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The purpose of this paper is to extend the penalty concept to treat partial slip, free surface, contact and related boundary conditions in viscous flow simulation.

The penalty partial‐slip formulation is analysed and related to the classical Navier slip condition. The same penalty scheme also allows partial penetration through a boundary, hence the implementation of porous wall boundaries. The finite element method is used for investigating and interpreting penalty approaches to boundary conditions.

The generalised penalty approach is verified by means of a novel variant of the circular‐Couette flow problem, having partial slip on one of the cylindrical boundaries, for which an analytic solution is derived. Further verificationis provided by consideration of viscous flow over a sphere with partial slip on the surface, and comparison of numerical and classical solutions. Numerical studies illustrate the versatility of the approach.

The penalty approach is applied to some different boundaries: partial slip and partial penetration with no/full slip/penetration as limiting cases; free surface; space‐ and time‐varying boundary conditions which allow progressive contact over time. Application is made to curved and inclined boundaries. Sensitivity of flow to penalty parameters is an avenue for continued research, as is application of the penalty approach for non‐Newtonian flows.

This is the first work to show the relation between penalty formulation of boundary conditions and physical boundary conditions. It provides a method that overcomes past difficulties in implementing partial slip on boundaries of general shape, and which handles progressive contact. It also provides useful benchmark problems for future studies.

The surface characteristics of wood such as surface roughness, surface free energy (SFE) and wettability are important properties influencing further manufacturing processes such as gluing and coating. The purpose of this study is to determine the influence of surface roughness of ten tropical woods on their SFE, wettability and bonding quality for water-based acrylic and solvent-based alkyd varnishes.

The woods tested in this study were fast-growing teak, afrika, sungkai, mindi, merbau, durian, lamtoro, pulai, acacia and kempas. Wood surfaces were prepared in unsanded and sanded using an abrasive paper of 120 grits. SFE values were calculated based on the Rabel method. Wettability values were measured based on the contact angle between varnish liquids and wood surfaces using the sessile drop method, and the S/G model was used to evaluate the wettability of the varnishes on the woods surface. The bonding quality of the varnishes was measured using a cross-cut test based on the ASTM 3359-02 standard.

The results show that unsanded kempas wood had the roughest surface with a Ra value of 16.24 µm, whereas sanded lamtoro wood has the smoothest surface with a Ra value of 6.86 µm. The unsanded afrika wood had the highest SFE value of 53.61 mJ/m², whereas sanded fast-growing teak had the lowest SFE value of 36.17 mJ/m². Sanded merbau woods had the lowest K value of 0.022 for the water-based acrylic varnish, whereas unsanded afrika wood had the highest K value of 9.253 for the alkyd varnish. Afrika wood with the highest K values (highest wettability) for both acrylic and alkyd varnishes produced the highest bonding quality (grade 4-5). Compared to the water-based acrylic varnish, the solvent-based alkyd varnish was more wettable and generated better bonding quality.

Improving the quality of fast-growing wood from plantation by painting could be considered to increase their use for higher value wood products.

Compared to water-based acrylic varnish, solvent-based alkyd varnish was more wettable and generated better bonding quality.

The originality of this research is to evaluate the values of surface free energy. SFE could be used to quantitatively determined the wettability of paints liquid in the surface of wood

Refurbishing may be the most practical approach under the low volume production. This effort aims to achieve robotic laser cladding with the main purpose of achieving maximum processing flexibility, predictably high quality, lower maintenance and operating costs. This study aims to focus on online measurement and cladding path generation toward automatic laser cladding.

Based on the specific requirements of automatic laser cladding, an approach was proposed toward an automatic laser cladding with powder injection for the refurbishment of components with free‐form surfaces. This study assessed the feasibility of integrating a non‐contact free‐form surface measurement system, an industrial robot, and an algorithm for generating cladding tool paths seamlessly.

3D laser scanning and laser cladding systems can be embedded into an existing robot motion control system. Online measurement based 3D surface reconstruction is a practical approach toward cladding tool path generation for on‐site refurbishment.

Robotic laser cladding may be a potential application by integrating other measurement devices, such as temperature sensor based monitoring system.

Refurbishing worn‐out components could have significant economic benefits. This study indicates that robotic laser cladding may potentially facilitate improved refurbishment of oversized components.

A simple economic analysis has revealed that in order for wind energy to be a viable alternative, wind-turbines (convertors of wind energy into electrical energy) must be able to operate for at least 20 years, with only regular maintenance. However, wind-turbines built nowadays do not generally possess this level of reliability and durability. Specifically, due to the malfunction and failure of drive-trains/gear-boxes, many wind-turbines require major repairs after only three to five years in service. The paper aims to discuss these issues.

The subject of the present work is the so-called white etch cracking, one of the key processes responsible for the premature failure of gear-box roller-bearings. To address this problem, a multi-physics computational methodology is developed and used to analyze the problem of wind-turbine gear-box roller-bearing premature-failure. The main components of the proposed methodology include the analyses of: first, hydrogen dissolution and the accompanying grain-boundary embrittlement phenomena; second, hydrogen diffusion from the crack-wake into the adjacent unfractured material; third, the inter-granular fracture processes; and fourth, the kinematic and structural response of the bearing under service-loading conditions.

The results obtained clearly revealed the operation of the white-etch cracking phenomenon in wind-turbine gear-box roller-bearings and its dependence on the attendant loading and environmental conditions.

The present work attempts to make a contribution to the resolution of an important problem related to premature-failure and inferior reliability of wind-turbine gearboxes.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

This paper presents the results of the simulation of the forging of a connecting rod. The calculation has been carried out by the code FORGE3 developed at the CEMEF laboratory. FORGE3 is a three‐dimensional finite element computer program that can simulate hot forging of industrial parts. The flow problem is solved using a thermomechanical analysis. The mechanical resolution and the thermal one are coupled by the way of the consistency K which is thermodependent, the plastic deformation in the volume of the material and the friction heat flux on the surface. The material behaviour is assumed to be incompressible and viscoplastic (Norton—Hoff law) with the associated friction law. The thermal resolution includes the case of non‐linear physical properties and boundary conditions. An explicit Euler scheme is used for the mechanical resolution and two‐step schemes for the thermal one. For the computation of other parameters, it is necessary to have a good approximation for the strain rate tensor. The Orkisz method has been used to determine the deviatoric stress tensor and p is calculated by an original smoothing method. The results show that it is possible to get good information on the flow and on the physical properties during forging of automotive parts. Comparisons have been made with experimental measurements with a reasonably good agreement.

Focuses on the inverse problems arising from the simulation of forming processes. Considers two sets of problems: parameter identification and shape optimization. Both are solved using an optimization method for the minimization of a suitable objective function. The convergence and convergence rate of the method depend on the accuracy of the derivatives of this function. The sensitivity analysis is based on a discrete approach, e.g. the differentiation of the discrete problem equations. Describes the method for non‐linear, non‐steady‐state‐forming problems involving contact evolution. First, it is applied to the parameter identification and to the torsion test. It shows good convergence properties and proves to be very efficient for the identification of the material behaviour. Then, it is applied to the tool shape optimization in forging for a two‐step process. A few iterations of the inverse method make it possible to suggest a suitable shape for the preforming tools.

The purpose of this paper is to obtain the reasonable dimensioning for each part and a full-dimension model of assembly dimensions.

The relational path graph of assembly dimension, the shortest-path spanning tree of functional dimension and a revised spanning tree are established in this paper.

The proposed method can obtain reasonable dimensioning of parts and establishment of dimension model in an assembly.

The proposed method can easily realise by computer and be more suitable to automatic dimensioning and establishment of dimension model of parts.

Artificial contamination of chicken pieces with bioluminescent E. coli DH5a (pLITE 27) was used to examine the relationship between food hygiene interventions and the extent of contamination in a model kitchen. Analysis showed that, during the preparation of chicken casserole, bacteria were widely disseminated throughout the kitchen and equipment used. Food hygiene interventions were shown to reduce the extent of contamination. Demonstrates that effective cleaning and hand washing are important in preventing cross‐contamination in the domestic kitchen.