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Keywords = arc flow formulation

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27 pages, 1661 KiB  
Article
Minimizing Waste and Costs in Multi-Level Manufacturing: A Novel Integrated Lot Sizing and Cutting Stock Model Using Multiple Machines
by Nesma Khamis, Nermine Harraz and Hadi Fors
Modelling 2025, 6(3), 56; https://doi.org/10.3390/modelling6030056 - 26 Jun 2025
Viewed by 338
Abstract
Lot sizing and cutting stock problems are critical for manufacturing companies seeking to optimize resource utilization and minimize waste. This paper addresses the interconnected nature of these problems, often occurring sequentially in industries involving cut items or packaging. We propose a novel mixed [...] Read more.
Lot sizing and cutting stock problems are critical for manufacturing companies seeking to optimize resource utilization and minimize waste. This paper addresses the interconnected nature of these problems, often occurring sequentially in industries involving cut items or packaging. We propose a novel mixed integer linear programming (MILP) model that integrates the capacitated lot sizing problem with the one-dimensional cutting stock problem within a multi-level manufacturing framework. The cutting stock problem is addressed using an arc flow formulation. Our model aims to minimize setup, production, holding, and waste material costs while incorporating capacity constraints, setup requirements, inventory balance, and the use of various cutting machines. The effectiveness of our model is demonstrated through numerical experiments using a commercial optimization package. While the model efficiently generates optimal solutions for most scenarios, larger instances pose challenges within the specified time limits. Sensitivity analysis is conducted to evaluate the effect of changing essential parameters of the integrated problem on model performance and to provide managerial insights for real-life applications. Full article
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33 pages, 20715 KiB  
Article
Enhancing Precision in Arc Welding Simulations: A Comprehensive Study of the Ellipsoidal Heat Source Model
by Senol Sert and Ergun Nart
Machines 2025, 13(4), 337; https://doi.org/10.3390/machines13040337 - 20 Apr 2025
Viewed by 517
Abstract
Arc welding is a complex multiphysics mitigation process, and the related finite element simulation requires significant computational resources for multiphysics modeling to determine the temperature distributions in engineering problems accurately. Engineers and researchers aim to achieve reliable results from finite element analysis while [...] Read more.
Arc welding is a complex multiphysics mitigation process, and the related finite element simulation requires significant computational resources for multiphysics modeling to determine the temperature distributions in engineering problems accurately. Engineers and researchers aim to achieve reliable results from finite element analysis while minimizing computational costs. This research extensively studies the application of conventional ellipsoidal heat source formulation to obtain improved temperature distribution during arc welding for practical applications. The ellipsoidal heat source model, which artificially modifies the coefficient of thermal conductivity in the welding pool area to simulate stirring effects, is proven to be scientifically valid by comparing its results with those of COMSOL’s multiphysics arc welding analyses. The findings from finite element analyses demonstrate that the temperature fields generated using the modified ellipsoidal approach exhibit strong agreement with those obtained from multiphysics simulations, especially within the core regions of the weld pool. The method can easily be implemented in all different welding methods in which a stirring effect is formed by either electromagnetic or buoyancy-driven flows in the weld pool area. Furthermore, the method offers computational efficiency without sacrificing accuracy, making it suitable for industrial applications where multiphysics modeling is not feasible but reliable thermal and structural predictions are essential. Full article
(This article belongs to the Section Advanced Manufacturing)
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19 pages, 13081 KiB  
Article
Tsunami Risk Mapping and Sustainable Mitigation Strategies for Megathrust Earthquake Scenario in Pacitan Coastal Areas, Indonesia
by Jumadi Jumadi, Kuswaji Dwi Priyono, Choirul Amin, Aditya Saputra, Christopher Gomez, Kuok-Choy Lam, Arif Rohman, Nilanchal Patel, Farha Sattar, Muhammad Nawaz and Khusnul Setia Wardani
Sustainability 2025, 17(6), 2564; https://doi.org/10.3390/su17062564 - 14 Mar 2025
Viewed by 2133
Abstract
The Pacitan Regency is at risk of megathrust earthquakes and tsunamis due to the seismic gap along the southern region of Java Island, making risk-reduction efforts crucial. This research aims to analyse the tsunami risk associated with a potential megathrust earthquake scenario in [...] Read more.
The Pacitan Regency is at risk of megathrust earthquakes and tsunamis due to the seismic gap along the southern region of Java Island, making risk-reduction efforts crucial. This research aims to analyse the tsunami risk associated with a potential megathrust earthquake scenario in Pacitan’s coastal areas and develop sustainable mitigation strategies. The research employs spatial analysis to evaluate the risk and subsequently formulate strategies for long-term mitigation. A weighted overlay method was utilised to integrate hazard (H) and vulnerability (V) datasets to produce a tsunami risk map (R). The hazard component was modelled using a tsunami propagation simulation based on the Shallow Water Equations in the Delft3D-Flow software, incorporating an earthquake scenario of Mw 8.8 and H-loss calculations in ArcGIS Pro 10.3. The vulnerability assessment was conducted by overlaying population density, land use, and building footprint from the Global Human Settlement Layer (GHSL) datasets. Finally, sustainable strategies were proposed to mitigate the tsunami risk effectively. The results show that Pacitan faces significant tsunami disaster risk, with tsunami waves at the coast reaching 16.6 m. Because the coast of Pacitan is densely populated, mitigation strategies are necessary, and in the present contribution, the authors developed holistic spatial planning, which prioritise the preservation and restoration of natural barriers, such as mangroves and coastal forests. Full article
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29 pages, 8434 KiB  
Article
Petri-Net-Based Charging Scheduling Optimization in Rechargeable Sensor Networks
by Huaiyu Qin, Wei Ding, Lei Xu and Chenzhi Ruan
Sensors 2024, 24(19), 6316; https://doi.org/10.3390/s24196316 - 29 Sep 2024
Cited by 1 | Viewed by 945
Abstract
In order to express the energy flow, motion flow, and control flow in wireless rechargeable sensor networks accurately and intuitively, and to maximize the charging benefit of MVs (mobile vehicles), a type of MTS-HACO (Mobile Transition Sequence Hybrid Ant Colony Optimization) is proposed. [...] Read more.
In order to express the energy flow, motion flow, and control flow in wireless rechargeable sensor networks accurately and intuitively, and to maximize the charging benefit of MVs (mobile vehicles), a type of MTS-HACO (Mobile Transition Sequence Hybrid Ant Colony Optimization) is proposed. Firstly, node places are grouped according to the firing time of node’s energy consumption transition to ensure that in each time slot, MV places only enable charging transitions for the node places with lower remaining lifetimes. Then, the FSOMCT (Firing Sequence Optimization of Mobile Charging Transition) problem is formulated under the constraints of MV places capacity, travelling arc weight, charging arc weight, and so on. The elite strategy and the Max–Min Ant Colony system are further introduced to improve the ant colony algorithm, while the improved FWA (fireworks algorithm) optimizes the path constructed by each ant. Finally, the optimal mobile charging transition firing sequence and charging times are obtained, ensuring that MVs have sufficient energy to return to the base station. Simulation results indicate that, compared with the periodic algorithm and the PE-FWA algorithm, the proposed method can improve charging benefit by approximately 48.7% and 26.3%, respectively. Full article
(This article belongs to the Special Issue Energy Harvesting Technologies for Wireless Sensors)
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16 pages, 1521 KiB  
Article
A Fluid Dynamic Approach to Model and Optimize Energy Flows in Networked Systems
by Massimo de Falco, Luigi Rarità and Alfredo Vaccaro
Mathematics 2024, 12(10), 1543; https://doi.org/10.3390/math12101543 - 15 May 2024
Cited by 1 | Viewed by 1334
Abstract
In this paper, attention is focused on the analysis and optimization of energy flows in networked systems via a fluid-dynamic approach. Considering the real case of an energy hub, the proposed model deals with conservation laws on arcs and linear programming problems at [...] Read more.
In this paper, attention is focused on the analysis and optimization of energy flows in networked systems via a fluid-dynamic approach. Considering the real case of an energy hub, the proposed model deals with conservation laws on arcs and linear programming problems at nodes. Optimization of the energy flows is accomplished by considering a cost functional, which estimates a term proportional to the kinetic energy of the overall system in consideration. As the real optimization issue deals with an integral formulation for which precise solutions have to be studied through variational methods, a decentralized approach is considered. First, the functional is optimized for a simple network having a unique node, with an incoming arc and two outgoing ones. The optimization deals with distribution coefficients, and explicit solutions are found. Then, global optimization is obtained via the local optimal parameters at the various nodes of the real system. The obtained results prove the correctness of the proposed approach and show the evident advantages of optimization procedures dealing with variational approaches. Full article
(This article belongs to the Topic Mathematical Modeling)
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16 pages, 1904 KiB  
Article
Robust Design Problem for Multi-Source Multi-Sink Flow Networks Based on Genetic Algorithm Approach
by Sahbi Boubaker, Noha Hamdy Radwan, Moatamad Refaat Hassan, Faisal S. Alsubaei, Ahmed Younes and Hameda A. Sennary
Mathematics 2023, 11(18), 3902; https://doi.org/10.3390/math11183902 - 13 Sep 2023
Viewed by 1507
Abstract
Robust design problems in flow networks involve determining the optimal capacity assignments that enable the network to operate effectively even in the case of events’ occurrence such as arcs or nodes’ failures. Multi-source multi-sink flow networks (MMSFNs) are frequent in many real-life systems [...] Read more.
Robust design problems in flow networks involve determining the optimal capacity assignments that enable the network to operate effectively even in the case of events’ occurrence such as arcs or nodes’ failures. Multi-source multi-sink flow networks (MMSFNs) are frequent in many real-life systems such as computer and telecommunication, logistics and supply-chain, and urban traffic. Although numerous studies on the design of MMSFNs have been conducted, the robust design problem for multi-source multi-sink stochastic-flow networks (MMSFNs) remains unexplored. To contribute to this field, this study addresses the robust design problem for MMSFNs using an approach of two steps. First, the problem is mathematically formulated as an optimization problem and second, a sub-optimal solution is proposed based on a genetic algorithm (GA) involving two components. The first component, an outer genetic algorithm, is employed to search the optimal capacity assigned to the network components with minimum sum. The second component, an inner genetic algorithm, is used to find the optimal flow vectors that maximize the system’s reliability. Through extensive experimentation on three different networks with different topologies, the proposed solution has been found to be efficient. Full article
(This article belongs to the Special Issue Graph Theory and Network Theory)
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17 pages, 2464 KiB  
Article
Boosted Arc Flow Formulation Using Graph Compression for the Two-Dimensional Strip Cutting Problem
by Tamer G. Ali, Mehdi Mrad, Ali Balma, Anis Gharbi, Ali Samhan and Mohammed A. Louly
Processes 2023, 11(3), 790; https://doi.org/10.3390/pr11030790 - 7 Mar 2023
Viewed by 1872
Abstract
Since the requirement for a material cutting process occurs in a wide variety of applied contemporary manufacturing, the cutting stock problem plays a critical role in optimizing the amount of raw material utilized in everyday production operations. In this paper, we address the [...] Read more.
Since the requirement for a material cutting process occurs in a wide variety of applied contemporary manufacturing, the cutting stock problem plays a critical role in optimizing the amount of raw material utilized in everyday production operations. In this paper, we address the two-dimension strip-cutting problem and implement the graph compression technique to improve the performance of the arc-flow formulation. The number of variables of the obtained mathematical model are substantially reduced. A comparative study on a large set of benchmark instances shows that our compressed model yields very good results for the non-unitary item demand case in contrast to the state-of-the-art mathematical models. Moreover, improved bounds are provided for 24 unsolved benchmark instances, among which 8 have been solved to optimality. Full article
(This article belongs to the Special Issue Computer-Aided Manufacturing Technologies in Mechanical Field)
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18 pages, 2500 KiB  
Article
An Improved Arc Flow Model with Enhanced Bounds for Minimizing the Makespan in Identical Parallel Machine Scheduling
by Anis Gharbi and Khaled Bamatraf
Processes 2022, 10(11), 2293; https://doi.org/10.3390/pr10112293 - 4 Nov 2022
Cited by 4 | Viewed by 1929
Abstract
In this paper, an identical parallel machine problem was considered with the objective of minimizing the makespan. This problem is NP-hard in the strong sense. A mathematical formulation based on an improved arc flow model with enhanced bounds was proposed. A variable neighborhood [...] Read more.
In this paper, an identical parallel machine problem was considered with the objective of minimizing the makespan. This problem is NP-hard in the strong sense. A mathematical formulation based on an improved arc flow model with enhanced bounds was proposed. A variable neighborhood search algorithm was proposed to obtain an upper bound. Three lower bounds from the literature were utilized in the improved arc flow model to improve the efficiency of the mathematical formulation. In addition, a graph compression technique was proposed to reduce the size of the graph. As a consequence, the improved arc flow model was compared with an arc flow model from the literature. The computational results on benchmark instances showed that the improved arc flow model outperformed the literature arc flow model at finding optimal solutions for 99.97% of the benchmark instances, with the overall percentage of the reduction in time reaching 87%. Full article
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17 pages, 5569 KiB  
Article
Longitudinal DC Discharge in a Supersonic Flow: Numerical Simulation and Experiment
by Alexander Firsov, Valentin Bityurin, Dmitriy Tarasov, Anastasia Dobrovolskaya, Roman Troshkin and Aleksey Bocharov
Energies 2022, 15(19), 7015; https://doi.org/10.3390/en15197015 - 24 Sep 2022
Cited by 13 | Viewed by 2349
Abstract
This work focuses on detailed descriptions of DC discharge properties in supersonic airflow and its applicability in combustion simulations. Due to the complexity of obtaining most of the data in the experiment, our experimental research was supplemented by a numerical simulation. Two packages, [...] Read more.
This work focuses on detailed descriptions of DC discharge properties in supersonic airflow and its applicability in combustion simulations. Due to the complexity of obtaining most of the data in the experiment, our experimental research was supplemented by a numerical simulation. Two packages, i.e., FlowVision (fast commercial CFD for 3D engineering) and Plasmaero (2D scientific code developed in JIHT RAS for MHD tasks), were used for modeling the arc DC discharge in a supersonic flow at Mach (M) = 2. Both will be considered for further use in plasma-assisted combustion modeling, so it is important to validate both codes using experimental data from the model configuration with discharge. Axisymmetric geometries of experiments with two coaxial electrodes located parallel to the flow were chosen to avoid the appearance of the current channel part perpendicular to the flow and the corresponding discharge pulsations. Such geometries allow performing numerical simulations in 2D formulation, making it possible to compare the results obtained in the experiments and calculations. As a result of this work, two-dimensional distributions involving temperature, current density, chemical composition, and other discharge and flow parameters were obtained for arc DC discharges 0.5–7 A in a supersonic flow (Pst = 22 kPa, T = 170 K, V~500 m/s). Good qualitative agreement between experimental and numerical results was achieved. The production of a significant amount of atomic oxygen, which accelerates combustion, was noted. Full article
(This article belongs to the Special Issue Energy Deposition for Aerospace Applications)
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21 pages, 3610 KiB  
Article
Evolution and Driving Mechanism of Tourism Flow Networks in the Yangtze River Delta Urban Agglomeration Based on Social Network Analysis and Geographic Information System: A Double-Network Perspective
by Yuewei Wang, Mengmeng Xi, Hang Chen and Cong Lu
Sustainability 2022, 14(13), 7656; https://doi.org/10.3390/su14137656 - 23 Jun 2022
Cited by 22 | Viewed by 4502
Abstract
This study’s purpose was to analyze the network structural characteristics, nodal roles, spatial structure, and evolution laws from the dual network perspective, and apply the Quadratic Assignment Procedure (QAP) to conduct correlation analysis and regression analysis on the influencing factors of tourism flow [...] Read more.
This study’s purpose was to analyze the network structural characteristics, nodal roles, spatial structure, and evolution laws from the dual network perspective, and apply the Quadratic Assignment Procedure (QAP) to conduct correlation analysis and regression analysis on the influencing factors of tourism flow networks in the Yangtze River Delta urban agglomerations. Using a mixed-method of social network and spatial analysis, Ucinet and ArcGIS software were used to comprehensively analyze the nodes in the travel routes covered in travel notes. The results show that the density of tourism flow network increases on the whole, while the spatial difference decreases, and the overall network density value is much lower than the average of the network density of provinces. Degree centrality, closeness centrality, betweenness centrality and the core–periphery structure analysis were used to examine the tourism function, distribution function, connection function and the position of nodes in the network, and nodes were divided into various types of roles according to their function. Meanwhile, the role changes of each node in different periods were also investigated. This study also builds an evaluation model of the influencing factors of the evolution of tourism flow network structure and uses QAP to find that the tourism network is affected by factors such as tourism resource endowment, transportation convenience, economic development level, tourism reception and service capacity. The research results are helpful for the Chinese government and tourism enterprises to understand the spatial behavior of tourists and its evolution rules, and to clarify the role and status of node cities in the tourism flow network and their influencing factors. It is of great significance for the formulation of joint marketing measures and promotion of the sustainable development of tourism in the Yangtze River Delta urban agglomeration. Full article
(This article belongs to the Special Issue Urban Climate Change, Transport Geography and Smart Cities)
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21 pages, 2872 KiB  
Article
Train Routing and Track Allocation Optimization Model of Multi-Station High-Speed Railway Hub
by Yidong Wang, Rui Song, Shiwei He and Zilong Song
Sustainability 2022, 14(12), 7292; https://doi.org/10.3390/su14127292 - 14 Jun 2022
Cited by 6 | Viewed by 2692
Abstract
A multi-station high-speed railway hub is the interaction of multiple high-speed railway lines, and its operation determines the efficiency of the whole network. In this study, we focus on the train routing problem for a multi-station railway hub and propose a flexible scheme [...] Read more.
A multi-station high-speed railway hub is the interaction of multiple high-speed railway lines, and its operation determines the efficiency of the whole network. In this study, we focus on the train routing problem for a multi-station railway hub and propose a flexible scheme to improve the capacity utilization. Based on the flexible scheme, a mixed-integer programming node-arc model is formulated to minimize the total cost of train and passenger routes. Specifically, for diversifying the train routes, we consider the individual train rather than the train flow as the basic unit, which differs from the approach in previous studies. For each train route, in addition to the macro-scale route between stations, the micro-scale track allocation inside stations is also considered. Afterward, the optimization solver Gurobi is used to solve the model and obtain the optimization scheme. A case study based on real data from the Zhengzhou railway hub in China is implemented to evaluate the effectiveness of the optimization model. By comparing the optimization scheme with the fixed scheme and the sequential scheme, the results show our method could reduce the total cost by 29.35% and 22.58%, and the line and track capacity utilization of the optimization scheme is more reasonable. We provide some suggestions to help railway managers improve the operation efficiency and service quality of multi-station high-speed railway hubs. Full article
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8 pages, 492 KiB  
Proceeding Paper
A Bicriteria Model for Saving a Path Minimizing the Time Horizon of a Dynamic Contraflow
by Hari Nandan Nath, Tanka Nath Dhamala and Stephan Dempe
Comput. Sci. Math. Forum 2022, 2(1), 2; https://doi.org/10.3390/IOCA2021-10897 - 25 Sep 2021
Viewed by 1600
Abstract
The quickest contraflow in a single-source-single-sink network is a dynamic flow that minimizes the time horizon of a given flow value at the source to be sent to the sink allowing arc reversals. Because of the arc reversals, for a sufficiently large value [...] Read more.
The quickest contraflow in a single-source-single-sink network is a dynamic flow that minimizes the time horizon of a given flow value at the source to be sent to the sink allowing arc reversals. Because of the arc reversals, for a sufficiently large value of the flow, the residual capacity of all or most of the paths towards the source, from a given node, may be zero or reduced significantly. In some cases, e.g., for the movement of facilities to support an evacuation in an emergency, it is imperative to save a path from a given node towards the source. We formulate such a problem as a bicriteria optimization problem, in which one objective minimizes the length of the path to be saved from a specific node towards the source, and the other minimizes the quickest time of the flow from the source towards the sink, allowing arc reversals. We propose an algorithm based on the epsilon-constraint approach to find non-dominated solutions. Full article
(This article belongs to the Proceedings of The 1st International Electronic Conference on Algorithms)
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23 pages, 5367 KiB  
Article
Hydrological Responses to Land Use Land Cover Changes in the Fincha’a Watershed, Ethiopia
by Urgessa Kenea, Dereje Adeba, Motuma Shiferaw Regasa and Michael Nones
Land 2021, 10(9), 916; https://doi.org/10.3390/land10090916 - 31 Aug 2021
Cited by 36 | Viewed by 4503
Abstract
Land use land cover (LULC) changes are highly pronounced in African countries, as they are characterized by an agriculture-based economy and a rapidly growing population. Understanding how land use/cover changes (LULCC) influence watershed hydrology will enable local governments and policymakers to formulate and [...] Read more.
Land use land cover (LULC) changes are highly pronounced in African countries, as they are characterized by an agriculture-based economy and a rapidly growing population. Understanding how land use/cover changes (LULCC) influence watershed hydrology will enable local governments and policymakers to formulate and implement effective and appropriate response strategies to minimize the undesirable effects of future land use/cover change or modification and sustain the local socio-economic situation. The hydrological response of the Ethiopia Fincha’a watershed to LULCC that happened during 25 years was investigated, comparing the situation in three reference years: 1994, 2004, and 2018. The information was derived from Landsat sensors, respectively Landsat 5 TM, Landsat 7 ETM, and Landsat 8 OLI/TIRS. The various LULC classes were derived via ArcGIS using a supervised classification system, and the accuracy assessment was done using confusion matrixes. For all the years investigated, the overall accuracies and the kappa coefficients were higher than 80%, with 2018 as the more accurate year. The analysis of LULCC revealed that forest decreased by 20.0% between the years 1994–2004, and it decreased by 11.8% in the following period 2004–2018. Such decline in areas covered by forest is correlated to an expansion of cultivated land by 16.4% and 10.81%, respectively. After having evaluated the LULCC at the basin scale, the watershed was divided into 18 sub-watersheds, which contained 176 hydrologic response units (HRUs), having a specific LULC. Accounting for such a detailed subdivision of the Fincha’a watershed, the SWAT model was firstly calibrated and validated on past data, and then applied to infer information on the hydrological response of each HRU on LULCC. The modelling results pointed out a general increase of average water flow, both during dry and wet periods, as a consequence of a shift of land coverage from forest and grass towards settlements and build-up areas. The present analysis pointed out the need of accounting for past and future LULCC in modelling the hydrological responses of rivers at the watershed scale. Full article
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17 pages, 4275 KiB  
Article
Analysis of Spatial and Temporal Characteristics and Spatial Flow Process of Soil Conservation Service in Jinghe Basin of China
by Ting Zheng, Zixiang Zhou, Yufeng Zou, Bakhtiyor Pulatov and Asim Biswas
Sustainability 2021, 13(4), 1794; https://doi.org/10.3390/su13041794 - 7 Feb 2021
Cited by 23 | Viewed by 2971
Abstract
The supply and demand of ecosystem services and their mutual feedback are important for the formulation of basin ecological environmental policies. Simulation of the spatial flow of ecosystem services can clarify the division of areas and can support policy development. This paper takes [...] Read more.
The supply and demand of ecosystem services and their mutual feedback are important for the formulation of basin ecological environmental policies. Simulation of the spatial flow of ecosystem services can clarify the division of areas and can support policy development. This paper takes the Jinghe Basin in the Loess Plateau of China as the case-study area to simulate the spatial flow of soil conservation service on different scales. The results showed that (1) soil erosion situations in Jinghe Basin improved overall, with a trend of first aggravating and then recovering between 2005 and 2015; (2) the amount of annual soil conservation in the basin accounted for more than 75% of the potential soil erosion and showed a trend of first increasing and then decreasing; and (3) using digital elevation model (DEM) data and ArcGIS software, the experiment divided the basin into sub-basins (58 in total) and hydrological response units (HRUs) (e.g., 2181 HRUs in sub-basin #1), which were used to quantify the spatial flow direction and the corresponding amount of soil conservation service on the “HRU—river-sub-basin” scale. The divided supply and demand helped quantify the spatial flow pattern of soil conservation services from HRU to the sub-basin. Full article
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16 pages, 5162 KiB  
Article
Digitized Stress Function-Based Feed Rate Scheduling for Prevention of Mesoscale Tool Breakage during Milling Hardened Steel
by Yifan Gao, Jeong Hoon Ko and Heow Pueh Lee
Metals 2021, 11(2), 215; https://doi.org/10.3390/met11020215 - 26 Jan 2021
Cited by 1 | Viewed by 1944
Abstract
In this article, a digitized stress function-based feed rate scheduling algorithm is formulated for the prevention of tool breakage while having an optimum material removal rate in mesoscale rough milling of hardened steel. Instead of setting limits to the cutting forces and material [...] Read more.
In this article, a digitized stress function-based feed rate scheduling algorithm is formulated for the prevention of tool breakage while having an optimum material removal rate in mesoscale rough milling of hardened steel. Instead of setting limits to the cutting forces and material removal rates, the presented method regulates the tool’s stresses. A 3D coupled Eulerian-Lagrangian finite element method (FEM) model is used to simulate a 3D chip flow-based stress according to the mesoscale tool’s rotation during cutting of hardened steel. Maximum uncut chip thickness and tool engaging angle of the uncut chip is identified as the fundamental driving factors of tool breakage in down milling configuration. Furthermore, a multiple linear regression model is formed to digitize the stress with two major factors for digitized feed scheduling. The optimum feed rates for each segment along the tool path can be obtained through finite element models and a multiple linear regression model. The feed rate scheduling method is validated through cutting experiments with tool paths of linear and arc segments. In a series of experimental validations, the algorithm demonstrated the capability of reducing the machining time while eliminating cutting tool breakages. Full article
(This article belongs to the Special Issue State-of-the-Art Processing of Metals and Alloys)
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