Modeling,Simulation and Experiment of Electro-hydraulic Screw Down Servo System of Seamless Tube Rolling Mill

Electro-hydraulic screw down servo system（HSDS） is widely used in seamless tube rolling mill in western companies.But in Chinese companies,mechanical screw down system（MSDS） is popularly equipped and has a serious disadvantage that the roller would often be locked when it is overloaded.For the purpose of designing the first set of domestic twin-roller,four-cylinder and six-framework electro-hydraulic HSDS of seamless tube rolling mill,an experiment system that can simulate the process of seamless tube rolling is constructed.A digital simulation model of the experiment system is built with AMESim software and validated by comparing the simulation results with experiment results.The sudden load response of the screw piston position is studied with the built model and the experiment system.To improve the HSDS＇s positioning accuracy with large load,a hybrid control scheme of combining load disturbance feedforward compensation（LDFC） method based on servo valve＇s pressure-stroke feature and anti-saturation integral control（ASIC） is proposed.Both results of simulation and experiment indicate that the transient response time of the single-roller HSDS with the proposed scheme decreases from 0.65 s to less than 0.2 s without static error.To improve the system dynamic stiffness and production qualified rate,a flow rate feedforward compensation（FFC） control strategy based on oil compressibility to dynamic position error is proposed.This FFC strategy is validated with experiments in which the transient error caused by sudden load is reduced to less than 25% of that without FFC.By extending the simulation model to HSDS of a twin-roller,four-cylinder rolling mill,analyzing the mill deformation,and applying the LDFC,ASIC and FFC to the HSDS,the dynamic performance and positioning accuracy of compensated multi-roller HSDS at biting moment are predicted.The research results provide a theoretical and experimental basis for the design of HSDS of seamless steel tube rolling mill.

Research on Computer Simulation System of Stretch Reducing Mill for Tube

The prototype,basic parameters,composition and structure of computer simulation system of stretch reducing mill for tubes were introduced.The software has an obvious style of object-oriented programming,and the modules were integrated in the simulation system.The system can optimize pass design,and it can automatically classify pass series according to the product syllabus,formulate the rolling table and simulate the rolling parameters in stretch reducing process.The simulation results were compared with the detailed technical data(used as experimental data) provided by Baotou Iron and Steel Company,and the comparison gave a clear proof of the precision of the models.

Improvements to conventional X-ray tube-based cone-beam computed tomography system

Conventional X-ray tube-based cone-beam computed tomography(CX-CBCT) systems have great potential in industrial applications. Such systems can rapidly obtain a three-dimensional(3D) image of an object.Conventional X-ray tubes fulfill the requirements for industrial applications, because of their high tube voltage and power. Continuous improvements have been made to CX-CBCT systems, such as imaging time shortening,acquisition strategy optimization, and imaging software development, etc. In this study, a CX-CBCT system is developed. Additionally, some improvements to the CX-CBCT system are proposed based on the hardware conditions of the X-ray tube and detector. A near-detector(ND)geometry condition is employed to obtain a sharper image and larger detection area. An improved acquisition strategy is proposed to simplify operations and reduce total imaging time. In the ND geometry condition, a simplified method called FBP slice stacking(SS-FBP) is proposed, which can be applied to 3D image reconstruction. SS-FBP is timesaving relative to traditional methods. Furthermore, imaging software for the CX-CBCT system is developed in the MATLAB environment. Several imaging experiments were performed. The results suggest that the CX-CBCT system works properly, and that the above improvements are feasible and practical.

Aerodynamic Design of a Subsonic Evacuated Tube Train System

The so-called Evacuated Tube Train(ETT)is currently being proposed as a high-speed transportation system potentially competitive with airplane transportation.Aerodynamic resistance is one of the most crucial factors for the successful design of an ETT.In the present work,a three-dimensional concept ETT model has been elaborated.The aerodynamic characteristics of the subsonic ETT have been numerically simulated under different conditions.The train’s running speed varies from 600 km/h up to 1200 km/h,and the blockage ratio is in the range between 0.1 and 0.3.As the blocking ratio and running speed increase,the resistance of the head car increases greatly,while the resistance of the middle car changes slightly.The aerodynamic resistance of the tail car is affected by the shock wave emerging in the wake flow.Two different design criteria for the maximum allowed aerodynamic resistance are proposed for aerodynamic parameter matching.With an increase in the blockage ratio and running speed,the atmospheric pressure in the tube should be decreased to achieve a balance.

Development of Neural-Based Generalized Predictive Control System of Strip Shape for a Reversal 6-High Mill

In order to develop a special CAD system for tube cold drawing, the practical data and experience have been put into consideration as usual, and with the help of MARC software, the finite element simulations have been carried out over 1 000 times under widely possible processing parameters. After being analyzed and modeled, the results of the simulations are directly introduced into the CAD system, so that the CAD is capable of helping tube manufacturers notonly arrange their drawing procedure system easily and efficiently, but also optimize their drawing processes in several aspects, such as drawing force, die geometry, plug geometry, distribution of reduction, accuracy of tube dimension, consumption of deforming work, quality of tube, and so on. The optimized cold drawing procedures are able to lower production cost by 1 %—5 % in average.

Design and development of high linearity millimeter wave traveling-wave tube for satellite communications

The linearity of the traveling-wave tube is a very important characteristic for a modern communication system. To improve the linearity of the traveling-wave tube at no expense of the saturated output power and overall efficiency, a modified pitch profile combined with a small adjustment of operating parameters is proposed. The optimal design of the helix circuit is evaluated theoretically by a large signal analysis, and the experimental test is also carried out to make a comparison of performance between the novel and original designed traveling-wave tubes. The experiments show that the saturated output powers and efficiencies of these two tubes are close to each other, while the linearity of the traveling-wave tube is obviously improved. The total phase shift and AM/PM conversion at saturation of the novel tube, averaged over the operating band, are only 30.6°/d B and 2.5°/d B, respectively, which are 20.1°/d B and 1.6°/d B lower than those of the original tube, respectively. Moreover, the third-order intermodulation of the novel tube is up to 2.2 d Bc lower than that of the original tube.

Pressurization System in Low Pressure Tube Hydroforming

Advanced high strength steels are the group of material with high strength and good formability, because high strength lesser gauge thickness can be used without compromising the function of component. In terms of economic forming process, hydroforming is the manufacturing option which uses a fluid medium to form a component by using high internal pressure. This process gained steep interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole projected part at the same time. Low pressure tube hydroforming considered an inexpensive option for forming these advanced high strength steel. This paper investigates the pressurization system used during the low pressure tube hydroforming cycle. It is observed that the usage of ramp pressure cycle during forming the part from low pressure tube hydroforming results in lesser die holding force. Also, the stress, strain and thickness distribution of the part during low pressure tube hydroforming are critically analysed.

Experimental study on thermo-hydraulic performances of nanofluids flowing through a corrugated tube filled with copper foam in heat exchange systems

Thermo-hydraulic characteristics of TiO_2-water nanofluids in thin-wall stainless steel test tubes(corrugated tube and circular tube) filled with copper foam(40 PPI) are experimentally investigated and compared with those in test tubes without copper foam. The effects of nanoparticle mass concentration on flow and heat transfer performances are investigated. In addition, the mutual restriction relationships between Reynolds number(Re), Nusselt number(Nu) and resistance coefficient(f) are discussed respectively. Also, the comprehensive coefficient of performance(CCP) between heat transfer and pressure drop is evaluated. The results show that core-enhancement region for heat transfer using experimental tubes filled with copper foam is notably different from that of tubes without copper foam. There is a corresponding Reynolds number(about Re = 2400) for the maximum CCP of each condition. And the heat transfer can be enhanced dramatically and sustained at 8000 ≤ Re ≤ 12000.

Integrated Systemfor Tube Bending Digital Manufacturing

An integrated CAD/CAPP/CAM system of tube manufacturing based on integration frame is presented. In this system, two kinds of data conventions describing tube shape are presented in tube CAD subsystem, the object-oriented concept and the goal-driven inference mechanism have been applied in the development of the knowledge-based CAPP subsystem and simulation of tube processing under tube bending simulation subsystem is performed based on the tube model＇s piecewise representation. A tube product case is considered to give the application of the integrated system, and the advantages of the system in the use of tube bending are revealed.

COMPUTER SIMULATION SYSTEM OF STRETCH REDUCING MILL

The principle of the stretch reducing process is analyzed and three models of pass design are established. The simulations are done about variables, such as, stress, strain, the stretches between the stands, the size parameters of the steel tube, and the roll force parameters. According to its product catalogs the system can automatically divide the pass series, formulate the rolling table, and simulate the basic technological parameters in the stretch reducing process. All modules are integrated based on the developing environment of VB6. The system can draw simulation curves and pass pictures. Three kinds of database including the material database, pass design database, and product database are devised using Microsoft Access, which can be directly edited, corrected, and searched.

FABRICATION OF DIAMOND TUBES IN BIAS-ENHANCED HOT-FILAMENT CHEMICAL VAPOR DEPOSITION SYSTEM

Deposition of diamond thin films on tungsten wire substrate with the gas mixture of acetone and hydrogen by using bias-enhanced hot filament chemical vapor deposition（CVD）with the tantalum wires being optimized arranged is investigated.The self-supported diamond tubes are obtained by etching away the tungsten substrates.The quality of the diamond film before and after the removal of substrates is observed by scanning electron microscope（SEM）and Raman spectrum.The results show that the cylindrical diamond tubes with good quality and uniform thickness are obtained on tungsten wires by using bias enhanced hot filament CVD.The compressive stress in diamond film formed during the deposition is released after the substrate etches away by mixture of H2O2 and NH4 OH.There is no residual stress in diamond tube after substrate removal.

Remote Control System of 37 mm Double Tube Antiaircraft Gun for Hunan Weather Modification

Hunan Weather Modification Center and Suizhou Dafang Precision Electromechanical Engineering Co.,Ltd. of Hubei commonly transformed and installed 83 double tube antiaircraft guns( 37 mm) of Hunan Province in order to realize remote control of computer. After transformation,loading capacity of ammunition feeding machine became large,which could shorten the time of filling shells in the case of short airspace time;one shell launch volume was more,which could improve hail suppression effect; the degree of automation was greatly improved,which could save manpower by more than 50%. It fully embodied the modernization level of Hunan weather modification operation.

SOLID-LIQUID SUSPENSION SYSTEM IN AGITATED TANK WITH DRAFT TUBE

Solid-liquid suspension in an agitated tank with a draft tube was investigated witha newly developed infrared turbidimeter for measuring solid concentration.The diameter of theflared inlet transition tube and the distance from the inlet to the tank bottom are two importantparameters for draft tube design The NAX-4 impeller,developed in this study,is characterized byits high flow efficiency and low power consumption.Some modifications are made to the Bald′smodel by considering the effects of solid concentration and fluid viscosity on the critical speed forcomplete off-bottom suspension.The modified equation fits the experimental data satisfactority andcan be used in scale-up

A comprehensive review of lunar lava tube base construction and field research on a potential Earth test site

The Moon,as the closest celestial body to the Earth,plays a pivotal role in the progression of deep space exploration,and the establishment of research outposts on its surface represents a crucial step in this mission.Lunar lava tubes are special underground caves formed by volcanic eruptions and are considered as ideal natural shelters and scientific laboratories for lunar base construction.This paper begins with an in-depth overview of the geological origins,exploration history,and distribution locations of lunar lava tubes.Subsequently,it delves into the presentation of four distinctive advantages and typical concepts for constructing bases within lava tubes,summarizing the ground-based attempts made thus far in lunar lava tube base construction.Field studies conducted on a lava tube in Hainan revealed rock compositions similar to those found during the Apollo missions and clear lava tube structures,making it a promising analog site.Lastly,the challenges and opportunities encountered in the field of geotechnical engineering regarding the establishment of lunar lava tube bases are discussed,encompassing cave exploration technologies,in-situ testing methods,geomechanical properties under lunar extreme environments,base design and structural stability assessment,excavation and reinforcement techniques,and simulated Earth-based lava tube base.

Study on the low mechanical anisotropy of extruded Mg-Zn-Mn-Ce-Ca alloy tube in the compression process

In this study,the extruded Mg-Zn-Mn-Ce-Ca alloy tube with a low compression anisotropy along the ED,45ED and TD was prepared.The effect of the second phases,initial texture and deformation behavior on this low mechanical anisotropy was investigated.The results revealed that the alloy tube contains the high content(Mg1-xZnx)11Ce phase and the low content of Mg12Ce phase.These second phases are respectively incoherent and coherent with the Mg matrix,and their influence can be ignored.Additionally,the alloy tube exhibited a weak basal fiber texture,where the c-axis was aligned along the 0°∼30°tilt from TD to ED.Such a texture made the initial deformation(at 1.0%∼1.6%strain)of the three samples controlled by comparable basalslip.As deformation progressed(1.6∼9.0%strain),larger amounts of ETWs nucleated and gradually approached saturation in the three samples,re-orienting the c-axis to a 0°∼±30°deviation with respect to the loading directions.Meanwhile,the prismatic and pyramidal<c+a>slips replaced the dominant deformation progressively until fracture.Eventually,the similar deformation mechanisms determined by the weak initial texture in the three samples contribute to the comparable strain hardening rates,resulting in the low compressive anisotropy of the alloy tube.

An Open Rectangular Waveguide Grating for Millimeter-Wave Traveling-Wave Tubes

Millimeter-wave traveling-wave tube （TWT） prevails nowadays as the amplifier for radar, communication and electronic countermeasures. The rectangular waveguide grating is a promising all-metal interaction circuit for the millimeter-wave TWT with advantages of high power capacity, fine heat dissipation, scalability to smaller dimen- sions for shorter wavelengths, compact structure and robust performance. Compared with the traditional closed structure, the open rectangular waveguide grating （ORWG） has wider bandwidth, lower cut-off frequency, and higher machining precision for higher working frequencies due to the open transverse. It is a potential structure that can work in the millimeter wave and even Terahertz band. The rf characteristics including dispersion and interaction impedance are investigated by both theoretic calculation and software simulation. The influences of the structure parameters are also discussed and compared, and the theoretical results agree well with the simula- tion results. Based on the study, the ORWG will favor the design of a broadband and high-power millimeter-wave TWT.

Wireless Network Architecture for Evacuated Tube Transportation System

Evacuated Tube Transportation(ETT)systems have been claimed to have considerable strengths,including ultra-highspeed,safety,and environmentally-friendly.However,the frequent handover caused by the high-speed brings a challenge for ETT mobile wireless communication to preserve steady link performance.Moreover,in such a special scenario,the wireless link between the base station and the passengers on the train needs to experience fading from both metal pipe and train,thus the free-wave coverage with antennas in traditional high-speed rail wireless communication systems is not suitable for ETT.Based on the characteristics of ETT,an improved architecture of wireless communication network is proposed,using distributed base stations with remote radio units(RRUs)and baseband units(BBUs)and leaky waveguides to form stable coverage.And a redundant BBUs or RRUs structure is designed for coverage enhancement.Based on this redundant architecture,a fast handover scheme is proposed to resolve the handover problem.The analytical and simulation results show that the proposed scheme is capable of reducing communication outage probability and handover failure probability remarkably.

Numerical simulation of flow and heat transfer of n-decane in sub-millimeter spiral tube at supercritical pressure

The flow and heat transfer characteristics of n-decane in the sub-millimeter spiral tube(SMST) at supercritical pressure(p = 3 MPa) are studied by the RNG k-ε numerical model in this paper. The effects of various Reynolds numbers(Re) and structural parameters pitch(s) and spiral diameter(D) are analyzed.Results indicate that the average Nusselt numberNu and friction factorNu increase with an increase in Re, and decrease with an increase in D/d(tube diameter). In terms of the structural parameter s/d, it is found that as s/d increases, the Nu first increase, and then decrease. and the critical structural parameter is s/d = 4. Compared with the straight tube, the SMST can improve Nu by 34.8% at best, while it can improve Nu by 102.1% at most. In addition, a comprehensive heat transfer coefficient is applied to analyze the thermodynamic properties of SMST. With the optimal structural parameters of D/d = 6 and s/d = 4, the comprehensive heat transfer factor of supercritical pressure hydrocarbon fuel in the SMST can reach 1.074. At last, correlations of the average Nusselt number and friction factor are developed to predict the flow and heat transfer of n-decane at supercritical pressure.

Numerical Simulation of Subcooled Boiling Inside High-Heat-Flux Component with Swirl Tube in Neutral Beam Injection System

In order to realize steady-state operation of the neutral beam injection（NBI） system with high beam energy,an accurate thermal analysis and a prediction about working conditions of heat-removal structures inside high-heat-flux（HHF） components in the system are key issues.In this paper,taking the HHF ion dump with swirl tubes in NBI system as an example,an accurate thermal dynamic simulation method based on computational fluid dynamics（CFD） and the finite volume method is presented to predict performance of the HHF component.In this simulation method,the Eulerian multiphase method together with some empirical corrections about the inter-phase transfer model and the wall heat flux partitioning model are considered to describe the subcooled boiling.The reliability of the proposed method is validated by an experimental example with subcooled boiling inside swirl tube.The proposed method provides an important tool for the refined thermal and flow dynamic analysis of HHF components,and can be extended to study the thermal design of other complex HHF engineering structures in a straightforward way.The simulation results also verify that the swirl tube is a promising heat removing structure for the HHF components of the NBI system.

Optimization for Hydroforming Loading Paths of Parallel Multi-branch Tubes Based on Grey System Theory

According to characteristic of hydroforming of parallel multi-branch tubes,multi-objective problems were transformed to single objective problem of relational grade comparison by grey system theory.Two different objectives were selected,according to the principle that process parameters were optimal which of grey relational grade were maximum,the optimal loading parameters under different objective condition were obtained,and loading paths were optimized.The results indicated that parallel multi-branch tubes hydroformed under loading paths optimized by grey system theory could meet with the requirement that objective was optimal.And the optimal loading paths under different objectives were different,and the appropriate objective should be selected according to forming characteristic.