Optimization of design and operating parameters in a pilot scale Jameson cell for slime coal cleaning

The Jameson flotation cell has been commonly used to treat a variety of ores (lead, zinc, copper etc.), coal and industrial minerals at commercial scale since 1989. It is especially known to be highly efficient at fine and ultrafine coal recovery. However, although the Jameson cell has quite a simple structure, it may be largely inefficient if the design and operating parameters chosen are not appropriate. In this study, the design and operating parameters of a pilot scale Jameson cell were optimized to obtain a desired metallurgical performance in the slime coal flotation. The optimized design parameters are the nozzle type, the height of the nozzle above the pulp level, the downcomer diameter and the immersion depth of the downcomer. Among the operating parameters optimized are the collector dosage, the frother dosage, the percentage of solids and the froth height. In the optimum conditions, a clean coal with an ash content of 14.90% was obtained from the sample slime having 45.30% ash with a combustible recovery of 74.20%. In addition, a new type nozzle was developed for the Jameson cell, which led to an increase of about 9% in the combustible recovery value.     

A genetic algorithm approach to determine the sample size for attribute control charts

Determining the sample size for control charts (CCs) is generally an important problem in the literature. In this paper, Kaya and Engin’s [?. Kaya, O. Engin, A new approach to define sample size at attributes control chart in multistage processes: an application in engine piston manufacturing process, Journal of Materials Processing Technology 183 (2007) 38-48] model based on minimum cost and maximum acceptance probability to determine the sample size for attribute control charts (ACCs), and solved by genetic algorithms (GAs) with linear binary representation structure, is handled to solve it by a linear real-valued representation. A new chromosome structure is also suggested to increase the efficiency of GAs. The performance of GAs depends on mutation and crossover operators, and their ratios. To determine the most appropriate operators, five different mutation and crossover operators are used and they are compared with each other. An application in a motor engine factory is illustrated. u-Control charts are constructed with respect to the sample size determined by GA in the model. The piston production stages in this factory are monitorized using the obtained control charts.     

Adaptive Q control for tapping-mode nanoscanning using a piezoactuated bimorph probe

A new approach, called adaptive Q control, for tapping-mode atomic force microscopy (AFM) is introduced and implemented on a homemade AFM setup utilizing a laser Doppler vibrometer and a piezoactuated bimorph probe. In standard Q control, the effective Q factor of the scanning probe is adjusted prior to the scanning depending on the application. However, there is a trade-off in setting the effective Q factor of an AFM probe. The Q factor is either increased to reduce the tapping forces or decreased to increase the maximum achievable scan speed. Realizing these two benefits simultaneously using standard Q control is not possible. In adaptive Q control, the Q factor of the probe is set to an initial value as in standard Q control, but then modified on the fly during scanning when necessary to achieve this goal. In this article, we present the basic theory behind adaptive Q control, the electronics enabling the online modification of the probe's effective Q factor, and the results of the experiments comparing three different methods: scanning (a) without Q control, (b) with standard Q control, and (c) with adaptive Q control. The results show that the performance of adaptive Q control is superior to the other two methods.     

Reactive scheduling in a dynamic and stochastic FMS environment

In this paper, we study the reactive scheduling problems in a dynamic and stochastic manufacturing environment. Specifically, we develop a simulation-based scheduling system for flexible manufacturing systems. We also propose several reactive scheduling policies (i.e. when-to-schedule and how-to-schedule policies) and test their performances under various experimental conditions, processing time variations, and machine breakdowns. Moreover, we compare offline and online scheduling schemes in a dynamic manufacturing environment. The results of extensive simulation experiments indicate that the variable-time-response is better than the fixed-time-response. The full scheduling scheme generally performs better than the partial scheduling. Finally, the online scheduling is more robust to uncertainty and variations in processing times than the optimum-seeking offline scheduling. A comprehensive bibliography is also provided in the paper.     

Vibro-acoustic analysis of free piston engine structure using finite element and boundary element methods

This paper presents the results of vibro-acoustic modeling and simulation using the finite element and the boundary element methods for the free piston engine structure. A model of the engine was constructed through the use of finite element software to perform a normal mode analysis of the engine structure. The objective was to determine the mode shapes and the natural frequency that contribute to engine structure vibration. Theoretical development of the engine balance motion and frequency response was also conducted. From the simulation and finite element analysis, the force response pattern of the engine vibration was determined and then compared with its natural frequency. The vibration data were used as the input data for noise analysis using the boundary element method. The integration of the finite element and the boundary element determined the noise-frequency data of the engine structure toward the occurrence of engine noise. The information can be used by designers to analyze engine specifications and structure, especially at the preliminary design stage.     

Investigation of surface roughness in the milling of Al7075 and open-cell SiC foam composite and optimization of machining parameters

In the present study, aluminum alloy 7075 (Al7075)-based open-cell silicon carbide (SiC) foam composite was fabricated and the machinability of both Al7075 and the open-cell SiC foam Al metal matrix composite was investigated during milling using an uncoated carbide tool. The machining trials were conducted using the Taguchi L₂₇ full-factorial orthogonal array, and the milling parameters were optimized for surface roughness. Analysis of variance was employed to determine the effect of the cutting variables on surface roughness. The experimental results were evaluated by signal-to-noise ratio, 3D surface graphs, artificial neural networks (ANNs) and main effect graphs. The analysis results show that the feed rate was the most significant milling parameter affecting surface roughness of both Al7075 and the open-cell SiC foam composite. Prediction models have been developed for the surface roughness through regression analysis and ANNs. Confirmation experiments were performed to identify the performance of mathematical models, and the surface roughness was predicted with a mean squared error equal to 1.6 and 0.24 % in the milling of Al7075 and open-cell SiC foam composite, respectively. The test result showed that the three-dimensional open-pore SiC foam network reinforcement was restricted the movement of the soft matrix and provided an acceptable surface quality in the milling of MMCs.

     

Comparison of the mechanical and biological properties of self-adhering materials

Purpose: The purpose of the present study was to compare the Vickers hardness numbers (VHNs), roughness numbers (RNs) and biological compatibility of glass carbomer (Glass Fill), resin-modified glass ionomer (Fuji II LC) and self-adhering flowable composite (Vertise Flow) materials. Materials and methods: Disc-shaped specimens of test materials (n = 15/group) were prepared, and VHNs and RNs were determined after 24 h. A direct contact test was used for cytotoxicity evaluation. Cell viability was measured for 24 h post-exposition with a photometric test (MTT assay; n = 16). Data were analysed using one-way analysis of variance with a post hoc Tukey’s test, the Kruskal–Wallis test and the Mann–Whitney U-test (p < 0.05). Results: Fuji II LC had the highest VHN. The VHN of Fuji II LC differed significantly from those of the other materials (p < 0.05). The RNs of Fuji II and Glass Fill were higher than that of Vertise Flow (p < 0.05). The self-adhering materials were not significantly cytotoxic compared with the control group (p > 0.05). Conclusions: The materials tested in this study showed a similar lack of cytotoxicity. The VHN of Fuji II LC was the highest, and the RN of Vertise Flow was the lowest.     

Determination of radiation attenuation coefficients of heavyweight- and normal-weight concretes containing colemanite and barite for 0.663 MeV γ-rays

Accurate measurements have been made to determine radiation transmission of concretes produced with barite, colemanite and normal aggregate by using beam transmission method for 0.663 MeV γ-rays energy of ¹³⁷Cs radioactive isotopes by using NaI(Tl) scintillation detector. Linear and mass attenuation coefficients of thirteen heavy- and four normal-weight concretes were calculated. It was determined that the linear attenuation coefficient (μ, cm⁻¹) decreased with colemanite concentration and increased with barite concentration in both type of the concretes. Mass attenuation coefficient values of our concretes were compared with the values proposed by the United States National Institute of Standards and Technology (NIST).     

The investigation of the effect of thermal barrier coating on the performance of Stirling engine

The shuttle heat transfer is one of the reasons reducing the performance of Stirling engines. This study is concerned with the reduction in shuttle heat transfer by coating the displacer. The displacer of a gamma type Stirling engine was coated with a layer of yttria‐stabilized zirconia (YSZ), and the effect of the coating on the engine performance was evaluated by comparing speed‐power and speed‐torque characteristics of the engine with coated and uncoated displacers. Characteristics were obtained for 700, 800 and 900°C heater temperatures. At each stage of the heater temperature, the charge pressure ranged from 1 to 3.5 bars with 0.5 bar increments. At 900°C heater temperature and 3 bars charge pressure, the shaft power before coating was 34.9 W, after coating the power increased to 43.8 W, which corresponds to a 25% increment. The temperature applied to the engine did not cause any damage on the coating layer. Copyright © 2008 John Wiley & Sons, Ltd.