Este trabalho avalia a influência do método e qualidade do esmerilhamento de tarugos na qualidade superficial de barras redondas de aço laminadas. Foi avaliada a rejeição de barras laminadas para três condições diferentes de acabamento superficial de tarugo – não esmerilhado, esmerilhado total simples, e esmerilhamento total duplo. Constatou-se que o esmerilhamento superficial de tarugos melhora a qualidade superficial de barras laminadas e, para os aços testados, o esmerilhamento total simples ofereceu melhor custo beneficio entre rendimento metálico e rejeição de barras por defeito superficial. Também se constatou que a profundidade de remoção da camada superficial do tarugo no esmerilhamento não é proporcional à redução de defeitos no produto laminado, sendo a aproximação da camada colunar uma variável com provável influência em tal resultado, assim como a presença de defeitos internos subsuperficiais, que tendem a aflorar com a redução da distância até a superfície da peça. / This work evaluates the influence of billet grinding method and quality in surface defects of hot rolling steel bars. It was evaluated bar rejection rates due to surface defects for three different billet surface conditions: without grinding, bright grinding of the entire surface and double bright grinding of the entire surface. The results show that the bright grinding of the entire surface with a single pass results in better cost benefit between yield loss and bar rejection rates. It was also observed that the grinding depth of the superficial layer of the billet is not proportional to the reduction of defects in the rolled product. This may occur in consequence of the reduction of the chill zone thickness, or even by the presence of sub superficial defects that can emerge to the surface with the reduction of the defect distance to the billet surface

Sistemas de geração de referências para as malhas de controle de laminadores a frio têm proporcionado elevados níveis de produtividade e de qualidade do material processado. No caso de falha da unidade de processamento responsável pela execução do sistema de geração de referências, a operação do laminador fica comprometida e necessita-se de um modo de operação emergencial. Nesse trabalho é desenvolvido um sistema alternativo para geração de referências que visa substituir o modo de operação de emergência de consulta a tabelas de referências pré-calculadas da planta em questão. O sistema de geração de referências desenvolvido, assim como o sistema usado em condições normais de operação, é composto por uma função custo que avalia o nível de produtividade e de qualidade que um conjunto de referências pode proporcionar. A função custo é minimizada pelo método simplex de Nelder e Mead e as variáveis do processo envolvidas na função custo são avaliadas por um modelo de laminação a frio composto somente por equações algébricas, enquanto que o sistema usado em condições normais de operação usa um modelo clássico, composto por equações algébricas e integrais. A comparação entre o sistema usado em condições normais de operação e o sistema desenvolvido mostrou que apesar desse sistema ser mais simples, menos preciso e robusto, as referências por ele calculadas são aceitáveis e podem proporcionar resultados superiores que o modo de operação de emergência baseado na consulta a tabelas. / Setup generation systems for cold mill control loops have provided rolling mill operation with high levels of quality and productivity. In case of malfunctioning in the process unit responsible to execute the setup generation system, the normal procedure for the operation of the mill is interrupted, being necessary the use of an emergency operation mode. This work develops an alternative system for references generation which aims to replace the current emergency operation mode based on pre-calculated, not continuous, setup tables for the rolling mill. The developed references generation system, like the normal system used during mill operation, is composed by a cost function which evaluated the mill quality and productivity operation level which a set of references may propose. The cost function is minimized using the Nelder and Mead simplex method and the process variables involved in the cost function are evaluated by a cold rolling mill model composed only by algebraic equations, while the normal operation system uses a classical model, made up by integrals and algebraic equations. Comparing the existing main setup system to the developed reference system it was observed that, despite its simplicity, less accuracy and less robustness, references calculated using this system were accurate enough to achieve better results than the one emergency table mode has provided.

Nos tratamentos ortodônticos, fios de diferentes ligas metálicas são utilizados nas etapas de alinhamento, nivelamento, correção da posição molar, fechamento espacial, acabamento e retenção. Com relação às duas últimas, responsáveis pelo posicionamento adequado dos dentes superiores sobre os inferiores, a preparação requer um fio que favoreça o torque de incisão, ou seja, que apresente grande resistência e rigidez associadas à ativação de pequeno alcance. Para este fim, os fios de aços inoxidáveis austeníticos retangulares são os preferidos em razão do módulo de elasticidade elevado e boa resistência à corrosão no meio bucal. Quanto à geometria retangular, o processo de fabricação requer desenvolvimento tecnológico adequado para a produção em escala industrial de fios com as características geométricas e propriedades mecânicas para melhor adequação às necessidades de uso. Com o objetivo de se produzir fios com tais características, foi desenvolvido um laminador para a fabricação de fios retangulares com a intuito de se dispor de uma alternativa de menor custo ao processo de produção por trefilação, de custo elevado, devido a complexidade das matrizes. Além da fabricação do laminador, foram avaliados os aspectos tecnológicos que envolveram os efeitos da deformação nas propriedades mecânicas dos fios, por meio de medidas de microdurezas e ensaios em tração e de flexão. Nos testes realizados, os fios apresentaram geometria, acabamento superficial e propriedades mecânicas adequadas à sua utilização em tratamentos ortodônticos. / In orthodontic treatments, wires of different metallic alloys are used for alignment, leveling, correction of the molar position, space closing, finish and retention. With respect to finish and retention, these wires are responsible for adequate positioning of the upper teeth on the lower teeth. Wires that are subjected to incisor torque require high resistance and stiffness. For this, wires of rectangular austenitic stainless steel are used due to high modulus of elasticity and good corrosion resistance in the oral environment. Because of the rectangular geometry, wire production requires process development suitable for industrial scale manufacture with geometric characteristics and mechanical properties better adapted to the use conditions. To obtain wires with such characteristics, a rolling mill was developed for the production of rectangular wires by a rolling process with the objective of reducing cost of the cold drawing process that is currently used, which utilize complex and expensive wiredrawing dies. In addition to the rolling process itself, wire deformation, microhardness, tension and bend tests were also performed. In these tests, wire geometry, surface finish and mechanical properties were successfully adapted for use in orthodontic treatments.

O trabalho apresenta inicialmente os conceitos clássicos de rolamento (sem escorregamento e sem pivotamento) de uma superfície sobre outra usando os triedros de Darboux das duas superfícies ao longo das respectivas curvas de contato. Mostra, ainda, a equivalência desses conceitos com outras definições. A seguir, estuda-se a controlabilidade no problema do rolamento de uma esfera sobre uma superfície S de revolução, tanto no caso de rolar sem escorregar como no caso de não escorregar e não pivotar; a controlabilidade visa determinar a atingibilidade entre dois 'estados' da esfera (posição em S e orientação), isto é, de elementos do espaço das configurações S×SO(3). Na seqüência, estabelecem-se condições nos controles para que os rolamentos sem escorregamento e sem pivotamento ocorram sobre geodésicas de S e obtém-se, também, a controlabilidade nesta situação. Finalmente, verifica-se que, quando S é um plano, 3 ou 4 rolamentos retilíneos, sem escorregamento e sem pivotamento, são suficientes para garantir a atingibilidade entre dois “estados" da esfera. / This work starts by presenting the classical concepts of rolling (without slipping and without slipping or twisting) of a surface over another one, using the Darboux referential frames of the two surfaces along their contact curves. It shows the equivalence between these concepts with other definitions. In the sequel one studies the controllability in the rolling problem of a ball over a surface of revolution S, including both: the non slipping and the non slipping or twisting cases; controllability aims to determine the reachability between two 'states'of the ball (position on S and orientation), that is, two elements of the configuration space S × SO(3). It follows by establishing conditions on controls in order that the rollings occur along geodesics of S and by studying the controllability in this situation. Finally, it is shown that if S is the plane, 3 or 4 retilinear moves without slipping or twisting are enough to guarantee reachability between two states of the ball.

The leading-edge vortex (LEV) is a structure found in unsteady aerodynamics that can alter the forces induced on wings and other rotating structures. This thesis presents an experimental study on LEV development on low aspect-ratio wing rolling in a uniform flow at high angles of attack. The flow structure dynamics of rotating wings in the presence of a free stream are not well understood due to the limited studies under these conditions. In this study, a broad parameter space with varying advance ratio and wing radius of gyration are analyzed using dye-visualizations. In most cases, either a conical LEV structure developed on the inboard part of the wing and persisted to a significant roll angle, as well as the arch structure. Plenoptic PIV was used to validate observations in flow visualizations as well as identify finer structures. A binary classification criterion was defined based on the formation and persistence of the inboard conical LEV structure. This criterion identified the LEV as either conical ,non-conical or transitional. Previous studies inspired the proposal of a ”rotation parameter” ,ΠRot, that was a based on a non-dimensional velocity gradient. A value of ΠRot = 0.17 was found to separate conical and non-conical LEV parameter, suggesting the fundamental importance of this parameter to LEV dynamics. Furthermore, the forces were analyzed to understand the impact of the flow structure on the forces. The conical LEVs had a transient peak followed by irregular udulations while the non-conical LEVs produced high frequency oscillations. In both cases, the force could be understood based on the time-evolution of the LEVs. Passive bleeding was considered within this study to perturb the flow. Four passive bleed configurations were experimented with at different hole locations and sizes. It was found that a hole applied near the wing root with a large diameter perturbed the flow and transformed the structure from conical to non-conical classifications. This provides a platform to further understand the flow mechanisms that govern LEV formation and evolution by drastically changing flow structures and maintaining the same geometric and kinematic parameters. Additional studies were done analyzing the changes on the forces on the wing. The lift on the passive bleeding did not seem to be affected however, the thrust was decreased to nearly 0.

Stability against capsizing is one of the most fundamental requirements to design a ship. In this research, for the first time, CFD is performed to predict main modes of capsizing. CFD first is conducted to predict parametric rolling for a naval ship. Then CFD study of parametric rolling is extended for prediction of broaching both by using CFD as input to NDA model of broaching in replacement of EFD inputs or by using CFD for complete simulation of broaching. The CFD resistance, static heel and drift in calm water and static heel in following wave simulations are conducted to estimate inputs for NDA and 6DOF simulation in following waves are conducted for complete modeling of broaching. CFD parametric rolling simulations show remarkably close agreement with EFD. The CFD stabilized roll angle is very close to those of EFD but CFD predicts larger instability zones. The CFD and EFD results are analyzed with consideration ship theory and compared with NDA. NDA predictions are in qualitative agreement with CFD and EFD. CFD and EFD full Fr curve resistance, static heel and drift in calm water, and static heel in following waves results show fairly close agreement. CFD shows reasonable agreement for static heel and drift linear maneuvering derivatives, whereas large errors are indicated for nonlinear derivatives. The CFD and EFD results are analyzed with consideration ship theory and compared with NDA models. The surge force in following wave is also estimated from Potential Theory and compared with CFD and EFD. It is shown that CFD reproduces the decrease of the surge force near the Fr of 0.2 whereas Potential Theory fails. The CFD broaching simulations are performed for series of heading and Fr and results are compared with the predictions of NDA based on CFD, EFD, and Potential Theory inputs. CFD free model simulations show promising results predicting the instability boundary accurately. CFD calculation of wave and rudders yaw moment explains the processes of surf-riding, broaching, and periodic motion. The NDA simulation using CFD and Potential Flow inputs suggests that CFD/ Potential Flow can be considered as replacement for EFD inputs.

<p>The hot rod and wire rolling process is widely used to produce rolled iron alloys in different shapes and dimensions. This industry has been under a constant development during the last decades. Today, complex geometries are produced at a high speed since it is possible to use several stands in each mill at the same time. A reason for the development is rising demands from customers. The most important demands are to save energy, to get better material properties and higher dimension accuracy. To meet these demands on speed and accuracy, a better control of how the material behaves in the process is needed. There is also a need to be able to quickly find a new setup of the mill in order to be able to produce other geometries.</p><p>The purpose with this Master Thesis is to model and simulate the hot rod and wire rolling process with the modeling language Modelica. The model is given the known inputs and the desired final result in order to compute the unknown inputs to the mill. To meet these goals, a model that depends on for example the gap between the rolls, the roll speeds and the tensions between different stands is needed. It should be possible to make simulations to find roll speeds or to calculate the tensions caused by known roll speeds.</p><p>With the help of models of the steps in the process, a model has been developed in Modelica. The model can be expanded to a mill with an arbitrary number of stands. In the search for the best way of modeling a hot rod and wire rolling mill, several algorithms have been simulated and analyzed in Modelica. The results from all simulations show that the billet and the groove should be described by different functions for the upper and the lower half. Furthermore, it is not a good solution to use only polynomials to describe the shapes in the process. A function with infinite derivative in the endpoints is needed to describe the billet in an acceptable way. The problem has also been solved using Matlab. In this work it is shown that the Modelica solution is preferred, compared to solving the optimization problems in Matlab. An advantage with the Modelica solution is that the model can be split into several easily connected sub models. Unfortunately it was even hard for Modelica to solve general problems. The describing functions made it hard to find the intersections and to keep the area constant during the rotation. The least square method could lead to bad approximations of the shapes.</p> / <p>Profilvalsning används idag globalt som en process för att tillverka metaller i olika former och har under de senaste årtiondena varit i en lång utvecklingsfas. Numera valsas komplicerade geometrier samtidigt som produktiviteten har ökat drastiskt tack vare möjligheten att valsa med flera valspar samtidigt. Under utvecklingsprocessen har även kraven från kunderna ökat, främst vad gäller energibesparing och noggrannhet på den slutgiltiga produktens dimensioner och materialegenskaper. För att kunna möta dessa krav på snabbhet och noggrannhet krävs större kontroll av hur materialet beter sig i valsningsprocessen och att det snabbt går att bestämma hur valsverket ska ställas in när en ny serie ska tillverkas.</p><p>Syftet med examensarbetet som redovisas i denna rapport är främst att modellera och simulera profilvalsningsprocessen med modelleringsspråket Modelica. Modellen ska sedan kunna användas för att utifrån givna indata till processen bestämma olika inparametrar till valsverket för att uppnå önskat slutresultat. För att nå dessa mål krävs en modell som bland annat beror på spelet mellan valsarna, valshastigheterna och dragen mellan olika valspar. Simuleringar ska kunna göras för att både bestämma önskade valshastigheter och för att beräkna vilka drag givna valshastigheter ger upphov till i valsverket.</p><p>Med hjälp av modeller och beskrivningar av de olika stegen i valsningsprocessen har en modell tagits fram i Modelica. Modellen har en given inprofil och kan sedan byggas ut till ett valsverk med önskat antal valspar. I Modelica har olika modeller och algoritmer simulerats och analyserats för att kunna svara på hur ett profilvalsverk modelleras på bästa sätt. Resultaten från de olika simuleringarna visar att heta och valsspår bör beskrivas med olika funktioner för den övre och för den undre delen av profilen. Det är ingen bra lösning att endast använda polynom för att beskriva de olika formerna. En basfunktion med oändlig derivata i ändpunkterna är nödvändig för att beskriva hetan på ett bra sätt. En fördel med Modelica är även att modellen enkelt kan delas upp i flera enkelt sammankopplade delmodeller. Tyvärr var det svårt även för Modelica att lösa generella problem. Funktionerna som användes för att beskriva de olika formerna gjorde det svårt att hitta skärningspunkter och att hålla arean konstant under rotationen. Minsta kvadratmetoden resulterade ibland i dåliga approximationer av de olika formerna.</p>

The aim of this thesis is to increase the understanding of wear in rolling/sliding contacts such as the wheel-rail contact for railroads and the roller-washer contact for roller bearings. The Stockholm commuter train network has been the subject of papers A and B in this thesis in which the wear and surface cracks on rails has been observed for a period of three years. By comparing the wear depth with the crack length, equilibrium between these two damage mechanisms was found for a lubricated rail. By using a lubricant with friction modifiers the stresses was low enough to prevent crack propagation; at the same time, the rail was hard enough to reduce the wear rate. This is probably the most favourable state in terms of rail maintenance cost. Roller bearings subjected to lubricant borne particles have been the subject of papers C, D and E in this thesis. Particles in the lubricating oil can have a significant impact on the wear in lubricated contacts. Even at low concentration levels can self-generated particles cause significant wear. The here presented results shows that filtration during run-in can significantly reduce both the mass loss and the number of self generated particles. A series of experiments has been carried out to study the wear of roller bearings by ingested lubricant borne hard particles. The form of the worn profile and the length of wear scratches correspond closely to the sliding within the contact. A count of the number of wear scratches on the rolling element surface indicates that the contact concentrates particles. A novel wear model based on the observation of a single point on the contacting surface when a concentration of particles passes through it has been developed and the necessary data for the model has been determined from the experiments. Comparison of the simulation results with the experimental results shows good qualitative agreement for the form change of the washer surfaces. / QC 20101015

The technique of DNA origami utilizes the specific and limited bonding properties of DNA to fold single stranded DNA sequences of various lengths to form a predesigned structure. One longer sequence is used as a scaffold and numerous shorter sequences called staples, which are all complementary to the scaffold sequence, are used to fold the scaffold into intricate shapes. The most commonly used scaffold is derived by extracting the genome of the M13 phage and the staples are usually chemically synthesized oligonucleotides. Longer single stranded sequences are difficult to synthesize with high specificity, which limits the choices of scaffold sequences available. In this project two main methods of single stranded amplification, Rolling Circle Amplification (RCA) and the usage of helper phages, were explored with the goal to produce both a 378 nt scaffold and staple sequences needed for folding a DNA origami structure. To facilitate imaging by Transmission Electron Microscopy (TEM) of this small structure, the DNA origami structure was created to form a polymer structure. Production of the scaffold sequence in high yield was unsuccessful and no well-defined polymers were found in the folded samples, though a few results showed promise for further studies and optimizations. Due to time constraints of this project, only production of the scaffold sequence was tested. Unfortunately the scaffold produced by the helper phages was of the complementary strand to that used to design the DNA origami structure, and could therefore not be used for folding. The correct strand was produced by the RCA where the yield was too low when using Phi29 DNA polymerase for proper folding to take place, though small scale RCA by Bst DNA polymerase on the other hand showed promising results. These results indicate that the scaffold production may not be far off but still more experience in producing intermediate size oligonucleotides may be necessary before succeeding in high yield production of this 378 nt long sequence. The promise given by this production is to enable high yield, high purity, low cost and also an easily scalable process set-up. This would be an important step in future DNA nanotechnology research when moving from small scale laboratory research to large scale applications such as targeted drug delivery systems.

The hot rod and wire rolling process is widely used to produce rolled iron alloys in different shapes and dimensions. This industry has been under a constant development during the last decades. Today, complex geometries are produced at a high speed since it is possible to use several stands in each mill at the same time. A reason for the development is rising demands from customers. The most important demands are to save energy, to get better material properties and higher dimension accuracy. To meet these demands on speed and accuracy, a better control of how the material behaves in the process is needed. There is also a need to be able to quickly find a new setup of the mill in order to be able to produce other geometries. The purpose with this Master Thesis is to model and simulate the hot rod and wire rolling process with the modeling language Modelica. The model is given the known inputs and the desired final result in order to compute the unknown inputs to the mill. To meet these goals, a model that depends on for example the gap between the rolls, the roll speeds and the tensions between different stands is needed. It should be possible to make simulations to find roll speeds or to calculate the tensions caused by known roll speeds. With the help of models of the steps in the process, a model has been developed in Modelica. The model can be expanded to a mill with an arbitrary number of stands. In the search for the best way of modeling a hot rod and wire rolling mill, several algorithms have been simulated and analyzed in Modelica. The results from all simulations show that the billet and the groove should be described by different functions for the upper and the lower half. Furthermore, it is not a good solution to use only polynomials to describe the shapes in the process. A function with infinite derivative in the endpoints is needed to describe the billet in an acceptable way. The problem has also been solved using Matlab. In this work it is shown that the Modelica solution is preferred, compared to solving the optimization problems in Matlab. An advantage with the Modelica solution is that the model can be split into several easily connected sub models. Unfortunately it was even hard for Modelica to solve general problems. The describing functions made it hard to find the intersections and to keep the area constant during the rotation. The least square method could lead to bad approximations of the shapes. / Profilvalsning används idag globalt som en process för att tillverka metaller i olika former och har under de senaste årtiondena varit i en lång utvecklingsfas. Numera valsas komplicerade geometrier samtidigt som produktiviteten har ökat drastiskt tack vare möjligheten att valsa med flera valspar samtidigt. Under utvecklingsprocessen har även kraven från kunderna ökat, främst vad gäller energibesparing och noggrannhet på den slutgiltiga produktens dimensioner och materialegenskaper. För att kunna möta dessa krav på snabbhet och noggrannhet krävs större kontroll av hur materialet beter sig i valsningsprocessen och att det snabbt går att bestämma hur valsverket ska ställas in när en ny serie ska tillverkas. Syftet med examensarbetet som redovisas i denna rapport är främst att modellera och simulera profilvalsningsprocessen med modelleringsspråket Modelica. Modellen ska sedan kunna användas för att utifrån givna indata till processen bestämma olika inparametrar till valsverket för att uppnå önskat slutresultat. För att nå dessa mål krävs en modell som bland annat beror på spelet mellan valsarna, valshastigheterna och dragen mellan olika valspar. Simuleringar ska kunna göras för att både bestämma önskade valshastigheter och för att beräkna vilka drag givna valshastigheter ger upphov till i valsverket. Med hjälp av modeller och beskrivningar av de olika stegen i valsningsprocessen har en modell tagits fram i Modelica. Modellen har en given inprofil och kan sedan byggas ut till ett valsverk med önskat antal valspar. I Modelica har olika modeller och algoritmer simulerats och analyserats för att kunna svara på hur ett profilvalsverk modelleras på bästa sätt. Resultaten från de olika simuleringarna visar att heta och valsspår bör beskrivas med olika funktioner för den övre och för den undre delen av profilen. Det är ingen bra lösning att endast använda polynom för att beskriva de olika formerna. En basfunktion med oändlig derivata i ändpunkterna är nödvändig för att beskriva hetan på ett bra sätt. En fördel med Modelica är även att modellen enkelt kan delas upp i flera enkelt sammankopplade delmodeller. Tyvärr var det svårt även för Modelica att lösa generella problem. Funktionerna som användes för att beskriva de olika formerna gjorde det svårt att hitta skärningspunkter och att hålla arean konstant under rotationen. Minsta kvadratmetoden resulterade ibland i dåliga approximationer av de olika formerna.