As a renewable and sustainable resource, lignocellulosic biomass serves as a crucial raw material for the production of biofuels, biochemicals, and various value-added products. This paper aims to develop and optimize a mild alkaline treatment of sawdust assisted by ultrasound, along with enzymatic hydrolysis of the pretreated material. The alkaline sonochemical pretreatment emerged as the optimal approach to enhance the susceptibility of cellulose to subsequent enzymatic hydrolysis to improve the yield of reducing sugars. A comparative study was performed using various ultrasonic applicators (horn and bath) and conventional assisted alkaline pretreatment. The ultrasonic-assisted pretreatment revealed a higher delignification of 68% (horn) and 57% (bath) compared with conventional pretreatment. Processes were optimized using a statistical analysis based on a 2³ factorial design. The ratios between sawdust and alkaline solution (R_SL = 0.5–1.5 g/100 mL), US amplitude (A = 20–60%), and working temperature (t = 30–50 °C) were selected as process factors. The optimal operating conditions to maximize the reducing sugar yield (138.15 mg GE/g_substrate) were found as follows: a solid/liquid ratio of R_SL,opt = 1.25 g/100 mL, US amplitude of A_opt = 60%, and pretreatment temperature of t_opt = 50 °C. The overall outcomes clearly confirmed the intensification of delignification by ultrasound-assisted alkaline pretreatment.

This work covers the finite element analysis of geometric and process parameters in hydraulic bulge tests in terms of the accuracy of the evaluated flow curve. The important parameters are identified and varied to cover the whole range of possible uses. The effects of these parameters are analyzed for three representative materials: aluminium, mid-strength steel, and high-strength steel. The flow curves of the materials for each set of parameters are calculated by using the results of the simulations and the membrane theory. It is seen that even with simulation results, it is not always possible to obtain the input flow curve, especially towards the end of the test. The dimensions of the sheet and the tooling affect the plastic strain development and geometry of the bulge, leading to errors in computed flow curves. In order to observe the effect of the material flow from the flange on the determined yield stresses, the function and position of the drawbeads are also examined. These parameters, together with the method used to calculate the radius of the bulge, determine the accuracy of the calculated flow curve. Guidelines for an accurate flow curve determination regarding the test set-up and calculation methods are given.

Thermomechanical ring rolling is an evolution of the process where deformation and heat treatment are combined to obtain a product with both the desired geometry and hardness or microstructure in a single step. However, the high sensitivity of the process to the initial condition and to various disturbances limits its repeatability and accuracy. In this paper, the authors implement a concept for hardness control of ring rolling in virtual experiments. A concept based on soft sensors and model predictive control is implemented on a digital twin. The operation of the different models needed for this control loop are detailed and the controller itself is illustrated.

In conventional forming processes, quasi-static conditions are a good approximation and numerical process optimization is the state of the art in industrial practice. Nevertheless, there is still a substantial need for research in the field of identification of material parameters. In production technologies with high forming velocities, it is no longer acceptable to neglect the dependency of the hardening on the forming speed. Therefore, a method for determining material characteristics in processes with high forming speeds was developed by designing and implementing a test setup and an inverse parameter identification. Two acceleration concepts were realized: a pneumatically driven one and an electromagnetically driven one. The method was verified for a mild steel and an aluminum alloy proving that the identified material parameters allow numerical modeling of high-speed processes with good accuracy. The determined material parameters for steel show significant differences for different stress states. For specimen geometries with predominantly uniaxial tensile strain at forming speeds in the order of 10⁴–10⁵/s the determined yield stress was nearly twice as high compared to shear samples; an effect which does not occur under quasi-static loading. This trend suggests a triaxiality-dependent rate dependence, which might be attributed to shear band induced strain localization and adiabatic heating.

Clinching is a joining process that is becoming more and more important in industry due to the increasing use of multi-material designs. Despite the already widespread use of the process, there is still a need for research to understand the mechanisms and design of clinched joints. In contrast to the tool parameters, process and material disturbances have not yet been investigated to a relatively large extent. However, these also have a great influence on the properties and applicability of clinching. The effect of process disturbances on the clinched joint are investigated with numerical and experimental methods. The investigated process variations are the history of the sheets using the pre-hardening of the material, different sheet thicknesses, sheet arrangements and punch strokes. For the consideration of the material history, a specimen geometry for pre-stretching specimens in uniaxial tension is used, from which the pre-stretched secondary specimens are taken. A finite element model is set up for the numerical investigations. Suitable clinching tools are selected. With the simulation, selected process influences can be examined. The effort of the numerical investigations is considerably reduced with the help of a statistical experimental design according to Taguchi. To confirm the simulation results, experimental investigations of the clinch point geometry by using micrographs and the shear strength of the clinched joint are performed. The analysis of the influence of difference disturbance factors on the clinching process demonstrate the importance of the holistic view of the clinching process.

Plastics, once regarded as a revolutionary material shaping modern society, now pose an unprecedented threat to our environment. Household solid waste sorting stations produce several fractions, one of which contains a high concentration of Low-Density Polyethylene (LDPE) film waste (packaging, sunscreen film, etc.). This fraction is difficult to recycle because it contains quite a lot of impurities. Usually, it is sent to cement factories that burn it together with other fuels. However, with some processing techniques such as catalytic pyrolysis, this fraction could be valorized. In this paper, experiments were carried out in batches at a laboratory-scale installation, with a processing capacity of 1–3 kg of waste. A pyrolysis reactor was connected to a distillation column, enabling separation of the fractions. The gaseous and liquid fractions were characterized by GC-FID-TCD (gases) and GC-MS (liquids) analysis. Natural catalysts such as bentonite or clinoptilolite were studied and used in the melting of plastic mass to simplify the process as much as possible. To test the activity of the catalysts, the pyrolysis of LDPE granules was initially studied. It was found that natural zeolites are much more active than bentonite and that a minimum concentration of 5–10% is needed to have a positive effect on the composition of the fractions (increasing the weight of the light fractions (C1–C6, C6–C10, and C11–C13) in relation to the heavy fractions (C13–C20 and C20+). Catalytic pyrolysis gives a completely different distribution of light hydrocarbons. The best catalyst selected from LDPE lab experiments was then tested upon the pyrolysis of plastic film waste obtained by a waste treatment plant. The research objective reported in this paper was to obtain a fraction of combustible gases in the largest possible proportion, which can be much more easily exploited by burning in an engine that drives an electric generator.