scholarly journals Process simulation-based evaluation of design and operational implications of water-laid paper machine conversion to foam technology

BioResources ◽  
2021 ◽  
Vol 16 (3) ◽  
pp. 5148-5186
Author(s):  
Lotta Sorsamäki ◽  
Antti Koponen ◽  
Eemeli Hytönen
Keyword(s):  
Process Simulation ◽  
Paper Industry ◽  
Simulation Software ◽  
Strategic Decision ◽  
Process Efficiency ◽  
Process Equipment ◽  
Paper Machine ◽  
Forming Process ◽  
Forming Technology ◽  
Foam Forming

Foam forming technology has attracted much attention during the past few years in the paper industry. Its advantages compared to conventional water forming are a new product portfolio and increased process efficiency. To support the paper industry in pushing foam forming technology forward, process simulation is needed to provide supporting data for strategic decision-making and as a basis for equipment dimensioning. This study examined the conversion of an existing wallpaper machine from water to foam forming technology using process simulation. To determine the required process configuration and parameter changes in the existing process, both published and unpublished data on the foam forming process were collected. This paper also describes modeling of the foam phase in the selected simulation software. The suitability of existing paper process equipment for foam was analyzed. Simulations revealed that undisturbed operation with foam requires some equipment modifications and re-arrangements in water circuits. With foam forming, the water balance in both short and long circulation changes remarkably compared to conventional water forming, leading to a large increase in the long circulation volume flows.

Upscaling of foam forming technology for pilot scale

TAPPI Journal ◽  
2019 ◽  
Vol 18 (8) ◽  
Author(s):  
JANI LEHMONEN ◽  
TIMO RANTANEN ◽  
KARITA KINNUNEN-RAUDASKOSKI
Keyword(s):  
Production Efficiency ◽  
Strength Loss ◽  
Pilot Scale ◽  
Foam Density ◽  
Forming Process ◽  
Production Scale ◽  
Forming Technology ◽  
Wet Pressing ◽  
Foam Forming ◽  
Board Industry

The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water- and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing.

The Forming Process Simulation of Magnesium Alloy Control Arm of Automobile and its Mold Design

2014 ◽  
Vol 494-495 ◽  
pp. 262-265 ◽  
Author(s):  
Shi Gang Wang ◽  
Fu Sheng Gao ◽  
Shun Chen
Keyword(s):  
Finite Element Analysis ◽  
Magnesium Alloy ◽  
Process Simulation ◽  
Squeeze Casting ◽  
Mold Design ◽  
Analysis Software ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Technology ◽  
Distribution Of Stress

Taking the control arm of automobile as subject, this thesis discusses the mold design with the squeeze casting forming technology and the simulation of magnesium alloy control arm of automobile in the isothermal forming process using finite element analysis software DEFORM. From the simulation, obtains the data of stress, the distribution of stress and temperature in the forming process, concluding that the best condition of forming 6061 control arm of automobile is under the temperature 400 , and rate 3 mm/s.

scholarly journals Radial basis neural tree model for improving waste recovery process in a paper industry

2018 ◽  
Author(s):  
TANUJIT CHAKRABORTY ◽  
Swarup Chattopadhyay ◽  
Ashis Kumar Chakraborty
Keyword(s):  
Paper Industry ◽  
Cost Effective ◽  
Recovery Process ◽  
Process Efficiency ◽  
Regularity Conditions ◽  
Paper Machine ◽  
Tree Model ◽  
Waste Recovery ◽  
Proposed Model ◽  
Radial Basis

In this article, we propose a novel hybridization of regression trees (RT) and radial basis function networks (RBFN), namely, radial basis neural tree (RBNT) model,for waste recovery process improvement in the paper industry. As a by-product of the paper manufacturing process, a lot of waste along with valuable fibers and fillerscome out from the paper machine. The waste recovery process (WRP) involves separating the unwanted materials from the valuable ones so that the recovered fibersand fillers can be further reused in the production process. This job is done by fiber-filler recovery equipment (FFRE). The efficiency of FFRE depends on severalcrucial process parameters and monitoring them is a difficult proposition. The proposed model can be useful to find the essential parameters from the set of availabledata and perform prediction task to improve waste recovery process efficiency. An idea of parameter optimization along with regularity conditions for the universal consistency of the proposed model are given. The proposed model has the advantages of easy interpretability and excellent performance when applied to the FFREefficiency improvement problem. Improved waste recovery will help the industry to become environmentally friendly with less ecological damage apart from being cost-effective.

scholarly journals Conductive Cellulose based Foam Formed 3D Shapes—From Innovation to Designed Prototype

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 430 ◽  
Author(s):  
Sanna Siljander ◽  
Pasi Keinänen ◽  
Anastasia Ivanova ◽  
Jani Lehmonen ◽  
Sampo Tuukkanen ◽  
...  
Keyword(s):  
Three Dimensional ◽  
Material System ◽  
Nanoparticle Dispersion ◽  
Forming Process ◽  
Electrically Conductive ◽  
Forming Technology ◽  
Foam Forming ◽  
First Time ◽  
3D Shapes ◽  
Processing Steps

In this article, we introduce for the first time, a method to manufacture cellulose based electrically conductive non-woven three-dimensional (3D) structures using the foam forming technology. The manufacturing is carried out using a minimum amount of processing steps, materials, and hazardous chemicals. The optimized solution applies a single surfactant type and a single predefined portion for the two main processing steps: (1) the dispersing of nanocellulose (NC) and carbon nanotubes (CNT) and (2) the foam forming process. The final material system has a concentration of the used surfactant that is not only sufficient to form a stable and homogeneous nanoparticle dispersion, but it also results in stable foam in foam forming. In this way, the advantages of the foam forming process can be maximized for this application. The cellulose based composite material has a highly even distribution of CNTs over the NC network, resulting a conductivity level of 7.7 S/m, which increased to the value 8.0 S/m after surfactant removal by acetone washing. Also, the applicability and a design product case ‘Salmiakki’ were studied where the advantages of the material system were validated for a heating element application.

Analysis of Lead Screw High-Speed Roll-Beating Forming

2010 ◽  
Vol 455 ◽  
pp. 151-155 ◽  
Author(s):  
Yan Li ◽  
L. Zhang ◽  
Ming Shun Yang ◽  
Qi Long Yuan
Keyword(s):  
Process Simulation ◽  
High Speed ◽  
Incremental Forming ◽  
Single Point ◽  
The Self ◽  
Forming Process ◽  
Lead Screw ◽  
Forming Technology ◽  
Cold Roll ◽  
Simulation Results

Lead screw high-speed cold roll-beating is a new single-point incremental forming technology which is die-free and unconstrained. The principle of the forming process is analyzed. Modeling, meshing and parameter selecting for forming process simulation with ABAQUS are discussed. The lead screw cold roll-beating forming process simulation is carried out; stress & strain changes and metal flowing law are analyzed. Experiments are carried out with the self-developed experimental equipment. The experimental results are consistent with the simulation results, thus the validity of the simulation and feasibility of the forming process are verified.

Research on the Simulation for Sheet Metal NC Incremental Forming

2013 ◽  
Vol 441 ◽  
pp. 498-501
Author(s):  
Hu Zhu ◽  
Nan Li ◽  
Jin Ju
Keyword(s):  
Sheet Metal ◽  
Process Simulation ◽  
Tool Path ◽  
Incremental Forming ◽  
Simulation Method ◽  
Simulation Software ◽  
Software System ◽  
Forming Process ◽  
Cnc Incremental Forming

In the sheet metal CNC incremental forming, the forming is realized by its tool's step by step and point by point extrusion movements along the pre-programmed contour tool path in the outline of the sheet part. Therefore, the correctness of the forming path used to control the tool's movement has a magnificent impact on the forming quality. And a NC incremental forming process simulation method which is used to verify the correctness is showed in this paper. Meanwhile the simulation software system is developed by using VC++ and OpenGL. The case study shows that the software system can be used in the verification of NC incremental forming path and the motion analysis of forming tool, and the software system runs steadily and reliably.

Simulation Study on the High-Speed Single-Point Accumulation Forming Process of Involute Spline

2010 ◽  
Vol 450 ◽  
pp. 441-444 ◽  
Author(s):  
Yan Li ◽  
Ming Shun Yang ◽  
Qi Long Yuan ◽  
Feng Kui Cui
Keyword(s):  
Process Simulation ◽  
High Speed ◽  
Single Point ◽  
Practical Application ◽  
Forming Process ◽  
Forming Mechanism ◽  
Fea Model ◽  
Forming Technology ◽  
Cold Roll ◽  
Involute Spline

The high-speed cold roll-beating technology is adopted to realize the single-point accumulation forming of involute spline. Firstly, the principle of the forming technology is analyzed. Then the FEA model of the cold roll-beating of involute spline is built, the forming process simulation is finished with the ANSYS/LS-DYNA software to obtain the stress, strain and the metal flowing law of the forming process. Finally the experiments are carried out to verify the feasibility of the simulative results. This study can provide guidance for further study of the forming mechanism and practical application of the single-point accumulation forming technology.

Application Of Cusum Chart In Control Of Paper Quality

GIS Business ◽  
2020 ◽  
Vol 14 (6) ◽  
pp. 1062-1069
Author(s):  
S.Ramesh ◽  
B.A.Vasu
Keyword(s):  
Process Parameters ◽  
Manufacturing Process ◽  
Paper Industry ◽  
Primary Data ◽  
Cusum Chart ◽  
Paper Machine ◽  
Statistical Control ◽  
Operating Characteristics ◽  
Small Shift

This paper is an attempt to assess if the manufacturing process of paper machine is in statistical control thereby improving the quality of paper being produced in a paper industry at the time of process itself. Quality is the foremost criteria for achieving the business target. Therefore, emphasis was made on controlling the quality of paper at the time of manufacturing process itself, rather than checking the finished lots at a later time.  This control on quality will help the industry deduct the small shift in the process parameters and modify the operating characteristics at the time of production itself rather than receiving complaints from customers at a later stage.  This paper describes controlling quality at the time of manufacture itself and helps the industry to concentrate on quality at low cost. The researcher has collected primary data at a leading paper industry during October, 2019.  Though X-bar and Range charges were primarily used, CUSUM charts were used to sense the minor shifts in manufacturing process, to explore the possibility of adjusting process parameters during manufacture of paper.

Schwingungsüberlagertes Axialformen/Superimposed Oscillated Axial Forming

2020 ◽  
Vol 110 (11-12) ◽  
pp. 838-843
Author(s):  
Philipp Müller ◽  
Bernd-Arno Behrens ◽  
Sven Hübner ◽  
Hendrik Vogt ◽  
Daniel Rosenbusch ◽  
...  
Keyword(s):  
Surface Quality ◽  
Economic Importance ◽  
Combined Effect ◽  
Wird Eine ◽  
Forming Force ◽  
Forming Process ◽  
Forming Technology ◽  
Great Economic Importance ◽  
Gear Geometry

Techniken zur Steigerung der Formgebungsgrenzen in der Umformtechnik sind von hoher wirtschaftlicher Bedeutung. In dieser Arbeit wird eine Schwingungsüberlagerung im Krafthauptfluss eines Axialformprozesses zur Ausprägung einer Verzahnungsgeometrie untersucht. Die Auswirkungen der Schwingung auf die erzielbare Ausfüllung der Zahnkavitäten werden analysiert sowie die Parameter Schmierung und Oberflächengüte der Halbzeuge in ihrer kombinierten Wirkung untersucht. Es konnte eine Reduzierung der mittleren Umformkraft sowie eine Erhöhung der Formfüllung festgestellt werden. Techniques for extending the production limits in forming technology are of great economic importance. In this research, a superimposed oscillation in the main force flow of an axial forming process to form an axial gear geometry is investigated. The effects of the superimposed oscillation on the achievable form-filling of the tooth cavities are analyzed and the parameters lubrication and surface quality of the semi-finished products are investigated in their combined effect. A reduction of the averaged forming force as well as an increase of the form-filling could be achieved.

Numerical Simulation and Process Optimization of Automotive Friction Materials in Warm Pressing Forming

2013 ◽  
Vol 788 ◽  
pp. 57-60
Author(s):  
Chun Cao ◽  
Chun Dong Zhu ◽  
Chen Fu
Keyword(s):  
Process Optimization ◽  
Heating Temperature ◽  
Maximum Energy ◽  
Heating Time ◽  
Product Performance ◽  
Forming Process ◽  
Friction Materials ◽  
Forming Technology ◽  
The Relationship ◽  
Temperature Heating

Warm pressing forming technology has been gradually applied to the forming of automotive friction materials. How to ensure product performance to achieve the target at the same time achieve the maximum energy saving is the research focus of this study. In this paper, by using finite element method, the field of automotive friction materials in warm pressing forming was analyzed, reveals the relationship between the temperature field and the heating temperature/heating time. Furthermore, the energy consumption was analyzed and compared it with hot pressing forming process. The results will have significant guiding to the process optimization in warm pressing forming.

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