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.     

Part based process performance monitoring (PbPPM)

The performances of completed manufacturing processes were evaluated using the surface response to excitation (SuRE) and Lamb wave methods. Both methods used the same piezoelectric elements attached to the surface of the workpiece. The SuRE method and the Lamb wave method were used to identify the structural changes created by welding, drilling, coating, filling a slot with glue, and composite patching. This study indicates that the tested methods are feasible for part based process performance monitoring (PbPPM) which evaluates the quality of the completed process with the sensors attached to the workpiece.     

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.     

Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy

Tool life has been a vital issue in machining titanium alloys. Recently, an atomization-based cutting fluid (ACF) application has been found to be an effective approach for cooling and lubrication in micromachining operations. In this study, an ACF spray system is developed for macro-scale turning of Ti–6Al–4V. The spray system is designed to minimize interaction between the fluid droplets, and the gas nozzle to control the divergence of the fluid droplets. Experiments are conducted to study the effect of five specific ACF spray parameters including fluid flow rate, spray distance, impingement angle, and type and pressure level of the droplet carrier gas on cutting forces, tool life, and chip characteristics. It has been observed that the combination of lower pressure (150 psi) air-mixed CO₂ with a higher flow rate (20 ml/min) and a larger spray distance (35 mm) produces a significantly longer tool life and broken chips. The results also reveal that the ACF spray system can extend tool life up to 40–50% over flood cooling.     

Building regional priorities in forests for development and adaptation to climate change in the Congo Basin

Indentifying common priorities in shared natural resource systems constitutes an important platform for implementing adaptation and a major step in sharing a common responsibility in addressing climate change. Predominated by discourses on REDD + (Reduced Emissions from Deforestation and Forest Degradation and conservation, sustainable management of forests and enhancement of forest carbon stocks in developing countries) with little emphasis on adaptation there is a risk of lack of policy measures in addressing climate change in the Congo Basin. Forest products and ecosystem services provide security portfolios for the predominantly rural communities, and play major roles in national development programmes in both revenue and employment opportunities. Thus, raising the profile of forests in the policy arena especially in the twin roles of addressing climate change in mitigation and adaptation and achieving resilient development is crucial. Within the framework of the Congo Basin Forests and Climate Change Adaptation project (COFCCA) project, science policy dialogue was conducted to identify and prioritize forest based sectors vulnerable to climate change but important to household livelihoods and national development. The goal of the prioritization process was for the development of intervention in forest as measures for climate change adaptation in Central Africa. Participants constituted a wide range of stakeholders (government, Non Governmental Organizations, research institutions, universities, community leaders, private sectors etc.) as representatives from three countries directly involved in the project: Cameroon, Central African Republic and Democratic Republic of Congo. Building on national priorities, four forest related sectors were identified as common priorities at the regional level for focus on climate change adaptation. These sectors included: (1) energy with emphasis on fuel wood and Charcoal; (2) Water principally quality, quantity, accessibility, etc.; (3) Food with emphasis on Non Timber Forest Products, and (4) Health linked to healthcare products (medicinal plants). Using these prioritized sectors, the project focused on addressing the impacts of climate change on local communities and the development of adaptation strategies in the three pilot countries of the Congo Basin region. The four sectors constitute the key for development in the region and equally considered as priority sectors in the poverty reduction papers. Focused research on these sectors can help to inject the role of forests in national and local development and their potentials contributions to climate change adaptation in national and public discourses. Mainstreaming forest for climate change adaptation into national development planning is the key to improve policy coherence and effectiveness in forest management in the region.     

Incorporating stakeholder decision support needs into an integrated regional Earth system model

A new modeling effort exploring the opportunities, constraints, and interactions between mitigation and adaptation at regional scale is utilizing stakeholder engagement in an innovative approach to guide model development and demonstration, including uncertainty characterization, to effectively inform regional decision making. This project, the integrated Regional Earth System Model (iRESM), employs structured stakeholder interactions and literature reviews to identify the most relevant adaptation and mitigation alternatives and decision criteria for each regional application of the framework. The information is used to identify important model capabilities and to provide a focus for numerical experiments. This paper presents the stakeholder research results from the first iRESM pilot region. The pilot region includes the Great Lakes Basin in the Midwest portion of the United States as well as other contiguous states. This geographic area (14 states in total) permits cohesive modeling of hydrologic systems while also providing strong gradients in climate, demography, land cover/land use, and energy supply and demand. The results from the stakeholder research indicate that, for this region, iRESM should prioritize addressing adaptation alternatives in the water resources, urban infrastructure, and agriculture sectors, including water conservation, expanded water quality monitoring, altered reservoir releases, lowered water intakes, urban infrastructure upgrades, increased electric power reserves in urban areas, and land use management/crop selection changes. For mitigation in this region, the stakeholder research implies that iRESM should focus on policies affecting the penetration of renewable energy technologies, and the costs and effectiveness of energy efficiency, bioenergy production, wind energy, and carbon capture and sequestration.     

Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites

The development and implementation of a microstructure-based finite element model for the machining of carbon fiber-reinforced polymer composites is presented. A new approach to interfacial modeling is introduced where the material interface is modeled using continuum elements, allowing failure to take place in either tension or compression. The model is capable of describing the fiber failure mode occurring throughout the chip formation process. Characteristic fiber length in the chips, and machining forces for microstructures with fibers orientated at 0°, 45°, 90°, and 135° are examined. For model validation purposes, the model-based machining performance predictions are compared to the machining responses from a set of orthogonal machining experiments. A parametric study is presented that identifies a robust tool geometry, which minimizes the effects of fiber orientation and size on the machining forces.     

Prompting safety-belt use in the context of a belt-use law: the flash-for life revisited

PROBLEM: Safety-belt use reduces motor vehicle crash-related morbidity and mortality, yet an estimated 18% of drivers do not consistently buckle up (NHTSA, 2005). In 1985, Geller and colleagues developed an interpersonal Flash-for-Life prompt that increased belt use among 22% of 1,087 unbuckled drivers (Geller, Bruff, & Nimmer, 1985). METHOD: The Flash-for-Life intervention was re-introduced at a large university with high safety-belt use (i.e., 80%). College students stood at parking-lot entrance/exits and "flashed" signs with the message, "Please Buckle Up, I Care" to unbuckled drivers. RESULTS: Of 427 unbuckled drivers observed, 30% of these complied with the prompt. Male drivers were significantly more likely to comply with prompts delivered by females. DISCUSSION: Compliance was higher than in the 1985 study, indicating a high baseline rate of safety-belt use does not negate potential beneficial influence of a prompting intervention. This intervention is particularly effective with college-aged males, a sub-group of the driving population least likely to buckle-up. IMPACT ON INDUSTRY: A simple behavioral prompt could be used at most industrial complexes to increase safety-belt use among vehicle occupants who are not buckled-up.     

The predictive validity of safety climate

PROBLEM: Safety professionals have increasingly turned their attention to social science for insight into the causation of industrial accidents. One social construct, safety climate, has been examined by several researchers [Cooper, M. D., & Phillips, R. A. (2004). Exploratory analysis of the safety climate and safety behavior relationship. Journal of Safety Research, 35(5), 497-512; Gillen, M., Baltz, D., Gassel, M., Kirsch, L., & Vacarro, D. (2002). Perceived safety climate, job Demands, and coworker support among union and nonunion injured construction workers. Journal of Safety Research, 33(1), 33-51; Neal, A., & Griffin, M. A. (2002). Safety climate and safety behaviour. Australian Journal of Management, 27, 66-76; Zohar, D. (2000). A group-level model of safety climate: Testing the effect of group climate on microaccidents in manufacturing jobs. Journal of Applied Psychology, 85(4), 587-596; Zohar, D., & Luria, G. (2005). A multilevel model of safety climate: Cross-level relationships between organization and group-level climates. Journal of Applied Psychology, 90(4), 616-628] who have documented its importance as a factor explaining the variation of safety-related outcomes (e.g., behavior, accidents). Researchers have developed instruments for measuring safety climate and have established some degree of psychometric reliability and validity. The problem, however, is that predictive validity has not been firmly established, which reduces the credibility of safety climate as a meaningful social construct. The research described in this article addresses this problem and provides additional support for safety climate as a viable construct and as a predictive indicator of safety-related outcomes. METHODS: This study used 292 employees at three locations of a heavy manufacturing organization to complete the 16 item Zohar Safety Climate Questionnaire (ZSCQ) [Zohar, D., & Luria, G. (2005). A multilevel model of safety climate: Cross-level relationships between organization and group-level climates. Journal of Applied Psychology, 90(4), 616-628]. In addition, safety behavior and accident experience data were collected for 5 months following the survey and were statistically analyzed (structural equation modeling, confirmatory factor analysis, exploratory factor analysis, etc.) to identify correlations, associations, internal consistency, and factorial structures. RESULTS: Results revealed that the ZSCQ: (a) was psychometrically reliable and valid, (b) served as an effective predictor of safety-related outcomes (behavior and accident experience), and (c) could be trimmed to an 11 item survey with little loss of explanatory power. IMPACT ON INDUSTRY: Practitioners and researchers can use the ZSCQ with reasonable certainty of the questionnaire's reliability and validity. This provides a solid foundation for the development of meaningful organizational interventions and/or continued research into social factors affecting industrial accident experience.