Linkage Infrastructure, Equipment And Facilities - Grant ID: LE140100003
Funder
Australian Research Council
Funding Amount
$280,000.00
Summary
Flexible forming facility for low cost light weight applications. Flexible forming facility for low-cost light-weight applications: This project will establish Australia’s first flexible roll forming facility. The facility will be unique in the world, being specifically designed to roll form the most advanced high strength alloys into complex three-dimensional shapes and investigate their material behaviour under a wide range of loading conditions. This technology represents a step change in com ....Flexible forming facility for low cost light weight applications. Flexible forming facility for low-cost light-weight applications: This project will establish Australia’s first flexible roll forming facility. The facility will be unique in the world, being specifically designed to roll form the most advanced high strength alloys into complex three-dimensional shapes and investigate their material behaviour under a wide range of loading conditions. This technology represents a step change in commercial processing and has the capacity to form materials with high strength and limited ductility. This will lead to the development of new techniques for the manufacture of new advanced materials including advanced high strength steels, composites, nano structured metals and light metal alloys for automotive and aerospace applications.Read moreRead less
An investigation of the mechanism of lacquer adhesion failure on electrolytic tinplate. "Tin" cans used for food packaging are actually made from tin-plated steel and, in most cases, the metal is coated with a lacquer. This lacquer is required to protect the can from corrosion and the contents from taint. The incidence of adhesion failure between the metal and the lacquer has increased recently for unknown reasons, causing considerable economic loss. This project will investigate the mechanisms ....An investigation of the mechanism of lacquer adhesion failure on electrolytic tinplate. "Tin" cans used for food packaging are actually made from tin-plated steel and, in most cases, the metal is coated with a lacquer. This lacquer is required to protect the can from corrosion and the contents from taint. The incidence of adhesion failure between the metal and the lacquer has increased recently for unknown reasons, causing considerable economic loss. This project will investigate the mechanisms of adhesion failure and improve our fundamental understanding of the problem. The results will be used to enable the selection of process conditions and lacquers that are more robust and reduce the incidence of adhesion failure.Read moreRead less
Metal folding fundamentals to shape new corrugated building products . FormFlow has developed a ground-breaking forming process enabling the use of corrugated iron as a structural element. This is a step change for Australia`s steel and building industry and will provide a direct benefit to fireproofing homes. Up scaling of this new technology poses significant challenges due to the lack of understanding in the new forming process and the effect of pre-processing on the incoming material. Fundam ....Metal folding fundamentals to shape new corrugated building products . FormFlow has developed a ground-breaking forming process enabling the use of corrugated iron as a structural element. This is a step change for Australia`s steel and building industry and will provide a direct benefit to fireproofing homes. Up scaling of this new technology poses significant challenges due to the lack of understanding in the new forming process and the effect of pre-processing on the incoming material. Fundamental knowledge of material behaviour will be developed with advanced models that account for the unique process deformation conditions. The intended outcome includes computer software for process design and new concepts for part shape control to improve product quality, repeatability and enable high volume manufacture.Read moreRead less
Large-volume gradient materials: Manufacturing and deformation mechanism. This project aims to develop a low-cost and high productivity process to produce large-volume metals with high strength and good ductility, suitable for engineering application. Ultrafine grained (UFG) materials and nano-grained (NG) materials are usually strong, but not very ductile. This project will use an accumulative skin-pass rolling (ASPR) technique to fabricate the metallic strips with gradient structure. The numer ....Large-volume gradient materials: Manufacturing and deformation mechanism. This project aims to develop a low-cost and high productivity process to produce large-volume metals with high strength and good ductility, suitable for engineering application. Ultrafine grained (UFG) materials and nano-grained (NG) materials are usually strong, but not very ductile. This project will use an accumulative skin-pass rolling (ASPR) technique to fabricate the metallic strips with gradient structure. The numerical simulations developed in the project are expected to contribute to understanding the deformation mechanism of gradient materials.Read moreRead less
Discovery Early Career Researcher Award - Grant ID: DE180100124
Funder
Australian Research Council
Funding Amount
$374,446.00
Summary
Fabrication of large-scale two-dimensional metallic nanosheets by accumulative rolling. This project aims to develop new techniques and insight into the thinning of metals from bulk to nano thicknesses which enables bulk manufacturing of large-scale two-dimensional (2D) metallic nanosheets. A novel rolling strategy will be adopted to achieve 2D metallic sheets with thicknesses less than 5nm and lateral sizes larger than 1mm, as well as demonstrating significantly improved electro-catalytic perfo ....Fabrication of large-scale two-dimensional metallic nanosheets by accumulative rolling. This project aims to develop new techniques and insight into the thinning of metals from bulk to nano thicknesses which enables bulk manufacturing of large-scale two-dimensional (2D) metallic nanosheets. A novel rolling strategy will be adopted to achieve 2D metallic sheets with thicknesses less than 5nm and lateral sizes larger than 1mm, as well as demonstrating significantly improved electro-catalytic performance. The proposed technique is expected to be a high-yield, low-cost alternative to traditional bottom-up techniques and is expected to be ready for implementation in industry for bulk manufacturing of 2D metallic nanosheets.Read moreRead less
Automated Integrity Assessment of Self-Piercing Rivet Joints: i4.0 Approach. Lightweighting in the car industry by the use of aluminium reduces emissions substantially. It entails joining the car body sections by self-piercing rivets rather than the traditional spot welds. We aim to fill the technology gap for effective quality control of these joints. The project expects to solve the problem by merging industry 4.0 principles, three-dimensional X-ray technology, machine learning computer vision ....Automated Integrity Assessment of Self-Piercing Rivet Joints: i4.0 Approach. Lightweighting in the car industry by the use of aluminium reduces emissions substantially. It entails joining the car body sections by self-piercing rivets rather than the traditional spot welds. We aim to fill the technology gap for effective quality control of these joints. The project expects to solve the problem by merging industry 4.0 principles, three-dimensional X-ray technology, machine learning computer vision and structural mechanics. The expected outcomes are technologies for automation-friendly assessment of these joints. This should benefit industries from medical to electronics to automatically spot a random and delicate abnormality within a solid of complex geometry, such as that in live tissue or an electronic circuit.Read moreRead less
Mechanics of transverse friction and roughness in cold strip rolling. The transverse friction and roughness have a significant effect on the shape and surface quality of the rolled strip. However, mechanics of transverse friction in cold rolling have not been identified clearly. In this project, a two-dimensional mixed film lubrication model, which couples with the strip deformation and the roll stacks deformation, will be developed to quantify the effects of transverse friction and roughness on ....Mechanics of transverse friction and roughness in cold strip rolling. The transverse friction and roughness have a significant effect on the shape and surface quality of the rolled strip. However, mechanics of transverse friction in cold rolling have not been identified clearly. In this project, a two-dimensional mixed film lubrication model, which couples with the strip deformation and the roll stacks deformation, will be developed to quantify the effects of transverse friction and roughness on strip shape and surface quality. It will extend the scope of friction and roughness analysis well beyond other existing models.Read moreRead less
Guaranteeing the safety of short welds in automotive applications. Most safety-critical welds in the automotive and related industries are of short duration (less than three seconds). We will develop a unified theoretical model of short welds which accounts for all important phenomena. Using this model, we will create the first system to check every safety-critical weld in real time, with 3D data objects that use all the data available from the non-stationary process. The outcomes will be a comp ....Guaranteeing the safety of short welds in automotive applications. Most safety-critical welds in the automotive and related industries are of short duration (less than three seconds). We will develop a unified theoretical model of short welds which accounts for all important phenomena. Using this model, we will create the first system to check every safety-critical weld in real time, with 3D data objects that use all the data available from the non-stationary process. The outcomes will be a comprehensive understanding of short welds, which will be an essential step towards the development of more reliable welding procedures, and a weld fault monitor ready for industrial application.Read moreRead less
Condition monitoring of large, horizontal low speed slew bearings. Remote sensing has often been used to collect vibration data .To date, no current analysis technique has produced results that appear consistent due to the low speed (less than 1 Hz), and the acyclic characteristic of the rolling element anti-friction bearing.
The contact vibration energy between rolling elements and races is low due to the low speed of the motion, and thus the vibration produced is masked by the general runnin ....Condition monitoring of large, horizontal low speed slew bearings. Remote sensing has often been used to collect vibration data .To date, no current analysis technique has produced results that appear consistent due to the low speed (less than 1 Hz), and the acyclic characteristic of the rolling element anti-friction bearing.
The contact vibration energy between rolling elements and races is low due to the low speed of the motion, and thus the vibration produced is masked by the general running vibration and is not readily distinguishable from the background vibration of the rotating structure. The aim of this project is to use remote sensors to collect information about the state of horizontal slew bearings and develop an analysis technique that will predict the short to medium term behaviour of horizontal slew bearings. The technique has the potential of saving $3.2 million in loss production per an unplanned breakdown of a slew bearing in a steel plant.
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Analysis of complex systems for the condition monitoring of a rolling mill. A knowledge of the relationships between input variables and measured output states of a rolling mill should enable significant improvements to dimensional stability of the product being produced and to an increase in availability of the rolling mill. The aim of this project is to develop a methodology for developing relationships between input variables that contribute to the measured output states of fully assembled r ....Analysis of complex systems for the condition monitoring of a rolling mill. A knowledge of the relationships between input variables and measured output states of a rolling mill should enable significant improvements to dimensional stability of the product being produced and to an increase in availability of the rolling mill. The aim of this project is to develop a methodology for developing relationships between input variables that contribute to the measured output states of fully assembled rolling mill stands and this enable the operator to identify and avoid undesirable mill states.Read moreRead less