Influence of welding speed and power on residual stress during gas tungsten arc welding (GTAW) of thin sections with constant heat input: A study using numerical simulation and experimental validation

The temperature distribution and residual stresses for a GTAW circumferential butt joint of AISI 304 stainless steel using numerical simulation have been evaluated. For evaluation of weld induced residual stresses, the analysis of heat source fitting was carried out with heat inputs ranging from 200 to 500 J/mm to arrive at optimal heat input for obtaining proper weld penetration and heat affected zone (HAZ). For this chosen heat input, the influence of different weld speeds and powers on the temperature distribution and the residual stresses is studied. The heat source analysis revealed the best choice of heat input as 300 J/mm. The residual stresses on the inner and outer surfaces, and along the radial direction were computed. Increase in temperature distribution as well as longitudinal and circumferential residual stresses was observed with the increase in weld speed and power. The validity of the results obtained from numerical simulation is demonstrated with full scale shop floor welding experiments.     

Scale-up modeling of the twin roll casting process for AZ31 magnesium alloy

In the present study, a 2-D finite-element method (FEM) thermal-fluid-stress model has been developed and validated for the twin roll casting (TRC) of AZ31 magnesium alloy. The model was then used to quantify how the thermo-mechanical history experienced by the strip during TRC would change as the equipment was scaled up from a laboratory size (roll diameter = 355 mm) to a pilot scale (roll diameter = 600 mm) and to an industrial scale (roll diameter = 1150 mm) machine. The model predictions showed that the thermal history and solidification cooling rate experienced by the strip are not affected significantly by caster scale-up. However, the mechanical history experienced by the strip did change remarkably depending on the roll diameters. Casting with bigger rolls led to the development of higher stress levels at the strip surface. The roll separating force/mm width of strip was also predicted to increase significantly when the TRC was scaled to larger sizes. Using the model predicted results, the effect of both casting speed and roll diameter was integrated into an empirical equation to predict the exit temperature and the roll separating force for AZ31. Using this approach, a TRC process map was generated for AZ31 which included roll diameter and casting speed.     

Application of CGP-cross route process for microstructure refinement and mechanical properties improvement in steel sheets

A modified method of severe plastic deformation (SPD) entitled constrained groove pressing-cross route (CGP-CR) was introduced for imposing a high magnitude of equivalent strain of about 2.32 per pass on the sheet form samples. The major benefit of this improved route compared to previous common route was the more homogeneity of strain in the rolling (RD) and transverse (TD) directions of sheets. In this study, low carbon steel samples were used for examination of evolutions in microstructure and mechanical properties during SPD via CGP-CR process. Mechanical properties improvement were measured by tensile and macro hardness tests. The results indicate that CGP-CR process can effectively improve tensile strength; and also, yield stress and hardness of as-received low carbon steel samples were improved up to about 100% after two deformation passes. Also, high magnitude of inhomogeneity can be observed in hardness distribution through first pass of the process which diminishes in the subsequent passes. Microstructural evolutions during process were monitored by optical microscopy observations and X-ray diffraction analysis. The results demonstrate that initial ferritic microstructure with grain size of about 30 μm was refined to a 225 nm cell structure after two passes of CGP-CR process.     

On wear resistance of tool steel

Maintaining a reasonably low cutting tool wear when producing forming tools is a general challenge in the development of new forming tool materials. The tool life of a hot forming tool steel (H13) has been significantly improved by reducing its Si-content from 1.0 to 0.06 wt.%. However, this modified H13 (MH13) also displays a reduced cutting tool life due to higher cutting forces and a stronger tendency to form built up layers (BUE) on the cutting edge. This paper explains why.Gleeble tests of MH13 revealed a significantly higher flow stress in the 820–900 °C temperature interval in MH13 compared to H13. Thermo-Calc simulations showed that when reducing the Si-content from 1.0 to 0.06 wt.% the initial temperature for ferrite-to-austenite transformation (A1) was reduced from 900 °C to 820 °C. Knowing that austenite has totally different mechanical and thermal properties than ferrite, the difference in A1 between the two steels explains the higher cutting forces and higher tendency for BUE-formation. The conclusion is that the difference in machinability between H13 and MH13 is primarily related to their difference in A1.An attempt was also made to find a new tool material composition that can combine the wear resistance of MH13 and the good machinability of H13. Thermo-Calc simulations were performed with slightly modified alloying content without changing its properties as a good forming tool material, with the aim to increase A1. For instance, reducing the Mn content from 0.5 to 0.05 wt.% proved to increase A1 from 820 to 850 °C.     

Water jet guided laser as an alternative to EDM for micro-drilling of fuel injector nozzles: A comparison of machined surfaces

To characterize the inner surface of the fuel injector nozzle holes drilled by EDM and water jet guided laser drilling (Laser Micro-Jet) a specifically conceived scanning probe microscopy technique with true non-contact operating mode was used. A difference in morphology of the drilled surfaces is evident from the acquired surface topography along the hole axis for the two compared drilling techniques. Results showed that the surface texture can be characterized by (i) maximum peak-to-valley distance and (ii) periodicity. Acquired maps confirm that electro-eroded surfaces are an envelope of craters randomly distributed with total excursion up to 1.7 μm with a crater size of 15 μm. While, the efficient melt expulsion and immediate cooling of water jet guided laser generates a peak to valley distance of 800 nm with a periodicity of 18 μm. Average R_q derived from the measured cylindrical surfaces was 450 nm and 150 nm for EDM and Laser Micro-Jet, respectively. Water jet guided laser drilling has proved to be a reliable alternative to EDM from the point of view of repeatability of the results and surface quality to facilitate the atomization of the fuel jet.     

Nanosecond pulsed laser micromachining of PMMA-based microfluidic channels

This paper reports an investigation into the effects of nanosecond laser processing parameters on the geometry of microchannels fabricated from polymethylmethacrylate (PMMA). The Nd:YAG solid-state pulsed laser has a wavelength of 1064 nm and a measured maximum power of 4.15 W. The laser processing parameters are varied in a scanning speed range of 400–800 pulses/mm, a pulse frequency range of 5–11 Hz, a Q-switch delay time range of 170–180 μs. Main effects plots and microchannel images are utilized to identify the effects of the process parameters for improving material removal rate and surface quality simultaneously for laser micromachining of microchannels in PMMA polymer. It is observed that channel width and depth decreased linearly with increasing Q-switch delay time (hence average power) and increased non-linearly with higher scanning rates and not much affected by the increase in pulse frequency.     

Minimizing greenhouse gas emissions through the application of solar thermal energy in industrial processes

The analysis of industrial energy usage indicates that low temperature processes (20 ≈ 200 °C) are used in nearly all industrial sectors. In principle there is the potential to use solar thermal energy in these lower temperature processes thus, reducing the environmental impact of burning fossil fuels. Using the model of an Austrian dairy plant, this research investigated the potential for, and the economic viability of, using solar energy heat processes in industry.Some industrial sectors such as food, chemistry, plastic processing, textile industry, building materials industry and business establishments can be identified as potential sectors for the application of solar energy heat processes. When assessing the (economic) feasibility of solar thermal energy, the investigation of these industries’ energy systems has to focus on an integrated analysis of cooling and heating demands and to take into account competing technologies. Amongst these are heat integration, cogeneration, new technologies and heat pumps. Pinch analysis was used to investigate industrial energy systems and heat integration possibilities and proved to be a viable tool. Working from the basis of energy balances, Sankey diagrams, pinch analysis and environmental cost accounting, a newly developed investigation tool was applied in the case study of an Austrian dairy plant. This enabled a fast optimization of the system. Two different options for the integration of solar thermal energy into the production line were calculated, option 1 with a solar field of 1000 m² and option 2 with a solar field of 1500 m². Natural gas savings of 85,000 for option 1 and 109,000 m³/a for option 2 can be achieved, resulting in a reduction of 170 tons of CO₂ per year, or 218 tons for options 1 and 2 respectively. Based upon option 1, return on investment is realised after less than three years of implementation. This research thus, indicates promising technical and economical feasibility of using solar thermal energy for industrial processes and provides an important step towards sustainable zero emission production in industry.     

Determining work-brush interface temperature in magnetic abrasive finishing process

Magnetic abrasive finishing (MAF) is a process in which the work surface is finished by removing the material in the form of micro chips by magnetic abrasive particles (MAPs) in the presence of magnetic field in the finishing zone. During the MAF process, the frictional heat is generated at the workpiece surface due to the rubbing action of magnetic abrasive particles with the work surface. The order of temperature rise is important to study, as finishing mechanism and surface integrity of work materials depend upon it. The measurement of temperature distribution during MAF operation at the interface of work piece and flexible magnetic abrasive brush (FMAB) interface is difficult. In the present analysis, finite element based ANSYS software has been used to model and simulate magnetic field distribution, magnetic pressure and temperature distribution at work-brush interface during the process. In this work the maximum magnetic flux density has been simulated of the order of 0.223 T at 0.91 A of current in electromagnet coil. Magnetic pressure on MAPs due to magnetic field of electromagnetic coil has been calculated to evaluate the frictional heat flux generated at the work-brush interface. Transient thermal analysis of workpiece domain has been performed to predict the temperature rise due to frictional heat flux. The predicted temperature on work-brush interface was found in the range of 34–51 °C. The developed simulation results based on FEA have been validated with experimental findings.     

Exceedance of modern ‘background’ fine-grained sediment delivery to rivers due to current agricultural land use and uptake of water pollution mitigation options across England and Wales

Excessive loss of fine-grained sediment to rivers is widely recognised as a global environmental problem. To address this issue, policy teams and catchment managers require an estimate of the ‘gap’ requiring remediation, as represented by the excess above ‘background’ losses. Accordingly, recent work has estimated the exceedance of modern ‘background’ sediment delivery to rivers at national scale across England and Wales due to (i) current agricultural land cover, cropping and stocking, and (ii) current land use corrected for the uptake of on-farm mitigation measures. This sectoral focus recognises that, nationally, agriculture has been identified as the principal source of fine sediment loss to the aquatic environment. Two estimates of modern ‘background’ sediment loss, based on paleolimnological evidence, were used in the analysis; the target modern ‘background’ (TMBSDR) and maximum modern ‘background’ (MMBSDR) sediment delivery to rivers. For individual (n = 4485) non-coastal water bodies, the sediment ‘gap’ in excess of TMBSDR and MMBSDR, due to current land cover, cropping and stocking, was estimated to range up to 1368 kg ha⁻¹ yr⁻¹ (median 61 kg ha⁻¹ yr⁻¹) and 1321 kg ha⁻¹ yr⁻¹ (median 19 kg ha⁻¹ yr⁻¹), respectively. The respective ranges in conjunction with current land cover, cropping and stocking but corrected for the potential impact of on-farm sediment mitigation measures were up to 1315 kg ha⁻¹ yr⁻¹ (median 50 kg ha⁻¹ yr⁻¹) and 1269 kg ha⁻¹ yr⁻¹ (median 8 kg ha⁻¹ yr⁻¹). Multiplication of the estimates of excess sediment loss corrected for current measure uptake, above TMBSDR and MMBSDR, with estimated maximum unit damage costs for the detrimental impacts of sediment pollution on ecosystem goods and services, suggested respective water body ranges up to 495 £ ha⁻¹ yr⁻¹ and 478 £ ha⁻¹ yr⁻¹. Nationally, the total loss of sediment in excess of TMBSDR was estimated at 1,389,818 t yr⁻¹ equating to maximum environmental damage costs of £523 M yr⁻¹, due to current structural land use, compared to 1,225,440 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹ due the uptake of on-farm sediment control measures. The corresponding total loss of sediment in excess of MMBSDR was estimated at 1,038,764 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹, compared with 890,146 t yr⁻¹ and £335 M yr⁻¹ correcting excess agricultural sediment loss for current implementation of abatement measures supported by policy instruments. This work suggests that the current uptake of sediment control measures on farms across England and Wales is delivering limited benefits in terms of reducing loadings to rivers and associated environmental damage costs.     

Performance and water-use efficiency (single-leaf vs. whole-canopy) of well-watered and half-stressed split-root Lambrusco grapevines grown in Po Valley (Italy)

‘Lambrusco a foglia frastagliata’ grapevines (Vitis vinifera L.) were grown outdoors at Piacenza (44°55′N, 9°44′E, Po Valley, Italy) with the root system split between two 30-L pots and subjected from pre-veraison (17 July) to harvest (5 September) to soil drying of half of the root system (HS) induced by withholding water from one of the two pots as compared to well-watered (WW) vines (both pots daily recharged at field capacity). Volumetric soil-water content, pre-dawn and mid-morning leaf water potential, single-leaf gas-exchange as assimilation rate, stomatal conductance and transpiration were monitored throughout the trial. Whole-canopy gas-exchange as net CO₂ exchange rate (NCER) and transpiration were tracked from 31 August to 7 September on three vines per treatment on a 24-h basis using an enclosure method. Primary leaf carbon isotope (δ¹³C) composition, yield components and must composition were determined at harvest.Withdrawing water from one pot triggered a water stress response showing higher stomatal sensitivity to changes in air vapour pressure deficit, relatively low assimilation rates, high intrinsic and extrinsic water-use efficiency (WUE) and earlier cessation of shoot growth. Yet, mid-morning leaf water potential was consistently lower in HS treatment over stress as compared to WW, indicating an anisohydric adjustment. Canopy NCER given on a leaf-area basis showed mean daily rates ranging from 3.9 to 4.9 μmol m² s^?1 in WW canopies against 2.6–3.0 μmol m^?2 s^?1 in HS. Conversely, canopy transpiration rates varied from 0.915 to 1.157 mmol m^?2 s^?1 for WW to 0.630–0.714 mmol m² s^?1 in HS. Increased leaf-based intrinsic and extrinsic WUE in HS did not match the canopy response, which to some extent resulted in an opposite outcome, i.e. higher canopy WUE in well-watered vines especially in the morning hours. Likewise, δ¹³C did not differ between treatments. This suggests caution when point-time determinations of single-leaf-based WUE are extrapolated to the whole-canopy behaviour when assessing the water saving strategies of a given genotype. The stressed vines achieved no variation in yield level and components and had improved grape composition as to soluble solids and total anthocyanins. This optimal behaviour is likely due to earlier shoot growth cessation, enhanced maturity and a buffering leaf-to-fruit ratio (3.61 m² kg^?1) that mitigated the effects of post-veraison stress.     

A comparative study on the effect of GTAW processes on the microstructure and mechanical properties of P91 steel weld joints

Modified 9Cr-1Mo (P91) steel is widely used in the construction of power plant components. In the present study, a comparative study on influence of activated flux tungsten inert gas (A-TIG), and gas tungsten arc (GTA) welding processes on the microstructure and the impact toughness of P91 steel welds was carried out. P91 steel welds require a minimum of 47 J during the hydrotesting of vessels as per the EN1557: 1997 specification. Toughness of P91 steel welds was found to be low in the as-weld condition. Hence post-weld heat treatment (PWHT) was carried out on weld with the objective of improving the toughness of weldments. Initially as per industrial practice, PWHT at 760 °C – 2 h was carried out in order to improve the toughness of welds. It has been found that after PWHT at 760 °C – 2 h, GTA weld (132 J) has higher toughness than the required toughness (47 J) as compared with A-TIG weld (20 J). The GTA weld has higher toughness due to enhanced tempering effects due to multipass welding, few microinclusion content and absence of δ-ferrite. The A-TIG weld requires prolonged PWHT (i.e. more than 2 h at 760 °C) than GTA weld to meet the required toughness of 47 J. This is due to harder martensite, few welding passes that introduces less tempering effects, presence of δ-ferrite (0.5%), and more alloy content. After PWHT at 760 °C – 3 h, the toughness of A-TIG weld was improved and higher than the required toughness of 47 J.     

Comparison of mechanical properties of pure copper welded using friction stir welding and tungsten inert gas welding

The objective of this research is to investigate the mechanical properties including bonding, tensile strength, and impact resistance of pure copper welded using friction stir welding (FSW) method and compare them with that of tungsten inert gas (TIG) welding. Micro-hardness tests are performed on pure copper, TIG welded copper and FSW welded copper to determine the effect of heat on the hardness of welded coppers. Tensile strength tests and notch tensile strength tests are performed to determine the mechanical properties of different weld process.In this experiment, it is found that the notch tensile strength and the notch strength ratio for FSW (212 MPa, 1.10) are significantly higher than those (190 MPa, 1.02) of TIG welding. For the impact tests, the weld zone and heat-affected zone energy absorption values for FSW (2.87 J, 2.25 J) are higher than those (1.32 J, 0 J) of TIG welding. XRD tests are performed to determine components of copper before and after welding process for TIG and FSW.     

Model-Based Design of Motorized Spindle Systems to Improve Dynamic Performance at High Speeds

High-speed motorized spindle systems are subjected to several effects during high-speed rotations that can cause substantial changes in their dynamic and thermal behaviors, leading to chatter, bearing thermal seizure, or premature spindle bearing failures. Therefore, it is important to consider these high-speed effects in the design stage of high-speed motorized spindles. This paper first develops a design flow chart to represent the overall spindle design problems. Based on this flow chart, eight design parameters are identified. A design sensitivity analysis of these eight design parameters is then conducted based on an integrated finite element method model to investigate their influence on the natural frequencies of the spindle system. Based on the rule of Maximum Improvement First, a set of systematic design procedures is proposed to suggest design changes to a custom-designed motorized spindle rated at 32 kW and 25,000 rpm. Based on the simulation results, it is shown that the first-mode frequency of this spindle system can be improved from 790.7 Hz to 934 Hz at 25,000 rpm by simply adjusting the front and rear bearing locations. At the optimal design, the first-mode frequency can reach 1454.3 Hz at 25,000 rpm, which represents more than 80 percent improvement over the original design.     

Simulation of retention and transport of copper,lead and zinc in a paddy soil of the Red River Delta,Vietnam

Heavy metal (HM) contaminations in the topsoil around handicraft villages with non-ferrous heavy metal recycling in the Red River Delta can impose serious threats to the subsoil as well as to the groundwater quality. This feature is very important for paddy soils due to relatively high leaching rates and the dissolution of Fe–Mn oxides under reducing conditions which can accelerate the amount of HM translocated to the subsoil and groundwater.The transport of Cu, Pb and Zn in paddy soils was simulated by numerical modeling of non-equilibrium solute transport with an adaptation of the Hydrus-1D model. For the simulation, a water layer on the soil surface was included, from which HM can infiltrate into the soil depending on the soil hydraulic properties. Sorption coefficients, obtained from batch experiments were used as input data for the simulations. Calculated leaching rates were compared with the binding forms of HM in the samples.The simulations show that leaching rates decrease in the order: Zn > Cu > Pb. This order is confirmed by the results of sequential extractions. Under constant flooded conditions at a water table of 20 cm, Cu, Pb and Zn were estimated to reach the soil depth of 1 m within 470, 495 and 370 days, respectively, emphasizing that reactive pollutants can reach groundwater in a relatively short time. A change of the water layer from 1 to 30 cm can accelerate the leaching rate of HM up to 36%. The hard pan layer was observed to induce a hysteresis in hydraulic conductivity and slow down the movement of HM. Uncertainties in modeling arise as several parameters in the simulation can be determined only with significant errors. However, Hydrus-1D is a suitable tool for simulation of the transport of HM in paddy soils.     

The effect of pitting corrosion on split sleeve cold hole expanded,bare 7075-T651 aluminium alloy

As part of an aircraft fleet fatigue life improvement program, investigation has been carried out into the effect pitting corrosion has on bare 7075-T651 which had undergone split sleeve cold hole expansion. Constant amplitude sinusoidal loading was applied to fatigue test coupons which had pitting corrosion induced upon them by a modified cyclic immersion process using a 3.5% NaCl solution. A pit depth of 39–58 μm was found to significantly reduce the increased fatigue life gains achieved by carrying out cold hole expansion. At 137.9 MPa fatigue life was reduced from achieving run out of ten million cycles to an average 371 × 10³ cycles, while at 165.5 MPa average fatigue life was reduced from 810 × 10³ to 65 × 10³ cycles. The fracture surfaces were analysed under a scanning electron microscope where each displayed an individual crack initiation site located on the material surface within the zone of residual circumferential stress.     

Using micro deep drawing with ironing stages to form stainless steel 304 micro cups

The needs of stainless steel 304 micro cups have been increasing tremendously due to the trend of miniaturization in medical and electronic devices, etc. For application purpose, it is highly desired to have stainless steel micro cups with high CH/OD (cup height/outer diameter) ratios. Due to the constraints of the limit draw ratio (LDR) of stainless steel 304 sheets in micro deep drawing, forming a micro cup with high CH/OD ratio at room temperature cannot be achieved by using a single stage deep drawing die. A process consisting of one micro deep drawing and two ironing stages was proposed for achieving this goal; three micro dies were designed, fabricated and used for experimental validation. A series of experiments were conducted by using the stainless steel 304 sheets of 200 μm thickness annealed at four different temperatures to understand the influence of size effects on this process for generating knowledge, know-how and technologies to form high quality stainless steel micro cups with large CH/OD ratio. No lubricant was used in this study. It was proven that the proposed process is a robust process as long as the sheets are annealed at the temperature no less than 900 °C for more than 3 min.     

Soil-profile organic carbon and total nitrogen during 12 years of pasture management in the Southern Piedmont USA

Soil organic C (SOC) and total soil N (TSN) sequestration estimates are needed to improve our understanding of management influences on soil fertility and terrestrial C cycling related to greenhouse gas emission. We evaluated the factorial combination of nutrient source (inorganic, mixed inorganic and organic, and organic as broiler litter) and forage utilization (unharvested, low and high cattle grazing pressure, and hayed monthly) on soil-profile distribution (0–150 cm) of SOC and TSN during 12 years of pasture management on a Typic Kanhapludult (Acrisol) in Georgia, USA. Nutrient source rarely affected SOC and TSN in the soil profile, despite addition of 73.6 Mg ha^?1 (dry weight) of broiler litter during 12 years of treatment. At the end of 12 years, contents of SOC and TSN at a depth of 0–90 cm under haying were only 82 ± 5% (mean ± S.D. among treatments) of those under grazed management. Within grazed pastures, contents of SOC and TSN at a depth of 0–90 cm were greatest within 5 m of shade and water sources and only 83 ± 7% of maximum at a distance of 30 m and 92 ± 14% of maximum at a distance of 80 m, suggesting a zone of enrichment within pastures due to animal behavior. During 12 years, the annual rate of change in SOC (0–90 cm) followed the order: low grazing pressure (1.17 Mg C ha^?1 year^?1) > unharvested (0.64 Mg C ha^?1 year^?1) = high grazing pressure (0.51 Mg C ha^?1 year^?1) > hayed (?0.22 Mg C ha^?1 year^?1). This study demonstrated that surface accumulation of SOC and TSN occurred, but that increased variability and loss of SOC with depth reduced the significance of surface effects.     

Modeling residual flood risk behind levees,Upper Mississippi River,USA

Flood protection from levees is a mixed blessing, excluding water from the floodplain but creating higher flood levels (“surcharges”) and promoting “residual risk” of flood damages. This study completed 2D hydrodynamic modeling and flood-damage analyses for the 459 km² Sny Island levee system on the Upper Mississippi River. These levees provide large economic benefits, at least $51.1 million per year in prevented damages, the large majority provided to the agricultural sector and a small subset of low-elevation properties. However these benefits simultaneously translate into a large residual risk of flood damage should levees fail or be overtopped; this risk is not recognized either locally in the study area nor in national policy. In addition, the studied levees caused surcharges averaging 1.2–1.5 m and locally as high as 2.4 m, consistent with other sites and studies. The combined hydraulic and economic modeling here documented that levee-related surcharge + the residual risk of levee overtopping or failure can lead to negative benefits, meaning added long-term flood risk. Up to 31% of residential structures in the study area, 8% of agricultural structures, and 22% of commercial structures received negative benefits, totaling $562,500 per year. Although counterintuitive, structures at the margin of a leveed floodplain can incur negative benefits due to greater flood levels resulting from levees purportedly built to protect them. National levee policies and plans for local projects are unbalanced, crediting levee benefits but rarely fully planning for adverse impacts or considering alternatives.     

A Study of the Optimization of Sheet Metal Drawing with Active Drawbeads

An experimental study is described in which active drawbead technology is used to attempt to optimize the sheet metal forming process. Oval AA 6111-T4 panels were drawn in a series of tests using various drawbead trajectories to establish the feasibility of the approach. The selection of drawbead trajectory was shown to have a dramatic effect on maximum attainable draw depth at fracture. Increasing drawbead penetration from zero to 5 mm in the early stages of the drawing process and retracting midway through the draw resulted in a 40% increase in draw depth compared to using a fixed 5 mm penetration. In the second part of the investigation, active drawbead technology was used to study its effect on highly nonsymmetric panel forming. Drawing limit curves in terms of drawbead depth versus blankholder forces (BHF) were plotted, and different drawbead trajectories were tested to determine an optimal drawbead trajectory scheme. A corresponding finite element model was also created. The results of strain path analysis successfully support the experiments.     

Process modification in the scouring process of textile industry

The effects of scouring parameters on the scouring efficiency, including the weight ratio of de-sizing agent and fabric (5–80 g/g fabric), temperature of de-sizing agent tank (60–90 °C) and dipping time (2–8 s), were investigated. The results demonstrated that weight loss of sizing agent was significantly observed only in the de-sizing agent tank particularly in the first de-sizing tank and was found to a small extent in water tank. The optimum condition in the scouring machine was found at a de-sizing agent to fabric ratio of 20 g/g fabric, with a temperature of the first de-sizing agent tank of 80 °C, a temperature of the second de-sizing agent tank of 90 °C, and dipping time of fabric of 7 s. According to these conditions, more than 89% of the sizing agent was eliminated and only 3.52 mg/g fabric of sizing agent remained in the scoured fabric which was in an acceptable range for feeding to the down stream process known as dyeing process. Application of our results to actual textile plant has shown that there is a cost reduction due to improved utilization of rinse water, chemicals and energy in the process and consequent decreases in the generation of wastewater. Furthermore, the production capacity was increased from 30 m/min to 34.4 m/min.