Jul 052018

ABSTRACT

In our laboratory, we are interested in a model based realization of complex system and the complex system we are looking at is a steel manufacturing process chain. Our industrial partners are Tata Consulting Services in India. Their goal is to be able to produce a gear that can be used in cars and other machines. Producing a gear consists of numerous intermediate stages starting from producing steel. The process that we are interested in is the hot rolling with the end goal of producing a rod, which can be further modified to produce a gear. Further processes that come after rolling have already been studied.

We look at the hot rod rolling problem in a top down approach i.e. identifying the goal first and then work backwards to find the factors and variables required to reach these goals. We have made some assumptions about the strain rate and the interpass time involved to provide a focus to this study. Relating to those are certain conflicting goals we have to achieve. Using a decision based construct, compromise Decision Support Problem (cDSP), we can explore the solution space and identify the most satisficing initial variable values that will provide the microstructure we require for the rod.

Feb 192018

Reflection – February 19, 2017  

Planned action items

This week

  • I had to learn more about hot forging
  • Read Anand’s recent paper
  • Through the inverse method Anand is following, learn more about the different recrystallization and its theoretical models

Achieved action items

  • I gained an insight that cDSP is a very important tool applied in numerous different scenarios from Dr. Mistree’s lecture on 2/13.
  • Hot forging
  • Importance of Anand’s research paper and his inverse method to be able to model the hot rod rolling phenomenon for TATA.
  • For my poster, I will be looking at solving a small problem dealing with grain growth and cDSP.
Feb 052018

Reflection – February 5, 2017

Planned action items

The plan was this week to finish off where I left reading from Wusatowski assigned by Anand. After that, get a head start on the recent publications from the lab. Also, I was supposed to make the personal presentation this week.

Achieved action items

This week was just to learn more about the hot rolling process and the different parameters involved.

  • More on recrystallization and different kings
  • Hot rolling and different conditions required.
  • Equipment required and various conditions that these must go through
  • Importance of different mechanisms such as grain growth and strain hardening
  • Constant volume law and its modifications during plastic deformations
  • Importance of IDEM – Integrated Design Exploration Method
  • Hot rolling in context of gear manufacturing
  • Importance of managing uncertainties
  • PowerPoint skills
Aug 022017

1.      Frame of reference

Previous three industrial revolutions happened due to the introduction of radical ideas, let it be, mechanics electricity or an introduction of the programmable logic[1]. The instigators of these revolutions have now become foundational to the numerous manufacturing processes. Similarly, in the recent times, Internet and advanced computational processes are becoming the upcoming platforms to expand the concurrent manufacturing sector. With such evidence of change in the current scenario and the exponential rate of acceptance in the industry, fourth industrial revolution is bound to take place in the next 20-30 years [1].

Current scenarios focus solely on the product development. However, it’s not just about the end-product anymore. As the US economy is moving towards becoming a service economy, the products need to be designed placing the customers at the pedestal. This is further amplified due to an ever-high level of competition between firms. For this purpose, an inverse goal-oriented decision based design (IGODBD) method is proposed to facilitate the movement from the design to the manufacturing unit quickly[2]. Another condition that will enable the manufacturing company to become a global leader will be how sustainable the processes involved are. Keeping these two in mind, the goal will be on innovation to provide a maximum utility to maximum customers. In the age of globalisation and interconnections between countries, the manufacturing company will also be required to reach other countries, either for personal technological advancements from other developed nations or to help create a technological revolution in other developing nations. Various research obstacles and mind-set changes will be required to make the manufacturing enterprise a global leader by 2030, which will be explained in detail in their corresponding sections. As displayed in Figure 1, our focus in on changing the manufacturing process instead of bringing new ideas or modifying the product. This is the challenge that how do we continue to satisfy our wants in the way we already are but in a more sustainable way.

Feb 262017

Reflection – February 26, 2017  

Planned action items

This week

  • Learn conceptually about the various parameters involved in the hot rod rolling process
  • Read about the case study of the Vanadium steel in the LPC book
  • Get started on the NSF Essay competition

Achieved action items

  • I gained a deeper understanding of the cDSP and the mathematics behind it by attending Dr. Mistree’s lecture on 2/20.
  • Learnt, conceptually, more about SRX, DRX, MDRX and GG – different stages of recrystallization and grain growth.
  • The case study helped me to connect the problem to the reality
  • Through the SRL presentation and the poster fair, I was bombarded with numerous ideas for my own poster.
Jan 292017

Reflection – January 29, 2017

Planned action items

The plan this week was to read enhance my knowledge in hot rolling processes. This week I was supposed to read the Chapter 1of Mathematical and Physics Simulation of the Properties of Hot Rolled Products by LPC (last name initials of the author) and get started on the first 30 pages of Fundamentals of Rolling by Wusatowski.

Achieved action items

This week was just to learn more about the hot rolling process and the different parameters involved.

  • Different processes involved in hot rolling and cold rolling and the difference between the two.
  • Looking at tribology involved in the hot rolling process. How is friction managed and the importance of lubrication
  • Plastic working of metals – elastic and plastic deformations
  • Stress and the elongation graph to show the elastic and plastic deformation limit of steel.
  • Different kinds of deformations and properties when deformed.
  • Cold work and strain hardening – measurement of degree of cold work
  • Recrystallization
Jan 222017

Reflection – January 22, 2017

Planned action items

My plan was to read Anand’s paper the way Dr. Mistree had asked me to in the email and also read a chapter from the more focused rolling book.

Achieved action items

I have tried to gain a thorough understanding of Anand’s paper on sequential, goal oriented manufacturing process, which has now been published.

Jan 062017

Reflection – January 06, 2017

Planned action items

  • Read Chapter 4, 6, 7 and 9 from William D. Callister book (7th edition)

Achieved action items

  • This week, I was able to go through the chapter 4, 6, 7 and 9 (until 9.8)
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