A Novel Failure Approach for Multi-stage Aluminium Sheet Forming. This project aims to reduce waste in the production of aluminium cans. Over 200 billion aluminium beverage cans per year are produced worldwide (including 30 billion in Australia), but there is a problematic level of waste due to aluminium sheet forming failure. Current simulation of a multi-stage sheet forming process for rigid-packaging components results in a higher rejection rate due to the inaccuracy of conventional forming a ....A Novel Failure Approach for Multi-stage Aluminium Sheet Forming. This project aims to reduce waste in the production of aluminium cans. Over 200 billion aluminium beverage cans per year are produced worldwide (including 30 billion in Australia), but there is a problematic level of waste due to aluminium sheet forming failure. Current simulation of a multi-stage sheet forming process for rigid-packaging components results in a higher rejection rate due to the inaccuracy of conventional forming and fracture limit models. A novel development in this work is the design of a nonlinear strain path which is intended to maximise the forming limit of aluminium alloys and also estimate the safety margin up to the necking or fracture limit in the early die design stage.Read moreRead less
A physically based abrasive wear model for high-speed steel at high temperature. The economic benefits of reducing roll wear, extending roll life and improving strip quality are very significant. This comprehensive project will provide new knowledge on tool wear to help the Australian manufacturing industry (e.g. steel and aluminium, machining) to better understand and optimise their processes to achieve maximum benefits.
A smart functional lubricant for hot strip rolling. This project aims to develop a new generation smart lubricant system through an innovative polymer micro-encapsulation strategy that allows in-situ creation of hierarchical coating before rolling and during hot rolling contacts. This coating is expected to deliver the integrated lubrication and functions to suppress secondary and tertiary scale growth while providing effective lubrication during the hot rolling. This project will make a signifi ....A smart functional lubricant for hot strip rolling. This project aims to develop a new generation smart lubricant system through an innovative polymer micro-encapsulation strategy that allows in-situ creation of hierarchical coating before rolling and during hot rolling contacts. This coating is expected to deliver the integrated lubrication and functions to suppress secondary and tertiary scale growth while providing effective lubrication during the hot rolling. This project will make a significant contribution to improved product yield, prolonged service life of work rolls, better strip surface quality, and overall improved process efficiency.Read moreRead less
A tribological approach to improve surface quality of silicon steel. This project aims to design a lubricant composite where multiple additives work in synergy and perform at high temperatures. In hot rolling of silicon and electrical steels, significant surface defects of red scales, severe work-roll wear and high friction are problems for traditional lubricant which cannot perform effectively under extreme thermal/loading conditions. The new lubricant is expected to eliminate red scale defects ....A tribological approach to improve surface quality of silicon steel. This project aims to design a lubricant composite where multiple additives work in synergy and perform at high temperatures. In hot rolling of silicon and electrical steels, significant surface defects of red scales, severe work-roll wear and high friction are problems for traditional lubricant which cannot perform effectively under extreme thermal/loading conditions. The new lubricant is expected to eliminate red scale defects, reduce oxidation and rolling force, improve surface quality and extend roll service life.Read moreRead less
A new adaptive composite phosphate-polymer lubricant for hot metal forming. The project proposes a new composite phosphate-polymer lubricant in aqueous solution for metal forming at high temperature. The lubricant is self-adaptive to the high pressure, shear and temperature, and will provide threefold synergistic functions: desired tribological performance (anti-wear and low friction); cooling effect; and, oxidation inhibition. This has the potential to significantly reduce overall costs, improv ....A new adaptive composite phosphate-polymer lubricant for hot metal forming. The project proposes a new composite phosphate-polymer lubricant in aqueous solution for metal forming at high temperature. The lubricant is self-adaptive to the high pressure, shear and temperature, and will provide threefold synergistic functions: desired tribological performance (anti-wear and low friction); cooling effect; and, oxidation inhibition. This has the potential to significantly reduce overall costs, improve product quality and lead to a cleaner working environment within the Australian manufacturing industry.Read moreRead less
Experimental and Numerical Investigation of Granular Flow in Hoppers. Handling and processing of bulk solids such as coal and metal ores perform a key function in many industries, and hoppers are the most common devices for storage and discharge of granular materials in this field. The proper design of this equipment is very important. This project provides a systematic investigation of granular flow in hoppers, which is essential in order to avoid structure failures and associated costs. It wil ....Experimental and Numerical Investigation of Granular Flow in Hoppers. Handling and processing of bulk solids such as coal and metal ores perform a key function in many industries, and hoppers are the most common devices for storage and discharge of granular materials in this field. The proper design of this equipment is very important. This project provides a systematic investigation of granular flow in hoppers, which is essential in order to avoid structure failures and associated costs. It will lead to a fundamental understanding of relevant industrial processes, improvement of their efficiency, and hence improved competitiveness of Australian mining/mineral/metallurgical industries.Read moreRead less
A Microstructure Based Approach to Steel Design for Improved Crash Performance. There is a continual need for the automotive industry to develop vehicles with increased fuel efficiency and safety. This research will establish how different types of new advanced steels can contribute to improved crash worthiness, while also helping to increase fuel efficiency through lighter weight. This will lead to the development of new steels that offer even better crash performance while also providing more ....A Microstructure Based Approach to Steel Design for Improved Crash Performance. There is a continual need for the automotive industry to develop vehicles with increased fuel efficiency and safety. This research will establish how different types of new advanced steels can contribute to improved crash worthiness, while also helping to increase fuel efficiency through lighter weight. This will lead to the development of new steels that offer even better crash performance while also providing more realistic computer models for car designers.Read moreRead less
Linkage Infrastructure, Equipment And Facilities - Grant ID: LE0775656
Funder
Australian Research Council
Funding Amount
$490,000.00
Summary
High Rate Testing System for Materials and Structures. Human or natural disasters such as terrorist attack or tsunami take place and they have catastrophic consequences, in terms of fatalities and psyche of fear among the population, as well as enormous financial loss. Vehicle accident is another example. In Australia, 1636 people were killed in 1481 road crashes, in 2005 alone. There is a great demand for research into devising novel materials and structures for optimum performance under such c ....High Rate Testing System for Materials and Structures. Human or natural disasters such as terrorist attack or tsunami take place and they have catastrophic consequences, in terms of fatalities and psyche of fear among the population, as well as enormous financial loss. Vehicle accident is another example. In Australia, 1636 people were killed in 1481 road crashes, in 2005 alone. There is a great demand for research into devising novel materials and structures for optimum performance under such circumstances. The proposed new high rate testing system will significantly advance research in this area. The facility will directly support a range of research projects in material and structural design in military and civil vehicles, aerospace industry and defence.Read moreRead less
Nonlinear modelling, analysis and prediction of optimal conditions for cold roll forming. This project investigates fundamental analytical and experimental aspects of the highly nonlinear process of cold roll forming of flat steel strip to shaped product in order to gain predictive understanding and determine optimal process conditions. The project aims to develop an innovative software system that will permit operators to balance and optimize mill productivity, energy consumption, mill downtim ....Nonlinear modelling, analysis and prediction of optimal conditions for cold roll forming. This project investigates fundamental analytical and experimental aspects of the highly nonlinear process of cold roll forming of flat steel strip to shaped product in order to gain predictive understanding and determine optimal process conditions. The project aims to develop an innovative software system that will permit operators to balance and optimize mill productivity, energy consumption, mill downtime, and product change over times and facilitate the development of new productsRead moreRead less
Optimal transitional surface for a new continuous press forming process. This project addresses the National Research Priority - Frontier Technologies for Building and Transforming Australian Industries through smart information use. This project aims to gain fundamental scientific understanding of a manufacturing process with the aim of developing a tool that will enhance existing manufacturing processes and controls from an 'art of expertise' to a scientific understanding and improvement. Th ....Optimal transitional surface for a new continuous press forming process. This project addresses the National Research Priority - Frontier Technologies for Building and Transforming Australian Industries through smart information use. This project aims to gain fundamental scientific understanding of a manufacturing process with the aim of developing a tool that will enhance existing manufacturing processes and controls from an 'art of expertise' to a scientific understanding and improvement. This manufacturing area represents a niche market for Australian manufacturing and the development of a product that enhances productivity and reduces costs has the potential to elevate Australian manufacturers in the export market and create economic benefit for Australia.Read moreRead less