The document discusses redesigning the structure of a main spindle box for a machine tool using polymer concrete instead of cast iron. It summarizes the process undertaken, which included static, dynamic, and thermal analysis of the original cast iron design and redesigned polymer concrete design. The analyses showed the polymer concrete design had higher natural frequencies, better damping performance, and a 50% reduced mass compared to the original cast iron design while still meeting structural requirements. The document concludes the redesign successfully demonstrated the feasibility of using polymer concrete for machine tool structures.
Walia International Machines is a multi divisional,vacuum de watering machine,vacuum dewatering machine,vacuum dewatering machines,vacuum de dewatering machines
Address : Walia International Machines Corporation,408 Vishwadeep , District Centre, Janak Puri New Delhi- 110058,India
Website : http://waliainternational.com
Telefax : 011 – 25546044 ,25521275
Emails : info@waliainternational.com
what is polymer concrete, types, properties, material used in manufacturing process , manufacturing process, applications and their advantages. case study on polymer composite concrete.
Abstract Concrete plays important role in the construction industry but it has some drawbacks . To overcome this drawbacks the search for durable and sustainable construction materials is the need of time. This leads to the developments of concrete composites in combination of various compounds to be used in many applications in world of cement concrete. A better knowledge of materials behaviour, especially in the field of admixtures, and a better understanding of curing processes allowed the development of highly performing mineral or modified mineral concretes, mortars and grouts. The world of concrete with fibres, as well as the world of concrete- with polymer has been undergoing major researches to enhance the properties of traditional concrete. Both worlds recognize, strive for and accept each other’s contribution to the synergic effects that are realized by the combination of classical building materials and polymers. This paper briefly review the use concrete composites in combination with polymer, where polymers are in the form of a polymerised matrix comingled with the hydrated cement paste. The micro-structure and properties of composite polymer modified concrete are described and some current possible applications are mentioned. It is observed that using fibers in combination with polymer show further enhancement.Various methodology, emerging trends as well as variations in curing techniques for polymer modified concrete are observed. Also the modern strengthening techniques used for improving the earthquake behaviour of structures, by aid of fibre reinforced polymers (FRP) are discussed for the use of rehabilitation of existing structures.Several recently published articles and technical papers dealing polymer modified concrete are critically reviewed. Keywords: Polymer, SBR latex, Acrylic polymer, Steel fiber.
Walia International Machines is a multi divisional,vacuum de watering machine,vacuum dewatering machine,vacuum dewatering machines,vacuum de dewatering machines
Address : Walia International Machines Corporation,408 Vishwadeep , District Centre, Janak Puri New Delhi- 110058,India
Website : http://waliainternational.com
Telefax : 011 – 25546044 ,25521275
Emails : info@waliainternational.com
what is polymer concrete, types, properties, material used in manufacturing process , manufacturing process, applications and their advantages. case study on polymer composite concrete.
Abstract Concrete plays important role in the construction industry but it has some drawbacks . To overcome this drawbacks the search for durable and sustainable construction materials is the need of time. This leads to the developments of concrete composites in combination of various compounds to be used in many applications in world of cement concrete. A better knowledge of materials behaviour, especially in the field of admixtures, and a better understanding of curing processes allowed the development of highly performing mineral or modified mineral concretes, mortars and grouts. The world of concrete with fibres, as well as the world of concrete- with polymer has been undergoing major researches to enhance the properties of traditional concrete. Both worlds recognize, strive for and accept each other’s contribution to the synergic effects that are realized by the combination of classical building materials and polymers. This paper briefly review the use concrete composites in combination with polymer, where polymers are in the form of a polymerised matrix comingled with the hydrated cement paste. The micro-structure and properties of composite polymer modified concrete are described and some current possible applications are mentioned. It is observed that using fibers in combination with polymer show further enhancement.Various methodology, emerging trends as well as variations in curing techniques for polymer modified concrete are observed. Also the modern strengthening techniques used for improving the earthquake behaviour of structures, by aid of fibre reinforced polymers (FRP) are discussed for the use of rehabilitation of existing structures.Several recently published articles and technical papers dealing polymer modified concrete are critically reviewed. Keywords: Polymer, SBR latex, Acrylic polymer, Steel fiber.
Concrete can form any shape, design, different color, pattern, texture. Coloured concrete is the best flooring option to enhance the richness of the floor.
The project was undertaken to design M50 grade concrete using GGBS cement and POZZOLANA cement and comparing the fresh concrete and hard concrete properties with concrete designed using conventional cement.
you would be aware about the different types of special concrete being used in india.All these types of concrete are being produced by ultratech concrete, for more details visit www.ultratechconcrete.com/concrete_types.html
Concrete is the most widely used construction material in India with annual consumption exceeding 100 million cubic meters.
High performance concrete is a concrete in which certain characteristics are developed for a particular application and environment, so that it will give excellent performance in the structure in which it will be placed.
A high-strength concrete is always a high performance concrete, but a high-performance concrete is not always a high-strength concrete.
concrete, presentation includes ingredients of concrete , how we can achieve high strength of concrete in less days of curing, practically shown in the presentation according to the standards of ACI.
Advanced Polymer Nanocomposites for 3D printing in SpaceColeman Fincher
Space and at-sea environments pose significant challenges due, in part, to logistics associated with repair and replacement of worn or damaged equipment. These technical and economic challenges may be significantly mitigated through the use of Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM) 3D printing, as a method to produce desired repair parts at the point of usage. However, most state-of-art polymers generally employed in AM possess relatively low melting points and poor ratings in terms of fire, smoke, and toxicity.
We have developed an FDM filament and modifications to an existing FDM process to allow printing of thermally stable and flame resistant polymeric parts.
Concrete can form any shape, design, different color, pattern, texture. Coloured concrete is the best flooring option to enhance the richness of the floor.
The project was undertaken to design M50 grade concrete using GGBS cement and POZZOLANA cement and comparing the fresh concrete and hard concrete properties with concrete designed using conventional cement.
you would be aware about the different types of special concrete being used in india.All these types of concrete are being produced by ultratech concrete, for more details visit www.ultratechconcrete.com/concrete_types.html
Concrete is the most widely used construction material in India with annual consumption exceeding 100 million cubic meters.
High performance concrete is a concrete in which certain characteristics are developed for a particular application and environment, so that it will give excellent performance in the structure in which it will be placed.
A high-strength concrete is always a high performance concrete, but a high-performance concrete is not always a high-strength concrete.
concrete, presentation includes ingredients of concrete , how we can achieve high strength of concrete in less days of curing, practically shown in the presentation according to the standards of ACI.
Advanced Polymer Nanocomposites for 3D printing in SpaceColeman Fincher
Space and at-sea environments pose significant challenges due, in part, to logistics associated with repair and replacement of worn or damaged equipment. These technical and economic challenges may be significantly mitigated through the use of Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM) 3D printing, as a method to produce desired repair parts at the point of usage. However, most state-of-art polymers generally employed in AM possess relatively low melting points and poor ratings in terms of fire, smoke, and toxicity.
We have developed an FDM filament and modifications to an existing FDM process to allow printing of thermally stable and flame resistant polymeric parts.
A crack is a complete or incomplete separation of concrete into two or more parts produced by breaking or fracturing.
Cracks are one kind of universal problems of concrete construction as it affects the building artistic and it also destroys the wall’s integrity, affects the structure safety and even reduce the durability of structure
Carbon dioxide penetrates into the concrete through the cracks and speed up carbonation around the cracks, thus shortening the structure usage.
The cracks in the concrete wall would cause the leakage of the building; it reduces the stiffness, durability and seismic performance of buildings.
Cracks on the wall surface damage to the later rendering, will affect to the appearance.
Reasons and solution to cracks in buildings.
<div dir="ltr"><br>Reasons and solution to cracks in buildings.<br><blockquote style="margin: 1.5em 0pt;"></blockquote></div>
COMPARATIVE ANALYSIS OF CHEMICAL AND PHYSICAL PROPERTIES OF MINI CEMENT PLANT...Journal For Research
This research is about analyzing the chemical and physical characteristics of cement and concrete. Cement can be classified based on its chemical properties. The sample taken for this research work is Kamal OPC 53 grade mini cement plant and Ultratech OPC 53 grade major cement plant. The difference can be analyzed by determining the chemical composition of the cement and its effect on physical properties of cement and concrete. Secondly, it is not necessary that in every structural member of a building, the cement used needs to be same. To determine that which cement is more suitable for which structural element this analysis is beneficial. Again, if any new type of admixture needs to be introduced in the concrete, it is important to understand the chemical composition of cement and how the new admixture may react with the cement. Also, this research is about how the changes in chemical composition of cement affect the physical properties of cement and concrete. It is noticed that due to lack in standardization of cement, even the same sample of cement gives different result.
The Research on Process and Application of Self-Compacting ConcreteIJERA Editor
Self-compacting concrete (SCC) is one kind of concrete with high workability and durability. First of all, this paper introduces the definition and history of Self-compacting concrete (SCC). Secondly, it introduces the raw material selection, equipped technology and the mix proportion design method of Self-compacting concrete. Finally, it analyzes the problems and countermeasures of self-compacting concrete and look ahead the application prospect of it.
Study Of Mechanical Properties Of High Strength Concrete By Partial Replaceme...dbpublications
Concrete is considered as durable and strong material. Concrete is one of the most popular material used for constructions. The present investigation deals with High strength concrete of M60 by adding fiber material to strengthen the concrete. Partial replacement of OPC with fly ash in percentages of 0%, 5% and10% in various ratios and also add Masterpel777, super plastisizer for workability purpose. Exposure periods of 7, 14 and 28 days on various tests. In this project we have designed M60 grade concrete using Design mix of Department of Environment method of various strengths.
Overview of Soil Stabilization :Cement / Lime :PPTAniket Pateriya
Soil-cement is frequently used as a construction material for pipe bedding, slope protection, and road construction as a sub-base layer reinforcing and protecting the subgrade. It has good compressive and shear strength, but is brittle and has low tensile strength, so it is prone to forming cracks.
Lime can be used to treat soils to varying degrees, depending upon the objective. The least amount of treatment is used to dry and temporarily modify soils. Such treatment produces a working platform for construction or temporary roads. A greater degree of treatment supported by testing, design, and proper construction techniques--produces permanent structural stabilization of soils.
Repairing of Concrete by Using Polymer-Mortar CompositesIJMER
Abstract: Replacement of concrete buildings, bridges, roadways and other structures is becoming more and more expensive as costs of materials and labor continue their upward spiral. Polymermodified or polymer cement mortar (PCM) and concrete (PCC) are a category of concrete-polymer composites which are made from cement mortar or concrete with polymers, The main application of
polymer cements is in concrete repair. In this research two sets of mixtures were prepared that consist of mortar and polymer to fabricate the polymer-cement composite. The first set include mortar with ratio (1:1) (cement-sand) without water, while the other set include mortar with ratio (1:2) (cementsand) without water. The polymer was Quickmast105 epoxy which is added to the mortar after mixing the resin with the hardener in proportion of (1:3). Each set was consist of different percentage of
polymer (50:50, 40:60 and 30:70). Tests were conducted, including compression, flexural and bonding strength, were several results obtained including, the highest compressive strength was about 102.889MPa and the highest value of flexural strength was about 57.648MPa for (1:1), the polymermortar with 40:60 ratio showed a higher bonding compressive strength. Proportionality between the
cement and sand and also between the polymer and mortar plays a major role in adhesion and strength are considered key factors in the bonding and portability to repairs.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
2. 1. INTRODUCTION
International of mcompetition in machine tool manufacture demands flexibility, high
quality, reaction to the market demands and low costs. Therefore the processes and
machines are designed with modular structure. A main spindle box could be such a
module achine tool.
The most important factor affecting machining accuracy is an accuracy of
the machine tool itself resulting from low stiffness and damping ratio of machine tool
structure. In this paperthe feasibility of applying new material is studied in order to
improve static and dynamicperformances of the structure to desire level. The new
design of a main spindle box structure is made of polymer concrete instead of cast iron
structure [1, 2, 3].
Polymer concrete consists of a mineral filler and a polymer binder. When
sand is used as filler, the composite is referred to as a polymer concrete. Generally,
any dry, non-absorbent, solid material can be used as filler [1, 2, 3].
The sand and the fillers are cheap and natural materials available for easy
use. The overall process of production of polymer concrete is performed on room
temperature and recycling of the materials is much easier than cast iron. Also, the
control of the properties of polymer concrete may be much easier and less costly in
comparison with cast iron. As a results of the above and some other advantages
(flexibility of the design, short development time, simple and less costly production
process) the overall competitive advantages of the company may significantly improve
[1].
4. 2. REDESIGN OF SPINDLE BOX WITH POLYMER CONCRETE
The aim of this investigation is the possibilities of use of polymer concrete in building
machine tools structures. For that purpose, the NC lathe Mazak QT 10 headstock’s
housing is completely redesigned and polymer concrete constructive material has been
chosen and applied.
The available references [1, 2, 3] have shown same examples of use of
polymer concrete in substitution of cast iron in the design of machine tool beds. We
have decided to investigate the possibilities of the use of polymer concrete in main
spindle housing design due to the more demanding requirements connected with the
dissipation of temperature, damping and high accuracy of the structure. To be able to
redesign the original housing for the purpose of material substitution, we have
performed static, dynamic and thermal analysis of the structure.
The differences in the material properties (table 1) have initiated an iterative
process of redesign with the aim to achieve properties of the original design. Both
models, of original and redesigned housing are shown on figure 1.
5. a. Original b. Redesigned
Figure 1. Models of main spindle housing
6. 3. THEORETICAL AND EXPERIMENTAL STUDY OF NEW DESIGN
We have performed wide numerical and experimental investigations of static, dynamic and
thermal behaviour of original and redesigned housing, part of which are presented in this article.
3.1. Statical Modelling and Analysis
Modelling and processing of housing were performed with the use of ALGOR
and I-DEAS commercial packages [1]. Figure 2 shows maximal principal stresses of both
models. Comparative analyses of the statical characteristics (displacements, Von Mises,
Maximal Principal Stress, Mass and Young’s module) of both housings (original and
redesigned) are shown on figure 3. Despite worsening of Von Mises and maximal Principal
Stress the new design satisfied the limits. We have reduction of mass of redesigned housing
for approximately 50% in comparison with the original design which strongly recommend
the use
of polymer concrete [1].
7. a. Original b. Redesigned
Figure 2: Maximal Principal Stress of Models
8. 3.2 Dynamical Modelling and Analysis
We have used the same models, developed with ALGOR and I-DEAS,
for dynamic analysis of both housings [1]. The comparative analysis of Eugene
frequencies of both models is shown in figure 4. As we can see the Eugene
frequencies of polymer concrete design are twice higher then those of cast iron
design which represents certain improvement of the design. Figure 5 shown
comparative analysis of the experimental data of the damping ratio of both
designs. The results show superior performances of polymer concrete housing in
comparison with cast iron structure [1].
12. While two types of aggregate, ocean sand and Sierra Nevada
pea gravel, are fed into the hopper of the mixer, a pipe mixer
adds blended polyester resin. A screw-type auger thoroughly
mixes these materials then feeds them into the slip form paver
for placement.
13. After placing the overlay, workers use
a nuclear density tester to test its
compaction and density. Compaction
on this job averaged 99% to 100% of
the standard, exceeding the minimum
specifications of 97%. The overlay also
was tested for polyester resin content.
Results showed a content of about 11.05%.
14. Before choosing a resin binder, check its specifications
carefully. A good binder should have:
• A low viscosity so it’s easy to mix, place, and finish (viscosity can be varied
somewhat to accommodate different applications methods)
• A 15- to 45-minute gel time to give workers enough time to place and finish the
overlay before it cures
• No solvents or ingredients that can evaporate during curing and cause
shrinkage cracking
• A minimum bond strength to concrete of 250 psi
• A compressive strength capability of more than 5000 psi
• A tensile elongation of at least 30% and a tensile strength of more than 2000 psi
(both indicate good flexibility and resilience) Resin binders having these physical
properties can produce polymer concrete overlays with life expectancies of 20
years or more if the overlays are properly installed
15. Mixing polymer concrete
Poor-quality polymer concrete overlays often are the result of inaccurate
proportioning and inadequate mixing of the binder components and aggregate. Mixing the
binder components at the ratios specified by the supplier is critical. Once the components
are mixed they start a chemical reaction that continues until the polymer concrete hardens.
Any variation of the mixing ratios can result in a soft, uncured overlay. Thorough mixing of
the binder components also is important. Failure to mix the components completely can
result in a non uniform overlay with soft and hard areas.
If the premixed method of overlay placement is used (described below), aggregate
must be added to the mixed polymer binder. Again, attention to specified mix ratios and
thorough mixing are necessary to ensure uniformity. Polymer concrete components can be
batch-mixed in a convention a concrete or mortar mixer.
However, better quality control is possible by using a machine that automatically
proportions, mixes, and dispenses components. This ensures mixing accuracy and
eliminates batch-to-batch inconsistencies.
The machine should be carefully calibrated and the calibrations should be checked
frequently during machine use.
16.
17. Two methods are generally used to apply polymer concrete overlays:
Premixed or slurry method—In this method, the binder components and aggregate are
premixed to form a polymer concrete which is then spread over the deck at the required
thickness. The mixture should contain an ll% to 14% resin content based on aggregate
weight. Using a trowel, bull float, or vibrating screed, apply the mixture over the primed deck
surface to meet specifications for compaction ,surface profile, and finish.
Use screed rails to establish a specified minimum application thickness.
Because polymer concrete has rheological properties different from portland cement
concrete, finishing tools may have to be modified somewhat to better handle
polymer concrete. Mechanical screeds designed to place polymer
concrete are available.
Immediately after placing the overlay, broadcast additional aggregate
onto it at a rate of about 2 pounds per square yard or until no wet spots are visible. The
aggregate adheres to the wet binder, forming a nonskid surface. Sweep away any un
bonded aggregate after the overlay cures.
18. Curing
A polymer concrete overlay cures much faster than a conventional portland
cement concrete overlay. But if polymer concrete isn’t allowed to cure
sufficiently before the overlay is opened to traffic, damage can result. Curing
time varies depending on temperature conditions and type of polymer used.
Generally, the warmer the ambient temperature, the shorter the cure time. At 95°
F, the overlay is ready to accept vehicle traffic in 1 to 3 hours; at 75° F, 2 to 6
hours is required.
An easy way to test for sufficient curing is to poke the overlay with a
screwd river. If the screwd river doesn’t leave a mark, the overlay is probably
ready fortraffic. However, have the project engineer or a representative of the
resin binder supplier confirm overlay readiness before reopening the bridge
deck.
19. Proven performance
Investigation into the use of polymers for preparing polymer concrete
and mortars began more than 30 years ago. But early attempts at using polymers for
bridge deck overlays met with limited success due to problems with material
properties and mixing and installation methods.
Most of these problems have been solved. In fact, the U.S. Department of
Transportation removed some polymer concrete systems from its list of experimental
materials in 1989. Now repair and rehabilitation projects using these systems may
be eligible for full federal funding. Technological advances in polymer materials have
improved their flexibility and their chemical compatibility with concrete, resulting in
overlays that are more durable and more resistant to shrinkage and cracking. Mixing
and application procedures have improved too, and equipment is now available to
speed these procedures and improve acc uracy.
Because of these advances, an increasing number of polymer concrete
overlays have been installed in the past 10 years in the United States and Canada.
Transportation departments are monitoring the performance of many of these
overlays and reports indicate that the overlays are performing well
20. Machine Mixing Instructions
The mixture is obtained by adding water into a clean container and
then gradually adding the powder. Add approximately 1 gallon of water for each
50 lb bag of Polymer Concrete Patcher to be used. If the mortar becomes too
difficult to mix, add additional water until the desired consistency is achieved.
The mixing process can be performed in a cement mixer or in a bucket (working
manually or with a mechanical agitator) or using a continuous mixer until
homogeneous, lump-free mixture is obtained. It is also possible to use a sprayer
to mix and simultaneously pump the mixture, using a rotor/ stator system
suitable for the granulometric gradation of the mixture.
21. Hand Mixing Instructions
Empty the bags into a suitable mixing container. Add approximately 1
gallon of water for each 50 lb bag of Polymer Concrete Patcher to be used. Work
the mix with the necessary tools, and add additional water as needed until the
desired consistency is achieved. Make sure all the material is adequately wet
before proceeding with the application.