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Keywords = based on flange center

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14 pages, 6935 KiB  
Article
Center-Punching Mechanical Clinching Process for Aluminum Alloy and Ultra-High-Strength Steel Sheets
by Ping Qiu, Xiaoxin Lu, Xuewei Dai, Boran Deng and Hong Xiao
Metals 2024, 14(10), 1190; https://doi.org/10.3390/met14101190 - 20 Oct 2024
Cited by 1 | Viewed by 1226
Abstract
In recent years, with the rapid advancement of automotive lightweight technology, the mechanical clinching process between aluminum alloy and ultra-high-strength steel sheets has received extensive attention. However, the low ductility of ultra-high-strength steel sheets often results in conventional mechanical clinching processes producing joints [...] Read more.
In recent years, with the rapid advancement of automotive lightweight technology, the mechanical clinching process between aluminum alloy and ultra-high-strength steel sheets has received extensive attention. However, the low ductility of ultra-high-strength steel sheets often results in conventional mechanical clinching processes producing joints that either fail to establish effective interlocks or cause the steel sheets to fracture. To address this issue, a novel mechanical clinching process is presented, called center-punching mechanical clinching (CPMC). This innovative process employs a method of punching, flanging, and bulging gradation to achieve the mechanical clinching of aluminum alloy and ultra-high-strength steel sheets in a single step. In order to determine the effects of different parameters on the quality and strength of the joint, an experimental study was carried out for various die depths and diameters based on the condition of constant punch size. Based on tensile and shear tests, the static strength and failure modes of CPMC joints were analyzed. The results indicated that the CPMC process significantly enhances the connectivity of joints for AA5052 aluminum alloy and DP980 ultra-high-strength steel. Optimal tensile and shear strengths of 1264 and 2249 N, respectively, were achieved at a die depth of 2.2 mm and a diameter of 10.4 mm. The CPMC process provides new ideas for the mechanical clinching of aluminum alloy and ultra-high-strength steels. Full article
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15 pages, 6042 KiB  
Article
A Ground-Based Electrostatically Suspended Accelerometer
by Hanxiao Liu, Xiaoxia He, Chenhui Wu and Rong Zhang
Sensors 2024, 24(12), 4029; https://doi.org/10.3390/s24124029 - 20 Jun 2024
Cited by 1 | Viewed by 1234
Abstract
In this study, we have developed an electrostatically suspended accelerometer (ESA) specifically designed for ground use. To ensure sufficient overload capacity and minimize noise resulting from high suspension voltage, we introduced a proof mass design featuring a hollow, thin-walled cylinder with a thin [...] Read more.
In this study, we have developed an electrostatically suspended accelerometer (ESA) specifically designed for ground use. To ensure sufficient overload capacity and minimize noise resulting from high suspension voltage, we introduced a proof mass design featuring a hollow, thin-walled cylinder with a thin flange fixed at the center, offering the highest surface-area-to-mass ratio compared to various typical proof mass structures. Preload voltage is directly applied to the proof mass via a golden wire, effectively reducing the maximum supply voltage for suspension. The arrangement of suspension electrodes, offering five degrees of freedom and minimizing cross-talk, was designed to prioritize simplicity and maximize the utilization of electrode area for suspension purposes. The displacement detection and electrostatic suspension force were accurately modeled based on the structure. A controller incorporating an inverse winding mechanism was developed and simulated using Simulink. The simulation results unequivocally demonstrate the successful completion of the stable initial levitation process and suspension under ±1g overload. Full article
(This article belongs to the Special Issue Advanced Inertial Sensors: Advances, Challenges and Applications)
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19 pages, 4065 KiB  
Article
Experimental Study on Shear Lag Effect of Long-Span Wide Prestressed Concrete Cable-Stayed Bridge Box Girder under Eccentric Load
by Yanfeng Li, Jiyuan Xie, Fengchi Wang, Di Wu, Jiahui Wang and Yanao Liu
Constr. Mater. 2024, 4(2), 425-443; https://doi.org/10.3390/constrmater4020023 - 20 May 2024
Viewed by 1095
Abstract
Based on the engineering background of the wide-width single cable-stayed bridge, the shear lag effects of the cross-section of these bridge box girders under the action of the eccentric load were experimentally studied. The behavior of shear lag effects in the horizontal and [...] Read more.
Based on the engineering background of the wide-width single cable-stayed bridge, the shear lag effects of the cross-section of these bridge box girders under the action of the eccentric load were experimentally studied. The behavior of shear lag effects in the horizontal and longitudinal bridge directions under eccentric load in the operational stage of a single cable-stayed bridge was analyzed by a model testing method and a finite element (FE) analytical method. The results showed that the plane stress calculation under unidirectional live load was similar to the results from spatial FE analysis and structural calculations performed according to the effective flange width described in the design specification. At the position of the main beam near the cable force point of action, the positive stress at its upper wing edge was greatest. At a distance from the cable tension point, the maximum positive stress position trend showed that from the center of the top flange to the junction of the top flange and the middle web to the junction of the top flange and the middle web and the side web. Under eccentric load, the positive and negative shear lag effects on the end fulcrum existed at the same time, and the shear lag coefficient on the web plate was larger than the shear lag coefficient on the unforced side. Due to the influence of constraint at the middle fulcrum near the middle pivot point, positive and negative shear lag effects were significant, and the coefficient variation range was large, resulting in large tensile stress on the roof plate in this area. According to FE analytical results, stress and shear forces of a single box three-chamber box girder under eccentric load were theoretically analyzed, the bending load decomposed into the accumulation of bending moment and axial force, using the bar simulation method, and the overall shear lag effect coefficient λ was obtained and verified. Full article
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21 pages, 10879 KiB  
Article
Submillimeter-Accurate Markerless Hand–Eye Calibration Based on a Robot’s Flange Features
by Velibor Đalić, Vedran Jovanović and Petar Marić
Sensors 2024, 24(4), 1071; https://doi.org/10.3390/s24041071 - 7 Feb 2024
Cited by 2 | Viewed by 2708
Abstract
An accurate and reliable estimation of the transformation matrix between an optical sensor and a robot is a key aspect of the hand–eye system calibration process in vision-guided robotic applications. This paper presents a novel approach to markerless hand–eye calibration that achieves streamlined, [...] Read more.
An accurate and reliable estimation of the transformation matrix between an optical sensor and a robot is a key aspect of the hand–eye system calibration process in vision-guided robotic applications. This paper presents a novel approach to markerless hand–eye calibration that achieves streamlined, flexible, and highly accurate results, even without error compensation. The calibration procedure is mainly based on using the robot’s tool center point (TCP) as the reference point. The TCP coordinate estimation is based on the robot’s flange point cloud, considering its geometrical features. A mathematical model streamlining the conventional marker-based hand–eye calibration is derived. Furthermore, a novel algorithm for the automatic estimation of the flange’s geometric features from its point cloud, based on a 3D circle fitting, the least square method, and a nearest neighbor (NN) approach, is proposed. The accuracy of the proposed algorithm is validated using a calibration setting ring as the ground truth. Furthermore, to establish the minimal required number and configuration of calibration points, the impact of the number and the selection of the unique robot’s flange positions on the calibration accuracy is investigated and validated by real-world experiments. Our experimental findings strongly indicate that our hand–eye system, employing the proposed algorithm, enables the estimation of the transformation between the robot and the 3D scanner with submillimeter accuracy, even when using the minimum of four non-coplanar points for calibration. Our approach improves the calibration accuracy by approximately four times compared to the state of the art, while eliminating the need for error compensation. Moreover, our calibration approach reduces the required number of the robot’s flange positions by approximately 40%, and even more if the calibration procedure utilizes just four properly selected flange positions. The presented findings introduce a more efficient hand–eye calibration procedure, offering a superior simplicity of implementation and increased precision in various robotic applications. Full article
(This article belongs to the Section Sensors and Robotics)
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26 pages, 12984 KiB  
Article
Practical Investigation on the Strengthening of the Built-Up Steel Main Girder of a Metro Station with Carbon-Fiber-Reinforced Polymer on the Inside Part of the Tensioned Flange
by Mohamed A. M. A. Mahmoud, Phan Viet Nhut and Yukihiro Matsumoto
Buildings 2023, 13(7), 1753; https://doi.org/10.3390/buildings13071753 - 10 Jul 2023
Cited by 1 | Viewed by 1700
Abstract
This study investigates the effectiveness of a carbon-fiber-reinforced polymer (CFRP) in enhancing the load-carrying capacity of a steel main girder in a metro station. The objective is to evaluate the applicability of CFRPs in sustaining increases in applied loads and assessing their effectiveness [...] Read more.
This study investigates the effectiveness of a carbon-fiber-reinforced polymer (CFRP) in enhancing the load-carrying capacity of a steel main girder in a metro station. The objective is to evaluate the applicability of CFRPs in sustaining increases in applied loads and assessing their effectiveness on curved surfaces. Finite element analysis (FEA) identified the most stressed areas of the girder under design loads. Based on the FEA results, a targeted strengthening procedure using CFRP sheets was proposed. Various arrangements of CFRP sheets were tested, including different orientations and thicknesses up to 60% of the girder’s flange thickness. To validate the FEA accuracy, two small-scale specimen beams were prepared and tested in the laboratory. One beam was strengthened with CFRP sheets on the tension part of the inner flange side, similar to the suggested strengthening method for the girder. The FEA results show that the CFRP increases stresses by an average of 8% to 10% for the steel main girder, with strengthening effects up to 19% at the center of the CFRP strengthening positions, differing from a regular straight flange shape. Significantly reducing stresses required a total CFRP layer thickness of at least 50% of the flange’s total thickness. Applying a CFRP on the inner face of the girder preserves its usability without the need for openings in finishes or the metal deck surface. The findings highlight CFRP’s potential to enhance load-carrying capacity on curved surfaces and sustain increased applied loads, offering a promising solution for strengthening infrastructure and similar applications. Full article
(This article belongs to the Special Issue Fibre-Reinforced Polymer Composites in Civil Engineering)
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18 pages, 5993 KiB  
Article
Electric Drive Solution for Low-Floor City Transport Trams
by Andrzej Chudzikiewicz, Igor Maciejewski, Tomasz Krzyżyński, Andrzej Krzyszkowski and Anna Stelmach
Energies 2022, 15(13), 4640; https://doi.org/10.3390/en15134640 - 24 Jun 2022
Cited by 7 | Viewed by 2294
Abstract
The urban transport system based on trams as the basic means of transport is one of the oldest systems of human transport in urban agglomerations. A tram is a more efficient, cheaper-to-operate, and greener means of transport compared to a bus. Striving to [...] Read more.
The urban transport system based on trams as the basic means of transport is one of the oldest systems of human transport in urban agglomerations. A tram is a more efficient, cheaper-to-operate, and greener means of transport compared to a bus. Striving to enable the use of this means of transport by elderly and disabled people, constructors and manufacturers of tram vehicles began to consider the requirements of the ordering parties—organizers of municipal public transport—in their solutions. The basic condition for disabled and elderly people to use tram transport is the possibility of safe and efficient entry and exit from the vehicle at tram stops. The fulfillment of this condition is possible only in the case of tram vehicles with a low 100% floor, and this, in turn, requires the replacement of trolleys with traditional wheelsets, that is, trolleys with independently rotating wheels, in the construction of the running gear. A wheelset with independently rotating wheels (IRW) does not have self-centering properties, and, thus, problems may arise with excessive wear of wheel and rail profiles and with continuous contact of the wheel flange with the rail, which may, consequently, lead to derailment. Driving a vehicle on the track in this case is governed by different laws. To prevent such phenomena, it is required to use the wheel drive control system, which allows for the stabilization of the vehicle movement on the track. Both the introduction of independently rotating wheels in the construction of the bogie and the drive connected to the wheel control system requires research and analysis to confirm the correctness of the assumptions made. The innovative solution of the control system in the case of a tram vehicle was patented and then the patent was implemented to produce a low-floor tram with 100% low floor by a Polish tram manufacturer. This article presents the results of the work carried out on the adoption of the concept of a running gear and drive solution for a low-floor tram vehicle with independently rotating wheels and the results of simulation analysis of the drive control of such a system, using mathematical models of the mechanical system (running gear) and the electrical system (motor drive control system). Full article
(This article belongs to the Special Issue Advances in Electric Transport System)
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17 pages, 13032 KiB  
Article
Biomedical Signals for Healthcare Using Hadoop Infrastructure with Artificial Intelligence and Fuzzy Logic Interpretation
by Shitharth Selvarajan, Hariprasath Manoharan, Tawfiq Hasanin, Raed Alsini, Mueen Uddin, Mohammad Shorfuzzaman and Abdulmajeed Alsufyani
Appl. Sci. 2022, 12(10), 5097; https://doi.org/10.3390/app12105097 - 18 May 2022
Cited by 24 | Viewed by 3224
Abstract
In all developing countries, the application of biomedical signals has been growing, and there is a potential interest to apply it to healthcare management systems. However, with the existing infrastructure, the system will not provide high-end support for the transfer of signals by [...] Read more.
In all developing countries, the application of biomedical signals has been growing, and there is a potential interest to apply it to healthcare management systems. However, with the existing infrastructure, the system will not provide high-end support for the transfer of signals by using a communication medium, as biomedical signals need to be classified at appropriate stages. Therefore, this article addresses the issues of physical infrastructure, using Hadoop-based systems where a four-layer model is created. The four-layer model is integrated with Fuzzy Interface System Algorithm (FISA) with low robustness, and data transfers in these layers are carried out with reference health data that are collected at various treatment centers. The performance of this new flanged system model aims to minimize the loss functionalities that are present in biomedical signals, and an activation function is introduced at the middle stages. The effectiveness of the proposed model is simulated by using MATLAB, using a biomedical signal processing toolbox, where the performance of FISA proves to be better in terms of signal strength, distance, and cost. As a comparative outcome, the proposed method overlooks the conventional methods for an average percentage of 78% in real-time conditions. Full article
(This article belongs to the Topic Machine Learning Techniques Driven Medicine Analysis)
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15 pages, 6824 KiB  
Article
Research on Identification Method for Interface Flange in Automatic Docking System of Fluid Loading and Unloading Arm for Bottom Loading
by Mingqin Liu, Zongzhou Li, Jie Liu, Zhongguo Mao, Minglong Xu and Sungki Lyu
Appl. Sci. 2022, 12(6), 3037; https://doi.org/10.3390/app12063037 - 16 Mar 2022
Cited by 4 | Viewed by 2554
Abstract
The automatic docking system of the loading and offloading arm of a tank car is the key link to realizing the unmanned operation of tank car loading and unloading. The spatial position detection of the flange port of a tank car can guide [...] Read more.
The automatic docking system of the loading and offloading arm of a tank car is the key link to realizing the unmanned operation of tank car loading and unloading. The spatial position detection of the flange port of a tank car can guide the automatic docking of the fluid loading and offloading arm and flange port of the tank car. In this paper, a flange position detection method based on image recognition was proposed. Firstly, the end state of the loading arm was analyzed to determine the expression mode of the loading arm’s spatial pose so as to form a unified expression with the flange position and docked pose on the tank car. Then, for the image processing of the flange port of the tank car, this paper binarized the edge of the flange end face based on the Otsu algorithm, used the Canny algorithm for edge detection, used the least squares method to fit the image edge coordinates into a spatial circle, calculated the center coordinates and normal vector of the flange end face, and used these parameters to guide the end of the loading arm to adjust the position and attitude so that it was consistent with the position and pose of the flange port to realize docking. Then, a circular object center detection and calibration experiment, a flange end face image experiment, and an automobile tank car flange port physical detection experiment were carried out. The test results show that the spatial coordinate accuracy of the flange port diameter and center detected by this method meets the requirements of the loading arm automatic docking system, providing a research idea for the design of an automatic docking system for the loading and unloading arm of a tank car. Full article
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15 pages, 5215 KiB  
Article
Development of a Position Measuring Device of a Deep-Sea Pipeline Based on Flange Center Positioning
by Zhuo Wang, Hong-xing Dang, Tao Wang and Bo Zhang
J. Mar. Sci. Eng. 2020, 8(2), 86; https://doi.org/10.3390/jmse8020086 - 1 Feb 2020
Cited by 4 | Viewed by 2874
Abstract
A deep-sea pipeline position and attitude-measuring device based on pipeline outer circle positioning can measure the spatial relative positions of the end faces of two oil pipelines in the deep sea. This device can provide the necessary data to make a transition pipeline [...] Read more.
A deep-sea pipeline position and attitude-measuring device based on pipeline outer circle positioning can measure the spatial relative positions of the end faces of two oil pipelines in the deep sea. This device can provide the necessary data to make a transition pipeline connecting two sections of oil pipelines together. However, after analyzing the data measured by this device, it is found that the measurement data has a large error because the error transmission coefficient of the measurement value is too large. In order to reduce the error transfer coefficient, a new measuring device for measuring the posture of deep-sea pipelines by a tensioning rope was proposed. Unlike previous measuring devices, this measuring device is based on the positioning of the flange center of the pipe instead of the pin on the outer circle of the pipe. With the comparison of positioning methods between fixing in the center of flange and fixing the outer wall of pipeline, the former can reduce the transition matrix in the process of solving the relative position of the two pipes, and then reduce the magnification of the measurement sensor error. It also reduces two measurement parameters. The solving formula of the position and attitude of the measuring device based on the outer circle positioning of the pipeline is analyzed. It is proved that the error transmission coefficient of the measuring device based on the flange center positioning is smaller. Experiments show that compared with the positioning method based on the outer circle of the pipe, the positioning method based on the flange center has a higher accuracy. Full article
(This article belongs to the Special Issue Advances in Oceanic and Mechatronic Systems Engineering)
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21 pages, 3985 KiB  
Article
Development of an On-Board Measurement System for Railway Vehicle Wheel Flange Wear
by Pacifique Turabimana and Celestin Nkundineza
Sensors 2020, 20(1), 303; https://doi.org/10.3390/s20010303 - 6 Jan 2020
Cited by 28 | Viewed by 9318
Abstract
The maintenance of railway systems is critical for their safe operation. However some landscape geographical features force the track line to have sharp curves with small radii. Sharp curves are known to be the main source of wheel flange wear. The reduction of [...] Read more.
The maintenance of railway systems is critical for their safe operation. However some landscape geographical features force the track line to have sharp curves with small radii. Sharp curves are known to be the main source of wheel flange wear. The reduction of wheel flange thickness to an extreme level increases the probability of train accidents. To avoid the unsafe operation of a rail vehicle, it is important to stay continuously up to date on the status of the wheel flange thickness dimensions by using precise and accurate measurement tools. The wheel wear measurement tools that are based on laser and vision technology are quite expensive to implement in railway lines of developing countries. Alternatively significant measurement errors can result from using imprecise measurement tools such as the hand tools, which are currently utilized by the railway companies such as Addis Ababa Light Rail Transit Service (AALRTS). Thus, the objective of this research is to propose and test a new measurement tool that uses an inductive displacement sensor. The proposed system works in both static and dynamic state of the railway vehicle and it is able to save the historical records of the wheel flange thickness for further analysis. The measurement system is fixed on the bogie frame. The fixture was designed using dimensions of the bogie and wheelset structure of the trains currently used by AALRTS. Laboratory experiments and computer simulations for of the electronic system were carried out to assess the feasibility of the data acquisition and analysis method. The noises and unwanted signals due to the dynamics of the system are filtered out from the sensor readings. The results show that the implementation of the proposed measurement system can accurately measure the wheel flange wear. Also, the faulty track section can be identified using the system recorded data and the operational control center data. Full article
(This article belongs to the Special Issue Achieving Predictive Maintenance using Sensors: Real or Fantasy?)
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23 pages, 41728 KiB  
Article
Experimental Assessment of the Fire Resistance Mechanisms of Timber–Steel Composites
by Truong Di Ha Le and Meng-Ting Tsai
Materials 2019, 12(23), 4003; https://doi.org/10.3390/ma12234003 - 2 Dec 2019
Cited by 18 | Viewed by 9605
Abstract
Hybrid structures known as timber–steel composites (TSCs) have been extensively studied due to their potential use as alternative construction materials that can satisfy demands related to sustainability. In addition to load capacity, fire resistance is a major consideration regarding the extensive use of [...] Read more.
Hybrid structures known as timber–steel composites (TSCs) have been extensively studied due to their potential use as alternative construction materials that can satisfy demands related to sustainability. In addition to load capacity, fire resistance is a major consideration regarding the extensive use of TSCs. In this study, 12 specimens were tested using a glulam timber material covering cold-formed steel at the center. Specifically, the TSCs were fabricated from two timber blocks and an I-shaped steel core assembled using dowels or glue as a major structure. In order to use additional timber as a fire protection layer to protect a major structure by its charcoal produced after being burned, an additional timber with 5 cm in thickness was used to cover the major structure. The 1-h fire testing of TSC following the ISO 834-1 standard was applied, in order to achieve the potential application for a 4-story timber building. The results showed that temperatures at the steel flange increased by more than 300 °C for the final 5 min in 10 out of the 12 TSC specimens, indicating that the fire protection provided by the timber structure was not sufficient. The charcoal layer surpassing the extra timber was originally set and entered the steel structure of the TSC, which was expected to retain its physical qualities after a fire. Methods for evaluating the charring properties, based on the conventional method for wood and the standard specification set by Eurocode 5, were used to assess the structural degradation of TSCs. The conventional assessments showed a divergence from the actual performance of TSCs. Such variations demonstrated the limitations of models for conventional wood in assessing the structure of a TSC. A realistic assessment was conducted to expand knowledge related to this composite under destructive processes and provide fire reference values for the practical implementation of TSCs. Full article
(This article belongs to the Section Construction and Building Materials)
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19 pages, 6076 KiB  
Article
Self-Calibration of an Industrial Robot Using a Novel Affordable 3D Measuring Device
by Martin Gaudreault, Ahmed Joubair and Ilian Bonev
Sensors 2018, 18(10), 3380; https://doi.org/10.3390/s18103380 - 10 Oct 2018
Cited by 52 | Viewed by 9604
Abstract
This work shows the feasibility of calibrating an industrial robot arm through an automated procedure using a new, low-cost, wireless measuring device mounted on the robot’s flange. The device consists of three digital indicators that are fixed orthogonally to each other on an [...] Read more.
This work shows the feasibility of calibrating an industrial robot arm through an automated procedure using a new, low-cost, wireless measuring device mounted on the robot’s flange. The device consists of three digital indicators that are fixed orthogonally to each other on an aluminum support. Each indicator has a measuring accuracy of 3 µm. The measuring instrument uses a kinematic coupling platform which allows for the definition of an accurate and repeatable tool center point (TCP). The idea behind the calibration method is for the robot to bring automatically this TCP to three precisely-known positions (the centers of three precision balls fixed with respect to the robot’s base) and with different orientations of the robot’s end-effector. The self-calibration method was tested on a small six-axis industrial robot, the ABB IRB 120 (Vasteras, Sweden). The robot was modeled by including all its geometrical parameters and the compliance of its joints. The parameters of the model were identified using linear regression with the least-square method. Finally, the performance of the calibration was validated with a laser tracker. This validation showed that the mean and the maximum absolute position errors were reduced from 2.628 mm and 6.282 mm to 0.208 mm and 0.482 mm, respectively. Full article
(This article belongs to the Section Physical Sensors)
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15 pages, 4757 KiB  
Article
Optimization of Processing Parameters for a Reverse Drawing–Flanging Combined Process for a B550CL High-Strength Steel Spoke Based on Grey Relational Analysis
by Yuli Liu, Zhiyuan Jiang and Chunmei Liu
Metals 2018, 8(1), 7; https://doi.org/10.3390/met8010007 - 26 Dec 2017
Cited by 6 | Viewed by 3527
Abstract
Undesired wall thickness distribution and flanging cracking easily occur in reverse drawing–flanging combined processes of steel spokes when improper process parameters are used. Thus, based on GRA (grey relational analysis) and FEM (finite element method), a GRA model for a reverse drawing–flanging combined [...] Read more.
Undesired wall thickness distribution and flanging cracking easily occur in reverse drawing–flanging combined processes of steel spokes when improper process parameters are used. Thus, based on GRA (grey relational analysis) and FEM (finite element method), a GRA model for a reverse drawing–flanging combined process for high strength steel B550CL spoke was established and validated. The results show that: (1) the most significant factors affecting uneven wall thickness distribution and excessive thinning in the mounting zone and center hole cracking are the friction coefficient and the shape of punch, respectively; (2) the non-uniformity of wall thickness U increases with the increase of the friction coefficient. The conical punch has a lower thinning ratio T, the spherical punch has a lower value of damage D; (3) considering synthetically the indexes of uneven wall thickness distribution, the excessive thinning in the mounting zone and center hole cracking, optimal results for the process parameters are obtained. Full article
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