scholarly journals A Methodology for the Application of Virtual Evaluation Methods within the Design Process of Cold Forged Steel Pinions

2019 ◽  
Vol 1 (1) ◽  
pp. 3451-3460 ◽  
Author(s):  
Andreas Rohrmoser ◽  
Björn Heling ◽  
Benjamin Schleich ◽  
Christoph Kiener ◽  
Hinnerk Hagenah ◽  
...  
Keyword(s):  
Service Life ◽  
Design Process ◽  
Evaluation Methods ◽  
Cold Forging ◽  
Machining Processes ◽  
Short Service Life ◽  
Productive Process ◽  
Machine Elements ◽  
The Cost ◽  
Operational Behaviour

AbstractGears are essential machine elements in the drivetrain and transmission technology. The operational behaviour of a gear pairing is influenced by the design of the gear kinematics as well as the component properties. With regard to an improvement of performance and service life, the targeted modification of tooth geometry and component properties offers a promising approach. Thus, the achievable geometric and mechanical component properties are influenced by the manufacturing process, which must be taken into account in the design process. The application of virtual evaluation methods is suitable for this purpose. For the manufacturing of steel gears, cold forging provides the potential of achieving beneficial mechanical properties in a highly productive process. Major challenges for the industrial application are the short service life of the cost- intensive tools and the low geometric accuracy in comparison to machining processes. Within this study the design of the tooth geometry as well as the associated forming tool are investigated. The aim is to derive recommendations regarding an optimization of the resulting component properties and operational behaviour.

scholarly journals Alloying working surface during electroslag surfacing

2021 ◽  
pp. 17-21
Author(s):  
V. G. Komkov ◽  
◽  
S. A. Gubar ◽  
G. G. Voskresensky ◽  
◽  
...  
Keyword(s):  
Service Life ◽  
Abrasive Wear ◽  
Slag Bath ◽  
Direct Introduction ◽  
Finished Part ◽  
Working Surface ◽  
Short Service Life ◽  
Deposited Metal ◽  
Scheelite Concentrate ◽  
The Cost

Parts subject to intense abrasive wear have a short service life. In the manufacture or restoration of such parts by electroslag surfacing, strengthening of the deposited metal is required. The use of ready-made alloying powders in surfacing increases the cost of the finished part, which necessitates the search for cheaper materials for alloying the parts being welded. The study of the efficiency of alloying the deposited metal through the melted insert, as well as by direct introduction of alloying powders into the slag bath has been carried out. Mixtures based on enriched mineral scheelite concentrate and graphite are used as alloying powders

Optimal Design on the Roller Hearth Furnace Linings in CSP Plant of WISCO

2014 ◽  
Vol 1081 ◽  
pp. 343-347
Author(s):  
Liang Qu ◽  
Mei Jie Zhang
Keyword(s):  
Service Life ◽  
Heating Furnace ◽  
Furnace Lining ◽  
Insulation Material ◽  
External Shell ◽  
Short Service Life ◽  
Contrast Analysis ◽  
Fiber Materials ◽  
The Cost ◽  
Insulation Performance

The heating furnace in CSP plant of WISCO has a lightweight lining which is built by all fiber templates. In light of its good thermal insulation performance and short service life, the lining material for heating furnace was optimized in this article by using heat transfer calculation while the thickness stays light and the insulation performance stays good. The castable was applied to substitute for lightweight fiber materials to prolong the service life of heating furnace lining. Also, this article shows a contrast analysis of heat insulation layer while using different insulation material: the fiber felt, nanoinsulation board and super hydrophobic insulation board. The effect on the temperature of external shell and heat loss was analyzed and discussed. The results generate a new design of material composition, which not only prolongs the service life of heating furnace lining, but also reduces the cost.

Design of Electrolytic Strengthening Machine for Cutting Edge of Cutter

2016 ◽  
Vol 693 ◽  
pp. 1585-1590
Author(s):  
Yi Zhuo Guo ◽  
Xian Guo Yan ◽  
Shu Juan Li ◽  
Hong Guo
Keyword(s):  
Service Life ◽  
Calculation Method ◽  
High Speed ◽  
High Speed Steel ◽  
Cutting Edge ◽  
The Cost ◽  
Electric Quantity

Many studies have proved the service life of cutter can be prolonged by electrolytic strengthening. Based on the theory of electrolytic strengthening technology, this paper introduced and developed prototype equipment for strengthening cutting edge of rotary cutter and put forward a calculation method of total electric quantity consumption during the electrolysis suitable for microcontroller. The M8 high-speed steel tap is taken as a strengthening example. After finished the strengthening process that it clearly see the results of the surface of tap was obviously polished by observing the micrograph. This equipment improves the reliability of electrolytic strengthening and the cost is relatively cheap.

Mechanical Response Analysis of the Composite Asphalt Pavement

2014 ◽  
Vol 1023 ◽  
pp. 28-31
Author(s):  
Li Min Li
Keyword(s):  
Service Life ◽  
Mechanical Response ◽  
Asphalt Pavement ◽  
Road Construction ◽  
Pavement Design ◽  
Rigid Base ◽  
Response Analysis ◽  
Early Failure ◽  
Short Service Life ◽  
Design Software

With the constant increasing of traffic flow and axle load, the early failure of semi-rigid base asphalt pavement is increasingly serious in China. The bad durability and short service life of pavement have become main obstacles in road construction development. Based on the experience of successful application, the early failure of semi-rigid base asphalt pavement is solved, and the service life of pavement is increased by using of the composite asphalt pavement. To solve the design problem of the composite asphalt pavement , its mechanical properties influence results of are obtained by the factors, such as shear strain, shear stress, compression strain on top of subgrade, etc, by a lot of calculation using Shell pavement design software. These provide theoretical basis for durable asphalt pavement design based on rut-resistance property.

Bringing Ergonomics to the Design of a Behavioural Care Unit

2000 ◽  
Vol 44 (8) ◽  
pp. 8-11
Author(s):  
Jacqueline B. Barnett
Keyword(s):  
Design Process ◽  
Iterative Process ◽  
User Needs ◽  
Work Processes ◽  
Team Members ◽  
Early Design ◽  
Design Changes ◽  
Final Design ◽  
The Individual ◽  
The Cost

The application of ergonomics is important when considering the built environment. In order to create an environment where form follows function, a detailed understanding of the tasks performed by the individuals who will live and work in the facility is required. Early involvement in the project is key to maximizing the benefit of ergonomics. At Sunnybrook and Women's College Health Sciences Centre in Toronto, Canada, this early intervention was embraced during the design process of a behavioural care unit for aggressive patients. The ergonomist was involved in three phases of design; user needs analysis, block schematics and detailed design. The user needs and characteristics were established using a combination of focus groups, interviews, direct observation, task analysis and critique of current working environments. The challenge was to present the information to the design team in a useful manner. The format chosen was a modification of Userfit (Poulson 1996) that outlined the various characteristics of the patient group and the design consequences with “what does this mean for me” statements. During the block schematics phase an iterative design process was used to ensure that the ergonomic principles and the user needs were incorporated into the design. Ergonomic input was used in determining the room sizes and layout and to ensure work processes were considered. Simple mock-ups and anthropometric data assisted in illustrating the need for design changes. Examples that highlight the areas of greatest impact of ergonomic intervention include the patient bathrooms, showers and tub room. Significant changes were made to the design to improve the safety of the work and living space of the end users. One of the greatest challenges was having an appreciation for the individual goals of the team members. Ensuring there was adequate space for equipment and staff often resulted in recommendations for increased space. This in turn would increase the cost of the project. The architect and, later in the project, the engineer had goals of bringing the project in on budget. The final design was very much a team effort and truly die result of an iterative process. The sum of the individual contributions could not match the combined efforts. It was only through the ergonomic contributions in this early design phase that the needs of the staff, patients and families could be so well represented. The success of the iterative process provides the foundation for bringing ergonomics considerations into the early design stages of future projects.

Synergetic Concept of Software Control of Machining Processes on Metal-Cutting Machines

2021 ◽  
pp. 24-36
Author(s):  
V.L. Zakovorotny ◽  
V.E. Gvindzhiliya
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Wear Testing ◽  
External Control ◽  
Machining Processes ◽  
Cutting Zone ◽  
Output Characteristics ◽  
The Cost ◽  
And Control ◽  
Cutting System

High precision metal-cutting machines ensure that the programmed machine actuator trajectories correspond to the real ones. For lathes these are the trajectories of the longitudinal and transverse calipers of the system, as well as the spindle. The purpose of processing is to produce parts of a given quality while minimizing the manufacturing costs. The condition of the dynamic cutting system, determined by the trajectories of forces and deformations, affects the quality indicators of parts and the cutting efficiency, which depends on the intensity of tool wear. The properties of the system change depending on the phase trajectory of the power of irreversible transformations of the energy supplied to the cutting zone by the work performed. Their changes related with the evolution of the parameters of the dynamic link formed by cutting are manifested in the development of tool wear and changes in the quality of the part. Thus, the power of irreversible energy transformations is one of the internal factors causing changes in the output characteristics of processing and the state of the process. In this regard, when processing on machine tools, there is a problem of synergistic coordination of external control (for example, the CNC program) with internal one, the source of which is the irreversible transformation of the energy supplied to the cutting zone. The article considers the problem of synergetic coordination of external and internal controls during cutting process, the solution of which will allow increasing the efficiency of processing on CNC machines. A mathematical model of a controlled dynamic cutting system and control algorithms are proposed to improve the efficiency of processing parts of a given quality while minimizing the intensity of tool wear. Testing of the developed algorithms has shown that their use reduces the cost of manufacturing parts by 1.2.

scholarly journals ESTIMATION OF VEHICLE OPERATING TIME TAKING INTO ACCOUNT THE INFLUENCE OF A NUMBER OF FACTORS

2021 ◽  
Vol 1 (37) ◽  
pp. 76-85
Author(s):  
A. Krasheninin
Keyword(s):  
Service Life ◽  
Operating Time ◽  
Material Resources ◽  
Number Of Factors ◽  
Additional Costs ◽  
Definition Of ◽  
Optimal Average ◽  
The Cost ◽  
The Impact ◽  
Standard Service

Modern vehicles operated on the railways of Ukraine have almost exhausted or exceeded their resource. The overuse of financial and material resources for their maintenance continues. The standard service life of vehicles was calculated on stable economic conditions of use of vehicles and their timely updating in process of aging. The service life of modern vehicles is determined by the influence of many factors, the disregard of which can lead to significant costs, even in compliance with the standard service life. For railway transport, these factors need modern clarification, as in operation their service life often exceeds the standard or, as for intermodal transport, the service life does not have a strict justification. Accordingly, the article analyzes the issues of assessing the impact on the service life of vehicles of the components of the cost of its maintenance and average daily mileage. It is shown that, firstly, the definition of the service life of vehicles must be linked to the cost of vehicle development, its creation, testing and production, the cost of operation and storage, as well as additional costs, and secondly , with the optimal average daily mileage, at which all the costs are minimal.

Study on the Strategies for Fabrication of Die Assembly with Typical Shaped Cavity by Using Electrical Discharge Machining

2012 ◽  
Vol 192 ◽  
pp. 118-122
Author(s):  
Ren Yu Feng ◽  
Min Wang ◽  
Zhi Jian Duan
Keyword(s):  
Service Life ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Thermal Characteristics ◽  
Suitable Method ◽  
Metallic Materials ◽  
Material Hardness ◽  
The Cost ◽  
Machining Strategies ◽  
Edm Process

Die assembly is a kind of special tools for fabrication of metal or non-metallic materials parts with required design and purpose. Generally, the high material hardness for die assembly should be selected to increase the service life and reduce the cost in manufactory industry. Electrical discharge machining (EDM) is a suitable method for fabrication of die assembly as the material remove in EDM process mainly depends on the material's thermal characteristics, regardless of the hardness. In this paper, the machining strategies for fabrication of die assembly with typical shaped cavity using EDM were discussed, according to the different cavity structures, the best machining strategies were proposed

Rotary Engine Rotor Side Seals Using New Machining Processes

2021 ◽  
pp. 1-46
Author(s):  
Yu-yuan Hsieh ◽  
Ming-Yi Tsai ◽  
Zhi-Zhe Xu
Keyword(s):  
Manufacturing Process ◽  
Electrical Discharge Machining ◽  
Iron Alloy ◽  
Machining Process ◽  
Machining Processes ◽  
Manufacturing Method ◽  
Rotary Engine ◽  
Traditional Manufacturing ◽  
The Cost ◽  
Engine Rotor

Abstract The study has developed a new machining process for the side seal components of gray cast iron alloy of rotor engine, which is different from the traditional WEDM (wire electrical discharge machining) process. The new manufacturing process (milling + grinding process) will save 78% of the cost and 83% of the time for making each side seal component, and the accuracy of the average surface roughness of the component will be 2.1 times that of the traditional manufacturing method. If the components are polished with a self-made polishing rod, the accuracy will be increased by almost 20 times compared with the new manufacturing process.

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