Optimization design of a novel X-type six-high rolling mill based on maximum roll system stiffness.

The present investigation devices a novel X-type six-high (X-6h) mill. In addition, parametric models of different roll layouts such as the four-high (4-h), I-type six-high (I-6h), and X-6h mills are established. Three-dimensional (3D) finite element (FE) contact analysis for a strip rolling process is conducted when the mills are subjected to a constant vertical load of 65 kN. Through comparative analysis of von Mises stress, contact stress and elastic deformation displacement in three roll layouts, the rigidity characteristic of each is obtained, and it is found that the proposed X-6h mill has the largest roll gap stiffness. The influence of different roll diameter ratios on the roll gap stiffness of the roll system is investigated, based on which an optimization design model is built. Further, by taking into account the roll gap stiffness of the roll system as the optimization objective, the optimum diameter ratios of backup roll (BUR) to work roll (WR) of the X-6h rolling mill is achieved via the genetic algorithm (GA) optimization method, obtaining the optimum structural parameters of BUR and WR as well. The reliability of the proposed design is verified by manufacturing a prototype mill which produced magnesium alloy and aluminum alloy strips of high quality.

Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel.

Friction stir spot welding (FSSW), a derivative of friction stir welding (FSW), is a solid-state welding technique that was developed in 1991. An industry application was found in the automotive industry in 2003 for the aluminum alloy that was used in the rear doors of automobiles. Friction stir spot welding is mostly used in Al alloys to create lap joints. The benefits of friction stir spot welding include a nearly 80% melting temperature that lowers the thermal deformation welds without splashing compared to resistance spot welding. Friction stir spot welding includes 3 steps: plunging, stirring, and retraction. In the present study, other materials including high strength steel are also used in the friction stir welding method to create joints. DP780, whose traditional welding process involves the use of resistance spot welding, is one of several high strength steel materials used in the automotive industry. In this paper, DP780 was used for friction stir spot welding, and its microstructure and microhardness were measured. The microstructure data showed that there was a fusion zone with fine grain and a heat effect zone with island martensite. The microhardness results indicated that the center zone exhibited a greater degree of hardness compared with the base metal. All data indicated that the friction stir spot welding used in dual phase steel 780 can create a good lap joint. In the future, friction stir spot welding can be used in high-strength steel welding applied in industrial manufacturing processes.

Maintaining knife sharpness in industrial meat cutting: A matter of knife or meat cutter ability.

Knife sharpness is imperative in meat cutting. The aim of this study was to compare the impact of knife blade steel quality with meat cutters' individual ability to maintain the cutting edge sharp in an industrial production setting. Twelve meat cutters in two different companies using three different knives during normal production were studied in this quasi-experimental study. Methods included were measuring knife cutting force before and after knife use, time knives were used, ratings of sharpness and discomfort and interviews. Results showed that the meat cutters' skill of maintaining sharpness during work had a much larger effect on knife sharpness during work than the knife steel differences. The ability was also related to feelings of discomfort and to physical exertion. It was found that meat cutters using more knives were more likely to suffer from discomfort in the upper limbs, which is a risk for developing MSD.

Research on the mechanical properties of a glass fiber reinforced polymer-steel combined truss structure.

An assembled plane truss structure used for vehicle loading is designed and manufactured. In the truss, the glass fiber reinforced polymer (GFRP) tube and the steel joint are connected by a new technology featuring a pretightened tooth connection. The detailed description for the rod and node design is introduced in this paper, and a typical truss panel is fabricated. Under natural conditions, the short-term load test and long-term mechanical performance test for one year are performed to analyze its performance and conduct a comparative analysis for a reasonable FEM model. The study shows that the design and fabrication for the node of an assembled truss panel are convenient, safe, and reliable; because of the creep control design of the rods, not only does the short-term structural stiffness meet the design requirement but also the long-term creep deformation tends towards stability. In addition, no significant change is found in the elastic modules, so this structure can be applied in actual engineering. Although the safety factor for the strength of the composite rods is very large, it has a lightweight advantage over the steel truss for the low density of GFRP. In the FEM model, simplifying the node as a hinge connection relatively conforms to the actual status.

A review on strengthening steel beams using FRP under fatigue.

In recent decades, the application of fibre-reinforced polymer (FRP) composites for strengthening structural elements has become an efficient option to meet the increased cyclic loads or repair due to corrosion or fatigue cracking. Hence, the objective of this study is to explore the existing FRP reinforcing techniques to care for fatigue damaged structural steel elements. This study covers the surface treatment techniques, adhesive curing, and support conditions under cyclic loading including fatigue performance, crack propagation, and failure modes with finite element (FE) simulation of the steel bridge girders and structural elements. FRP strengthening composites delay initial cracking, reduce the crack growth rate, extend the fatigue life, and decrease the stiffness decay with residual deflection. Prestressed carbon fibre-reinforced polymer (CFRP) is the best strengthening option. End anchorage prevents debonding of the CRRP strips at the beam ends by reducing the local interfacial shear and peel stresses. Hybrid-joint, nanoadhesive, and carbon-flex can also be attractive for strengthening systems.

Effect of damping and yielding on the seismic response of 3D steel buildings with PMRF.

The effect of viscous damping and yielding, on the reduction of the seismic responses of steel buildings modeled as three-dimensional (3D) complex multidegree of freedom (MDOF) systems, is studied. The reduction produced by damping may be larger or smaller than that of yielding. This reduction can significantly vary from one structural idealization to another and is smaller for global than for local response parameters, which in turn depends on the particular local response parameter. The uncertainty in the estimation is significantly larger for local response parameter and decreases as damping increases. The results show the limitations of the commonly used static equivalent lateral force procedure where local and global response parameters are reduced in the same proportion. It is concluded that estimating the effect of damping and yielding on the seismic response of steel buildings by using simplified models may be a very crude approximation. Moreover, the effect of yielding should be explicitly calculated by using complex 3D MDOF models instead of estimating it in terms of equivalent viscous damping. The findings of this paper are for the particular models used in the study. Much more research is needed to reach more general conclusions.

Seismic response of 3D steel buildings considering the effect of PR connections and gravity frames.

The nonlinear seismic responses of 3D steel buildings with perimeter moment resisting frames (PMRF) and interior gravity frames (IGF) are studied explicitly considering the contribution of the IGF. The effect on the structural response of the stiffness of the beam-to-column connections of the IGF, which is usually neglected, is also studied. It is commonly believed that the flexibility of shear connections is negligible and that 2D models can be used to properly represent 3D real structures. The results of the study indicate, however, that the moments developed on columns of IGF can be considerable and that modeling buildings as plane frames may result in very conservative designs. The contribution of IGF to the lateral structural resistance may be significant. The contribution increases when their connections are assumed to be partially restrained (PR). The incremented participation of IGF when the stiffness of their connections is considered helps to counteract the no conservative effect that results in practice when lateral seismic loads are not considered in IGF while designing steel buildings with PMRF. Thus, if the structural system under consideration is used, the three-dimensional model should be used in seismic analysis and the IGF and the stiffness of their connections should be considered as part of the lateral resistance system.

Structural damage identification based on rough sets and artificial neural network.

This paper investigates potential applications of the rough sets (RS) theory and artificial neural network (ANN) method on structural damage detection. An information entropy based discretization algorithm in RS is applied for dimension reduction of the original damage database obtained from finite element analysis (FEA). The proposed approach is tested with a 14-bay steel truss model for structural damage detection. The experimental results show that the damage features can be extracted efficiently from the combined utilization of RS and ANN methods even the volume of measurement data is enormous and with uncertainties.

Numerical simulation of monitoring corrosion in reinforced concrete based on ultrasonic guided waves.

Numerical simulation based on finite element method is conducted to predict the location of pitting corrosion in reinforced concrete. Simulation results show that it is feasible to predict corrosion monitoring based on ultrasonic guided wave in reinforced concrete, and wavelet analysis can be used for the extremely weak signal of guided waves due to energy leaking into concrete. The characteristic of time-frequency localization of wavelet transform is adopted in the corrosion monitoring of reinforced concrete. Guided waves can be successfully used to identify corrosion defects in reinforced concrete with the analysis of suitable wavelet-based function and its scale.

Flexural toughness of steel fiber reinforced high performance concrete containing nano-SiO2 and fly ash.

This paper aims to clarify the effect of steel fiber on the flexural toughness of the high performance concrete containing fly ash and nano-SiO2. The flexural toughness was evaluated by two methods, which are based on ASTM C1018 and DBV-1998, respectively. By means of three-point bending method, the flexural toughness indices, variation coefficients of bearing capacity, deformation energy, and equivalent flexural strength of the specimen were measured, respectively, and the relational curves between the vertical load and the midspan deflection (P(V)-δ) were obtained. The results indicate that steel fiber has great effect on the flexural toughness parameters and relational curves (P(V)-δ) of the three-point bending beam specimen. When the content of steel fiber increases from 0.5% to 2%, the flexural toughness parameters increase gradually and the curves are becoming plumper and plumper with the increase of steel fiber content, respectively. However these flexural toughness parameters begin to decrease and the curves become thinner and thinner after the steel fiber content exceeds 2%. It seems that the contribution of steel fiber to the improvement of flexural toughness of the high performance concrete containing fly ash and nano-SiO2 is well performed only when the steel fiber content is less than 2%.

Monitoring corrosion of steel bars in reinforced concrete structures.

Corrosion of steel bars embedded in reinforced concrete (RC) structures reduces the service life and durability of structures causing early failure of structure, which costs significantly for inspection and maintenance of deteriorating structures. Hence, monitoring of reinforcement corrosion is of significant importance for preventing premature failure of structures. This paper attempts to present the importance of monitoring reinforcement corrosion and describes the different methods for evaluating the corrosion state of RC structures, especially hal-cell potential (HCP) method. This paper also presents few techniques to protect concrete from corrosion.

Ductility enhancement of post-Northridge connections by multilongitudinal voids in the beam web.

Since the earthquakes in Northridge and Kobe in 1994 and 1995, respectively, many investigations have been carried out towards improving the strength and ductility of steel beam to column pre- and post-Northridge connections. In order to achieve these objectives, recent researches are mainly focused on three principles: reducing the beam section to improve the beam ductility, adding different kinds of slit damper to beam and column flanges to absorb and dissipate the input earthquake energy in the connection and strengthening the connection area using additional elements such as rib plates, cover plates, and flange plates to keep the plastic hinges away from the column face. This paper presents a reduced beam section approach via the introduction of multilongitudinal voids (MLV) in the beam web for various beam depths varying from 450 mm to 912 mm. ANSYS finite element program was used to simulate the three different sizes of SAC sections: SAC3, SAC5, and SAC7. Results showed an improvement in the connection ductility since the input energy was dissipated uniformly along the beam length and the total rotation of the connection was over four percent radian.

Pre-processing of data coming from a laser-EMAT system for non-destructive testing of steel slabs.

Non destructive test systems are increasingly applied in the industrial context for their strong potentialities in improving and standardizing quality control. Especially in the intermediate manufacturing stages, early detection of defects on semi-finished products allow their direction towards later production processes according to their quality, with consequent considerable savings in time, energy, materials and work. However, the raw data coming from non destructive test systems are not always immediately suitable for sophisticated defect detection algorithms, due to noise and disturbances which are unavoidable, especially in harsh operating conditions, such as the ones which are typical of the steelmaking cycle. The paper describes some pre-processing operations which are required in order to exploit the data coming from a non destructive test system. Such a system is based on the joint exploitation of Laser and Electro-Magnetic Acoustic Transducer technologies and is applied to the detection of surface and sub-surface cracks in cold and hot steel slabs.

Design and implementation of an automated secondary cooling system for the continuous casting of billets.

This paper describes a heat transfer model based automatic secondary cooling system for a billet caster. The model aims to minimize the variation in surface temperature and excessive reheating of the billet strands. It is also used to avoid the low ductility trough of the solidifying steel, which aggravates the tendency of steel to crack. The system has been designed and implemented in an integrated steel plant. A Programmable Logic Controller (PLC) based automation system has been developed to control the water flow in the secondary cooling zones of the strand. The results obtained through field trials have shown complete elimination of internal and off-corner cracks for the fifty billet samples that were monitored.

Evaluation of lead equivalence of patient and hardware materials in medical diagnostic x-ray shielding.

In the estimation of additional shielding requirements for primary beam apart from that provided by patient and hardware in the x-ray beam, there is the need to distinguish between attenuation and hardening properties of materials in comparison. In this work, numerical comparison of attenuation and hardening properties of phantom (Lucite, soft tissue, water) and hardware (aluminum and steel) materials with those of lead have been carried out. Results presented show that the shielding affordable by lead attenuation equivalent thicknesses (LAE) and lead hardening equivalent thicknesses (LHE) is not strictly equivalent to that affordable by thicknesses of substitutes (phantom materials, aluminum and steel) when there are differences in attenuation and hardening properties. Even though beams through LAE that are not "exact" have equal exposure values, the half value layers are higher than those through thicknesses of lead substitutes. Example calculations show that the use of lead thickness (LAE) that are not "exact" to account for the shielding afforded by the thickness of the patient (water phantom) produces lesser reduction of the primary radiation level in the area indicated for shielding. The "exact" LAE that will reduce the primary radiation level equally as the patient and radiographic table may be higher by close to 20% or more of that which is not "exact."

Failures of pin removal after in situ pinning of slipped capital femoral epiphyses: a comparison of different pin types.

We reviewed 75 pin retrievals after in situ pinning of 35 children with slipped capital femoral epiphysis (SCFE). Four types of pins were used. Ten pins in 8 hips could not be removed because of pin breakage or stripping. Our failure rate was significantly related to pin type and size (p less than 0.039). As compared with the expected values using the chi-square method of analysis, the noncannulated large steel pins and cannulated steel pin groups had fewer failures (p less than 0.001) as compared with the cannulated titanium and noncannulated small steel pin groups. We now avoid using cannulated titanium or noncannulated small pins in treatment of SCFE.

[Hygienic evaluation of proposed materials for an oxygen-converter plant]. / Gigienicheskaia otsenka proektnykh materialov kislorodno-konverternogo tsekha.

The proposed article presents results of a hygienic assessment of a converter shop project at a metallurgic plant. Labour conditions in similar metallurgic plants in the country were studied at the preliminary sanitary control stage. 81 per cent of the sanitary authorities' reclamations were met, including dust discharge control measures, out-flowing gases purification, decrease of fluorine compounds discharge measures, etc.

An analysis of the changes in the surfaces of metallic femoral components in hip prostheses. A study of 60 prostheses removed after 1-20 years.

A study of 60 femoral prosthetic components removed after 1-20 years allowed us to study the behaviour of the metallic surface in real life conditions. Changes were observed exclusively in cemented prostheses. They consisted of corrosion phenomena characteristic of the components of steel EN 58 J and 316 S, and wear phenomena secondary to mobilisation. The latter were observed in steel components as well as in those in Co-Cr alloy. The areas of corrosion in the steel prostheses were characteristically distributed, indicating a combination of causal factors, including an insufficient capacity of passivation of the metal and the particular situation of the cement-to-metal interface.