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In the early-stage development of sheet metal parts, key design properties of new structures must be specified. As these decisions are made under significant uncertainty regarding drawing configuration changes, they sometimes result in the development of new parts that, at a later design stage, will not be drawable. As a result, there is a need to increase the certainty of experience-driven drawing configuration decisions.
Complementing this process with a global sensitivity analysis can provide insight into the impact of various changes in drawing configurations on drawability, unveiling cost-effective strategies to ensure the drawability of new parts. However, when quantitative global sensitivity approaches, such as Sobol's method, are utilized, the computational requirements for obtaining Sobol indices can become prohibitive even for small application problems. To circumvent computational limitations, we evaluate the applicability of different surrogate models engaged in computing global design variable sensitivities for the drawability assessment of a deep-drawn component.
Here, we show in an exemplary application problem, that both a standard kriging model and an ensemble model can provide commendable results at a fraction of the computational cost. Moreover, we compare our surrogate models to existing approaches in the field. Furthermore, we show that the error introduced by the surrogate models is of the same order of magnitude as that from the choice of drawability measure. In consequence, our surrogate models can improve the cost-effective development of a component in the early design phase.
AbstractRegularized static friction models have been used successfully for many years. However, they are unable to maintain static friction in detail. For this reason, dynamic friction models have been developed and published in the literature. However, commercial multibody simulation packages such as Adams, RecurDyn, and Simpack have developed their own specific stick-slip models instead of adopting one of the public domain approaches. This article introduces the fundamentals of these commercial models and their behavior from a practical point of view. The stick-slip models were applied to a simple test model and a more sophisticated model of a festoon cable system using their standard parameters.
The human nose serves as the primary gateway for air entering the respiratory system and plays a vital role in breathing. Nasal breathing difficulties are a significant health concern, leading to substantial healthcare costs for patients. Understanding nasal airflow dynamics is crucial for comprehending respiratory mechanisms. This article presents a detailed study using tomo-Particle Image Velocimetry (PIV) to investigate nasal airflow dynamics while addressing its accuracy. Embedded in the OpenNose project, the work described aims to provide a validation basis for different numerical approaches to upper airway flow. The study includes the manufacturing of a transparent silicone model based on a clinical CT scan, refractive index matching to minimize optical distortions, and precise flow rate adjustments based on physiological breathing cycles. This method allows for spatial high-resolution investigations in different regions of interest within the nasopharynx during various phases of the breathing cycle. The results demonstrate the accuracy of the investigations, enabling detailed analysis of flow structures and gradients. This spatial high-resolution tomo-PIV approach provides valuable insights into the complex flow phenomena occurring during the physiological breathing cycle in the nasopharynx. The study's findings contribute to advancements in non-free-of-sight experimental flow investigation of complex cavities under nearly realistic conditions. Furthermore, reliable and accurate experimental data is crucial for properly validating numerical approaches that compute this patient-specific flow for clinical purposes.
Test Setup for Investigating the Impact Behavior of Biaxially Prestressed Composite Laminates
(2024)
Instrumented impact testing and compression-after-impact testing are important to adequately qualify material behavior and safely design composite structures. However, the stresses to which fiber-reinforced plastic components are typically subjected in practice are not considered in the impact test methods recommended in guidelines or standards. In this paper, a test setup for investigating the impact behavior of composite specimens under plane uniaxial and biaxial preloading is presented. For this purpose, a special test setup consisting of a biaxial testing machine and a specially designed drop-weight tower was developed. The design decisions were derived from existing guidelines and standards with the aim of inducing barely visible impact damage in laminated carbon fiber-reinforced plastic specimens. Several measurement systems have been integrated into the setup to allow comprehensive observation of the impact event and specimen behavior. A feasibility test was performed with biaxially prestressed carbon fiber-reinforced plastic specimens in comparison with unstressed reference tests. The compressive-tensile prestressing resulted in lower maximum contact forces, higher maximum deflections, higher residual deflections and a different damage pattern, which was investigated by light microscopic analysis. Finally, the functionality of the experimental setup is discussed, and the results seem to indicate that the test setup and parameters were properly chosen to investigate the effect of prestresses on the impacts behavior of composite structures, in particular for barely visible subsequent damages.
Progress in additive manufacturing is leading to the emergence of new areas of application. Laser Powder Bed Fusion (L-PBF) is increasingly used for the development of metallic medical implants, but for high-risk implants like vascular support structures (stents), surface quality is critical to ensure successful implantation without harming the surrounding tissue and ensure the patients’ health. Therefore, enhancing the surface quality is crucial. Electropolishing is a method for removing surface roughness by smoothing out micro-peaks and valleys. However, L-PBF structures have a high surface roughness due to metal particles adhering on the surface. To achieve a smooth surface for additively manufactured implants like stents using electropolishing, the removal of these particles needs to be studied in more detail.
The objective of this study is to examine the electropolishing mechanism of 316L stainless steel samples additively manufactured through Laser Powder Bed Fusion (L-PBF). The main objective is to investigate the removal properties and surface characteristics during electropolishing. To achieve this, various surfaces were characterized for morphology and roughness during Hull cell experiments. Markings are utilized on the Hull cell sample surfaces to identify points of interest during quasi-in-situ measurements. The surfaces are then analyzed after multiple time steps, applying different currents to investigate particle dissolution. The surface characteristics are analyzed through scanning electron microscopy, and surface roughness is analyzed using laser scanning microscopy.
The results show that the electropolishing process preferentially removes the adhering particles present on the surface of the samples. Increasing the current density results in faster particle dissolution and a smoother surface (see Figure 1a and b). The mechanism of material removal of various surface features, as shown in Figure 1 (red circle, yellow arrow and red square), was assessed based on the experimental results of the surface structures seen on the SEM images. It was found that different surface features were removed during the experiment at different polishing times and current densities. The amount of charge flowed was found to correlate with surface morphology.
Based on the obtained results, various surface features (such as large adherent particles, agglomerates of smaller particles, and valleys) and their changes with increasing test duration and current density were observed by quasi-in situ analyses. A reduction in the diameter of round particles adhering to the surface was observed at both low and higher current densities (see Figure 1a red circle a). Increasing the polishing time resulted in leveling of both large particles and valleys (see Figure 1b red square). Also, dissolution of agglomerates of smaller particles occurred at different polishing times as a function of current density and polishing time (see Figure 1a yellow arrow) are observed.
Smoothed surface structures can be observed in regions with equivalent surface charge density (see Figure 2). As a result, comparable surface morphologies may appear at the same area charge density, irrespective of a specific current density. So, it may be adequate to only consider the amount of charge flowed to describe the electropolishing of additive materials.
In conclusion, comprehending the dissolution characteristics of particles on L-PBF surfaces is essential for attaining satisfactory surface finish in electropolishing. The results of this study offer valuable perspectives into the electropolishing mechanism of additively manufactured 316L stainless steel and can guide future investigations on surface finishing and polishing of additive manufactured implants like stents.
Figure 1
Increasingly stringent emission limits have made particulate filters necessary for gasoline engines. Similar to diesel applications, gasoline particulate filters (GPFs) can be monitored by differential pressure measurement or by the radio-frequency-based filter diagnosis (RF sensor). In addition to measuring the soot loading, ash detection is critical for monitoring the GPF over the entire vehicle lifetime. Because the RF sensor detects the filter loading through a change in the dielectric properties of the GPF, it can detect not only soot but also ash. In diesel applications, the RF sensor has already demonstrated its potential for ash detection. To verify the feasibility of simultaneous ash and soot monitoring for GPFs, filters were loaded with ash on an engine test bench and measured on a lab test bench under defined synthetic exhaust gas conditions. By evaluating resonant modes, soot and ash could be clearly distinguished, as ash mainly affects the resonant frequency, while soot also changes the quality factor due to its high dielectric losses. However, higher soot loadings could not be detected by the resonant parameters, but instead by a frequency-averaged transmission signal. While the presence of ash caused an offset in this signal, its sensitivity to soot was not affected. Thus, the influence of ash can be corrected if the signal in the soot-free filter state is known, e.g., from the behavior of the resonant parameters. Therefore, even with a continuously increasing ash loading over the lifetime of a vehicle, an accurate soot detection is possible with the RF sensor.
Preliminary considerations on the form-finding of a tensegrity joint to be used in dynamic orthoses
(2024)
Early motion therapy plays an important role for effective long-term healing of joint injuries. In many cases, conventional dynamic orthoses fail to address the intricate movement possibilities of the underlying joints, limited by their simplistic joint representations, often represented by revolute joints, enabling rotations by only one axis. In this paper, a two-dimensional compliant tensegrity joint for use in biomedical applications is investigated. It consists of two compressed members and five compliant tensioned members. Relative movement possibilities are realized by the intrinsic compliance of the structure. In the development of these systems, the first step is the determination of the static stable equilibrium. This analysis is conducted in this paper by considering the potential energy approach or by using the geometric nonlinear finite element method. The mechanical behavior of the structure is assessed with a specific emphasis on its mechanical compliance. The primary objective of this study is the investigation of the influence of structural parameters on the overall stiffness and movability of the structure. The results underscore the significant effect of member parameters on the stiffness and movability of the compliant tensegrity joint, particularly under varying load magnitudes. These findings provide insights for optimizing the joint’s performance, contributing to its potential application in advanced orthotic and exoskeleton devices.
The pandemic caused by the SARS-CoV-2 virus has claimed more than 6.5 million lives worldwide. This global challenge has led to accelerated development of highly effective vaccines tied to their ability to elicit a sustained immune response. While numerous studies have focused primarily on the spike (S) protein, less is known about the interior of the virus. Here we propose a methodology that combines several experimental and simulation techniques to elucidate the internal structure and mechanical properties of the SARS-CoV-2 virus. The mechanical response of the virus was analyzed by nanoindentation tests using a novel flat indenter and evaluated in comparison to a conventional sharp tip indentation. The elastic properties of the viral membrane were estimated by analytical solutions, molecular dynamics (MD) simulations on a membrane patch and by a 3D Finite Element (FE)-beam model of the virion's spike protein and membrane molecular structure. The FE-based inverse engineering approach provided a reasonable reproduction of the mechanical response of the virus from the sharp tip indentation and was successfully verified against the flat tip indentation results. The elastic modulus of the viral membrane was estimated in the range of 7-20 MPa. MD simulations showed that the presence of proteins significantly reduces the fracture strength of the membrane patch. However, FE simulations revealed an overall high fracture strength of the virus, with a mechanical behavior similar to the highly ductile behavior of engineering metallic materials. The failure mechanics of the membrane during sharp tip indentation includes progressive damage combined with localized collapse of the membrane due to severe bending. Furthermore, the results support the hypothesis of a close association of the long membrane proteins (M) with membrane-bound hexagonally packed ribonucleoproteins (RNPs). Beyond improved understanding of coronavirus structure, the present findings offer a knowledge base for the development of novel prevention and treatment methods that are independent of the immune system.
Isogeometric sheet metal forming simulation is a numerical simulation technique that is used to predict the behavior of sheet metal parts during the forming process [1] and tries to tighten the link with the Computer Aided Design (CAD) description. This technique uses the isogeometric analysis (IGA) approach, which combines the well-established framework of traditional finite element analysis (FEA) and the power of non-uniform rational B-splines (NURBS). In contrast to the approach in a “classical” FEA framework, IGA directly uses the ansatzspace of the CAD geometry for analysis, which opens the possibility to work directly on the exact geometry. Furthermore, the smoothness of the NURBS basis functions results in a more accurate simulation [2].
A powerful method to reduce the computational effort is adaptive mesh refinement, that has been developed and optimized for sheet metal forming applications over several years for standard Finite Elements. However, it remains an open question how an efficient local adaptive mesh refinement strategy can be implemented for complex industrial sheet metal forming simulations based on trimmed NURBS models, which are typically the description in Boundary Representation (B-Rep) CAD-models [3]. First investigations for explicit dynamics have been made in [4].
In this contribution, a detailed comparison between FEA and IGA sheet metal forming applications is conducted. The state of the art for FEA and IGA will be contrasted and the need for an efficient adaptive mesh refinement strategy will be discussed. The goal of our research is to develop an efficient adaptive mesh refinement strategy for isogeometric sheet metal forming simulations in LS-DYNA. This will contribute to closing the efficiency gap between IGA and FEA in explicit dynamics, accelerate the product development process and enable the application of IGA in industrial sheet metal forming simulations.
In fatigue strength assessment, the methods based on ideal elastic stresses according to Basquin and the less established method based on elastic-plastic stress quantities according to Manson, Coffin and Morrow are applied. The former calculates loads using linear-elastic stresses, the latter requires elasticplastic evaluation parameters, such as stresses and strains. These can be determined by finite element analysis (FEA) with a linear-elastic constitutive law, and subsequent conversion to elastic-plastic loads, using the macro support formula by Neuber. In this contribution, an alternative approach to approximate elastic-plastic parameters proposed by Glinka is compared to the the strain-life method using Neuber's formula, as well as the stress-life method of Basquin. Several component tests on 42CrMoS4-QT specimens are investigated. To determine the input data for the fatigue strength evaluations, the entire test setup is computed by FEA. The nodal displacements from these validated full-model simulations are used as boundary conditions for a submodel simulation of a notch, whose results serve as input for the fatigue strength assessments. It is shown that all approaches provide a reliable assessment of components. Our key result is that the strain-life method using the concept by Glinka for notch stress computation, yields improved results in fatigue strength assessments.
Although magnesium and its alloys are promising candidates as biodegradable implant materials, the tendency for localized corrosion mechanism in physiological environment limit their biomedical application. Electropolishing is an attractive strategy for improving the corrosion behaviour of metals, but it is still largely unexplored in magnesium materials. In this study, the characterization of electropolished surfaces of AM50 and pure magnesium was performed, focussing on their in vitro degradation behaviour in cell medium. Corrosion rates were evaluated using potentiodynamic polarisation. The surface morphology before and after the onset of corrosion was investigated by scanning electron microscopy and confocal laser scanning microscopy. The presented electropolishing process led to improved surface performances, observable by significantly lower corrosion rates (0.08 mm·year-1 in Dulbecco's modified Eagle's medium), lower arithmetical mean height (0.05 µm), lower water contact angle (25-35°) and lower micro hardness (35-50 HV 0.1) compared to mechanically and chemically treated surfaces. MgO/Mg(OH)2 could be detected on electropolished surfaces. The localized corrosion mode could be reduced, but not entirely prevented. Electropolishing shows great potential as post-treatment of magnesium-based components, but detailed tests of the long-term corrosion behaviour are an important area of future research.
One major goal of production system design is to decide on space requirements in the plant. In this phase, detailed information about the supply chain network (e.g. which suppliers deliver which parts) is often unavailable. Nevertheless, typical decisions in supply chain management, like the definition of replenishment processes and quantities or make-or-buy decisions, impact space requirements and the capital investment in raw materials. Therefore, it should be considered in factory and production planning. This research article proposes a simulation approach for a production simulation in which raw material replenishment is integrated to evaluate the capital investment and space requirements for raw materials.
A factory has to adapt to a future production program and increasing volumes. The planning of new factories must therefore already take expansion stages and reconfigurations into account. This leads to an increase in the complexity of planning, as different variants have to be planned and put into a chronologically reasonable and cost-optimized sequence. A factory data model that covers expansion stages manages the planning data amount and reduces complexity. Based on existing models from the literature, a factory data model was developed and modeled in the Unified Modeling Language standard. The factory data model shows which classes are interdependent and how planning results are stored reusable for other variants. An example is used to explain the developed factory data model and highlighting its advantages. The aim is to enable factory planners to document variant sequences and expansion stages in a comprehensible way, which supports the interdisciplinarity of factory planning projects.
The present study investigates the interface between carbon steel and titanium samples annealed at different temperatures (𝜗1 = 800 ◦C and 𝜗2 = 1050 ◦C). In both cases, an observable layer forms at the interface, with its thickness increasing from t𝜗1= 2.75 ± 0.15 μm at 800 ◦C to t𝜗2= 8.86 ± 0.29 μm at 1050 ◦C. The layer’s composition and thickness evolve with temperature. Analysis reveals approximately 40 at.-% carbon concentration in the exterior region, indicating likely titanium carbide creation. X-ray diffraction identifies titanium carbide peaks, while microscopy and elemental mapping confirm compositional gradients at the interface.
Electron Backscatter Diffraction (EBSD) shows a gradient in grain size near the TiC surface, reflecting TiC nucleation rates. XRD data detect both titanium carbide and titanium phases, with TiC becoming more prominent at 1050 ◦C. Rietveld analysis further confirms TiC formation. Notably, distinct diffraction patterns on the contact and rear sides suggest a Ti(C, O, N) presence. Depth profiles exhibit varying surface and depth carbon concentrations, attributed to temperature effects. The study successfully demonstrates TiC coating fabrication through hot pressing, wherein Ti(C, O, N) coatings arise from titanium’s affinity for reacting with oxygen and nitrogen. This research contributes to the understanding of phase transformations and interfacial properties in titanium-carbon steel systems.
The low-cycle and high-cycle fatigue behavior of the Mg-base wrought alloy AZ31 is investigated in the temperature range 20– 300 °C using total-strain-controlled push – pull tests. It is shown that the mechanical properties of the material are substantially influenced by the direction dependent formation of deformation twins and resulting deformation asymmetry. As a consequence tensile mean stresses develop during total-strain-controlled fatigue tests without mean strain.
Effects of Deep Rolling on the Fatigue Behavior of Ti-6Al-4V at Ambient and Elevated Temperatures
(2003)
Several specimens of AZ31 magnesium alloy were taken in different directions from a rolled plate and subjected to tensile, compressive and four-point bending tests. Tensile and compressive tests allowed to characterize the mechanical properties of the material in the rolling and cross rolling directions. The bending tests were carried out in four different specimen types to take the effect of the anisotropy induced by the rolling procedure itself into account. Six strain gages per specimen allowed to observe the evolution of the strain with the bending moment during the tests. All bending specimens were bent until a total compressive deformation of 2.5 %. It was observed that the corresponding tensile strain was significant lower and slightly different for each specimen type. In addition, a characteristic non-uniform distribution of deformation twinning was observed. The induced residual stresses after bending were characterized by X-ray diffraction (XRD) and incremental hole-drilling (IHD). Due to the different mechanical behavior in tension and compression, an asymmetric residual stress distribution after bending could be observed. The neutral axis was, in all cases, shifted towards the tensile side. This observation agrees with the strain measurements during bending tests.
Review of elasto-static models for three-dimensional analysis of thick-walled anisotropic tubes
(2023)
Most shell or beam models of anisotropic tubes under bending have no validity for thick-walled structures. As a result, the need to develop three-dimensional formulations which allow a change in the stress, strain and displacement distributions across the radial component arises. Basic formulations on three-dimensional anisotropic elasticity were made either stressor displacement-based by Lekhnitskii or Stroh on plates. Lekhnitskii also was the first to expand these analytical formulations to tubes under various loading conditions. This paper presents a review of the stress and strain analysis of tube models using three-dimensional anisotropic elasticity. The focus lies on layered structures, like fiber-reinforced plastics, under various bending loads, although the basic formulations and models regarding axisymmetric loads are briefly discussed. One section is also dedicated to the determination of an equivalent bending stiffness of tubes.
Following a ban on many materials containing bisphenol-A, new bisphenol-free Boron silicates have been found as substitutes. The purpose of this study is to describe the mechanical properties of these bisphenol-free magnetoactive borosilicate polymers containing hard magnetic particles. Samples of 0%, 33% and 66% by wt. were loaded for compression using a universal testing machine. The maximum forces occurring for different travel speeds were compared before and after post-magnetization treatments. The post-magnetization included 2 stages. In addition, the change in mechanical properties within 24 hours after the post-magnetization process was investigated. Furthermore, the influence of speed and particle content were investigated. In general, there is a correlation between the required compressive force and, the level of post-magnetization stress, the increase in travel speed and particle content in the boron silicate. Comparison of the non-post-magnetized and post-magnetized samples using two-tailed t-tests shows that the p-values for all weight fraction changes in NdPrFeB particles and travel speeds are less than 0.001. Also, a comparison between tests in which the traverse speed was varied also showed significant changes in the resulting compression forces. The same is valid for changes in the weight ratio of the NdPrFeB particles in the samples. For post-magnetized samples, no significant difference can be observed in the first 24 hours following magnetization. In summary, the material presents viscoelastic, plastic force-displacement behavior, which can be well recognized by its bi-linear curve shape.
The investigation shows that borosilicate polymers based on NdPrFeB can have their mechanical behavior modified and controlled by post-magnetization processes. This opens new possibilities for many future applications.
BACKGROUND: Thrombosis remains a critical complication during venovenous extracorporeal membrane oxygenation (VV ECMO). The involvement of neutrophil extracellular traps (NETs) in thrombogenesis has to be discussed. The aim was to verify NETs in the form of cell-free DNA (cfDNA) in the plasma of patients during ECMO.
METHODS: A fluorescent DNA-binding dye (QuantifFluor®, Promega) was used to detect cell-free DNA in plasma samples. cfDNA concentrations from volunteers (n = 21) and patients (n = 9) were compared and correlated with clinical/technical data before/during support, ECMO end and time of a system exchange.
RESULTS: Before ECMO, patients with a median (IQR) age of 59 (51/63) years, SOFA score of 11 (10/15), and ECMO run time of 9.0 (7.0/19.5) days presented significantly higher levels of cfDNA compared to volunteers (6.4 (5.8/7.9) ng/μL vs. 5.9 (5.4/6.3) ng/μL; p = 0.044). Within 2 days after ECMO start, cfDNA, inflammatory, and hemolysis parameters remained unchanged, while platelets decreased (p = 0.005). After ECMO removal at the end of therapy, cfDNA, inflammation, and coagulation data (except antithrombin III) remained unchanged. The renewal of a system resulted in known alterations in fibrinogen, d-dimers, and platelets, while cfDNA remained unchanged.
CONCLUSION: Detection of cfDNA in plasma of ECMO patients was not an indicator of acute and circuit-induced thrombogenesis.
This paper presents a comprehensive analysis of a three-dimensional compliant tensegrity joint structure, examining its actuation, kinematics, and response to external loads. The study investigates a baseline configuration and two asymmetric variants of the joint. The relationship between the shape parameter and the parameters of the tensioned segments is derived, enabling the mathematical description of cable lengths for joint actuation. Geometric nonlinear static finite element simulations are performed to analyze the joint's response under various load conditions. The results reveal the joint's range of motion, the effect of different stiffness configurations, and its deformation behavior under external forces. The study highlights the asymmetric nature of the joint and its potential for targeted motion restriction. These findings advance the general understanding of the behavior of the considered tensegrity joint and provide valuable insights for their design and application in soft robotic systems.
Um die Leistungsfähigkeit von nachgiebigen Robotersystemen („Soft Robotics“) zu verbessern, werden immer neue Möglichkeiten zur Realisierung dieser Systeme gesucht. In vielen Anwendungen ist der Einsatz von mechanisch vorgespannten nachgiebigen Strukturen in diesen Systemen von Vorteil. Die Steifigkeit dieser Strukturen kann gezielt und gegebenenfalls reversibel variabel eingestellt werden. Die Formveränderung kann nur durch wenige Aktuatoren erzeugt werden.
Nachgiebige Tensegrity-Strukturen, die auf hochelastischen Materialien basieren, entsprechen einer speziellen Klasse von mechanisch vorgespannten Strukturen. Sie werden durch druck- und zugbelastete Segmente gebildet, wobei die druckbelasteten Segmente untereinander nicht direkt verbunden sind. Die resultierende Form dieser Strukturen wird durch ihre Vorspannung bestimmt. Weiche Roboter, die auf diesen Strukturen basieren, bieten mehrere vorteilhafte Eigenschaften, wie z. B. Faltbarkeit/Entfaltbarkeit, geringe Masse, hohes Festigkeits-Gewichts-Verhältnis und stoßdämpfende Fähigkeiten [1]. Diese Strukturen haben eine ausgeprägte Fähigkeit, sowohl ihre Form als auch ihre Steifigkeit zu verändern. In den letzten Jahren hat das Interesse an der Erforschung von Robotersystemen, die auf diesen Strukturen basieren, zugenommen. Aktuelle Arbeiten konzentrieren sich auf die Entwicklung von mobilen Robotern [2]–[7] und Manipulatoren, die auf diesen Strukturen basieren [8]–[10]. Tensegrity-Manipulatoren werden typischerweise durch Kaskadierung von gleichartigen elementaren Einheiten gebildet, die nach dem Tensegrity-Prinzip untereinander verbunden werden. Die elementaren Einheiten sind entweder selber konventionelle Tensegrity-Strukturen oder einteilige planare bzw. räumliche Strukturen. In klassischen Tensegrity-Manipulatoren werden starre Drucksegmente und nicht elastische Zugsegmente verwendet. Die Formänderung dieser Systeme wird durch Änderung der Längen ausgewählter Zugsegmente realisiert. Dem gegenübergestellt können nachgiebige Tensegrity-Manipulatoren realisiert werden, indem die Zugsegmente der Struktur eine hohe Nachgiebigkeit aufweisen. Um die mechanische Nachgiebigkeit und Formänderungsfähigkeit von diesen nachgiebigen Manipulatoren zusätzlich
zu erhöhen, ist auch der Einsatz von Tensegrity-Strukturen auf der Basis nachgiebiger Drucksegmente denkbar.
Im vorliegenden Beitrag werden zwei nachgiebige Tensegrity-Manipulatoren vorgestellt und in Hinblick auf ihre mechanischen Eigenschaften und Formänderungsfähigkeit gegenübergestellt. Sie unterscheiden sich in ihrer Topologie, in der Art der Aktuierung und auch in der mechanischen Nachgiebigkeit. Die mechanische Nachgiebigkeit des ersten Systems beruht auf der Elastizität der Zugsegmente, die Drucksegmente sind starr. Die elementaren Einheiten bilden einteilige Strukturen. Das zweite System beruht auf elementaren Einheiten, die selbst räumliche Tensegrity-Strukturen sind. In diesem System sind sowohl die Zug- als auch die Drucksegmente nachgiebig. Die Aktuierung des ersten Systems erfolgt durch Längenänderung der Zugsegmente. Im zweiten System wird die Formänderung des Gesamtsystems durch Änderung der Form der nachgiebigen Drucksegmente realisiert. Die theoretischen Untersuchungen erfolgen unter Anwendung
der statischen geometrisch nichtlinearen FE-Methode. Mit diesen Untersuchungen wird die Formveränderungsfähigkeit der beiden Systeme unter Variation ihrer Vorspannung untersucht und gegenübergestellt. Die experimentellen Untersuchungen an zwei Demonstratoren bestätigen die theoretischen Ergebnisse und zeigen die Anwendbarkeit von Systemen auf Basis dieser Strukturen als Manipulatoren auf.
Theoretical considerations on a 2D compliant tensegrity joint in context of a biomedical application
(2023)
In this paper, a two-dimensional compliant tensegrity joint was investigated for potential biomedical applications such as orthotics or exoskeletons. The structure consists of two compressed members connected by five compliant tensioned members. The concept is based on the tensegrity principle, which allows the realization of dynamic orthoses without conventional hinge joints. Another advantage is the adaptability to the individual needs of the patient through a suitable design of the structure and the careful selection of the characteristics of the elements. Using geometric nonlinear analysis, the mechanical behavior of the structure was investigated, focusing on mechanical compliance. The main objective was to determine the influence of the initial length and stiffness of the tensioned members and the influence of the magnitude of external forces on the overall stiffness of the movable member of the structure. The results highlight the significant impact of member parameters on the structure's stiffness and movability under varying load magnitudes. The research laid the foundation for future development of dynamic orthoses based on this structure.
In diesem Beitrag erfolgt die theoretische Untersuchung einer zweidimensionalen nachgiebigen Tensegrity-Struktur in Hinsicht auf ihre potenzielle Eignung als Basisstruktur für eine dynamische Handorthese. Translatorische und rotatorische relative Bewegungsmöglichkeiten zwischen den Drucksegmenten der Struktur sind möglich, da diese Segmente durch nachgiebige Zugsegmente miteinander verbunden sind. Die Form der Struktur und ihre Vorspannung in einer statisch stabilen Gleichgewichtskonfiguration werden mit Hilfe der Minimierung des Kräfte- und Momentenungleichgewichts, der Betrachtung der potentiellen Energie der Struktur und einem Ansatz mittels statischer Finite-Elemente-Methode (FEM) in Abhängigkeit der Segmentparameter untersucht.
Combined Ash and Soot Monitoring in Gasoline Particulate Filters with a Radio-Frequency-Based Sensor
(2022)
In recent years, it turned out that primarily the number of ultrafine particles and not their mass is relevant in terms of harmful health effects. Therefore, exhaust emission standards are constantly being tightened with regard to the particulate number. To meet the emission limits, particulate filters have become necessary for gasoline engines. Similar to diesel applications, gasoline particulate filters (GPFs) can be monitored via differential pressure measurement or via a radio-frequency approach (RF-sensor). The latter is based on the influence of the soot conductivity on the electromagnetic field. To control the GPF, ash detection is of crucial importance besides the soot load monitoring. With the differential pressure system, this is only possible with high uncertainties due to the low pressure increase caused by ash. The RF-sensor, however, has already demonstrated its potential for ash detection in diesel applications. In order to verify the applicability of the system for GPFs, filters were loaded via a method for fast ash loading. Thereby, it was shown that by evaluating resonant modes – especially the resonant frequency – the ash loading can easily be measured as long as the filter is soot-unloaded. In contrast, soot loading can be determined independently from this by considering a frequency-averaged transmission signal between the antennas of the RF-sensor. Using a setup for radio-frequency material characterization, the dielectric parameters of the generated ash were also measured. In comparison with the properties of the synthetic soot PrintexU, ash showed significantly lower dielectric losses. Thus, the evaluation of the loss-dependent quality factor, which is only possible at low soot loadings, allows a precise conclusion whether the filter is completely soot-free. Furthermore, using synthetic soot loading, it could be shown that soot detection via the averaged transmission signal is not affected by ash. In summary, it could be shown that with the RF-sensor, ash and soot can be simultaneously detected.
Aufgrund der steigenden Lebenserwartung und dem damit einhergehenden demographischen Wandel wird der Bedarf an Rehabilitations-Behandlungen in absehbarer Zukunft stark ansteigen. Ein Beispiel für diesen Trend ist die physiotherapeutische Behandlung nach Erhalt einer Knie-Totalendoprothese (Knie-TEP). So gehen Modellrechnungen basierend auf dem Bevölkerungswachstum und der bisherigen Prävalenz von Knie-TEPs davon aus, dass die Anzahl an durchgeführten Eingriffen in einkommensstarken Ländern wie Deutschland weiter zunehmen wird. Weiterhin stoßen traditionelle Rehabilitationsverfahren, gerade in strukturschwachen Regionen, schon heute an ihre Grenzen. Deutlich zu sehen war das während den Hochphasen der aktuellen Covid-19-Pandemie, als der Kontakt zwischen Therapeut*in und Patient*in flächendeckend eingeschränkt war. Eine erhöhte Nachfrage nach neuartigen Reha-Angeboten ist die logische Konsequenz. Innovative Konzepte sind daher dringend notwendig, um die daraus resultierenden technischen, sozialen und ökonomischen Herausforderungen zu bewältigen.
Schlussbericht zum Verbundvorhaben NAMOSYN: Nachhaltige Mobilität durch synthetische Kraftstoffe
(2023)
Im Labor für Verbrennungsmotoren und Abgasnachbehandlung der OTH-Regensburg sollten im Zuge des NAMOSYN-Projektes zwei Vertreter klimaneutraler Kraftstoffe an verschiedenen Systemprüfständen (Motor-, Einspritzprüfstand, optisch zugängliche Einspritzkammer, …) und mit Hilfe von Simulationsmethoden für den Einsatz in bestehenden Verbrennungsmotoren untersucht werden. Synthetische Kraftstoffe aus der Gruppe der Oxymethylenether (OME) stellen eine CO2-neutrale Alternative zu fossilem Dieselkraftstoff dar. Für Ottomotoren wurde untersucht, ob der synthetische Kraftstoff DMC/MeFo (Dimethylcarbonat & Methylformiat) einen Ersatz für Ottokraftstoff darstellen kann, bzw. eine Drop-In-Fähigkeit gegeben ist.
Die OTH Regensburg bearbeitete 2 unabhängige Teilvorhaben zur motorischen Testung von synthetischen Kraftstoffen: „FC 1A: Motorische Testung von OME“ und „FC 2: Untersuchung von C1-Oxygenaten für Ottomotoren“. Die Projektlaufzeit betrug 3,5 Jahre, inkl. kostenneutraler Verlängerung um 6 Monate aufgrund der Corona-Pandemie.
Im FC1A "AP2-Nachrüstung Dieselmotoren" der OTH Regensburg lag der Fokus auf der Erforschung der Potentiale und der Umrüstung eines Einzylinder-Dieselmotors mit Pumpe-Leitung-Düse-(PLD)-Einspritzsystem des Projektpartners Motorenfabrik Hatz GmbH und Co. KG für OME-Betrieb.
Im AP2.1 wurden umfangreiche Daten gesammelt und Simulationsmodelle des Motors und PLD-Einspritzsystems erstellt und mit Dieselkraftstoff und OME validiert. Nachfolgend wurden Parameterstudien zur Geometrie des Einspritzsystems und der physikalischen Eigenschaften von OME durchgeführt.
In AP2.2 und AP2.3 wurden umfangreiche Untersuchungen an einem Motor- und Einspritzsystemprüfstand mit Diesel und OME durchgeführt und der Steuergerätedatensatz für den OME-Betrieb optimiert.
Die Ergebnisse zeigen, dass die Umstellung des Kraftstoffs auf OME, insbesondere bei einfachen Motoren mit rudimentärer Einspritztechnik und ohne Mittel zur NOx-Reduzierung (keine AGR oder SCR), ein enormes Potenzial zur Steigerung des Wirkungsgrads bei gleichzeitiger Reduzierung aller regulierten Schadstoffe (NOx, 𝑃N, 𝑃M, CO und 𝑉OC) eröffnet. Die Ergebnisse und generierten Simulationsmodelle unterstützen eine schnelle Serienentwicklung und Einführung von OME-Umrüstlösungen.
In FC 2 werden die vielversprechenden Kraftstoffe Methylformiat (MeFo) und Dimethylcarbonat (DMC) motorisch getestet. Untersuchungen am Kraftstoffsystem und wichtigen Komponenten dienen als Grundlage für das AP3.
Im AP3 wird die Machbarkeit der DMC/MeFo-Verbrennung am Vollmotor demonstriert und die erwarteten Emissionsvorteile gegenüber herkömmlichen Ottokraftstoffen gezeigt. Abweichend von der ursprünglichen Planung werden an der OTH Regensburg Kraftstoffblends aus Benzin und MeFo untersucht, um den Einsatzbereich des Kraftstoffs zu erweitern.
In AP5 werden potentielle Mischungsverhältnisse analysiert und die Eigenschaften der ausgewählten Kraftstoffmischungen an einem Einspritzratenprüfstand, an der Einspritzkammer und am Vollmotor untersucht. Es werden Einspritzverhalten, Gemischaufbereitung und Abgasemissionen bewertet.
Zudem wird eine Kraftstoffmischanlage entwickelt und ein optischer Zugang am Vollmotor ermöglicht. Eine Ölverdünnungsmesstechnik wird eingesetzt, um den Kraftstoffeintrag ins Motoröl zu untersuchen
In this paper, the movement behavior of amoeboid locomotion system is investigated and the theoretical proof of the locomotion of the system is provided with the finite element method. It is shown that not only the speed of locomotion but also its direction can be influenced by the drive frequency. Depending on the drive frequency, a movement from the home position and a subsequent movement in opposite directions can be achieved. In addition, high speeds of movement can be achieved in a limited frequency range.
BACKGROUND:
Tracheobronchial mucus plays a crucial role in pulmonary function by providing protection against inhaled pathogens. Due to its composition of water, mucins, and other biomolecules, it has a complex viscoelastic rheological behavior. This interplay of both viscous and elastic properties has not been fully described yet. In this study, we characterize the rheology of human mucus using oscillatory and transient tests. Based on the transient tests, we describe the material behavior of mucus under stress and strain loading by mathematical models.
METHODS:
Mucus samples were collected from clinically used endotracheal tubes. For rheological characterization, oscillatory amplitude-sweep and frequency-sweep tests, and transient creep-recovery and stress-relaxation tests were performed. The results of the transient test were approximated using the Burgers model, the Weibull distribution, and the six-element Maxwell model. The three-dimensional microstructure of the tracheobronchial mucus was visualized using scanning electron microscope imaging.
RESULTS:
Amplitude-sweep tests showed storage moduli ranging from 0.1 Pa to 10000 Pa and a median critical strain of 4 %. In frequency-sweep tests, storage and loss moduli increased with frequency, with the median of the storage modulus ranging from 10 Pa to 30 Pa, and the median of the loss modulus from 5 Pa to 14 Pa. The Burgers model approximates the viscoelastic behavior of tracheobronchial mucus during a constant load of stress appropriately (R2 of 0.99), and the Weibull distribution is suitable to predict the recovery of the sample after the removal of this stress (R2 of 0.99). The approximation of the stress-relaxation test data by a six-element Maxwell model shows a larger fit error (R2 of 0.91).
CONCLUSIONS:
This study provides a detailed description of all process steps of characterizing the rheology of tracheobronchial mucus, including sample collection, microstructure visualization, and rheological investigation. Based on this characterization, we provide mathematical models of the rheological behavior of tracheobronchial mucus. These can now be used to simulate mucus flow in the respiratory system through numerical approaches.
Datenerfassung für die Anwendung lernender Algorithmen bei der Herstellung von Blechformteilen
(2020)
Der industrielle Fertigungsprozess von Blechformteilen unterliegt dem Einfluss einer Vielzahl von Parameterschwankungen, die das Umformergebnis signifikant mitbestimmen. Daher treten Qualitätsprobleme scheinbar zufällig auf und verursachen Ausschuss und einen Verlust an Produktivität. Ein vielversprechendes Mittel zur Verbesserung derartiger Prozesse ist der Einsatz von Datenanalysen und lernenden Algorithmen, die jedoch eine große Datenmenge voraussetzten. Bisher fehlten die Datenbasis und geeignete Möglichkeiten zur Datenerfassung für den Einsatz dieser Methoden.
In dieser Arbeit wurde eine allgemeingültige und übertragbare Methode zur Erfassung und Speicherung relevanter Einfluss- und Ergebnisgrößen des Herstellprozesses von Blechformteilen entwickelt. Die Methode und die resultierenden Daten sind die Grundlage für die Analyse von Zusammenhängen im Prozess, die Vorhersage der Qualität durch maschinelles Lernen und die Berechnung geeigneter Maschineneinstellungen. Diese Anwendungen wurden in der Arbeit erprobt und die Ergebnisse bewertet. Dadurch konnten die Funktionalität der Datenerfassung und die erwarteten Potentiale bestätigt werden.
Festigkeits- und zeitoptimierte Prozessführung beim quasi-simultanen Laser-Durchstrahlschweißen
(2022)
Mit Blick auf Leichtbauanwendungen ist der Bedarf an thermoplastischen Strukturbauteilen sowohl in der Automobil- als auch in der Luftfahrtindustrie in den letzten Jahren deutlich angestiegen. Das quasi-simultane Laser-Durchstrahlschweißen ist ein etabliertes Kunststoffschweißverfahren, welches jedoch zur Herstellung von tragenden und sicherheitsrelevanten Bauteilen bislang kaum in Betracht gezogen wird. In der vorliegenden Arbeit wird die Korrelation zwischen dem Prozessablauf und der Schweißnahtfestigkeit beim quasi-simultanen Laser-Durchstrahlschweißen von Polyamid 6 (Ultramid B3s) erstmalig untersucht. Zur Prozessanalyse wird ein 3D-Scanner mit integriertem Pyrometer realisiert und für die Messaufgabe kalibriert. Es wird gezeigt, dass die detektierte Wärmestrahlung dem Kern der Schweißnaht zuzuordnen ist. Die Kerntemperatur in der quasi-stationären Prozessphase steht in direkter Korrelation mit der Schweißnahtfestigkeit. Mit steigender Kerntemperatur bzw. Molekülbeweglichkeit erhöht sich die Wahrscheinlichkeit der Bildung von Molekül-Verschlaufungen in der Fügeebene. Zur Ermittlung der Kerntemperatur ist sowohl die in dieser Arbeit entwickelte Temperaturmesstechnik als auch die realisierte numerische Prozesssimulation nutzbar. Die Erkenntnisse in dieser Arbeit sind für eine festigkeits- und zeitoptimierten Prozessführung des quasi-simultanen Laser-Durchstrahlschweißens nutzbar.
LuGre or not LuGre
(2023)
The LuGre model is widely used in the analysis and control of systems with friction. Recently, it has even been made available in the commercial multibody dynamics simulation software system Adams. However, the LuGre model exhibits well-known drawbacks like too low and force rate-dependent break-away forces, drift problems during sticking periods, and significant differences in non-stationary situations between the pre-defined friction law and the one produced by the LuGre model. In the present literature, these problems are supposed to come from the model dynamics or its nonlinear nature. However, most of these drawbacks are not simple side effects of a dynamic friction model but are caused in the LuGre approach, as shown here, by a too simple and inconsistent model of the bristle dynamics. Standard examples and a more practical application demonstrate that the LuGre model is not a “what you see is what you get” approach. A dynamic friction model with accurate bristle dynamics and consistent friction force is set up here. It provides insight into the physical basis of the LuGre model dynamics. However, it results in a nonlinear and implicit differential equation, whose solution will not be easy because of the ambiguity of the friction characteristics. The standard workaround, a static model based on simple regularized characteristics, produces reliable and generally satisfactory results but definitely cannot maintain a stick. The paper presents a second-order dynamic friction model, which may serve as an alternative. It can maintain a stick and produces realistic and reliable results.
Titanium is used in many areas due to its excellent mechanical, biological and corrosion-resistant properties. Implants often have thin and filigree structures, providing an ideal application for fine cutting with laser. In the literature, the main focus is primarily on investigating and optimizing the parameters for titanium sheets with thicknesses greater than 1 mm. Hence, in this study, the basic manufacturing parameters of laser power, cutting speed and laser pulse of a 200 W modulated fiber laser are investigated for 0.15 mm thick grade 2 titanium sheets. A reproducible, continuous cut could be achieved using 90 W laser-power and 2 mm/s cutting-speed. Pulse pause variations between 85 and 335 μs in 50 μs steps and a fixed pulse width of 50 μs show that a minimum kerf width of 23.4 μm, as well as a minimum cut edge roughness Rz of 3.59 μm, is achieved at the lowest pulse pause duration. An increase in roughness towards the laser exit side, independent of the laser pulse pause duration, was found and discussed. The results provide initial process parameters for cutting thin titanium sheets and thus provide the basis for further investigations, such as the influence of cutting gas pressure and composition on the cut edge.
Friction has long been an important issue in multibody dynamics. Static friction models apply appropriate regularization techniques to convert the stick inequality and the non-smooth stick–slip transition of Coulomb’s approach into a continuous and smooth function of the sliding velocity. However, a regularized friction force is not able to maintain long-term stick. That is why dynamic friction models were developed in recent decades. The friction force depends herein not only on the sliding velocity but also on internal states. The probably best-known representative, the LuGre friction model, is based on a fictitious bristle but realizes a too-simple approximation. The recently published second-order dynamic friction model describes the dynamics of a fictitious bristle more accurately. It is based on a regularized friction force characteristic, which is continuous and smooth but can maintain long-term stick due to an appropriate shift in the regularization. Its performance is compared here to stick–slip friction models, developed and launched not long ago by commercial multibody software packages. The results obtained by a virtual friction test-bench and by a more practical festoon cable system are very promising. Thus, the second-order dynamic friction model may serve not only as an alternative to the LuGre model but also to commercial stick–slip models.
Digital twins enable the digital representation of physical systems and provide comprehensive modelling and analysis capabilities. An online data exchange between the Digital twin and SAP is feasible, through integration of a transport control systems (SAP) via RESTful API. This interface allows decision making in resource allocation and furthermore the adaptation of the digital model if the real system changes. Despite the associated challenges in terms of data synchronisation, the integration has benefits such as a reduction in modelling effort and an increase in the lifetime of the digital twin. In the context of this work, the design of the interface between the simulation software and a SAP transport control system via RESTful API is described.
Current challenges in the planning and control of internal logistics systems are based on permanent changes in the requirements on the system, e.g., due to fluctuating order numbers or changes in their structure. For the representation and planning of in-house logistics processes, digital twins offer the possibility to verify different operational decisions such as predictive workforce scheduling. In this context, the quality of the results and their in-time presentation plays a decisive role. However, both target criteria are influenced by the detail-level of the digital representation. Based on a case study, this paper investigates the influence of the level of detail on the simulation runtime and result divergence to provide an evaluation for detail levels in the modelling of intralogistic transport systems.
Owing to increasingly stringent emission limits, particulate filters have become mandatory for gasoline-engine vehicles. Monitoring their soot loading is necessary for error-free operation. The state-of-the-art differential pressure sensors suffer from inaccuracies due to small amounts of stored soot combined with exhaust gas conditions that lead to partial regeneration. As an alternative approach, radio-frequency-based (RF) sensors can accurately measure the soot loading, even under these conditions, by detecting soot through its dielectric properties. However, they face a different challenge as their sensitivity may depend on the engine operation conditions during soot formation. In this article, this influence is evaluated in more detail. Various soot samples were generated on an engine test bench. Their dielectric properties were measured using the microwave cavity perturbation (MCP) method and compared with the corresponding sensitivity of the RF sensor determined on a lab test bench. Both showed similar behavior. The values for the soot samples themselves, however, differed significantly from each other. A way to correct for this cross-sensitivity was found in the influence of exhaust gas humidity on the RF sensor, which can be correlated with the engine load. By evaluating this influence during significant humidity changes, such as fuel cuts, it could be used to correct the influence of the engineon the RF sensor.
Product sounds with clearly audible tonal components are often perceived as unpleasant or annoying. If different simultaneously operating aggregates are present in a system, for example vehicle engines and gearboxes, the interaction of tonal components, similar to music, can evoke additional sensations in human auditory perception. Supplementary to a pronounced tonality, such sounds can also yield distinct degrees of consonance or dissonance between tones. Previous studies showed that the perceived dissonance had a high impact on preference judgements for sounds with similar tonality. In experiments of the present study, sounds that differed in tonality were rated with respect to the auditory sensations sharpness, tonality and dissonance by one group of participants while another group only carried out a preference task. Thereout a model for predicting perceived preference is derived from the subjective judgements of auditory sensations. The performance of the preference predictions based on subjective udgements will be compared against purely model-based predictions using different algorithms for acoustic attributes.
Fused layer modeling (FLM) is widely used and is gaining more acceptance in the industry mainly due to its material variety and low costs. However, the usage is limited by a process-related anisotropy of the produced parts. The strength and ductility of the printed parts are significantly lower in the build-up direction than perpendicular to it. This is caused by insufficient interlayer bonding resulting from a reduced surface temperature in the process zone. To overcome this problem, a diode laser is integrated into the conventional FLM process to increase the surface temperature between the already printed surface and the newly applied substrate directly at the deposition zone. The investigations carried out show a significant improvement in the mesostructure, as well as a clear reduction in the anisotropy of the printed test specimens.
This work aims first to develop a dynamic lumped model for the isothermal reactions of hydrogen/steam with a single iron oxide/iron pellet inside a tubular reactor and to validate the model results against the experimental reaction kinetic data with the help of our STA device. To describe the temporal change in mass, and consequently, the temporal heat of reaction, the shrinking core model, based on the geometrical contracting sphere, is applied. It turned out that, the simulation model can reproduce the experimental, temporal concentration and temperature-dependent conversion rates with a maximum deviation of 4.6% during the oxidation reactions and 3.1% during the reduction reactions. In addition, a measured isothermal storage process comprising one reduction and one oxidation phase with a holding phase in between on a single reacting pellet could be reproduced with a maximum absolute deviation in the conversion rate of 1.5%. Moreover, a lumped, non-isothermal simulation model for a pelletized tubular redox-reactor including 2kg of iron oxide pellets has been established, in which the heat of reaction, heat transfer to the ambient and heat transfer between the solid and gas phases are considered. The temporal courses of the outlet gas concentration as well as the temperatures of the gas stream and the solid material at a constant input gas flow rate and a constant reacting gas inlet concentration but different input gas temperatures are estimated. Because of the endothermic nature of the reduction reaction, the inlet reacting gas temperature shall be kept high to prevent the severe temperature drop in the solid phase and, consequently, the significant reduction of the reaction rate. Contrary to that, the oxidation process requires lower input gas temperatures to avoid the excessive overheating of the reaction mass and, consequently, the sintering of the reacting pellets. Finally, five of the previous reactors have been connected in series to explore the influence of the changing inlet gas temperatures and concentrations on the dynamic performance of each storage mass.
Absorber-free laser transmission welding enables clean and precise joining of plastics without additives or adhesives. It is therefore well suited to produce optical and medical devices, which place high demands on cleanliness and accuracy.
However, the weld usually has an undesirably large vertical expansion, causing bulges and distortion. To improve this, the intensity distribution of the laser beam as well as the processing strategy must be adapted. Due to the complexity, this is aided by process simulation. However, simulation parameter calibration and verification are usually done considering the seam width and height, which is of limited significance. To overcome this, we propose a new method for image processing of microtome sections, determining the spatially resolved geometry of the weld. Thus, the deviation between experiment and simulation can be calculated pixel by pixel. This spatially resolved value is predestined for the calibration of the simulation parameters: For a parameter field with 18 different settings, the total deviation between experiment and simulation is less than 11 % after calibration.
Für Fußballer:innen stellen muskuläre Verletzungen der unteren Extremitäten ein großes Problem dar. Ein Beispiel hierfür liefert die Nationalmannschaftsstürmerin Alexandra Popp, die aufgrund muskulärer Probleme das EM-Finale 2022 in Wembley kurzfristig verpasste. Oftmals stehen gerade hohe Anspannungssituationen in zeitlichem Zusammenhang mit Verletzungen, der Einfluss der psychischen Beanspruchung auf die biomechanischen Belastungen wird jedoch meist nur wenig beachtet.
To avoid dislocation of the shoulder joint after reverse total shoulder arthroplasty, it is important to achieve sufficient shoulder stability when placing the implant components during surgery. One parameter for assessing shoulder stability can be shoulder stiffness. The aim of this research was to develop a temporary reverse shoulder implant prototype that would allow intraoperative measurement of shoulder stiffness while varying the position of the implant components. Joint angle and torque measurement techniques were developed to determine shoulder stiffness. Hall sensors were used to measure the joint angles by converting the magnetic flux densities into angles. The accuracy of the joint angle measurements was tested using a test bench. Torques were determined by using thin-film pressure sensors. Various mechanical mechanisms for variable positioning of the implant components were integrated into the prototype. The results of the joint angle measurements showed measurement errors of less than 5° in a deflection range of ±15° adduction/abduction combined with ±45° flexion/extension. The proposed design provides a first approach for intra-operative assessment of shoulder stiffness. The findings can be used as a technological basis for further developments.
Microchips are intensively used in almost all nowadays electronic devices. With the continuous advancement of our technologies, they get smaller in size than ever before. They generate high-intensity heat loads that need to be transported effectively such that they may function properly. Heat pipes have proven to be very effective in transporting relatively large heat loads from miniature components. They are of seamless structure that involves a working fluid capable of evaporation and condensation at the working temperature of the electronic chips. The working fluid is derived to move from the condenser to the evaporator via multiple microgrooves using capillary forces. It is important that the condensate reaches the evaporator at a proper rate such that no dry-out or flooding occur. In this work, we are particularly interested in the case of capillary-driven flows in rectangular microchannels. A generalized model is developed that works for axe-symmetric rectangular channels of arbitrary, moderately varying width profiles. It also accounts for any contrast of viscosity between the liquid and the vapor under isothermal conditions. The model shows to reduce to the special case of imbibition in straight and uniform microchannels, for which comparisons with experimental and modeling works show an excellent match. Cases representing linearly and quadratically varying converging/diverging width profiles have been explored. It is found that the viscosity ratio has a significant influence on the rate at which the meniscus advances. The model also negates the common practice found in the literature of using the formula developed for imbibition rates in capillary tubes for rectangular microchannels by replacing the diameter of the tube with the hydraulic diameter. It is also found that the channel profile has an influential effect on the imbibition rates. For tapered microchannels, the capillary force increases along the channel length while it decreases for diverging ones. It is interestingly demonstrated that, for quadratically tapered microchannel, the speed of the meniscus increases towards the end of the microchannel compared with linearly varying microchannels. On the other hand, for diverging microchannels, the speed of the meniscus decreases due to the increase in the cross-sectional area. Computational fluid dynamics (CFD) analysis has been conducted to provide a framework for confirmation and verification for which very good match has been established, which builds confidence in the modeling approach.
Developing new deep-drawn sheet metal parts is a challenging task due to conflicting demands for low costs, durability, and crash properties. Ensuring manufacturability throughout geometrical changes adds to the complexity, leading engineers to rely on experience-driven iterative design changes that compromise requirements and lack reproducibility. Finite Element (FE) simulation models are employed to ensure manufacturability, albeit at the expense of high computational costs and delays in part development.
To improve efficiency, a Machine learning (ML)-centered approach was proposed to ensure manufacturability. However, the limited availability of data raises uncertainty about whether a low- or high-dimensional ML approach is most suitable for drawability assessment.
This work compares the accuracy of a low-dimensional, feature-based Linear Support Vector surrogate and an adapted high-dimensional PointNet model under different dataset sizes. The dataset is composed of parametrically generated, U-shaped structural sheet metal parts.
We use a one-step simulation scheme and evaluate results with a Forming Limit Diagram (FLD) to label drawability. Results show the point of transition to be at about 500 training samples, from which onwards Deep learning is advantageous.
Moreover, the generalizability of these models is tested on a second dataset with topologically similar components. This is to assess the potential for a geometrically more comprehensive evaluation. We discuss several influences on model performances and outline future potentials.
New structural sheet metal parts are developed in an iterative, time-consuming manner. To improve the reproducibility and speed up the iterative drawability assessment, we propose a novel low-dimensional multi-fidelity inspired machine learning architecture. The approach utilizes the results of low-fidelity and high-fidelity finite element deep drawing simulation schemes. It hereby relies not only on parameters, but also on additional features to improve the generalization ability and applicability of the drawability assessment compared to classical approaches. Using the machine learning approach on a generated data set for a wide range of different cross-die drawing configurations, a classifier is trained to distinguish between drawable and non-drawable setups. Furthermore, two regression models, one for drawable and one for non-drawable designs are developed that rank designs by drawability. At instantaneous evaluation time, classification scores of high accuracy as well as regression scores of high quality for both regressors are achieved. The presented models can substitute low-fidelity finite element models due to their low evaluation times while at the same time, their predictive quality is close to high-fidelity models. This approach may enable fast and efficient assessments of designs in early development phases at the accuracy of a later design phase in the future.
Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced.
Appropriate climate change mitigation requires solutions for all actors of the energy system. The residential sector is a major part of the energy system and solutions for the implementation of a seasonal hydrogen storage system in residential houses has been increasingly discussed. A global analysis of prosumer systems including seasonal hydrogen storage with water electrolyser, hydrogen compressor, storage tank, and a fuel cell studying the role of such a seasonal household storage in the upcoming decades is not available. This study aims to close this research gap via the improved LUT-PROSUME model, which models a fully micro sector coupled residential photovoltaic prosumer system with linear optimisation for 145 regions globally. The modelling of the cost development of hydrogen storage components allows for the simulation of a residential system from 2020 until 2050 in 5-year steps in hourly resolution. The systems are cost-optimised for either on- or off-grid operation in eight scenarios including battery electric vehicles, which can act as an additional vehicle-to-home electricity storage for the system. Results show that implementation of seasonal hydrogen systems only occurs in least cost solutions in high latitude countries when the system is forced to run in off-grid mode. In general, a solar photovoltaic plus battery system including technologies that can cover the heat demand is the most economic choice and can even achieve lower cost than a full grid supply in off-grid operation for most regions until 2050. Additional parameters including the self-consumption ratio, the demand cover ratio, and the heat cover ratio can therefore not be improved by seasonal storage systems if economics is the main deciding factor for a respective system. Further research opportunities and possible limitations of the system are then identified.
Kombinationen aus kraft- und formschlüssigen Verbindungen erhöhen die Leistung bei im Hybridguss verbundenen Gussteilen mit Anbau- oder Einlegeteilen und machen separate Fügeprozesse überflüssig. Simulations-Methoden unterstützen das Design kraft- und formschlüssiger Verbindungen. Ergebnisse eines Ausdrückversuchs zeigen eine relativ gute Übereinstimmung zwischen gemessenen und mittels Simulation ermittelten Kraft-Weg-Kurven.
Mechanical surface treatments such as deep rolling or laser-shock peening can markedly affect the cyclic performance of light-weight alloys, especially if significant thick work hardened surface regions are induced. At room temperature, the cyclic deformation behaviour is strongly influenced by the nature of the induced near-surface microstructures provided that they remain stable during fatigue loading. At elevated temperatures, the stability of near-surface work hardening and local microstructures plays an even more important role since the process-induced residual compressive stresses are likely to anneal out partially or completely. This overview illustrates to what extent deep rolling can effect the cyclic performance of various wrought light alloys being fatigue loaded in stress control at ambient and elevated temperatures.
Bauteilfertigung
(2009)
Mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly stressed metallic components. Deep rolling is an especially attractive technique since it is possible to generate deep, near-surface compressive residual stresses and work hardening while retaining a relatively smooth surface finish. Indeed, this technique is best known for increasing the fatigue strength and lifetime of steel components such as crankshafts. Although most work on deep rolling has been on steels, recently it has also been applied with reasonable success to titanium alloys. Accordingly, in this investigation, we examine the effect of deep rolling on the high-cycle fatigue behavior of Ti-6Al-4V, with particular emphasis on the thermal and mechanical stability of the residual stress states and near-surface microstructures. Preliminary results on laser shock peened Ti-6Al-4V are also presented for comparison. In addition, we examine whether these surface treatments are effective in retaining fatigue strength at the higher temperatures of 300 to 450C. Based on the cyclic deformation and stress/life behavior, together with the X-ray and microstructural observations, it is found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti-6Al-4V at such higher temperatures, despite the almost complete relaxation of the residual stresses at the surface. This clearly implies that, in addition to residual stresses, near-surface microstructures, which in Ti-6Al-4V consist of ultrafine near-surface nanostructures, play a critical role in the enhancement of fatigue lifetimes by mechanical surface treatments.
In this paper, the high-temperature fatigue behavior and residual stress states of a Ti-6Al-4V alloy are investigated after mechanical surface treatment. In particular, the two surface treatments investigated, laser shock peening and deep rolling, were observed to result in significantly different residual stress states. The consequent isothermal fatigue behavior at elevated temperatures, characterized using cyclic deformation curves, are discussed in terms of the stability of the near-surface work hardening and compressive residual stresses. Despite pronounced relaxation of the residual stresses, both laser shock peening and deep rolling led to a significant improvement in the cyclic deformation behavior and, hence, increased fatigue lifetimes at elevated temperatures as compared to untreated materials states.
Dual front steering axles are quite common in multi-axled heavy duty trucks. In standard layouts of such axle combinations, the steer motions of the wheels depend not only on the rotation of the steering wheel but also on the movements of the axles. As a consequence, the model complexity of the steering system should match with the complexity of the suspension model. The development of new technologies like advanced driver assistance systems or autonomous driving can only be accomplished efficiently using extensive simulation methods. Such kind of applications demand for computationally efficient vehicle models. This paper presents a steering system model for dual front axles of heavy duty trucks which supplements the suspension model of the axles. The model takes the torsional compliance of the steering column as well as the stiffness of the tie rods and the coupling rod into account. A quasi-static solution provides a straight forward computation including the partial derivatives required for an efficient implicit solver. The steering system model matches perfectly with comparatively lean, but sufficiently accurate multibody suspension models.
A prototype of a thermal insulation system to offer high selectivity of the solar gain regarding the solar incidence angle (SATIS) was applied to a typical solid brick masonry for existing buildings in Germany. Light conducting elements (LCEs) inclined at 19 ° were incorporated in SATIS, which equals the average solar noon angle in southern Germany during winter. The entire wall construction was experimentally investigated in a differential climatic chamber test bench at four different irradiation angles according to a dynamic test procedure. In addition, a conventional wall construction (CWC) has been measured. At SATIS’ design angle of 19 °, the SATIS wall construction shows a solar gain (SG) of 394.5 Wh/m², while the SG of the CWC amounts to only 25.4 Wh/m². The validated transient model of the SATIS wall construction showed that, at the end of the irradiation period of the dynamic test procedure (8 h), the solar heat penetrates to a depth of 253 mm and 111 mm inside the 385 mm thick brick wall masonry at the irradiation angles of 19 ° and 50 °, respectively. During the same time, the stored solar energy at 50 ° amounts to only 24.4 % of that stored at 19 °.
Introduction The most well known effect of mechanical surface treatments on metallic materials is the improvement in fatigue properties. It is therefore not surprising that most of the archival literature on mechanical surface treatments, such as shot peening, deep rolling and laser shock peening, deals with the effect of near-surface properties on fatigue behavior. Most of these studies, however, are confined to room temperature fatigue behavior; in comparision, the effect of mechanical surface treatment on fatigue behavior at high temperatures has been rarely investigated [1-5]. The reason for this disparity can be found in the popular belief that fatigue strength improvement by mechanical surface treatments is mainly due to the presence of compressive residual stresses, and since such stresses should anneal out at elevated temperatures, mechanical surface treatments for high temperature applications would appear questionable. However, this view may be over simplistic as there is always a possibility that the residual stresses may be at least partially stable at elevated temperatures [6]; in addition, other factors may be involved, such as the nature of the near-surface microstructure. Accordingly, it is the objective of this study to examine the role of mechanical surface treatments on the high temperature fatigue behavior of several metallic engineering materials. Moreover, it is the aim of this work to clarify what are the critical temperature "thresholds' at which near-surface microstructures and residual stresses become unstable and whether this can explain the observed fatigue behavior.
It is well known that mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly-stressed metallic components. Deep rolling (DR) is particularly attractive since it is possible to generate, near the surface, deep compressive residual stresses and work hardened layers while retaining a relatively smooth surface finish. In the present investigation, the effect of DR on the low-cycle fatigue (LCF) and high-cycle fatigue (HCF) behavior of a Ti–6Al–4V alloy is examined, with particular emphasis on the thermal and mechanical stability of the residual stress states and the near-surface microstructures. Preliminary results on laser shock peened Ti–6Al–4V are also presented for comparison. Particular emphasis is devoted to the question of whether such surface treatments are effective for improving the fatigue properties at elevated temperatures up to ∼450 °C, i.e. at a homologous temperature of ∼0.4T/Tm (where Tm is the melting temperature). Based on cyclic deformation and stress/life (S/N) fatigue behavior, together with the X-ray diffraction and in situ transmission electron microscopy (TEM) observations of the microstructure, it was found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti–6Al–4V at such higher temperatures, despite the almost complete relaxation of the near-surface residual stresses. In the absence of such stresses, it is shown that the near-surface microstructures, which in Ti–6Al–4V consist of a layer of work hardened nanoscale grains, play a critical role in the enhancement of fatigue life by mechanical surface treatment.
Hydrogen storage based on the repeated reduction and oxidation (redox) reactions of iron oxide/iron composites represents a promising technology. This work is dedicated to studying the influence of the amount of water added during the pelletizing process on the cycle stability and structure of iron oxide pellets. The storage composites were prepared from iron oxide (Fe2O3) and 10 wt.-% support material (cement) with different amounts of water (18 and 33 wt.-%) in a laboratory-scale pelletizing disk. To evaluate the cycle stability of the composites, the kinetics of the redox reactions were experimentally measured at 800 ∘
C in an atmosphere of 50% N2 and 50% H2 (reduction) or 50% steam (oxidation), respectively. Moreover, the structure of the pellets was analyzed by micro-computed tomography scans. It turned out that pellets with higher water contents attained faster kinetics and a higher cycle stability. The sample with the least water content (18 wt.-%) needed about 26 min and 19 min to reach a conversion rate of 80% during the reduction and oxidation reactions of the sixth redox cycle, respectively. In contrast, the sample with the highest water content (33 wt.-%) could achieve the same conversion rate after 18 min (reduction) and 13 min (oxidation) during the ninth redox cycle.
Increasing the lifetime of titanium implants through a diffusion-controlled surface treatment
(2023)
Multi-fidelity optimization of metal sheets concerning manufacturability in deep-drawing processes
(2023)
Multi-fidelity optimization, which complements an expensive high-fidelity function with cheaper low-fidelity functions, has been successfully applied in many fields of structural optimization. In the present work, an exemplary cross-die deep-drawing optimization problem is investigated to compare different objective functions and to assess the performance of a multi-fidelity efficient global optimization technique. To that end, hierarchical kriging is combined with an infill criterion called variable-fidelity expected improvement. Findings depend significantly on the choice of objective function, highlighting the importance of careful consideration when defining an objective function. We show that one function based on the share of bad elements in a forming limit diagram is not well suited to optimize the example problem. In contrast, two other definitions of objective functions, the average sheet thickness reduction and an averaged limit violation in the forming limit diagram, confirm the potential of a multi-fidelity approach. They significantly reduce computational cost at comparable result quality or even improve result quality compared to a single-fidelity optimization.
The movement of a meniscus inside a capillary tube has been extensively studied in the context of displacing one fluid with another immiscible one. This phenomenon exists in many applications including pharmaceutical, oil production, filtration and separation processes, and others. When one of the phases is entrapped inside a capillary tube, it forms what is called a ganglion with two menisci between the two fluids. In a straight uniform capillary tube, a stagnant entrapped ganglion is symmetric. The situation is different if the capillary tube is tapered in which case the two menisci assume different curvatures. Such inhomogeneity of the capillary pressure self-propels the ganglion to move. The fate of the ganglion inside the tapered tube depends on whether it is wetting or nonwetting to the tube wall. That is, after the initial movement, a wetting ganglion accelerates towards the tapered end of the tube while a nonwetting one decelerates towards the wider end before reaching a terminal configuration. Such fates are linked to the variations of the capillary pressure, which continuously increases for a wetting ganglion and decreases for the nonwetting one. In this work, a generalized model is developed that not only describes capillary-driven dynamics over a wide range of viscosity and density contrasts but also pressure-driven scenarios with/without gravity. The model, however, neglects the inertial effect of the two fluids on account of the fact that it is confined to the very early time of the movement process. A first-order nonlinear ordinary differential equation is developed that describes the dynamic behavior of both the wetting and nonwetting ganglions. A fourth-order Runge-Kutta algorithm is developed to solve the model equations. Furthermore, a computational fluid dynamics (CFD) analysis was used to provide a comparison and verification framework.
In Vitro Analysis of Human Cartilage Infiltrated by Hydrogels and Hydrogel-Encapsulated Chondrocytes
(2023)
Osteoarthritis (OA) is a degenerative joint disease causing loss of articular cartilage and structural damage in all joint tissues. Given the limited regenerative capacity of articular cartilage, methods to support the native structural properties of articular cartilage are highly anticipated. The aim of this study was to infiltrate zwitterionic monomer solutions into human OA-cartilage explants to replace lost proteoglycans. The study included polymerization and deposition of methacryloyloxyethyl-phosphorylcholine- and a novel sulfobetaine-methacrylate-based monomer solution within ex vivo human OA-cartilage explants and the encapsulation of isolated chondrocytes within hydrogels and the corresponding effects on chondrocyte viability. The results demonstrated that zwitterionic cartilage–hydrogel networks are formed by infiltration. In general, cytotoxic effects of the monomer solutions were observed, as was a time-dependent infiltration behavior into the tissue accompanied by increasing cell death and penetration depth. The successful deposition of zwitterionic hydrogels within OA cartilage identifies the infiltration method as a potential future therapeutic option for the repair/replacement of OA-cartilage extracellular suprastructure. Due to the toxic effects of the monomer solutions, the focus should be on sealing the OA-cartilage surface, instead of complete infiltration. An alternative treatment option for focal cartilage defects could be the usage of monomer solutions, especially the novel generated sulfobetaine-methacrylate-based monomer solution, as bionic for cell-based 3D bioprintable hydrogels.
Maintaining dimensional accuracy is a major challenge of laser powder bed fusion (L-PBF) preventing its application for more complex and filigree L-PBF structures in industrial practice. Previous studies have shown that residual stresses and distortion of benchmark L-PBF components may be predicted by sequential thermo-mechanical analyses. However, the reliability of these analyses for more complex structures must be critically questioned, as comprehensive validation and sensitivity analyses are scarce. In this paper, we present a calibrated and validated low-fidelity sequential thermo-mechanical finite element analysis (FEA) of a tubular L-PBF lattice structure, i.e., an aortic stent, where pronounced local deformation is expected. As a first step, the finite element model was extensively calibrated using experimental data to ensure reproducibility of the simulation results. Thereupon, geometric features critical to the distortion of L-PBF lattice structures and measures to compensate for the distortion, such as inversion of the distorted L-PBF structure, were investigated. It was found that the distortion of the L-PBF lattice structures can be reduced, but not completely prevented, by increasing the strut angles, increasing the strut thickness, and decreasing the transition radius in the area of merging struts. FEA-based inversion of the numerically predicted deformed structure minimized distortion, resulting in the L-PBF aortic stent approximating the intended CAD geometry even with a small strut thickness. This work shows that low-fidelity sequential thermo-mechanical FEA can be used not only for the analysis and deformation compensation of reference structures, but also for the analysis of more complex filigree structures with pronounced local deformation.
This communication presents an experimental and analytical study on the evaporation mechanism in a closed-structured asymmetric plate heat exchanger (PHE) employed as a stagnant water evaporator for the application in an adsorption heat transformation appliance. To this aim, an experimental unit is constructed, which comprises two identical PHEs, one acting as an vaporator/condenser and the second, as an adsorber/desorber. Two endoscopes are mounted inside the investigated evaporator to visualize the evaporation mechanism when performing adsorption-evaporation processes under different boundary conditions. It turned out that the evaporation mechanism is a partially covered, thin film evaporation. A heat transfer analysis is performed to evaluate the heat transfer coefficient of the thin film evaporation () inside the investigated evaporator, resulting in -values between 1330 and 160 [W∙m−2∙K−1] over the investigated adsorption-evaporation time. Correlating the obtained () to the film thickness and the wetted area results in -values between 0.34 and 0.78 [mm] and wetted to total area ratios of 0.78 to 0.16. Besides, an analytical model has been developed and introduced to correlate the overall evaporator heat transfer coefficient with the adsorption potential and the time rate of change of the water uptake.
Additive Manufacturing (AM) is a future-oriented manufacturing technology that is experiencing an enormous boom in the times of Industry 4.0. As a result, various AM technologies and printer models from different manufacturers are entering the market over a short time span. With the advancing establishment of this manufacturing technology for series applications, the expectations and requirements of the fabricated components are also increasing. However, a major challenge is the application-specific selection of the most suitable AM process due to a lack of comparable data. Furthermore, there needs to be more know-how regarding the geometrical and mechanical characteristics of AM parts. This paper addresses this problem by comparing the three most common plasticbased AM processes in the areas of surface quality, dimensional accuracy, and mechanical properties. Roughness measurements, evaluation of a benchmark artifact, tensile tests, and load increase tests are carried out. Based on the results, the individual possibilities and limitations of the compared AM processes can be detected.
Friction has long been an important issue in multibody dynamics. Static friction models apply appropriate regularization techniques to convert the stick inequality and the non-smooth stick-slip transition of Coulomb’s approach into a continuous and smooth function of the sliding velocity. However, a regularized friction force is not able to maintain long-term stick. That is why, dynamic friction models were developed in the last decades. The friction force depends herein not
only on the sliding velocity but also on internal states. The probably best known representative, the LuGre friction model, is based on a fictitious bristle but realizes a too simple approximation. The recently published second order dynamic friction model describes the dynamics of a fictitious bristle more accurately. Its performance is compared here to stick-slip friction models, developed and launched not long ago by commercial multibody software packages.
Dieses Lehr- und Übungsbuch vermittelt auf anschauliche Weise die Methoden der Mehrkörpersimulation und verdeutlicht deren Vor- und Nachteile bei der praktischen Anwendung anhand konkreter Beispiele. Die einzelnen Methoden werden durch Matlab-Skripte und -Funktionen verdeutlicht, wobei die Modellbildung, die mathematische Beschreibung und die numerische Simulation von Systemen starrer Körper die Schwerpunkte bilden. Die vorliegende Auflage wurde unter anderem um Matlab-Live-Skripte erweitert, welche kleine Animationen zur Veranschaulichung der Dynamik der Probleme enthalten. Die Lösungen zu den Übungsbeispielen und die integrierten Matlab-Skripte sowie weitere Beispiele und Anwendungen stehen über QR-Codes zum Download zur Verfügung und ermöglichen dadurch auch ein effizientes Selbststudium.
Nach dem Aufbau eines Mehrkörper-Simulationsmodells muss dieses auf Richtigkeit, Funktionalität und Wirtschaftlichkeit getestet werden. Die Ermittlung der Gleichgewichtslage stellt dabei eine erste Plausibilitäts-Kontrolle dar. Eine Linearisierung mit anschließender Analyse der Eigendynamik liefert Aussagen über die Frequenzen und das Dämpfungsverhalten des Modells. Einfache Erregersignale ermöglichen einen ersten Einblick in das nichtlineare dynamische Verhalten des Modells. Modell-Parameter, die nicht genau bekannt sind, können durch gezielte Variationen plausibel geschätzt oder über eine Optimierung sogar mit optimalen Werten belegt werden. Nach all diesen Tests steht das Mehrkörper- Simulationsmodell dann für praktischeUntersuchungen zurVerfügung, die neben reinen Zeitsimulationen auch Methoden der Inversen Kinematik und der Inversen Dynamik mit einschließen.
Due to the complexity and the number of factors involved in factory layout planning, computers were identified as an efficient tool to support the process. However, so far no method for computer-aided layout planning has gained wide acceptance in practical application. One reason for this is that in present approaches either the user or the computer designs the layout, neglecting either the qualitative or the quantitative goals. To bridge this gap, this article introduces a concept for human-computer-integration based on evaluative feedback and inverse reinforcement learning. A key element of the concept is the interactive planning process in which user and computer alternately design and improve the layout until a satisfactory layout is found. The user evaluates the layouts according to qualitative criteria, adjusts them intuitively and specifies objectives and restrictions in an explorative way. The computer on the other hand – in form of a reinforcement algorithm – generates possible layouts and incorporates the user’s feedback into its policy. This synergy is expected to generate better results than an expert or an algorithm alone could. Furthermore, in the context of learning factories, it encourages critical thinking and allows students to develop a deeper understanding of the factors that contribute to efficient manufacturing processes. Both an architecture for the implementation is proposed and the requirements for the user interface are specified.
Produkt- bzw. Maschinengeräusche mit deutlich hörbaren tonalen Komponenten werden häufig als lästig empfunden. Wenn zusätzlich eine Interaktion mehrerer tonaler Komponenten in Geräuschen stattfindet, was in realen Szenarien beispielsweise durch die Überlagerung tonaler Komponenten durch verschiedene Aggregate, wie Motoren und Getrieben, stattfindet, dann können Geräusche unterschiedlich tonal, aber auch unterschiedlich konsonant und dissonant wahrgenommen werden. Vorangehende Hörexperimente haben gezeigt, dass die Dissonanz bei ähnlicher Tonhaltigkeit der Geräusche einen großen Einfluss auf die Präferenzurteile hat. Des Weiteren konnte bereits ein grundlegendes Empfindungsmodell für die ”Dissonanz” sowie ein Präferenz-Prädiktor entwickelt werden, die die Subjektivdaten in hoher Güte vorhersagen konnten. In den hier vorgestellten Versuchen wurde das Zusammenspiel zwischen der empfundenen Tonhaltigkeit und der sich aus mehreren Tonkomponenten ergebenden Dissonanz auf die Präferenzurteile untersucht. In der Analyse wird aufgezeigt, auf welche Weise und in welchem Umfang die wahrgenommene Ausgeprägtheit der Tonhaltigkeit durch Interaktion mehrerer Tonkomponenten die allgemeine Geräuschqualität beeinflusst. Da verschiedene Grade der Dissonanz nur durch die gleichzeitige Anwesenheit tonaler Komponenten entstehen können, ist das Zusammenspiel beider Größen bei der Bildung eines Präferenzurteils von einer speziellen Natur. Dies wird sowohl bei der Modellierung der Interaktion beider Größen als auch im Vorhersagemodell der Dissonanz berücksichtigt.
It is generally known that project-based learning is a very important part of engineering education to connect theoretical knowledge with practical work. Students learn to apply their knowledge to real-world challenges as it is the case in their later professional life. If students are not used to project work or the scientific topic is new and relatively complex, they may be overwhelmed. The consequence is that students achieve poor results, are frustrated, and therefore learning success is low. Semi-structured projects are introduced that combine the advantages of structured experiments with projects. The project work is structured into several parts with detailed descriptions of the tasks. In the end, students get similar results to doing a free project, but the success rate is higher due to higher guidance. Therefore, these semi-structured projects are seen to be an appropriate method to guide students to learn how to do project work. The feedback from most students is very positive. Some students with no previous lab experience complained about the project work and wished for more guidance to become familiar with lab work. In sum, the student feedback is encouraging to develop semi-structured projects further.
Although many composite structures are inconsistently curved, such as the leading edges of aircraft wings, the variety of research in impact engineering is almost limited to the impact performance of plates or cylindrically curved specimens. It is not known whether the findings obtained from standardized tests can be transferred to curved structures or which adaptions are required. Therefore, a deeper understanding of the deformation and damage behavior of inconsistently curved structures is essential to transfer the observed impact behavior of flat specimens to general curved structures and therefore to utilize the full lightweight potential of a load-specific design. An accurate description of the procedure as well as the results of the experimental and numerical study of the low-velocity impact behavior of differently single-curved elliptic specimens is presented. To close the research gap of the impact behavior of geometries with curvatures between the plates and simplified leading edges, novel specimens geometries have been derived from established impact test standards. Glassfiber-reinforced specimens are subjected to an instrumented impact test at constant impact energy. This is numerically investigated by a stacked-layer model, which used cohesive zone modeling to enable the simulation of matrix cracking, fiber fracture and delamination. The resulting projected damage areas, as well as the force and deflection histories, were evaluated and section cuts were examined to discuss the damage morphology, formation and propagation process. Significant effects on maximum deflection, compliance and dynamic behavior on the size and morphology of damage were found.
In the treatment of hand injuries in the context of orthopedic care, movable hand orthoses are used in many cases. Early motion therapy is in most cases advantageous for adequate, rapid, and successful long-term healing of the hand. Conventional mobile hand orthoses can only be used for movement therapy to a limited extent since they represent the wrist as a simple rotating joint and neglect the complexity of the movement possibilities of the hand. In this paper, a novel concept for movable hand orthoses based on prestressed compliant structures is presented. The advantage with this concept is that it replicates the multiaxial motion capabilities without the need for conventional joints. Besides the derivation and description of the concept, a first three-dimensional CAD design is shown. Additionally, the next planned steps in the development of such a novel dynamic hand orthosis are described.
In the treatment of hand injuries in the context of orthopedic care, movable wrist hand orthoses are used in numerous instances. Early motion therapy is in most cases advantageous for adequate, rapid and successful long-term healing of the hand. Conventional dynamic wrist hand orthoses can only be used for movement therapy to a limited extent since they represent the wrist as a simple rotating joint and neglect the complexity of the hand movement possibilities. In this paper, a preliminary concept for dynamic wrist hand orthoses based on prestressed compliant structures is presented. The distinctive feature of this concept lies in the enabling of multiaxial motion capabilities of the human hand without applying conventional joints. According to the concept the wrist region is surrounded by a prestressed compliant structure. Besides the derivation and description of the concept, a first three-dimensional computer-aided design is shown. Additionally, the necessary steps in the development of such a novel dynamic wrist orthosis are discussed.
Surgical Smoke is generated during the cauterization of tissue with high-frequency (HF) devices and consists of 95% water vapor and 5% cellular debris. When the coagulation tweezers, which are supplied with HF voltage by the HF device, touch tissue, the electric circuit is closed, and smoke is generated by the heat. In-vivo investigations are performed during tracheotomies where surgical smoke is produced during coagulation of tissue. Furthermore, in-vitro parametric studies to investigate the particle number and size distribution and the spatial distribution of surgical smoke with laser light sheet technique are conducted. With higher power of the HF device, the particles generated are larger in size and the total number of particles generated is also higher. Adding artificial saliva to the tissue shows even higher particle counts. The study by laser light sheet also confirms this. The resulting characteristic size distribution, which may include viruses and bacterial components, confirms considering the risk arising from surgical smoke. Furthermore, the experiments will provide the database for further numerical investigations.
High Spatial Resolution Tomo-PIV of the Trachea Focussing on the Physiological Breathing Cycle
(2023)
Investigations of complex patient-specific flow in the nasopharynx requires high resolution numerical calculations validated by reliable experiments. When building the validation base and the benchmark of computational fluid dynamics, an experimental setup of the nasal airways was developed. The applied optical measurement technique of tomo-PIV supplies information on the governing flow field in three dimensions.
This paper presents tomo-PIV measurements of the highly complex patient-specific geometry of the human trachea. A computertomographic scan of a person’s head builds the basis of the experimental silicone model of the nasal airways. An optimised approach for precise refractive index matching avoids optical distortions even in highly complex non-free-of-sight 3D geometries. A linear-motor-driven pump generates breathing scenarios, based on measured breathing cycles. Adjusting of the CCD cameras‘ double-frame-rate PIV-Δt enables the detailed analysis of flow structures during different cycle phases. Merging regions of interest enables high spatial resolution acquisition of the flow field.
Introduction
Shear induced multimerisation of von-Willebrand-factor (vWF) is supposed to play an important role in coagulation inside extracorporeal membrane oxygenators. However, there is no proof that links observed vWF structures to computed or measured flow conditions.
Methods
The structures of multimeric vWF fibers, observed in clinically used membrane oxygenators is examined using immunofluorescence microscopy (IFM) using Carstairs’ staining method (positive ethics committee vote). The flow around the membrane fibres inside the oxygenator is investigated in terms of shear rate, wall shear velocity and streamlines by using CFD (RANS, Carreau-Yasuda viscosity, geometry remodelled after high-resolution µCT-scans). By interpreting the histological and numerical results in this common context, indications for shear induced coagulation mechanisms can be identified.
Results
The fibre structures of multimeric vWF build regular but not exactly symmetric formations around the contact face (CF) between the crosswise stacked oxygenator fibres (OF), see fig.1B, vWF marked red. Annular around the CF arranged, cells are likely to be found, see fig.1B, nuclei marked blue.
The computed streamlines around the OF show attached flow around the circular fibres. However, the irregular arrangement of real OF produce considerable cross flow between the interconnected neighbouring channels, in contrast to previous 2D-simulations. Thus, the CF are washed around closely by blood, also from neighbouring channels. The wall shear velocity streamlines form regular, slightly asymmetric shapes around the contact faces. The occurring maximum shear rates are in the range of 1,000 1/s.
Discussion
The shapes of vWF structures found in clinically used oxygenators match the computational results in terms of wall shear velocity and streamlines well. The accumulation of cells close to the CF can also be explained by fluid mechanics, as there are small shear gradients and slow velocities. However, occurring shear rates between OFs are too low to trigger multimerisation of vWF. That raises the question where in the circuit the actual activation of vWF is started and how, at least partly chained, vWF multimeres are attracted towards the OF surface. A next step will be the investigation of the actual shear rate triggered (or mediated) multimerisation of vWF. Towards this end, microfluidic experiments with shear triggered coagulation will be performed. Also of big interest is the computation of the flow situation in the oxygenator in proximity to chaining threads, which have been ignored in computations so far. However, first a realistic representation of the effective viscosity in computations is needed, which is not available yet.
In the context of production and factory planning, the expansion of the factory must already be taken into account during initial planning. This results in an increase in planning complexity, as the involved planners have to know the expansion stages of the factory in the different time periods and have to evaluate concept modifications across all time periods. This paper presents an idea for a planning tool, which takes expansion stages into consideration. The data model contains all relevant information to generate a simulation model of the factory in an almost automated way. The aim is to enable factory planners to quickly investigate concept changes with the help of simulation, for example, to identify bottlenecks.
One major goal of green-field factory planning is to decide on space requirements in the plant. In this phase, detailed information about the supply chain network (e.g. which suppliers deliver which parts) is often unavailable. Nevertheless, typical decisions in supply chain management, like the definition of replenishment processes and quantities or make-or-buy decisions, impact space requirements in the factory and should therefore be considered in the factory planning. This research article proposes a simulation approach for a factory simulation in which raw material replenishment is integrated to evaluate the space requirements for raw materials.
To evaluate the performance of a ropeway in an urban environment, simulations of the dynamic passenger transport characteristics are required. Therefore, a modular simulation model for urban ropeway networks was developed, which can be flexibly adapted to any city and passenger volume. This simulation model was used to analyze the ropeway network concept of the German city Regensburg and to determine the expected operating conditions. The passenger volume, different types of persons, their occurrence probability and their destination distribution is depending on the location and daytime and can be defined for each individual station. In an initial analysis, the number of passengers currently occurring in bus traffic were projected onto the ropeway network. To enable climate-friendly and efficient operation, different strategies were developed to significantly reduce the number of gondolas. The best fitting strategies resulted in significant cost savings while passenger comfort, as represented by queue time, remained unchanged.
Simulation Based Approach for Reconfiguration and Ramp up Scenario Analysis in Factory Planning
(2022)
Structural changes in production entail a potential economic risk for manufacturing companies. It is necessary to identify a suitable strategy for the reconfiguration process and to continue to meet the demand during the change in the factory structure and ramp-up phase. A simulation offers the possibility to analyze different ramp-up scenarios for the factory structure and to select a suitable concept for the reconfiguration process. A discrete event simulation approach is presented that can be used to evaluate variants of structural changes and serves as a basis for deciding on a reconfiguration strategy. This approach is demonstrated using a specific production step of a plant producing hydrogen electrolyzers, the results and generalized conclusions are discussed.
Für Mutter und Kind konnte das Risiko der Geburt durch die Weiterentwicklung der Medizin drastisch reduziert werden. Doch wie ist es um das Wohl derer bestellt, die die Gebärende unterstützen? Eine Studie der Ostbayerischen Technischen Hochschule Regensburg hat sich mit den muskuloskelettalen Beschwerden von Geburtshelfer:innen auseinandergesetzt
Osteoporosis is a common disease of old age. However, in many cases, it can be very well prevented and counteracted with physical activity, especially high-impact exercises. Wearables have the potential to provide data that can help with continuous monitoring of patients during therapy phases or preventive exercise programs in everyday life. This study aimed to determine the accuracy and reliability of measured acceleration data at different body positions compared to accelerations at the pelvis during different jumping exercises. Accelerations at the hips have been investigated in previous studies with regard to osteoporosis prevention. Data were collected using an IMU-based motion capture system (Xsens) consisting of 17 sensors. Forty-nine subjects were included in this study. The analysis shows the correlation between impacts and the corresponding drop height, which are dependent on the respective exercise. Very high correlations (0.83–0.94) were found between accelerations at the pelvis and the other measured segments at the upper body. The foot sensors provided very weak correlations (0.20–0.27). Accelerations measured at the pelvis during jumping exercises can be tracked very well on the upper body and upper extremities, including locations where smart devices are typically worn, which gives possibilities for remote and continuous monitoring of programs.
This work aims at investigating the kinetic mechanisms of the reduction/oxidation (redox) reactions of iron oxide/iron pellets under different operating conditions. The reaction principle is the basis of a thermochemical hydrogen storage system. To simulate the charging phase, a single pellet consisting of iron oxide (90% Fe2O3, 10% stabilising cement) is reduced with different hydrogen (H2) concentrations at temperatures between 600 and 800 °C. The discharge phase is initiated by the oxidation of the previously reduced pellet by water vapour (H2O) at different concentrations in the same temperature range. In both reactions, nitrogen (N2) is used as a carrier gas. The redox reactions have been experimentally measured in a thermogravimetric analyser (TGA) at a flow rate of 250 mL/min. An extensive literature review has been conducted on the existing reactions’ kinetic mechanisms along with their applicability to describe the obtained results. It turned out that the measured kinetic results can be excellently described with the so-called shrinking core model. Using the geometrical contracting sphere reaction mechanism model, the concentration- and temperature-dependent reduction and oxidation rates can be reproduced with a maximum deviation of less than 5%. In contrast to the reduction process, the temperature has a smaller effect on the oxidation reaction kinetics, which is attributed to 71% less activation energy (Ea,Re=56.9 kJ/mol versus Ea,Ox=16.0 kJ/mol). The concentration of the reacting gas showed, however, an opposite trend: namely, to have an almost twofold impact on the oxidation reaction rate constant compared to the reduction rate constant.