Optimization of the Interface Between Catalyst Layer and Proton Exchange Membrane via rolled technique

Optimization of the interface between the catalyst layer (CL) and the proton exchange membrane (PEM) plays an important role in performance enhancement in proton exchange membrane fuel cells (PEMFCs). Here, a rolled technique was used to optimize the PEM|CL interface to obtain a smooth CL surface with decreased roughness from 0.347 to 0.266 μm due to the reduction of protrusions after the rolled process. Advantages of the optimized PEM|CL interface formed after decal transfer method were carefully evaluated. First, the internal resistance of the rolled CL is significantly reduced from 61.5 to 47.5 mΩ cm2@2000 mA/cm2, which is ascribed to the higher contact area between CL and PEM. Meanwhile, owning to the alleviation of liquid water accumulation at the interface, the oxygen transport resistance at no back pressure of CL dropped from 0.21 to 0.15 s/cm. The relieved ohm polarization and mass transfer polarization promote a 28.5% increase of performance. Rolled technique with proper calendrer roll space could result in an optimized interface with well-maintained internal structural integrity of CL. However, a lower calendrer roll gap will damage the structure of CL and have a negative effect on the interface optimization.

Investigation of the wear of rolls in asymmetric rolling

In the present work, both symmetric and asymmetric rolling processes were investigated by means of numerical approaches. From the algorithm presented, the values of rolling pressure and sliding velocity in the roll gap were determined. These variables allow the estimation of tribological parameters of a given material. To determine the wear of the rolls and rolled materials the Archard's law has been employed. Results of numerical simulations show that the quantitative characteristics of the wear reveal a slight change for slower roll. Whereas the wear value for the faster roll increases with an increase of roll velocity ratio. It was found that for a given roll velocity ratio, rise of friction coefficient causes insignificant change in the wear value for the slower roll, while this value tends to decrease rapidly for the faster roll.

Advancement of Roll-Gap Control to Curb the Camber in Heavy-Plate Rolling Mills

The quality of steelwork products depends on the geometric precision of flat products. Heavy-plate rolling mills produce plates for large-diameter pipes and for use in shipbuilding, mechanical engineering, and construction. This is why the precision requirements are so stringent. Today’s Mills 5000 produce flat products of up to 5 m in width; the operation of these units shows ‘camber’ defects and axial shift of the roll at the stand exit point. This induces greater loss of metal due to edge trimming and involves a higher risk of accidents. These defects mainly occur due to the asymmetry in the roll gap, which is in turn caused by their misalignment in rolling. As a result, the feed varies in gauge, and the strip moves unevenly. The paper’s key contribution consists in theoretical and experimental substantiation and development of a set of control methods intended to address roll-gap asymmetry. The methods effectively compensate for the asymmetry resulting from the “inherited” wedge, which preexists before the strip enters the stand. They also compensate for the “ongoing” roll misalignment that is caused by the difference in force on the opposite side of the stand during rolling. This comprehensive approach to addressing camber and axial displacement of the feed has not been found in other sources. This paper presents a RAC controller connection diagram that ensures that the roll gap is even across the feed. The paper notes the shortcomings of the design configuration of the controller and shows how it could be improved. The authors have developed a predictive roll-gap asymmetry adjustment method that compensates for the deviations in gauge during the inter-passage pauses. They have also developed a method to control gap misalignment during rolling. The paper showcases the feasibility of a proportional-derivative RAC. The methods have been tested by mathematical modeling and experimentally. The paper further shows oscillograms sampled at Mill 5000 after implementing the developed solutions. Tests confirm far better precision of the screw-down mechanisms on the opposite sides of the stand. This reduces the variation in gauge across the feed and thus curbs the camber defect. As a result, the geometry of the flat improves, and less metal is lost in trimming. The paper further discusses how the RAC controller interacts with the automatic gauge control system. The conclusion is that these systems do not interfere with each other. The developed systems have proceeded to pilot testing.

Experimental Validation and Numerical Simulation of Flexible and Micro-scale Roll Gap Control Technology

To obtain a better ability of strip flatness control, this paper proposes a new flexible and micro-scale roll gap control technology. According to the principle of roll profile electromagnetic control technology (RPECT), a new electromagnetic control rolling mill with the function of roll profile control and large diameter ratio rolling is designed and built. To analyze the flatness control ability of this mill, a comprehensive finite element model (FEM) is established and verified, which includes a FEM for predicting the electromagnetic control roll profile and a FEM of rolling process. The simulation results show that the crown control ability of RPECT is stronger than the quadratic crown control ability, and the effect of tension on the roll gap shape crown is small. The results in the indentation experiment and the rolling experiment show that increasing the roll crown of electromagnetic control roll can adjust the strip shape form edge wave to non-wave, and middle wave. The feasibility of using RPECT to adjust the roll gap shape has been verified, and the roll gap control goal of uniform transverse size distribution can be achieved.

An Investigation into the Effect of Rolling Reduction on 3D Curved Parts Rolling Process

Rolling technology based on arc-shaped rollers is a novel method for rapid manufacturing of 3D curved parts. The method uses a pair of arc-shaped rollers (a convex roller and a concave roller) as forming tools, forming an unevenly distributed roll gap. The sheet metal has both transverse bending and longitudinal uneven extension during rolling, so that surface parts with double curvature are processed. The curvature of the formed surface part can be changed by changing the rolling reduction. Changing the vertical distance between the rollers will cause the overall change of the roll gap height, which will inevitably have a great impact on the forming effect of formed 3D curved parts. In this paper, a finite element model and experiment with different rolling reductions was designed; the influence of rolling reduction on the bending deformation and shape accuracy of formed 3D curved parts was studied. The results show that, with the slight increase of rolling reduction (from 0.04 to 0.12 mm), the longitudinal bending deformation of the formed 3D curved part increases significantly, but its transversal bending is almost not affected. When the maximum rolling reduction is 0.04 and 0.06 mm (the corresponding minimum rolling reduction is less than or equal to zero), the shape accuracy of the formed 3D curved parts is not good enough; when the maximum rolling reduction is greater than 0.06 mm (the corresponding minimum rolling reduction is greater than zero), the shape accuracy of the formed 3D curved parts is significantly better. This indicates that, for the rolling of 3D curved parts based on arc-shaped rollers, ensuring that the minimum rolling reduction is greater than zero is the key to ensuring good shape accuracy of the formed 3D curved parts.

Effect of Forage Processor Roll Gap Width and Storage Length on Fermentation Profile, Nutrient Composition, Kernel Processing Score, and Starch Disappearance of Whole-Plant Maize Silage Harvested at Three Different Maturities

Our objective was to assess the effect of forage processor roll gap width and storage length on fermentation, nutrient composition, kernel processing score (KPS), and ruminal in situ starch disappearance (isSD) of whole-plant maize silage harvested at different maturities. Samples from a single maize silage hybrid at three harvest maturities (1/4, 1/2, and 3/4 kernel milk line (early, intermediate, and late, respectively)) processed with two roll gap widths (1 and 3 mm) were collected and stored in quadruplicate vacuum pouches for 0, 30, 120, or 240 d. Lactic acid concentrations were greater, and pH was reduced in early and intermediate maturity silage compared to late maturity silage. Ruminal isSD was greatest for early maturity silage, intermediate for the intermediate maturity silage, and lowest for the late maturity silage, but differences in isSD due to maturity were diminished after prolonged storage. Kernel processing score was greatest in late maturity silage processed through a 1 mm roll gap and lowest in late maturity silage processed through the 3 mm roll gap. For early and intermediate maturity silages, no differences in KPS were observed between the two roll gap widths. Minimal effects of maturity and roll gap width on fatty acids (FA) and amino acids (AA) were observed. Concentrations of total AA decreased as storage length progressed. Results support the premise that the silo is a dynamic system that undergoes numerous chemical changes throughout the storage period.

Methods for online measurement and control of section deviations during hot rolling of wire rod and bars

In the joint project PIREF, the metal forming group of the University of Duisburg-Essen has collaborated with the University of Applied Sciences Ruhr-West Mülheim (Ruhr), the University of Siegen, EMG Automation GmbH and SMS group GmbH to develop sensors, for an online measurement of material velocity and cross section as well as control models for the rolling process of wire rod and bars. The University of Duisburg-Essen provided a metal forming process model for the rolling process to assess the influencing parameters on the rolled section precision. A technique was found to segregate height- from width- influencing parameters from a measured cross-sectional area and actual roll gap. With this measuring technology and with help of the process model, rules for control of the rolling process to achieve close tolerances were obtained. The modelling was accompanied by rolling trials on a laboratory rolling mill at the University of Duisburg-Essen, where a typical Round-OvalRound pass sequence was used for validation of the rolling model concerning lateral spread, inlet and outlet velocity as well as rolling force and torque calculation. The present paper shows how the material flow and the distribution of the velocity in the roll gap can be described. In subsequent rolling of bar and rod in a continuous rolling mill the dimensions can be influenced by application of longitudinal stresses and screwdown. The application of stress can be achieved by an inter-stand velocity mismatch. With the developed models the necessary velocity mismatch can be calculated.

Potential of process information transfer along the process chain of hybrid components for process monitoring of the cutting process

The production of hybrid components involves a long process chain, which leads to high investment costs even before machining. To increase process safety and process quality during finishing, it is necessary to provide information about the semi-finished parts geometry for the machining process and to identify defect components at an early stage. This paper presents an investigation to predict variations in dimension and cavities inside the material during cross-wedge rolling of shafts based on measured tool pressure. First, the process is investigated with respect to the variation in diameter for three roll gaps and two materials. Subsequently, features are generated from the hydraulic pressures of the tools and multi-linear regression models are developed in order to determine the resulting diameters of the shaft shoulder. These models show better prediction accuracy than models based on meta-data about set roll gap and formed material. The features are additionally used to successfully monitor the process with regard to the Mannesmann effect. Finally, a sensor concept for a new cross-wedge rolling machine to improve the prediction of the workpiece geometry and a new approach for monitoring machining processes of workpieces with dimensional variations are presented for upcoming studies.

The Difficulties of Predicting the Coefficient of Friction in Cold Flat Rolling

The flat rolling process is initiated when the frictional forces draw the strip to be rolled into the roll gap. These forces depend on the coefficient of friction, knowledge of which is essential to understand, describe, and analyze the process. Several predictive formulae for the coefficient have been presented in the technical literature. Contradictions are observed, however, when their predictions are compared to each other. The data obtained while cold rolling aluminum and steel strips are used in the analyses. A model of the rolling process—accounting for strain hardening, frictional events, and varying speeds—is then used to determine the coefficients of friction. The use of statistical analyses is found to yield more reliable results than the use of the predictive relations.