Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

High formability Mg-Zn-Gd wire facilitates ACL reconstruction via its swift degradation to accelerate intra-tunnel endochondral ossification

After reconstructing the anterior cruciate ligament(ACL),unsatisfactory bone tendon interface healing may often induce tunnel enlargement at the early healing stage.With good biological features and high formability,Magnesium-Zinc-Gadolinium(ZG21)wires are developed to bunch the tendon graft for matching the bone tunnel during transplantation.Microstructure,tensile strength,degradation,and cytotoxicity of ZG21 wire are evaluated.The rabbit model is used for assessing the biological effects of ZG21 wire by Micro-CT,histology,and mechanical test.The SEM/EDS,immunochemistry,and in vitro assessments are performed to investigate the underlying mechanism.Material tests demonstrate the high formability of ZG21 wire as surgical suture.Micro-CT shows ZG21 wire degradation accelerates tunnel bone formation,and histologically with earlier and more fibrocartilage regeneration at the healing interface.The mechanical test shows higher ultimate load in the ZG21 group.The SEM/EDS presents ZG21 wire degradation triggered calcium phosphate(Ca-P)deposition.IHC results demonstrate upregulation of Wnt3a,BMP2,and VEGF at the early phase and TGFβ3 and Type II collagen at the late phase of healing.In vitro tests also confirmed the Ca-P in the metal extract could elevate the expression of Wnt3a,βcatenin,ocn and opn to stimulate osteogenesis.Ex vivo tests of clinical samples indicated suturing with ZG21 wire did not weaken the ultimate loading of human tendon tissue.In conclusion,the ZG21 wire is feasible for tendon graft bunching.Its degradation products accelerated intra-tunnel endochondral ossification at the early healing stage and therefore enhanced bone-tendon interface healing in ACL reconstruction.

Capillary Property of Entangled Porous Metallic Wire materials and Its Application in Fluid Buffers:Theoretical Analysis and Experimental Study

Strong impact does serious harm to the military industries so it is necessary to choose reasonable cushioning material and design effective buffers to prevent the impact of equipment.Based on the capillary property entangled porous metallic wire materials(EPMWM),this paper designed a composite buffer which uses EPMWM and viscous fluid as cushioning materials under the low-speed impact of the recoil force device of weapon equipment(such as artillery,mortar,etc.).Combined with the capillary model,porosity,hydraulic diameter,maximum pore diameter and pore distribution were used to characterize the pore structure characteristics of EPMWM.The calculation model of the damping force of the composite buffer was established.The low-speed impact test of the composite buffer was conducted.The parameters of the buffer under low-speed impact were identified according to the model,and the nonlinear model of damping force was obtained.The test results show that the composite buffer with EPMWM and viscous fluid can absorb the impact energy from the recoil movement effectively,and provide a new method for the buffer design of weapon equipment(such as artillery,mortar,etc.).

Mass transfer enhancement and hydrodynamic performance with wire mesh coupling solid particles in bubble column reactor

It is of vital significance to investigate mass transfer enhancements for chemical engineering processes.This work focuses on investigating the coupling influence of embedding wire mesh and adding solid particles on bubble motion and gas-liquid mass transfer process in a bubble column.Particle image velocimetry(PIV)technology was employed to analyze the flow field and bubble motion behavior,and dynamic oxygen absorption technology was used to measure the gas-liquid volumetric mass transfer coefficient(kLa).The effect of embedding wire mesh,adding solid particles,and wire mesh coupling solid particles on the flow characteristic and kLa were analyzed and compared.The results show that the gas-liquid interface area increases by 33%-72%when using the wire mesh coupling solid particles strategy compared to the gas-liquid two-phase flow,which is superior to the other two strengthening methods.Compared with the system without reinforcement,kLa in the bubble column increased by 0.5-1.8 times with wire mesh coupling solid particles method,which is higher than the sum of kLa increases with inserting wire mesh and adding particles,and the coupling reinforcement mechanism for affecting gas-liquid mass transfer process was discussed to provide a new idea for enhancing gas-liquid mass transfer.

Mechanical property of cylindrical sandwich shell with gradient core of entangled wire mesh

To explore the wide-frequency damping and vibration-attenuation performances in the application of aerospace components,the cylindrical sandwich shell structure with a gradient core of entangled wire mesh was proposed in this paper.Firstly,the gradient cores of entangled wire mesh in the axial and radial directions were prepared by using an in-house Numerical Control weaving machine,and the metallurgical connection between skin sheets and the gradient core was performed using vacuum brazing.Secondly,to investigate the mechanical properties of cylindrical sandwich shells with axial or radial gradient cores,quasi-static and dynamic mechanical experiments were carried out.The primary evaluations of mechanical properties include secant stiffness,natural frequency,Specific Energy Absorption(SEA),vibration acceleration level,and so on.The results suggest that the vibration-attenuation performance of the sandwich shell is remarkable when the high-density core layer is at the end of the shell or abuts the inner skin.The axial gradient material has almost no influence on the vibration frequencies of the shell,whereas the vibration frequencies increase dramatically when the high-density core layer approaches the skin.Moreover,compared to the conventional sandwich shells,the proposed functional grading cylindrical sandwich shell exhibits more potential in mass reduction,stiffness designing,and energy dissipation.

Modeling asymmetric fracture mechanics of Mg alloy wire in drawing process

In this study,a numerical analysis was conducted on the ductile fracture of a 2-mm diameter Mg-1Zn-0.5Mn-0.5Sr-0.1Ca alloy wire during drawing.The hexagonally close-packed crystal structure of Mg alloys causes asymmetric fracture behavior,especially in the compression region.The aim of this study is to develop a comprehensive damage model for Mg alloy wire that accurately predicts ductile fracture,with a focus on the compression region.A novel experimental method was introduced to measure the ductile fracture of Mg alloy wires under different stress states.The wire drawing process was simulated using the Generalized Incremental Stress-State dependent damage(GISSMO)Model and the Semi-Analytical Model for Polymers(SAMP)model.The damage model's prediction and the experimental results were found to be in excellent agreement,especially in determining crack initiation.Computational analysis established a safe zone diagram for die angle and reduction ratio,and experimental validation confirmed the feasibility of this approach.The proposed damage model can provide a practical and reliable analysis for optimizing the drawing process of Mg alloy wire.

3D reconstruction and defect pattern recognition of bonding wire based on stereo vision

Non-destructive detection of wire bonding defects in integrated circuits(IC)is critical for ensuring product quality after packaging.Image-processing-based methods do not provide a detailed evaluation of the three-dimensional defects of the bonding wire.Therefore,a method of 3D reconstruction and pattern recognition of wire defects based on stereo vision,which can achieve non-destructive detection of bonding wire defects is proposed.The contour features of bonding wires and other electronic components in the depth image is analysed to complete the 3D reconstruction of the bonding wires.Especially to filter the noisy point cloud and obtain an accurate point cloud of the bonding wire surface,a point cloud segmentation method based on spatial surface feature detection(SFD)was proposed.SFD can extract more distinct features from the bonding wire surface during the point cloud segmentation process.Furthermore,in the defect detection process,a directional discretisation descriptor with multiple local normal vectors is designed for defect pattern recognition of bonding wires.The descriptor combines local and global features of wire and can describe the spatial variation trends and structural features of wires.The experimental results show that the method can complete the 3D reconstruction and defect pattern recognition of bonding wires,and the average accuracy of defect recognition is 96.47%,which meets the production requirements of bonding wire defect detection.

In vivo and in vitro study of resorbable magnesium wires for medical implants:Mg purity,surface quality,Zn alloying and polymer coating

Magnesium is an excellent material in terms of biocompatibility and its corrosion products can serve as an active source for new bone formation.However,localized corrosion and H_(2)generation limit the potential of Mg-based implants.Utilizing low-alloyed Mg-Zn wires can strongly reduce problems with large H_(2)bubbles and improve the mechanical properties considerably while maintaining excellent long-term biocompatibility.Acidic pickling and a polymer coating can be effectively used to lower the rate of in vivo degradation.In this work,microstructural,mechanical,and in vitro characterization of 250μm and 300μm extruded wires made from ultra-pure Mg,commercially pure Mg,Mg-0.15Zn,Mg-0.4Zn and Mg-1Zn was performed.Additionally,Mg-0.4Zn wires together with a variant coated with a copolymer of L-lactide andε-caprolactone were tested in vivo on artificially damaged Wistar rat femurs.Based on the observed Mg-induced osteogenesis,polymer-coated Mg wires with a small addition of Zn are a perspective material for bone-support applications,such as cerclage and fixation wires.

Enhancing fatigue performance of AZ31 magnesium alloy components fabricated by cold metal transfer-based wire arc directed energy deposition through LPB

Cold Metal Transfer-Based Wire Arc Directed Energy Deposition(CMT-WA-DED)presents a promising avenue for the rapid fabrication of components crucial to automotive,shipbuilding,and aerospace industries.However,the susceptibility to fatigue of CMT-WA-DED-produced AZ31 Mg alloy components has impeded their widespread adoption for critical load-bearing applications.In this study,a comprehensive investigation into the fatigue behaviour of WA-DED-fabricated AZ31 Mg alloy has been carried out and compared to commercially available wrought AZ31 alloy.Our findings indicate that the as-deposited parts exhibit a lower fatigue life than wrought Mg alloy,primarily due to poor surface finish,tensile residual stress,porosity,and coarse grain microstructure inherent in the WA-DED process.Low Plasticity Burnishing(LPB)treatment is applied to mitigate these issues,which induce significant plastic deformation on the surface.This treatment resulted in a remarkable improvement of fatigue life by 42%,accompanied by a reduction in surface roughness,grain refinement and enhancement of compressive residual stress levels.Furthermore,during cyclic deformation,WA-DED specimens exhibited higher plasticity and dislocation density compared to both wrought and WA-DED+LPB specimens.A higher fraction of Low Angle Grain Boundaries(LAGBs)in WA-DED specimens contributed to multiple crack initiation sites and convoluted crack paths,ultimately leading to premature failure.In contrast,wrought and WA-DED+LPB specimens displayed a higher percentage of High Angle Grain Boundaries(HAGBs),which hindered dislocation movement and resulted in fewer crack initiation sites and less complex crack paths,thereby extending fatigue life.These findings underscore the effectiveness of LPB as a post-processing technique to enhance the fatigue performance of WA-DED-fabricated AZ31 Mg alloy components.Our study highlights the importance of LPB surface treatment on AZ31 Mg components produced by CMT-WA-DED to remove surface defects,enabling their widespread use in load-bearing applications.

Utilizing Iso-Value Field Curves in Lieu of Magnetic Field Lines Amid Infinite and Parallel Electrical Wires

Building on a new model proposed recently for calculating constant electro-magnetic field values, the present article explores the electro-magnetic field configuration generated by parallel electrical wires. This imposes a reevaluation of the drawing procedure for constructing field curves with a constant field values around multiple parallel electrical conducting wires. To achieve this, we employ methods akin to those used for creating contours on topographical maps, ensuring a consistent numerical field value along the entire length of the field curves. Subsequent calculations will be conducted for scenarios where wires are not parallel.

Design and Application of a Novel Wire Stripper

With the rapid development of the power industry,the work of the power electrician is becoming increasingly heavy,and the demand for improving work efficiency and reducing work intensity is becoming increasingly prominent.As one of the common tools of electric power,the design and application of wire stripper has an important influence on the efficiency and safety of electric power.This paper briefly analyzes the design and application of ceramic wire for electric power and electricians to provide a reference for the development of related fields.

Magnetic Field Curves and Magnetic Equipotential Surfaces around Crossing Electrical Wires Replacing Classical Magnetic Field Lines

This article is based on a recent model specifically defining magnetic field values around electrical wires. With this model, calculations of field around parallel wires were obtained. Now, this model is extended with the new concept of magnetic equipotential surface to magnetic field curves around crossing wires. Cases of single, double, and triple wires are described. Subsequent article will be conducted for more general scenarios where wires are neither infinite nor parallel.

STRESS ANALYSIS OF ROLL RING FOR HIGH SPEED WIRE ROLLING MILLS

This paper introduces a new method for fixing type of the tungsten carbide roll ring for high speed wire rolling mills, and analyses the stresses of the roll ring. The lifetime of roll pass is twice longer that of the old one.

Effect of grain refinement induced by wire and arc additive manufacture (WAAM) on the corrosion behaviors of AZ31 magnesium alloy in NaCl solution

Additive manufacturing(AM)of Mg alloys has become a promising strategy for producing complex structures,but the corrosion performance of AM Mg components remains unexploited.In this study,wire and arc additive manufacturing(WAAM)was employed to produce single AZ31 layer.The results revealed that the WAAM AZ31 was characterized by significant grain refinement with non-textured crystallographic orientation,similar phase composition and stabilized corrosion performance comparing to the cast AZ31.These varied corrosion behaviors were principally ascribed to the size of grain,where cast AZ31 and WAAM AZ31 were featured by micro galvanic corrosion and intergranular corrosion,respectively.

Study on anisotropy of microstructure and mechanical properties of AZ31 magnesium alloy fabricated by wire arc additive manufacturing

Based on wire arc additive manufacturing(WAAM)technology,AZ31 magnesium alloy in bulk was successfully fabricated,and its microstructure as well as mechanical properties in different planes were observed and analyzed.The AZ31 magnesium alloy has a similar microstructure in the building direction(Z)and travel direction(X),both of which are equiaxed grains.There are heat-affected zones(HAZs)with coarse grains below the fusion line.The second phase is primarily composed of the Mg17Al12 phase,which is evenly distributed in different directions.In addition,the residual stress varies in different directions.There is no significant difference in the hardness of the AZ31 alloy along the Z and X directions,with the average hardness being 68.4 HV and 67.9 HV,respectively.Even though the specimens’ultimate tensile strength along the travel direction is higher in comparison to that along the building direction,their differences in elongation and yield strength are smaller,indicating that the anisotropy of the mechanical properties of the material is small.

Enhanced strength-ductility synergy in a wire and arc additively manufactured Mg alloy via tuning interlayer dwell time

Strength-ductility trade-off is a common issue in Mg alloys. This work proposed that a synergistic enhancement of strength and ductility could be achieved through tuning interlayer dwell time(IDT) in the wire and arc additive manufacturing(WAAM) process of Mg alloy.The thermal couples were used to monitor the thermal history during the WAAM process. Additionally, the effect of different IDTs on the microstructure characteristics and resultant mechanical properties of WAAM-processed Mg alloy thin-wall were investigated. The results showed that the stable temperature of the thin-wall component could reach 290 ℃ at IDT=0s, indicating that the thermal accumulation effect was remarkable. Consequently, unimodal coarse grains with an average size of 39.6 μm were generated, and the resultant room-temperature tensile property was poor. With the IDT extended to 60s, the thermal input and thermal dissipation reached a balance, and the stable temperature was only 170 ℃, closing to the initial temperature of the substrate. A refined grain structure with bimodal size distribution was obtained. The remelting zone had fine grains with the size of 15.2 μm, while the arc zone owned coarse grains with the size of 24.5 μm.The alternatively distributed coarse and fine grains lead to the elimination of strength-ductility trade-off. The ultimate tensile strength and elongation of the samples at IDT=60s are increased by 20.6 and 75.0% of those samples at IDT=0s, respectively. The findings will facilitate the development of additive manufacturing processes for advanced Mg alloys.

Force Parameter Model of 3-Roll Mills for Continuous Cold Rolling Wires

Based on experimental data, the mathematical model of rolling force parameters of 3-roll mills was studied. The structure ofthe model was theoretically set up and the coefficients were determined by static analysis of the data. The torque in continuous rollingwas measured, and the characteristics and efficiency of 3-roll mills are investigated.

Force Analysis and Curve Design for Laying Pipe in Loop Laying Head of Wire Rod Mills

Laying head is a high-precision engineering device in hot-rolled high speed wire rod production line. Previously research works are focused on the laying pipe wear-resisting. Laying pipe curve design method based on wire rod kinematics and dynamics analyses are not reported before. In order to design and manufacture the laying pipe, the motion and force process of the wire rod in the laying pipe should be studied. In this paper, a novel approach is proposed to investigate the force modeling for hot-rolled wire rod in laying pipe. An idea of limited element method is used to analysis and calculates the forces between laying pipe inner surface and wire rod. The design requirements of laying pipe curve for manufacturing are discussed. The kinematics and dynamics modeling for numerical calculation are built. A laying pipe curve equation is proposed by discussing design boundary conditions. Numerical results with di erent laying pipe curves design parameters are plotted and compared. The proposed approach performs good result which can be applied for laying pipe curve design and analysis for engineering application.

High-Speed Wire Rod Finishing Mill

The high-speed wire rod finishing mill production line consisting of more than 10 key items of equipment such as a heating furnace,major rolling mill, secondary rolling mill,preliminary refining mill, finishing mill, carrier roller, wire-drive machine, coiler, and packing machine, is a technology-intensive product combining modern rolling technology with the high-technology of machinery, electronics,hydromatic drive and instrumentation, which only a few countries in the world can produce.

A nanoparticle formation model considering layered motion based on an electrical explosion experiment with AI wires

To study the evolution of nanoparticles during Al wire electrical explosion,a nanoparticle formation model that considered layered motion was developed,and an experimental system was set up to carry out electrical explosion experiments using 0.1 mm and 0.2 mm Al wires.The characteristic parameters and evolution process during the formation of nanoparticles were calculated and analyzed.The results show that the maximum velocities of the innermost and outermost layers are about 1200 m·s-1and 1600 m·s-1,and the velocity of the middle layer is about 1400 m·s-1,respectively.Most of the nanoparticles are formed in the temperature range of2600 K-2500 K.The characteristic temperature for the formation of Al nanoparticles is~2520K,which is also the characteristic temperature of other parameters.The size distribution range of the formed nanoparticles is 18 to 110 nm,and most of them are around 22 nm.The variation of saturated vapor pressure determines the temperature distribution range of particle nucleation.There is a minimum critical diameter of particles(~25 nm);particles smaller than the critical diameter can grow into larger particles during surface growth.Particle motion has an effect on the surface growth and aggregation process of particles,and also on the distribution area of larger-diameter particles.The simulation results are in good agreement with the experiments.We provide a method to estimate the size and distribution of nanoparticles,which is of great significance to understand the formation process of particles during the evolution of wire electrical explosion.