Warm forming die design,part I: Experimental validation of a novel thermal finite element modeling code

Finite element analysis (FEA) has become an invaluable tool in the design of sheet metal stamping dies and processes. FEA has gained widespread acceptance as the best method of optimizing dies for conventional stamping processes. More recently, FEA has been shown to be an effective method of designing tooling for sheet forming processes. In this work, an FEA based approach is applied to the warm stamping (warm forming) process. This work introduces a new thermal finite element analysis software called PASSAGE®/Forming (PASSAGE) that enables the up-front design of the thermal management of warm forming dies. This thermal finite element analysis software is designed to specifically handle the forming and optimization scenarios related to the heating of a stamping die while minimizing user interface time. In this work, PASSAGE has been applied to a simple block of steel embedded with cartridge heaters to validate the prediction capability of this software under two different heating conditions. The results show that PASSAGE is capable of predicting the actual steady-state temperature distribution within the block with an acceptable level of accuracy while yielding notable information to the user with respect to specifying power requirements. A finite element software package like PASSAGE is a valuable tool that will aid greatly in the implementation of warm forming as a manufacturing process beyond the scope of the laboratory and into production.     

Shear cutting and counter shear cutting of sandwich materials

New lightweight sandwich materials challenge existing forming processes as well as following process steps. As such the manufacturing potential of shear cutting has to be evaluated. Two cutting methods are compared. Method commonly used is shear-cutting within one stroke engaged, the other one is known as counter-shear cutting, which uses two strokes.The challenges of cutting sandwich materials are variation of hole diameter within the different layers, fraying of the textiles, deformation of the hole contour and burr formation. These effects occur in conventional shear cutting as the intermediate layer and the lower sheet metal are cut by the scrap of the upper sheet instead of the cutting punch.The following methodology included shear cutting with closed cutting edge i.e. cutting of holes into five different sandwich materials. The sandwiches exemplarily represent multiple kinds of possible material designs. For instance, aluminum and steel face sheets, different thicknesses of intermediate layers and different intermediate layers materials such as integrated textile fibers have been used. Adequate cutting parameters such as die clearance and the use of a blank holder have been determined. To achieve good results a stiff machine design with good guidance and precise control of punch position was crucial.Observations of conventional shear cutting revealed the need of small cutting clearance of 4%. High burnish area is possible for the upper face sheet due to the superimposed force by the lower face sheet. The major conclusion depicted that high cutting quality of sandwich materials requires counter shear cutting. Hence, the roll-over of the lower sheet facing the intermediate layer, the burnish area at the lower sheet, good cutting quality of the fibers improve significantly and burr formation is avoided completely. Summarized this paper provides cutting parameters for sandwich materials based on experimental work.     

Resistance mash welding for joining of copper conductors for electric motors

The automotive industry is developing designs and manufacturing processes for a new generation of electric motors intended for use in hybrid and electric vehicles. This paper is focused on using solid-state welding to join rectangular wires in the fabrication of motor stators. Resistance welding has not typically been applied to copper due to its very high electrical conductivity; however through optimization of the current and pressure profiles, excellent quality copper-to-copper joints have been demonstrated with a technique known as resistance mash welding. A better understanding of resistance mash welding characteristics will help advancements in its application for stators. The limitations of this application will be discussed.     

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.     

Development of a biaxial loading frame for sheet metal

Characterization of the evolving yield loci and forming limit diagrams for sheet materials under biaxial loading is necessary for the development of accurate sheet metal forming process simulations. Biaxial tension testing has been shown to have significant advantages over the current computational and experimental methods for such material characterization; however, the few commercially available loading frames are far too large and expensive to be practical for most metal forming research laboratories. In this paper, the design of a practical servohydraulic biaxial loading frame is presented. The design, control, and operation of the loading frame are discussed in detail, and experimental data is provided to validate the effectiveness of the control system with respect to specimen center shifting.     

Shellfish-Borne Viral Outbreaks: A Systematic Review

Investigations of disease outbreaks linked to shellfish consumption have been reported in the scientific literature; however, only few countries systematically collate and report such data through a disease surveillance system. We conducted a systematic review to investigate shellfish-borne viral outbreaks and to explore their distribution in different countries, and to determine if different types of shellfish and viruses are implicated. Six databases (Medline, Embase, Scopus, PubMed, Eurosurveillance Journal and Spingerlink electronic Journal) and a global electronic reporting system (ProMED) were searched from 1980 to July 2012. About 359 shellfish-borne viral outbreaks, alongside with nine ProMED reports, involving shellfish consumption, were identified. The majority of the reported outbreaks were located in East Asia, followed by Europe, America, Oceania, Australia and Africa. More than half of the outbreaks (63.6 %) were reported from Japan. The most common viral pathogens involved were norovirus (83.7 %) and hepatitis A virus (12.8 %). The most frequent type of consumed shellfish which was involved in outbreaks was oysters (58.4 %). Outbreaks following shellfish consumption were often attributed to water contamination by sewage and/or undercooking. Differences in reporting of outbreaks were seen between the scientific literature and ProMED. Consumption of contaminated shellfish represents a risk to public health in both developed and developing countries, but impact will be disproportionate and likely to compound existing health disparities.     

Detection of Viruses in Coastal Seawater Using <Emphasis Type="Italic">Mytilus Galloprovincialis</Emphasis> as an Accumulation Matrix

The purpose of this study was to demonstrate that shellfish can be used to detect enteric viruses in marine waters where they are present at very low concentrations. Aqua-cultured mussels were placed in the sea just off the mouth of a drainage channel affected by human and animal faecal contamination. Samples were taken from the channel, the sea and the mussels at intervals over two 4-week periods. The samples were tested to verify the presence of both rotaviruses and E. coli. Rotaviruses were detected by Real Time-PCR, typed by multiplex PCR and subsequently sequenced. E. coli was enumerated in water matrices by a filtering method and in mussels by the MPN method. The presence of E. coli in the examined matrices demonstrates contamination of faecal origin throughout the studied environments. Rotaviruses were recorded in channel waters, but not in sea water. In both experiments, rotaviruses were detected in mussels 21 and 28 days after being placed in the sea water off the channel mouth. The use of mussels thus enabled the detection of rotaviruses in waters where the high dilution rendered direct investigation impossible. This study indicates that mussels can be used in marine virological surveillance programs.     

Management strategies to mitigate the impacts of climate change on sea turtle’s terrestrial reproductive phase

Climate change poses a serious threat to sea turtles (Cheloniidae) as their terrestrial reproductive phase is only successful within a limited range of environmental and physical conditions. These conditions are likely to become less optimal as climate change progresses. To date, management and conservation of sea turtles has focused almost entirely on non-climatic stressors, due at least in part to practitioners not knowing what strategies to take and the feasibility and risks of potential strategies. To aid the management of sea turtles in a changing environment, we identified management strategies via a focus workshop and surveys to mitigate the impacts of climate change to the terrestrial reproductive phase of sea turtles. The effectiveness, ecological risks and potential social and logistical constraints associated with implementing each of the identified management strategies is discussed. Twenty management strategies were identified; strategies varied from habitat protection to more active and direct manipulation of nests and the nesting environment. Based on our results, we suggest a three-pronged approach to sea turtle conservation in light of climate change, where managers and researchers should: 1) enhance sea turtle resilience to climate change by mitigating other threats; 2) prioritise implementing the ‘no regret’ and ‘reversible’ management strategies identified here; and 3) fill the knowledge gaps identified to aid the trial and implementation of the potential strategies identified here. By combining these three approaches our collective toolkit of sea turtle management strategies will expand, giving us an array of viable approaches to implement as climate change impacts become more extreme.     

Dimensional analysis and scaling in mechanical mixing for fabrication of metal matrix nanocomposites

For a successful enhancement of mechanical properties of metal matrix nanocomposites, a homogeneous nanoparticle dispersion and distribution in the solidified metal is required. Mechanical mixing can be used for initial break-up of agglomerates, and its study can be simplified with dimensional analysis. Using this technique, mixing time and vortex height were assessed while varying fluid properties, impeller angle, and angular speed. Three relevant dimensionless numbers were recognized: the Reynolds (Re), Froude and Galilei (Ga) numbers. Based on blade and impeller shaft angles, a modified Froude number (Fr*) was defined. These parameters were calculated experimentally, varying angular speed from 200 to 1000 rpm for three different impeller angles: 0°, 15° and 30°. This procedure was performed with three fluids: water, and two aqueous glycerin solutions (25% and 50% by volume). Digital images were taken and processed to measure vortex height. Mixing time was measured for water at 0° impeller angle, angular speed ranging from 200 to 1200 rpm. Results showed an optimal dimensionless mixing time with respect to Re. A linear relationship was found between dimensionless vortex height and Fr*. The first had a second order polynomial relationship with the product ReFr*, regardless of impeller angle. This relationship, together with the Ga, specific for each fluid, allows scaling the results to other fluids such as molten pure aluminum. This study allows experimenting in simpler systems that involve transparent fluids, room temperature and low cost, to then elaborate a prediction of vortex height in fluids where measurements are difficult and costly, such as molten metals.     

Greenhouse gas mitigation and offset options for suckler cow farms: an economic comparison for the Swiss case

We assessed the economic suitability of 4 greenhouse gas (GHG) mitigation options and one GHG offset option for an improvement of the GHG balance of a representative Swiss suckler cow farm housing 35 Livestock units and cultivating 25 ha grassland. GHG emissions per kilogram meat in the economic optimum differ between the production systems and range from 18 to 21.9 kg CO₂-eq./kg meat. Only GHG offset by agroforestry systems showed the potential to significantly reduce these emissions. Depending on the production system agroforestry systems could reduce net GHG emissions by 66% to 7.3 kg CO₂-eq./kg meat in the most intensive system and by 100% in the most extensive system. In this calculation a carbon sequestration rate of 8 t CO₂/ha/year was assumed. The potential of a combination of the addition of lipids to the diet, a cover of the slurry tank and the application of nitrification inhibitors only had the potential to reduce GHG emissions by 12% thereby marginal abatement costs are increasing much faster than for agroforestry systems. A reduction of the GHG emissions to 7.5 kg CO₂-eq./kg meat—possible with agroforestry only—raised costs between 0.03 CHF/kg meat and 0.38 CHF/kg meat depending on the production system and the state of the system before the reduction. If GHG emissions were reduced maximally average costs ranged between 0.37 CHF/kg meat, if agroforestry had the potential to reduce net GHG emissions to 0 kg CO₂-eq., to 1.17 CHF/kg meat if also other options had to be applied.