Search Results (172)

Extrusion of AlZnMgCu alloys is associated with a very high plastic resistance of the materials at forming temperatures and significant friction resistance, particularly at the contact surface between the ingots and the container. In technological practice, this translates into high maximum extrusion forces, often close to the capacity of hydraulic presses, and the occurrence of surface cracking of extruded profiles, resulting in a reduction in metal exit speed (production process efficiency). The accuracy of mathematical material models describing changes in the plastic stress of a material as a function of deformation, depending on the forming temperature and deformation speed, plays a very important role in the numerical modelling of extrusion processes using the finite element method (FEM). Therefore, three mathematical material models of the tested aluminium alloy were analysed in this study. In order to use the results of plastometric tests determined on the Gleeble device, they were approximated with varying degrees of accuracy using the Hnsel–Spittel equation and then implemented into the material database of the QForm-Extrusion^® programme. A series of numerical FEM calculations were performed for the extrusion of Ø50 × 3 mm tubes made of 7075 aluminium alloy using chamber dies for two different billet heating temperatures, 480 °C and 510 °C, and for three different material models. The metal flow was analysed in terms of geometric stability and dimensional deviations in the wall thickness of the extruded tube and its surface quality, as well as the maximum force in the extrusion process. Experimental studies of the industrial extrusion process of the tubes, using a press with a maximum force of 28 MN and a container diameter of 7 inches, confirmed the significant impact of the accuracy of the material model used on the results of the FEM numerical calculations. It was found that the developed material model of aluminium alloy 7075 number 1 allows for the most accurate representation of the actual conditions of deformation and quality of extruded tubes. Moreover, the material data obtained on the Gleeble simulator made it possible to determine the limit temperature of the extruded alloy, above which the material loses its cohesion and cracks appear on the surface of the extruded profiles. Full article

Objectives: Polymethyl methacrylate (PMMA) bone cement is vital for prosthetic fixation in orthopedic surgery, yet its exothermic polymerization can exceed 80 °C, surpassing the 50 °C threshold for thermal osteonecrosis, risking implant failure. This pilot study assesses two cooling strategies—precooling cement components and saline irrigation on the polymerization temperature and compressive strength of antibiotic-loaded PMMA, comparing hand mixing (HM) and vacuum mixing (VM) to optimize thermal management while preserving mechanical integrity in controlled settings relevant to orthopedic applications. Methods: Antibiotic-loaded Simplex bone cement (Stryker, Kalamazoo, MI, USA) was prepared using HM and VM, per ISO 5833. Each batch was divided into three groups: control, precooled (components at 6 °C overnight), and saline irrigation (8 °C saline during setting). Each group included 20 cylindrical samples (1.5 cm × 3 cm), cured for 24 h. Core temperatures were monitored with embedded thermometers, and compressive strength was measured in megapascals (MPa) using a hydraulic press (C092-06, MATEST). Welch’s t-test was used for statistical analysis. Results: HM controls reached 76.2 °C, precooled 63.6 °C, and saline 66 °C; VM controls hit 71.8 °C, precooled 58.8 °C, and saline 63.6 °C. HM strengths were 16–17 MPa, with precooling reducing to 16.49 MPa (p = 0.051) and saline maintaining 17.07 MPa (p = 0.820). VM strengths were 76–80 MPa, with precooling at 78.45 MPa (p < 0.001) and saline at 76.77 MPa (p = 0.010). Failure modes varied: controls (uniform cracking), precooled (shear failure), and saline (mixed cracking/crumbling). Conclusions: Precooling significantly lowers temperatures but compromises strength in HM samples, limiting its use in load-bearing applications. Saline irrigation offers moderate thermal control while preserving mechanics, particularly in HM, suggesting a viable strategy for reducing thermal necrosis risk. VM ensures superior strength, supporting safe cooling application. Full article

This paper presents a study that investigates the operational reliability of directional control valves used in hydraulic press systems by applying the Taguchi method and regression analysis. The research focuses on key hydraulic parameters—kinematic viscosity, internal leakage, pressure, and temperature—to identify their influence on valve reliability. Three valves (DCV1–DCV3) were tested under identical conditions using an L8 orthogonal array to optimize the experimental design while maintaining statistical validity. The Taguchi analysis revealed that internal leakage is the dominant factor affecting valve reliability, consistently confirmed across all statistical evaluations, including signal-to-noise (S/N) ratios and ANOVA results. Regression models were developed for each valve to quantify the effect of each factor and showed excellent predictive accuracy (R² > 98%). The study concludes that minimizing internal leakage, maintaining lower temperatures, and applying higher operating pressures significantly enhance valve reliability, while viscosity had negligible effect within the tested range. Valve DCV2 demonstrated the highest predicted reliability. These findings offer valuable insights for the optimization of hydraulic valve design and maintenance strategies, contributing to the improved performance and longevity of industrial hydraulic systems. Full article

Wastes, biomasses, and nanoparticles have motivated reformulations of adhesives in the wood-based-panel industry. This study investigated the incorporation of glass wool (GW) waste as a filler material in urea–formaldehyde (UF) adhesive, evaluating its effects on the adhesive properties as well as on the physical, mechanical, fire-retardant, and acoustic properties of particleboards. Panels with a target density of 700 kg m⁻³ were produced with different proportions of glass wool in the adhesive (T1: 0%; T2: 3.34%; T3: 4.93%; T4: 6.52%; T5: 9.49%; T6: 12.35%). The adhesive-coated particle mat was pressed in a hydraulic press at 160 °C under a compression force of 72 tons for 10 min. The panels were subjected to analyses of their physical, mechanical, fire-retardant, and acoustic properties, as well as scanning electron microscopy (SEM) analyses. Statistical analysis involved regression, analysis of variance, and a Scott–Knott test (p < 0.05). The results indicated that adding 3.34% GW to the adhesive improved the modulus of rupture, internal bond strength, screw withdrawal resistance, and acoustic efficiency of the panels. A glass wool content of 12.35% enhanced the hardness and the damping factor. These findings highlight the potential of glass wool as a functional filler material in UF adhesive, promoting the development of stronger and more sustainable particleboards. Full article

Snow construction plays a crucial role in military operations in cold regions, providing tactical fortifications, thermal insulation, and emergency infrastructure in environments where conventional building materials are scarce or require extensive infrastructure for support. Current snow construction methods, including manual piling and compaction, are labor-intensive and inconsistent, limiting their use in large-scale or time-sensitive operations. This study explores the feasibility of adapting a compressed earth block (CEB) machine to produce compressed snow blocks (CSBs) as modular, uniform building units for cold-region applications. Using an AECT Impact 2001A hydraulic press, naturally occurring snow was processed with a snowblower and compacted at maximum operating pressure (i.e., 20,684 kPa) to evaluate block formation, dimensional consistency, and density. The machine successfully produced relatively consistent CSBs, but the initial 3–4 blocks following block height adjustment were generally unsuccessful (e.g., incorrect block height or collapsed/broke) while the machine reached its steady state cyclic condition. These blocks were discarded and excluded from the dataset. The successful CSBs had mean block heights of 7.76 ± 0.56 cm and densities comparable to ice (i.e., 0.83 g/cm³). Variations in block height and mass may be attributed to manual snow loading and minor material impurities. While the dataset is limited, the results warrant further investigation into this technology, particularly regarding CSB strength (i.e., hardness and compressive strength) and performance under variable snow and environmental conditions. Mechanized snow compaction using existing CEB technology is technically feasible and capable of producing uniform, structurally stable CSBs but requires further investigation and modifications to reach its full potential. With design improvements such as automated snow feeding, cold-resistant components, and system winterization, this approach could enable scalable CSB production for rapid, on-site construction of snow-based structures in Arctic environments, supporting the military and civilian needs. Full article

Approximately 27.6% of Italian beaches are currently affected by erosion, despite the widespread implementation of coastal defence structures. Around 10,500 installations—mainly groins and detached breakwaters—occupy nearly 24.6% of the national shoreline. Although primarily designed to protect tourist beaches, these hard-engineered structures often degrade coastal landscapes, alter nearshore circulation, and pose risks to swimmers. Nevertheless, beaches remain a fundamental asset for the “3S” (Sun, Sea, Sand) tourism sector, which contributes approximately 2.2% to Italy’s GDP, accounting for over 175 million tourists’ overnight stays in 2024, frequently concentrated near protected coastal zones. In this study, drowning incidents along the Italian coastline were analyzed using press reports complemented by official statistics. Between 2016 and 2021, an average of 145 fatalities occurred per bathing season. Sudden drownings following medical emergencies accounted for 41% of cases, non-swimmers for 18%, accidental falls into the water for 3%, and water sports activities for an additional 3%. Rip currents on natural beaches were responsible for 22% of drownings, whereas those generated by coastal defence structures accounted for 12%. A further 12% of non-swimmer fatalities are suspected to have resulted from falls into depressions or channels formed in proximity to these structures. Evidence from previous studies and seabed morphology analyses indicates that coastal defence structures can generate rip currents through two main mechanisms: (1) hydraulic pressure exerted against groins, which drives offshore flow, and (2) water outflow between pairs of breakwaters resulting from wave setup behind them. Both processes, though often less intense, are also observed near submerged structures. The erosional channels formed by these currents may persist well beyond storm events, maintaining dangerous conditions for bathers. As Italy continues to rely predominantly on hard coastal protection measures, improving the understanding of drowning dynamics associated with these structures is crucial. This should be accompanied by regulatory updates requiring designers and coastal managers to systematically assess related hazards and to propose effective mitigation and safety strategies. Full article

Accumulative Roll Bonding (ARB) is a severe plastic deformation process typically used to produce ultra-fine-grained structures. This study investigates the feasibility of using the ARB process to recycle aluminum chips from an Al-Mg-Si alloy (AA6063). The chips were first compacted under a 200 kN hydraulic press and then directly hot-rolled at 550 °C without prior heat treatment to a final sheet thickness of 1.5 mm. Subsequent ARB cycles were then applied to achieve full consolidation. Mechanical properties were evaluated through tensile testing and microhardness measurements, while microstructure was characterized using Optical Microscopy and SEM-EBSD. These analyses revealed significant grain refinement and improved homogeneity with increasing ARB cycles. Mechanical testing showed that the ARB process substantially enhanced both tensile strength and hardness of the recycled AA6063 chips while maintaining good ductility. The best results were obtained after two ARB cycles, yielding an ultimate tensile strength (UTS) of 170 MPa and an elongation at rupture of 15.7%. The study conclusively demonstrates that the ARB process represents a viable and effective method for recycling aluminum chips. This approach not only significantly improves mechanical properties and microstructural characteristics but also offers environmental benefits by eliminating the energy-intensive melting stage. Full article

Composite materials are replacing traditional metals across various industries as they offer lighter weight and affordability, as well as excellent mechanical properties. In the present work, a hybrid composite was developed by combining randomly oriented S-glass fibers and coconut fibers within an epoxy matrix by using the hand lay-up method. The laminate was prepared by using two sheets of raw coconut fiber and eight layers of 200 GSM S-glass fiber, maintaining an epoxy-to-hardener ratio of 10:1. The laminate was cured under a hydraulic press at 80 °C for two hours and then post-cured at a temperature of 100 °C for four hours. In order to assess the performance of the composites, a series of tests, including mode II interlaminar fracture toughness, tensile strength, impact resistance, and hardness, as well as thermal conductivity, were performed. SEM analysis of the fracture surfaces confirmed the combined presence of fiber pull-out and good fiber–matrix bonding, supporting the observed improvements in mechanical properties. The results indicate that the hybrid composite has clear advantages over the composites reinforced with individual fibers alone. It showed a 358% higher tensile strength, a 30% increment in impact strength, and roughly 31% better flexural strength as compared to the coconut fiber composite. In comparison to the glass fiber composite, the hybrid composite offered enhanced toughness and better thermal stability, along with lower material costs and improved sustainability due to the addition of the natural fibers. Considering the rising need for lightweight, strong, and eco-friendly materials for industries, this fabricated hybrid composite appears to be a promising option for structural applications in fields like automotive, aerospace, and construction, where reducing weight without compromising strength is essential. Full article

To address the challenges of short allowable motion windows and complex motion planning inherent in dual forging manipulator systems, this study proposes a coordinated motion pattern tailored to dual-manipulator operations, focusing on forging deformation behavior and press control characteristics. First, six representative long-shaft forging materials were classified based on typical industrial applications. Using DEFORM-3D (V11.0) software, the deformation process during the elongation operation was analyzed, and the velocity and displacement characteristics at both ends of the forgings were extracted to clarify the compliant motion requirements of the grippers. Next, a segmented computation method for manipulator allowable motion time was developed based on the motion–time curve of the hydraulic press, significantly improving the time utilization efficiency for coordinated control. Furthermore, experimental tests were carried out to verify the dynamic response performance and motion accuracy of the dual-manipulator system. Finally, the dual-manipulator forging cycle was systematically divided into four stages—pre-forging adjustment, inter-pass compliance, execution phase, and forging completion—resulting in a structured and implementable coordination control framework. This research provides both a theoretical foundation and practical pathway for achieving efficient and precise coordinated motion control in dual forging manipulator systems, offering strong potential for engineering application and industrial deployment. Full article

This study investigates cross-border cascading hazards and infrastructure vulnerabilities in the Sava River Basin, a seismically active and flood-prone region spanning the Slovenia–Croatia border. Conducted within the CROSScade project, the research focuses on assessing cross-border hazards and the vulnerabilities of levees and bridges. Key earthquake and flood scenarios were identified using advanced hydraulic and seismic modelling, forming the basis for evaluating the cascading effects of these events, including the potential failure of hydropower plants and associated flood protection systems. The analysis reveals that levees are particularly vulnerable to failure during the recession phase of flooding that follows an earthquake. At the same time, bridges are primarily affected by seismic loading, with minimal structural impact from flood forces. These findings underscore the pressing need for enhanced cross-border collaboration, updated design standards, and the reinforcement of critical infrastructure. The study provides essential insights for multi-hazard resilience planning and emphasises the importance of integrated risk assessments in managing cascading disaster impacts across national boundaries. Full article

This study focuses on realistic modeling of forming load and microstructural evolution during hot metal extrusion, emphasizing the effects of friction models and hydraulic press behavior. Rather than merely predicting load magnitudes, the objective is to replicate actual press operation by integrating a load limit response into finite element modeling (FEM). By applying Coulomb and shear friction models under both constant and hydraulically controlled press conditions, the resulting impact on grain size evolution during deformation is examined. The hydraulic press simulation features a maximum load threshold that dynamically reduces die velocity once the limit is reached, unlike constant presses that sustain velocity regardless of load. P91 steel is used as the material system, and the predicted grain size is validated against experimentally measured data. Incorporating hydraulic control into FEM improves the representativeness of simulation results for industrial-scale extrusion, enhancing microstructural prediction accuracy, and ensuring forming process reliability. Full article

Low-commercial-value natural pistachios (broken, closed, or immature) can be revalorised through oil extraction, obtaining a high-quality oil and partially defatted flour as by-product. This study evaluated the techno-functional and nutritional properties of the flours obtained by hydraulic press (HP) and single-screw press (SSP) systems, combined with pretreatment at 25 °C and 60 °C. The extraction method significantly influenced flour’s characteristics, underscoring the need to tailor processing conditions to the specific technological requirements of each food application. HP-derived flours presented lighter colour, greater tocopherol content, and higher water absorption capacity (up to 2.75 g/g), suggesting preservation of hydrophilic proteins. SSP-derived flours showed higher concentration of protein (44 g/100 g), fibre (12 g/100 g), and minerals, and improved emulsifying properties, enhancing their suitability for emulsified products. Pretreatment at 25 °C enhanced functional properties such as swelling power (~7.0 g/g) and water absorption index (~5.7 g/g). The SSP system achieved the highest oil extraction yield, with no significant effect of pretreatment temperature. The oils extracted showed high levels of unsaturated fatty acids, particularly oleic acid (~48% of ω-9), highlighting their nutritional and industrial value. The findings support the valorisation of pistachio oil extraction by-products as functional food ingredients, offering a promising strategy for reducing food waste and promoting circular economy approaches in the agri-food sector. Full article

The internal curve hydraulic motor valve plate has a clearance self-compensation performance that can effectively improve the working efficiency of the valve plate. However, the dynamic characteristics of the valve plates require further investigation. This study considers the self-compensating ‘floating’ valve plate as the research object, proposes a dynamic characteristic analysis method for the internal curve hydraulic motor valve plate, and explores the changing rule of oil film thickness and surplus pressing force of the valve plate. The results showed that an increase in the inlet pressure and oil temperature led to an increase in the thickness of the oil film, and the amplitude of the oil film thickness was larger, whereas the rotational speed of the oil film thickness of the valve plate pair was not obvious. When the inlet pressure is lower than 8 MPa, and the oil temperature is in the range of 20–30 °C, the oil film is mainly subjected to the squeezing effect of the valve plate, and the displacement of the valve plate decreased with increasing rotational speed. The inlet pressure is the main factor affecting the displacement of the ‘floating’ valve plate, and when the inlet pressure reaches 8.7 MPa, the valve plate is in hydrostatic balance support. In addition, the surplus pressing force coefficient of the valve plate decreased with increasing inlet pressures. This study provides theoretical support for the design of variable pressing force valve plates for internal curve hydraulic motors by investigating the dynamic characteristics of “floating” valve plates. Full article

The aim of this work was to study the influence of temperature and strain rate on the formability and structure of C22 steel. This study was based on tensile and compression tests. In the case of the compression test, the study of the influence that the process parameters (temperature and strain rate) have on the nonuniformity of the deformation was taken into account. This work presents an experimental analysis of the effects of temperature and strain rate on the mechanical and structural properties of C22 mild steel. Uniaxial tension and compression testing at high temperatures (800 °C, 900 °C, 1000 °C, and 1100 °C) and strain rates 0.001 1/s, 0.012 1/s, and 0.089 1/s for tension and 6.35 1/s, 5.72 1/s, 4.67 1/s and, respectively, 0.106 1/s for the compression hammer and hydraulic press served as the foundation for the studies. Analysis was carried out on how temperature and strain rate affected yield stress, strain to fracture, hardness, and structural evolution. Additionally, the nonuniformity of the deformations obtained at various temperature and strain rate values was examined. The fracture behavior of C22 steel can be enhanced by raising the deformation temperature and lowering the strain rate. In the tensile tests, the study of stress and strain distribution and the variation in the normalized Latham–Cockroft failure criterion was performed by numerical simulation using FORGE^® NxT 4.1 software. Full article

Pneumatic artificial muscles (PAMs) consist of an elastomeric bladder wrapped in a Kevlar braid. When inflated, PAMs expand radially and contract axially, producing large axial forces. PAMs are often utilized for their high specific work and specific power, as well as their ability to produce large axial displacements. Although the axial behavior of PAMs is well studied, the radial behavior has remained underutilized and is poorly understood. Modeling was performed using a force balance approach to capture the effects that bladder strain and applied axial load have on the anchoring force. Radial expansion testing was performed to validate the model. Force due to anchoring was recorded using force transducers attached to sections of aluminum pipe using an MTS servo-hydraulic testing machine. Data from the test were compared to the predicted anchoring force. Radial expansion in large-diameter (over 50.8 mm) PAMs was then used in worm-like robots to create anchoring forces that allow for a peristaltic wave, which creates locomotion through acrylic pipes. By radially expanding, the PAM presses itself into the pipe, creating an anchor point. The previously anchored PAM then deflates, which propels the robot forward. Modeling of the radial expansion forces and anchoring was necessary to determine the pressurization required for proper anchoring before slipping occurs due to the combined robot and payload weight. Full article