Kong Special Administrative Region,China(No.PolyU5317/06E)
文摘Seamless bra cup moulding is an important manufacturing technique for the apparel industry,and in particular,for bra production.Polyurethane(PU)foams and/or fabric-foam laminated sheets are moulded into a desirable cup shape in order to fit the three-dimensional(3D)breast contour.Such foam cups not only provide a wide range of designs combined with different levels of softness and support,but also reduce production costs with minimum cutting and sewing of seams.In this study,two selected PU foam and fabric materials typically used for bra cup moulding were examined.Their respective performance behaviour in relation to different moulding temperatures and time changes were recorded and analyzed.The results reveal that cup heights are greatly affected by the use of foam and/or fabric-foam laminated materials.High moulding temperatures and/or prolonged dwell time could be required when deforming laminated materials and setting large cup sizes.Nevertheless,cup height cannot be taken as the only criteria to determine the optimal moulding conditions,and this is especially the case for large cup sizes.The design of mould heads is a major factor that affects the dimension changes of foam cups.In this respect,to control the foam moulding process,it is suggested that bra manufacturers examine the fabric/foam material properties to determine the optimal moulding condition,and quantify the shape of foam cups to enhance the design and development process of aluminum mould heads.
文摘The solvent debinding of water soluble binder in powder injection moulding (MIM) was investigated systematically, including the effects of solvent types, temperature and the thickness of green parts on the solvent debinding rate. After studying the debinding of a green part with a thickness of 4.26 mm, it was found that, the debinding rate of polyethylene glycol(PEG) in water and alcohol was high initially, and then decreased; however, it would increase with temperature increasing. At room temperature, the dissolution rate of PEG in water was higher than that in alcohol, but the latter would be much faster with temperature increasing because the debinding activation energy in alcohol was 51.44 kJ·mol -1 ·K -1 , much higher than 24.23 kJ·mol -1 ·K -1 in water. With a green part thickness larger than 4.26 mm, the debinding was controlled by diffusion; but with that smaller than 2.36 mm, the debinding was controlled by both dissolution and diffusion.
基金supported by the National Natural Science Foundation of China (Grants 41572310, 41272351)the Strategic Priority Research Program of the Chinese Academy of Sciences (Grants XDB10030301, XDB10030304)support provided by the CAS-TWAS Presidential Fellowship, University of Chinese Academy of Sciences, Beijing, China
文摘Failure of rock mass that is subjected to compressive loads occurs from initiation, propagation, and linkage of new cracks from preexisting fissures. Our research investigates the cracking behaviour and coalescence process in a brittle material with two non-parallel overlapping flaws using a high-speed camera. The coalescence tensile crack and tensile wing cracks were the first cracks to occur from the preexisting flaws. The initiation stresses of the primary cracks at the two tips of each flaw were simultaneous and decreased with reduced flaw inclination angle. The following types of coalescence cracks were identified between the flaws: primary tensile coalescence crack, tensile crack linkage, shear crack linkage, mixed tensile-shear crack, and indirect crack coalescence. Coalescence through tensile linkage occurred mostly at pre-peak stress. In contrast, coalescence through shear or mixed tensile-shear cracks occurred at higher stress.Overall, this study indicates that the geometry of preexisting flaws affect crack initiation and coalescence behaviour.
文摘A kind of Cu base composite reinforced by 0 1μm Al 2O 3 particles were prepared by hot pressing and sintering process for steel continuous casting mould. The microstructure and properties were studied. The results show that the Al 2O 3 particle distribution is uniform, and the particles refine the grain size. The tensile fracture is a mixture of quasi cleavage and dimple due to the moderate interface strength. As a result, the composite has better soft resistance and wear resistance than those of Cu and Cu alloy. With increase in super fine Al 2O 3, the density and electric conductivity of the composite decrease, but hardness and strength increase.
文摘Further development of the technology for making moulding and core sands will be strictly limited by tough requirements due to protection of the natural environment. These tendencies are becoming more and more tense, so that we will reach a point when even processes, that from technological point of view fulfill high requirements of the foundry industry, must be replaced by more ecologically-friendly solutions. Hence, technologies using synthetic resins as binding materials will be limited. This paper presents some predictable development tendencies of moulding and core sands. The increasing role of inorganic substances will be noticed, including silicate binders with significantly improved properties, such as improved knock-out property or higher reclamation strength. Other interesting solutions might also be moulding sands bonded by geo-polymers and phosphate binders or salts and also binders based on degradable biopolymers. These tendencies and the usefulness of these binders are put forward in this paper.
文摘The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achieving cost and durability performance somewhere between that of cast and machined from solid(MFS) aluminium alloy wheels.Experimental results show SSM material has a superior microstructure and mechanical properties over cast and comparable to MFS materials.Component testing including durability testing,using accelerated speed cycle tests,proves SSM compressor wheels emerge as being significantly more durable than cast equivalents and approaching that of MFS impellers.Further challenges for semi-solid processing in manufacture of other complex components and other materials in automotive industry in terms of both cost and durability are also discussed.
文摘Coupling the quasi 3D numerical simulation of electromagnetic field and the experiments with some metals such as tin, aluminum, copper and steel, the electromagnetic characteristics of continuous casting with soft contacted mould, especially the influences of power frequency, the mould structure, and the inductor position, size and current on the electromagnetic force and pressure on the billet, were analyzed. The result shows that, in continuous casting with soft contacted mould, the electromagnetic pressure on the surface of billet increases with the rising of the power frequency as a logarithmically parabolic function and, with that of inductor current as a parabolic function. The design principle of the soft contacted mould is that 1) the mould structure should be ‘more segments and thin slits’; 2) the topside of inductor should be at the same location with the meniscus of molten metal; 3) the inductor should cover the initial solidifying shell of billet.
文摘The finite element analysis and the optimum design of aluminum profile extrusion mould were investigated using the ANSYS software and its parameterized modeling method. The optimum dimensions of the mould were obtained. It is found that the stress distribution is very uneven, and the stress convergence is rather severe in the bridge of the aluminum profile extrusion mould. The optimum height of the mould is 70.527 mm, and the optimum radius of dividing holes are 70.182 mm and 80.663 mm. Increasing the height of the mould in the range of 61.282 mm to 70.422 mm can prolong its longevity, but when the height is over 70.422 mm, its longevity reduces.
基金Beijing Everest Green Building Technology Ltd. for the funding
文摘This study proposes an innovative precast shear wall system, called an EVE precast hollow shear wall structure (EVE-PHSW). Precast panels in EVE-PHSW are simultaneously precast with vertical and horizontal holes. Noncontact lap splices of rebars are used in vertical joints connecting adjacent precast panels for automated prefabrication and easy in situ erection. The seismic behavior of EVE walls was examined through a series of tests on six wall specimens with aspect ratios of 1.0~1.3. Test results showed that EVE wall specimens with inside cast-in situ concrete achieved the desired “strong bending and weak shear” and failed in shear mode. Common main diagonal cracks and brittle shear failure in squat cast-in situ walls were prevented. Inside cast-in situ concrete could signifi cantly improve the shear strength and stiff ness of EVE walls. The details of boundary elements (cast-in situ or prefabricated) and vertical joints (contiguous or spaced) had little eff ect on the global behavior of EVE walls. Noncontact lap splices in vertical joints could enable EVE walls to exhibit stable load-carrying capacity through extensive deformations. Evaluation on design codes revealed that both JGJ 3-2010 and ACI 318-14 provide conservative estimation of shear strength of EVE walls, and EVE walls achieved shear strength reserves comparative to cast-in situ walls. The recommended eff ective stiff ness for cast-in situ walls in ASCE 41-17 appeared to be appropriate for EVE walls.
文摘High pressure squeeze is the most popular moulding process applied in modern moulding machines.Because of the unique characters of moulding sand and nonlinearity of squeezing process,the mechanical model is of key importance for computer simulation.Drucker-Prager/Cap is a typical soil mechanical theory model and it was used to simulate the squeezing process in this study,while ABAQUS software is used to simulate dynamic stress/strain evolution during the process.The simulation agrees well with the experimental results.We conclude that Drucker-Prager/Cap is an appropriate model for the squeezing compaction of moulding sand,and that the associated nonlinearity can be solved well with ABAQUS software.
基金co-financed by the European Union within the European Social Fund in the project"Mloda Kadra 2015+"
文摘The paper presents the research results of using an innovative method to reclaim the waste moulding sands containing water glass. Two of the examined processes are connected with "dry" or "wet" activation of inorganic binder in waste moulding sand mixtures physically hardened by microwave radiation. The sand mixtures consisting of high-silica sand and water-glass with average molar module 2.5, were subjected to the following cyclical process: mixing the components, compacting, microwave heating, cooling-down, thermally loading the mould to 800 °C, cooling-down to ambient temperature, and knocking-out. After being knocked-out, the waste moulding sands were subjected to either dry or wet activation of the binder. To activate thermally treated inorganic binder, each of the examined processes employed the surface phenomenon usually associated to mechanical reclamation. The study also covered possible use of some elements of wet reclamation to rehydrate waste binder. To evaluate the effectiveness of the two proposed methods of waste binder activation, selected strength and technological parameters were measured. After each subsequent processing cycle, the permeability, tensile strength and bending strength were determined. In addition, the surface of activated sand grains was examined with a scanning electron microscope. Analysis of the results indicates that it is possible to re-activate the used binder such as sodium silicate, and to stabilize the strength parameters in both activation processes. Permeability of the refreshed moulding sands strongly depends on the surface condition of high-silica grains. The wet activation process by wetting and buffering knocked-out moulding sands in closed humid environment makes it possible to reduce the content of refreshing additive in water-glass. The moulding sands cyclically prepared in both processes do not require the addition of fresh high-silica sand. The relatively high quality achieved in the refreshed moulding sands allows them to be reused for manufacture of next moulds. Thus, the two proposed methods for cyclically processing used moulding sands containing sodium silicate, subject to microwave hardening, are suitable for economic and ecological circulation moulding mixtures.
文摘The study on the fluid flow, meniscus oscillation, slag entrapment in continuous casting mould was conducted mathematically and experimentally. The results show that the injection of argon into submerged nozzle enhances the meniscus oscillation, thus increases the probability of slag entrapment, and the critical argon blowing flow rate, which will give rise to slag entrapment, is around 10l/min. The trajectory of bubble is affected by the bubble diameter and the molten steel flow, and the bubble diameter is dominant. The bubble with diameter 1.4mm floats fastest with 0.47m/s terminal velocity.
