Condition Monitoring to Enable Predictive Maintenance on a Six-Die Nut Manufacturing Machine through Force Data Analysis

Nut fasteners are produced by machines working around the clock. Companies generally operate with a run-to-failure or planned maintenance approach. Even with a planned maintenance schedule, however, undetected damage to the dies and non-die parts occurring between maintenance periods can cause considerable downtime and pervasive damage to the machine. To address this shortcoming, force data from the fourth and sixth dies of a six-die nut manufacturing machine were analysed using correlation to the best health condition on the force profile and on the force shock response spectrum profile. Fault features such as quality adjustments and damage to both die and non-die parts were detectable prior to required maintenance or machine failure. This detection was facilitated by the determination of health thresholds, whereby the force SRS profile generated a longer warning period prior to failure. The analytical approach could benefit the industry by identifying damage that would normally go undetected by operators, thereby reducing downtime, extending die life, enabling “as needed” maintenance, and optimising machine operation.

Development of smart cold forging die life cycle management system based on real-time forging load monitoring

Cold forging dies are manufactured through the shrink fit process to withstand high pressure loads, but fatigue failure eventually occurs due to repeated compressive stresses. The life cycle until fatigue failure was defined as the limit life, and attempts were made to predict the die life based on finite element method (FEM). However, accurate prediction was impossible owing to uncontrollable environmental variables. Consequently, it is impossible to clearly determine the die replacement cycle, resulting in negative consequences such as poor quality, production delay, and cost increase. Various environmental factors affecting the prediction of die life cycle result in the increase or decrease of the forming load, which is an important variable that determines the die life cycle. In this study, a system for monitoring load data generated from forging facilities was developed based on a piezo sensor. In addition, the die life cycle was more accurately predicted by using the forming load data measured in real time, and a die life management system that can determine the die replacement cycle was applied to the automobile steering parts production line.

A Covering and protection Type Porthole Die For Semi-Hollow Al-Profiles

A new structure named covering type for the semi-hollow Al-profiles was present. through a common actual case, the determination of structure parameters was introduced in detail. Mainly including the arrangement of portholes, the structure design of chamber and the selection of bearing. The method of checking the die strength was introduced. According to the extrusion results, the structure of the traditional solid die and the covering type structure were compared. The characteristics of the latter structure were simple and easy to process. The practical application shows that the new die structure can enhance the die life, improve the production efficiency and reduce the cost. The high precision and the surface brightness of the profiles were obtained. The structure is worth promoting. The aim is to provide reliable data and reference for the further research and development on the structure for semi-hollow Al-profiles.

Nickel-Based Slag-Remelted Superalloy for Ti-Alloys Isothermal Forging Die-Tool

The work purpose is to evaluate the application of nickel-based CrNi73CuBeTeAl superalloy (tungsten-free), made by electroslag remelting as a die tool material for isothermal forming. Isothermal deformation was simulated by tests for high-temperature cyclic creep. The specimens with high and × in plan dimensions (both parallel and perpendicular to the ingots central axis) were cut from the bottom, top and central zone, near the lateral surface and in the ingots central axis area. The tests were performed at 900, 940 and 980 °C constant temperature with 100, 200 and 300 MPa cyclic pressure in 0.02, 0.2 and 2.0 mm/s velocities range corresponded to 10-3-10-1 1/s strain rates. Such tools application field is compressor blades Ti-forgings die forging and sizing with ε = 1.0-3.0% residual upsetting deformation of dies during operation. It is shown that the die life can be extended to 400-700 loading cycles at 850-950 °C operating temperature and pressure up to 150 MPa.

On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

Analysis of Micro Cracks and Die Erosion in Die Casting

Die soldering is challenging issue on die life and casting quality in High Pressure Die Casting (HPDC) Industry. Itincreases die down time which causes increasing production cost per piece. Die soldering can be tackled by surfaceheat treatment operations like gas nitriding and other PVD coatings. Used and scraped die is selected from the diecasting industry for investigation of die soldering issue. Chemical distribution of elements and surface condition ofaffected die soldering zone is investigated. The study reveals that, there are abundant micro cracks, micro holes andmicro cavities at soldering portion. The radius of micro holes is about 0.25 μm and the radius of macro holes isabout 8μm. The die inserts are made up of H13 die steel and LM24 Aluminum alloy is used for casting operation. Atthe die soldering cross section region, distribution of aluminum and die soldering mechanism and its causes studied.The die soldering mechanism is classified as chemical, physical, mechanical and mixed soldering. The solderingphenomena have been researched based on die temperature and its chemistry, metal temperature and its chemistry,injection pressure and its velocity, and die surface roughness. The spread and formation of die soldering on used andscraped die is also discussed in this article.

“The State was Patiently Waiting for Me to Die”: Life without the Possibility of Parole as Punishment

Despite its growing use over past decades, there has been relatively little public or scholarly discussion of life sentences that deny the possibility of parole. This essay outlines the labyrinthine legal and political developments that have rendered life imprisonment difficult to address—including the intertwined histories of the death penalty and civil death—and draws upon the life writing of those serving life to theorize a more distinct understanding of this punishment. Witnesses reveal how the possibility of life despite the impossibility of parole punishes by subverting the goals of human growth and development. The potentiality of what can be done in the present grinds up against the futility of what could have been done and what could be done were release an option. Considered alongside the laws and court opinions and claims that characterize its convoluted development, these testimonies reveal this punishment’s role in the American imagination. Life without the possibility of parole reinforces and relies upon a vision that not simply some people are unable to change, but that anyone in a democracy—no matter their position—is some steps away from irretrievable exclusion. Permanent confinement denies a restorative vision of democracy: any effort to abolish or amend it must include the voices of those imprisoned.