Coiler drums are integral components of the Steckel mill reversing hot strip rolling process. A Steckel mill produces hot rolled strip steel from cast slabs, which are heated before being converted, via roughing, to a transfer bar, of which the thickness is subsequently reduced to the desired gauge by means of a reverse rolling process performed by the Steckel mill. Coiler drums are located inside two Steckel furnaces, which are positioned on both sides of the mill stand. As the strip thickness is reduced during each pass, the length increases. In order to obtain high rolling speeds and retain temperature, the strip is successively coiled and uncoiled, under tension, onto and from the heated coiler drums during processing. As coiler drums have a high unit cost and a significant impact on the quality of the finished product, coiler drum performance is important to Steckel mill operators. The high cost is associated with the high alloy composition of the casting and the specialised manufacturing process required for the production of coiler drums. Deterioration of the coiler drum condition over its service lifespan can adversely affect the quality of the final product, namely coiled strip. This investigation was therefore undertaken to gain insight into coiler drum failure mechanisms, which will benefit Steckel mill operators, mill suppliers and coiler drum suppliers. / Professor R.F. Laubscher

L'objectif principal de cette étude consiste à réduire les temps de calcul des simulations de procédés de mise en forme continus sous le logiciel Forge3®. Ces procédés, tel que le laminage et le tréfilage, sont caractérisés par des pièces dont la longueur est très importante en comparaison des dimensions de la section ainsi que de la zone de contact. Une approche incrémentale générale implique des temps de calcul conséquents allant de quelques heures à plusieurs jours. En se concentrant sur le régime quasi permanant de ces procédés, une formulation stationnaire est développée pour accélérer leur simulation. Le domaine de calcul correspond initialement à une estimation de la forme de l'écoulement solution au voisinage des outils. Une étape de correction du domaine est ajoutée en plus du calcul stationnaire de l'écoulement. Comme les conditions aux limites sont modifiées, ces deux étapes sont répétées jusqu'à convergence.L'étude s'est concentrée principalement sur l'étape de correction du domaine correspondant à la résolution d'un problème de surface libre par la méthode des éléments finis. Le caractère purement convectif du problème ainsi que la prise en compte du contact nécessite l'utilisation de formulations faibles faisant apparaître un décalage amont (SUPG). Deux nouvelles formulations basées sur la méthode des moindres carrés sont développées avec succès (MC_supg et MC_lc). Pour appliquer la méthode à des géométries complexes, différentes méthodes de généralisations sont développées où un 2ème degré de liberté est ajouté aux nœuds de surface. La méthode la plus performante (CSL_dif) consiste à utiliser ce 2ème degré de liberté pour le calcul de surface libre uniquement sur les nœuds appartenant à une arête géométrique, pour les autres une régularisation du maillage dans la direction tangente y est effectuée. Des résultats excellents ont été observés sur un grand nombre de cas tests analytiques. Le contact est appliqué par une méthode de pénalisation aux nœuds. Afin de renforcer le couplage entre cette étape et celle du calcul de l'écoulement, un contact bilatéral glissant est attribué aux nœuds en compression alors que pour les autres nœuds un contact unilatéral est employé. Un algorithme spécifique est développé pour déterminer avec précision la zone de contact.Cette formulation itérative pour la recherche de l'état stationnaire a été appliquée avec succès sur un grand nombre de cas tests de mise en forme. Des accélérations comprises entre 10 et 60 ont été obtenues par rapport à Forge3®. / The aim of this study is to reduce the computational time for the simulation of continuous material forming processes with Forge3® software. These processes, like rolling and wire drawing, are characterized by an important length of the pieces in comparison to their sectional's dimensions and to the local contact area. A general and incremental approach requires important computational times ranging from a few hours to several days. By focusing on the quasi permanent regime of these processes, a stationary approach is developed to speed up their simulation. The computational domain consists of an initial guess of the steady flow near the tools. A domain correction stage is added after the computation of the steady flow. As boundary conditions are changed, these two stages are repeated until the convergence is reached.Most of the works is concentrated on the domain correction which is a free surface problem solved by the finite elements method. As it is a case of a pure convection problem where the treatment of contact is necessary, weak formulations have to show up an upwind shift (SUPG). Two new formulations based on the least squares method have been successfully developed (MC_supg, MC_lc). To take into account complex geometries, severals new methods have been developed by adding a second degree of freedom for surface nodes. The most efficient method (CSL_dif) uses this second degree of freedom for free surface computation only for nodes belonging to geometric edges, whereas the other nodes have a mesh regularization in tangent direction of the surface. Excellent results are obtained for many analytical test cases. A penalization method is used to apply contact equations on nodes. In order to enforce the coupling between this stage and the one for the computation of the flow, a bilateral sliding contact is assigned to the nodes in compression, whereas for the others a unilateral contact is used. A specific algorithm has been developed to efficiently compute the contact area.This iterative formulation for the search of the steady state is successfully used on a large number of material forming test cases. Important accelerations are gained compared to Forge3®, ranging from 10 to 60.

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.

Recent development of super-resolution (SR) fluorescence microscopy techniques has provided a new tool for direct visualization of subcellular structures and their dynamics in cells. The homing of Hematopoietic stem/progenitor cells (HSPCs) to bone marrow is a multistep process that is initiated by tethering of HSPCs to endothelium and mediated by spatiotemporally organised ligand-receptor interactions of selectins expressed on endothelial cells to their ligands expressed on HSPCs which occurs against the shear stress exerted by blood flow. Although molecules and biological processes involved in this multi-step cellular interaction have been studied extensively, molecular mechanisms of the homing, in particular the nanoscale spatiotemporal behaviour of ligand-receptor interactions and their role in the cellular interaction, remain elusive. Using our new method of microfluidics-based super-resolution fluorescence imaging platform we can now characterize the correlation between both nanoscale ligand-receptor interactions and tethering/rolling of cells under external shear stress. We found that cell rolling on E-selectin caused significant reorganization of the nanoscale clustering behavior of CD44 and CD43, from a patchy clusters of ~ 200 nm in size to an elongated network-like structures where for PSGL-1 the clustering size did not change significantly as it was 85 nm and after cell rolling the PSGL-1 aggregated to one side or even exhibited an increase in the footprint. Furthermore, I have established the use of 3D SR images that indicated that the patchy clusters of CD44 localize to protruding structures of the cell surface. On the other hand, a significant amount of the network-like elongated CD44 clusters observed after the rolling were located in the close proximity to the E-selectin surface. The effect of the nanoscale reorganization of the clusters on the HSPC rolling over selectins is still an open question at this stage. Nevertheless, my results further demonstrate that this mechanical force-induced reorganisation is accompanied by a large structural reorganisation of actin cytoskeleton. Our microfluidics-based SR imaging also demonstrate an essential role of the nanoscale clustering of CD44 on stable rolling behaviours of cells. Our new experimental platform enhances understanding of the relationship between nanoscopic ligand-receptor interactions and macroscopic cellular interactions, providing a foundation for characterizing complicated HSPC homing

The objective of this work is to develop a band saw tensioner from the drafting of the specifications to the testing of the prototype while finding the optimal solutions technologically and financially. This development covers the mechanical design and dimensioning of the entire machine. In this repport every step of the project are covered, the benchmark, the specifications, the design and dimensioning, and finally the financial study.

The present thesis deals with the determination of procedural parameters of given bending profile including the calculation of spring-back, especially the bending force. It compares the differences and the benefits of two different technologies of producing a blank, the simple bending and the technology of rolling. The technological process suggested involves technical-economical evaluation, supplemented with the drawing documentation.

Requirements for the creation of a new technological process of manufacturing of towing hooks were cost savings by optimizing the initial blank and by creating semi automatic workplace. Selecting longitudinal rolling technology for manufacturing preform piece occurs to shorten production times and substantial material savings. By rolling of blank are secured always the exact dimensions of the preform piece and through a chain conveyors is facilitated handling with material for workers and reduced production time of forging line. By introduction of the proposed manufacturing method of towing hooks depending on the size of the series 30000 hooks per year will be achieved annually savings of over 4.000.000 CZK. Return of investments for the acquisition and adjustment of forging rolls and conveyors is 2,2 years.

Orientador: Marcelo dos Santos Pereira / Banca: Antonio Jorge Abdalla / Banca: Rafael Humberto Mota de Siqueira / Resumo: O uso de perfis tubulares estruturais, sejam eles de seção circular, quadrada ou retangular, na construção civil ou em equipamentos mecânicos ainda é incipiente no Brasil. Isto se deve, entre outros fatores, ao baixo número de pesquisas nacionais sobre o tema. Para contribuir neste campo, este trabalho teve o objetivo de realizar um estudo comparativo entre seções quadradas laminadas a quente com as conformadas a frio, pois, no Brasil, a maior parte dos tubos são fabricados por conformação a frio e também por haver grande interesse internacional pela comparação direta entre os perfis produzidos por estes dois processos distintos. Para isto, análises dimensionais da seção transversal, das composições químicas e metalográficas e ensaios de dureza por microindentação, de impacto Charpy, de tração e de compressão foram realizados em tubos de 80x80x10 mm de aço carbono para aplicação estrutural com tensão de escoamento mínima de 355 MPa. Os resultados demonstraram que o tubo conformado a frio com posterior tratamento térmico de alívio de tensão possui área de seção transversal 2,7% menor, distribuição de dureza e propriedades mecânicas praticamente uniformes na seção transversal, ótima tenacidade em baixas temperaturas e maior resistência à tração e à compressão quando comparado com a mesma seção laminada a quente. Portanto, para a seção analisada, ficou comprovada a equivalência estrutural dos tubos laminados a quente com os conformados a frio com posterior alívio de tensão por t... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The use of hollow structural sections, be them circular, square or rectangular hollow section, at civil construction or at mechanical equipment is still incipient in Brazil. This is due, among other factors, the low number of national researches about the matter. To contribute in this field, this work had the goal to realize a comparative study between square hollow sections hot rolled with the cold formed because most tubes are produced by cold forming in Brazil and also because the great international interesting for the direct comparison between the profiles produced by these two different processes. For this, cross section dimension, chemical composition and metallographic analyzes and microindentation hardness, Charpy impact, tension and compression tests were realized in tubes of 80x80x10 mm of carbon steel for structural application with minimum yield stress of 355 MPa. The results demonstrated that the cold formed tube with subsequent heat treatment of stress relieve has cross sectional area 2,7% lower, uniform hardness distribution and mechanical properties in the cross section, great toughness at low temperatures and higher tension and compression resistance when compared with the same section hot rolled. Therefore, for the section analyzed, was proved the structural equivalence of the hot rolled tubes with the cold formed plus stress relieve by heat treatment. / Mestre

<p>Rolling contact fatigue (RCF) is the primary mode of failure in tribological contacts like rolling-element bearings (REBs), gears, and cam-follower systems. RCF processes have a crack initiation phase followed by a propagation and coalescence phase, resulting in spalls that lead to catastrophic failure. Crack initiation is a highly localized process that is strongly influenced by the inhomogeneity of the material microstructure. Therefore, a microstructure-sensitive model is required to simulate the damage evolution and failure due to RCF loading. This document presents the development of a microstructure-based finite element (FE) framework for RCF, which accounts for the inhomogeneity of bearing steel microstructure by using an explicit definition of polycrystal topology and material anisotropy. The granular topology of the bearing steel microstructure is described using randomly generated Voronoi tessellations. A cubic elastic material definition with a random spatial orientation is specified for each Voronoi grain to simulate the material anisotropy. The Voronoi grains generated using this approach were used to model the critically stressed microstructural volume in RCF loading. A domain size study was conducted to estimate the minimum number of grains that need to be contained by the critically stressed volume such that the macroscopic material response of the polycrystalline aggregate matches the linear elastic material properties of bearing steel. The estimated critically stressed volume was then embedded into a semi-infinite domain for the FE simulation of RCF line contact loading. The RCF domains developed were then subjected to a moving Hertzian pressure over the surface to simulate a bearing load cycle. A boundary averaging scheme was used to estimate the effective stresses along the grain boundaries of the Voronoi cells. Due to the anisotropy of the polycrystalline material, local stress concentrations occur at the grain boundaries as compared to isotropic models. The resolved grain boundary stresses were used to predict critical locations for RCF crack initiation, which closely match observations from RCF bench test data. Since RCF failures typically exhibit subsurface locations for the first crack initiation, the model uses the critical resolved shear stress (RSS) reversal along the grain boundaries and the corresponding subsurface location of the maxima as the driving parameters for RCF fatigue failures. The parameters from the model were fit into a Weibull distribution to estimate the stochasticity in initiation life. The Weibull predictions corroborate well with experimentally measured RCF life scatter. The framework was then extended using a coupled damage mechanics - cohesive element method (DM-CEM) to individually model the crack initiation and propagation phases in RCF. An explicit definition of the grain boundaries was incorporated using cohesive elements. Damage is initiated at the grain boundaries by degradation of the cohesive elements and the rate of damage/degradation is used to characterize the evolution of fatigue life. The rate of damage was calculated at each grain boundary using a fatigue damage law based on the RSS reversal parameter. The model is able to simulate the crack initiation and the propagation/ coalescence phases in RCF, with distinct life estimates for each phase. This model framework is further extended to investigate the effects of lubrication conditions in RCF by integrating an elastohydrodynamic lubrication (EHL) model to simulate the pressure load with the DM-CEM model. Further improvements to the fatigue life predictions using the DM-CEM model are made by coupling it with a crystal plasticity (CP) based submodel approach to predict the crack initiation life in RCF. CP-based metrics are used to correlate the microplasticity developed under RCF loading with the formation of fatigue micro-cracks and the corresponding initiation life estimations. The resulting final spall patterns and RCF life estimates were found to match well with experimental data available in the open literature.</p> <p><br></p>

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