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High loads can appear in the individual joints of the human foot while the driver uses the pedals, in particular, during breaking. Measuring these internal forces is very difficult or almost impossible; therefore, advanced models are necessary to perform musculoskeletal simulations. The objective of this investigation was to see what loads are acting in the individual foot joints from the phalanges to calcaneus and talus during different brake scenarios. The Glasgow-Maastricht AnyBody Foot Model with 26 separate segments, connected by joints, ligaments and muscles was used inside the AnyBody Modeling System to compute individual mid foot joint loads. The amount, the direction of the force and additionally also the load insertion point was varied for several simulations. Figure 1: Seated musculoskeletal body model with applied brake force and forces for the lateral, intermediate and medial cuneiform-navicular joint for two different brake forces. The simulation showed that for the different brake scenarios, different muscles will be activated in the human and therefore different loads are apply in the fore-and mid-foot, respectively. The torso of the subject was assumed to be fixed in the seat. Further studies are ongoing to simulate the seat as an elastic element that allows different H-point locations according to the different loadings in the foot from the brake pedal using a new inverse dynamics analysis method called force-dependent kinematics.
Purpose:
A route to manufacture porous carbon fiber reinforced plastic (CFRP) for study purposes is described.
Design/methodology/approach:
The porous CFRP is characterized using standard techniques such as matrix digestion as well as the more sophisticated method of high resolution Microfocus X-Ray Tomography (μCT). A comparison of the results of those methods is presented. The mass gains of specimens with a wide range of porosity have been measured both in constant humidity and in alternating environments.
Findings:
It could be shown that severe temperature changes can temporarily increase the moisture content of porous CFRP. However, after the return to a constant environment, the moisture content returns back to saturation levels. Furthermore, it could be shown by X-Ray Tomography that even under severe climatic conditions no permanent liquid water condensates inside the pores.
Research limitations/implications:
Using Microfocus Computed Tomography it could be shown that even after nearly a year under hot-wet conditions and more than 150 severe temperature cycles there is no liquid water detectable inside the pores.
Originality/value:
In this paper the effects of severe temperature changes and high humidity on porous CFRP.
The worldwide growing energy demand with the exploration of new gas fields has promoted the development of high toughness seamless pipeline steels which should sustain the increasing demands resulting from the complex loading situations. One of the most important prerequisites for safe installation and operation of long distance gas transmission pipelines is the detailed knowledge and characterization of their fracture performance for specific applications. However, recent industry experience has revealed concerns related to the limitations and reliability of current test methods for brittle-to-ductile transition evaluation. Regarding the transition temperature evaluation, the critical issues involve Drop-Weight Tear Testing (DWTT) and full-scale West-Jefferson (WJ) test applied to the smaller pipes with diameter less than 500mm. The DWTT leads frequently to invalid results in terms of abnormal fracture appearance and inverse fracture occurrence. It is still not clear if this behavior is only owed to a testing effect, which material characteristics cause it and how far it reflects the full-scale behavior. Similar observations were made for the West-Jefferson tests, which could not be assessed in the standard manner either. Again, the question was towards testing effects and the behavior of the pipeline transporting gaseous media remains unanswered. Therefore, this paper aims at identifying open questions on basis of a literature study and own experimental results and showing possible ways forward in demonstrating safety in design against propagating fracture.
The safety assessment of flawed pressurized pipes requires the knowledge of toughness properties which are usually provided in terms of impact energy from standard full-sized CVN notch specimens. For pipes with wall thickness less than 10mm different Charpy standards allow for the application of sub-sized specimens. However, it is still not fully clear how the impact energy from sub-sized specimens can be used to evaluate the fracture resistance of the pipes and how this energy correlates to the one from the full-sized specimen. Although different empirical correlations between sub-sized and full-sized specimens exist in the literature their validity is questionable since they are based on the results for older generation of steels. In the recent years the application of damage mechanics models has been promoted to assess the fracture behavior and deformation capacity of pipelines. The main advantage of these models can be found in their capability to link the damage evolution and the underlying stress/strain condition.
In this paper damage mechanics approach is applied to describe fracture behavior of X65 pipeline material. Within the damage mechanics approach, Gurson-Tvergaard-Needleman (GTN) model is considered to be adequate for the simulation of ductile fracture. For brittle fracture, GTN model is extended by a propagation criterion which examines if the cleavage fracture stress is reached by the maximal principal stresses. The model parameters are calibrated and verified by means of load-displacement curves obtained from instrumented impact tests on different sized CVN specimens. This damage model is subsequently employed to simulate ductile-brittle transition behavior.
Assessment of collapse resistance of UOE pipes – comparison of full-scale and ring collapse tests
(2014)
Fracture propagation control in gas transmission gas pipelines belongs to the major design requirements for safe operation at high internal pressures. However, the current tests such as Drop-Weight-Tear Test (DWTT) and full-scale West-Jefferson (WJ) test reach the limits of their applicability with respect to transition temperature evaluation for seamless quenched and tempered small diameter pipes reflecting nowadays alloying concepts related to mechanical properties. Hereby, different geometry and material effects are evident which might lead to misinterpretation and unreliability of testing results. This paper aims to discuss open issues addressed in the literature and in own experimental findings with respect to reliability and transferability of testing methods, fracture parameters and their representativeness of seamless quenched and tempered pipeline behavior. By applying damage mechanics approach, it is possible to quantify the prevailing stress state and thus to understand the mechanisms controlling specific fracture appearance (ductile or brittle). Furthermore, studies were performed with objective to quantify the effect of different parameters (geometry, material and loading) on the fracture performance of the pipeline. The results from these investigations will serve as a basis for a safe pipeline design against propagating fracture.
In former works, the optical material properties of different polymer powders used for Laser Beam Melting (LBM) at room temperature have been analyzed. With a measurement setup using two integration spheres, it was shown that the optical material properties of polymer powders differ significantly due to multiple reflections within the powder compared to solid bodies of the same material. Additionally, the absorption behavior of the single particles shows an important influence on the overall optical material properties, especially the reflectance of the powder bed. Now the setup is modified to allow measurements at higher temperatures. Because crystalline areas of semi-crystalline thermoplastics are mainly responsible for the absorption of the laser radiation, the influence of the temperature increase on the overall optical material properties is analyzed. As material, conventional polyamide 12 and polypropylene as new polymer powder material, is used. By comparing results at room temperature and at higher temperatures towards the melting point, the temperature-dependent optical material properties and their influence on the beam-matter interaction during the process are discussed. It is shown that the phase transition during melting leads to significant changes of the optical material properties of the analyzed powders.
Investigation of Bolted Composite Joints with Different Reinforcement Elements at the Bolt Hole
(2014)
Least squares pose estimation of cylinder axes from multiple views using contour line features
(2015)
In this paper, a new method for a minimum-error pose estimation of cylinder axes based on apparent contour line features from multiple views is presented. Novel model equations for both single and particularly multiple views are derived, and based upon these, an iterative algorithm for least squares fitting the model to imaged cylinder contour line features is introduced. The good performance and fast convergence of the proposed algorithm is shown by solving exemplary fitting problems.
Modeling, identification and control of an antagonistically actuated joint for telerobotic systems
(2015)
Within this paper a modeling, identification and control technique for an antagonistically actuated joint consisting of two pneumatically actuated muscles is presented. The antagonistically actuated joint acts as a test bench for control architectures which are going to be used to control an exoskeleton within a telerobotic system. A static and dynamic model of the muscle and the joint is derived and the parameters of the models are identified using a least-squares algorithm. The control architecture, consisting of a inner pressure and an outer position controller is presented. The pressure controller is evaluated using switching valves compared against proportional valves.
In this paper, a new method for a minimum-error pose estimation of cylinder axes based on apparent contour line features from multiple views is presented. Novel model equations for both single and particularly multiple views are derived, and based upon these, an algorithm for least squares fitting the model to imaged cylinder contour line features is introduced. The good performance of the proposed algorithm is shown by solving an exemplary fitting problem.
Lines are one of the basic features that are used to characterise the content of an image and to detect objects. Unlike edges or segmented blobs, lines are not only an accumulation of certain feature pixels but can also be described in an easy and exact mathematical way. Besides a lot of different detection methods, the Hough transform has gained much attention in recent years. With increasing processing power and continuous development, computer vision algorithms get more powerful with respect to speed, robustness and accuracy. But there still arise problems when searching for the best parameters for an algorithm or when characterising and evaluating the results of feature detection tasks. It is often difficult to estimate the accuracy of an algorithm and the influences of the parameter selection. Highly interdependent parameters and preprocessing steps continually lead to only hardly comprehensible results. Therefore, instead of pure trial and error and subjective ratings, a systematic assessment with a hard, numerical evaluation criterion is suggested. The paper at hand deals with the latter ones by using a human-generated ground truth to approach the problem. Thereby, the accuracy of the surveyed Kernel-based Hough transform algorithm was improved by a factor of three. These results are used for the tracking of cylindrical markers and to reconstruct their spatial arrangement for a biomedical research application.
This paper addresses the problem of properly placing a given task in the manipulator workspace by a heuristic and numeric approach. Thus, the task is placed relatively to the manipulator for each element of the discretized workspace and the required joint torques are determined. The results are are by a torque-based optimization criterion. The modularity of this approach ensures general applicability on various systems and tasks while the high computational effort is treated by GPU parallelization. The method is presented for a given 6DOF manipulator and a highly dynamic trajectory. The resulting interactive map of the manipulator workspace gives an overview of the task dependent dynamic performance, detailed evaluation of certain solutions will show the dexterity of the proposed approach.
In deep-drawing dies for steel sheet parts of car bodies huge masses are moved. To prevent vibrations, which occur by sudden acceleration or stopping of those masses, elastomeric tubular dampers [1] are used. The dampers are made out of carbon filled elastomers. A good knowledge about the material behaviour of metals is available. But for the numerical investigation of complete deep-drawing dies the elastomeric dampers must be taken into account, too. To characterize the material behaviour of the elastomers tensile tests and pressure tests were carried out. The received material data from the tests were read into LS-DYNA [2]. Simulation models of the tensile test and the pressure test were created for LS-DYNA according to the real dimensions and boundary conditions. For validation purposes, calculations of loading cycles were done to enable a comparison between test data and simulation results. For the calculations the implemented material model *MAT_SIMPLIFIED_RUBBER_WITH_DAMAGE (*MAT_183) was used. The comparison shows a good fitting between the test data and the calculation results with respect to the mechanical material behaviour by using this material model in single loading cases. The settings from the simulations of material tests were transferred to simulations of dampers, which are used in deep-drawing dies.
Finite element simulation of blankholder’s lift-off in a deep drawing tool using Abaqus/Standard
(2015)
In the deep drawing tools for forming car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the deep drawing tool and on the press. Therefore a detailed knowledge about the blankholder’s lift-off event is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of a blankholder’s lift-off in a selected automotive deep drawing tool is presented enabling identification of regions of critical stresses. The FEM model is built within the Abaqus/CAE environment and solved with Abaqus/Standard. Each dynamic analysis is preceded by a static analysis where the gravity load is applied and the lifting bolts are pre-stressed. A special emphasis is put on modeling the elastomer dampers, which are installed between lifting bolts and the blankholder to avoid hard impacts during the lift-off event. Those dampers are modelled using a hyperelastic material with hysteresis. In addition, an experimental validation of a blankholder’s vibration under operating loading was carried out. The simulation results are in good agreement with the measurements.
A Graphical User Interface for Simulating Resin-Transfer-Molding Combining LS-DYNA and OpenFOAM
(2015)
The paper describes parts of the joint research project Swim-RTM including several industrial and academic partners. Its goal is to combine LS-DYNA and the open-source CFD solver OpenFOAM to simulate the production process of continuous fiber-reinforced plastics, particularly the resin-transfer-molding (RTM) process, in which the layers of dry fabric (unidirectional or woven) are formed in the mold (draping) and then filled with liquid resin with high pressure at injection points. Through a combined analysis of both the structural mechanical and the fluid dynamical phases, a better prediction and thereby optimization of the textile components properties as well as injection points can be achieved, improving the manufacturing process. The draping simulation of the fabric layers is carried out with LS-DYNA, while the injection simulation of the matrix material is performed in full 3D with OpenFOAM. A key question in this research project is how local porosities can be derived from the structural computation in the draping step. The purpose of the presented subproject is to develop a graphical user interface (GUI) to enable the simulation of the entire RTM process of long-fiber-reinforced components including the transfer of results between the draping and injection phases. The complete simulation task is relatively complex and involves several software packages, meaning a high effort for the user to get familiarized with. To circumvent this, the GUI aims at requiring from the user only the minimum necessary input data, creating and running the simulation and mapping tasks in the background, and showing graphically all demanded intermediate and final results. For the draping step several current fabric materials such as *MAT_034, *MAT_234, *MAT_235, *MAT_249 are available. Several modelling techniques for the composite setup are also conceivable, including a workflow similar to metal forming applications. In the injection step the fabric is modelled as a porous medium and different transport models and liquid resin types are at hand. For the data transfer between the draping and injection models, i.e. the mapping of data between shell and volume meshes within the developed GUI, first the OpenFOAM volume mesh is converted to LS-DYNA format and the necessary passing parameters are extracted from the output files, then the mapping tool DYNAmap [3] from DYNAmore GmbH is invoked, and finally the OpenFOAM command files are created. After the injection simulation is started and successfully terminated, information, such as the distribution of air inclusions or the shear stress distribution to analyze the reorientation of component fibers, is available and can be transferred from the 3D fluid mesh to an LS-DYNA shell mesh for further computations, for instance a crash simulation. This backward data mapping between volume and shell meshes can then be performed inside the GUI.
Manual tasks in industrial production are often monotonous, leading to a decrease in concentration and motivation of the worker and thus to deficiencies in the products. With quality as well as performance requirements getting more and more stringent, workers need additional support by their work environment. We developed a novel approach providing worker assistance and inline quality assurance for manual workplaces. The prototypical system Smart Workbench (SWoB) uses a multimodal sensor interface consisting of a 3D depth sensor in combination with a 2D camera to control quality aspects of the product and track the work progress. The bidirectional flow of information is handled via an image processing driven gestural interface and the displaying of advice directly on the work surface. In this paper the developed system is introduced and the current state of evaluating its industrial usage with a manual quality control and packaging task reported.
By Laser Beam Melting of polymers (LBM), parts with almost any geometry can be built directly out of CAD files without the need for additional tools. Thus, prototypes or parts in small series production can be generated within short times. Up to now, no multi-material parts have been built by LBM, which is a major limitation of the technology. To realize multi-material parts, new mechanisms for depositing different polymer powders as well as a new irradiation strategy are needed, by which polymers with different melting temperatures can be warmed to their specific preheating temperatures and be molten simultaneously. This is achieved by simultaneous laser beam melting (SLBM). In the process, two different materials are deposited next to each other and preheated a few degrees below their melting temperatures by infrared emitters and laser radiation (λ = 10.60 µm), before in the last step the two preheated powders are molten simultaneously by an additional laser (λ = 1.94 µm). So far, multi-material tensile bars have been realized and analyzed regarding their boundary zone between both materials. The experiments showed that the temperature gradients in the boundary zone and along the building direction seem to be of great importance for the process stability and the resulting part properties. Therefore, a detailed analysis of the occurring temperature gradients during the process is needed to identify adequate process adjustments regarding the temperature controlling. To analyze the temperature gradients, thermocouples positioned inside the powder bed are used. By varying the temperature of the building platform, the influence of different temperature gradients on the resulting part properties is shown.
In this report, the delivery of polyamide 12 (PA 12) powder and powder layer preparation by vibrating steel nozzles is investigated and discussed with respect to its application for laser beam melting. Therefore, a setup was realized which includes a steel nozzle attached to a piezo actor as well as a positioning system. In order t o investigate the mass flow characteristics in dependency on the applied vibration state, a weighing cell is used enabling time-resolved mass flow measurements. Moreover, single-layer patterns consisting of colored and uncolored polyamide 12 were created and characterized regarding surface homogeneity and selectivity before as well as after the melting of the powder layers by a hot plate.
Im Rahmen dieses Beitrags wird das Schmelzeemulgieren als Verfahren zur Herstel-lung von Polymermikropartikeln vorgestellt. In diesem Prozess wird zunächst ein Polymergranulat in einer kontinuierlichen Phase in Gegenwart geeigneter Additive in einem Rührbehälter aufgeschmolzen, die Rohemulsion in einer Rotor-Stator-Einheit feinemulgiert und anschließend zu einer Suspension abgekühlt. Der Einfluss von Prozessparametern und Systemzusam-mensetzung auf das Emulgierergebnis wird diskutiert und die Anwendbarkeit des Verfahrens für polymere Mikropartikeln anhand von Polypropylen (PP) und Polyethylen (PE-HD) dargestellt. Die erhaltenen Suspensionen werden zur Überführung in Pulverform sprühgetrocknet und die Fließeigenschaften des Pulvers analysiert. Durch trockenes Beschichten mit pyrogener Kieselsäure kann die Fließfähigkeit der erhaltenen Partikeln weiter verbessert werden. Das Verfahren bietet somit einen neuen Zugang zur Herstellung neuer Ausgangsmaterialien für die Additive Fertigung.
Early meta-level: deeper understanding of connectivity-states and consequences for state definition
(2015)
The musculoskeletal load scenario of computer-assisted Femur-First THR up to one year after surgery
(2015)
Thoracolumbar spine model with articulated rigcage for the prediction of dynamic spinal loading
(2015)
Navigated Femur First Total Hip Arthroplasty leads to improved Biomechanical Outcome after surgery
(2015)
Rechenzeitoptimierte Temperaturfeldberechnung beim quasisimultanen Laser-Durchstrahlschweißen
(2015)
Beim quasisimultanen Laser-Durchstrahlschweißen von Kunststoffen wird bisher die FEM-Simulation wegen der Vielzahl von Umläufen des Laserstrahls und der damit verbundenen hohen Rechenzeit kaum eingesetzt. Um die Temperaturfeldberechnung zur Prozessauslegung und -optimierung praktikabel nutzen zu können, ist eine Reduktion der Rechenzeit zwingend erforderlich.
Zur Simulation von Schweißvorgängen in ANSYS-CLASSIC werden die
thermischen Lasten mithilfe von Ersatzwärmequellen auf Basis von APDL-Routinen berechnet. Im Gegensatz dazu wird in dieser Arbeit eine analytische Lastfunktion zur Berechnung der thermischen Last für das quasismultane Laser-Durchstrahlschweißen vorgestellt.
Im Vergleich zur Temperaturfeldberechnung mit Ersatzwärmequelle
kann bei der Berechnung eines dreidimensionalen Modells die
Rechenzeit von mehreren Wochen auf wenige Stunden und für ein zweidimensionales auf nur wenige Minuten reduziert werden.
Modelling and simulation of safety relevant Driver Assistance Systems (DAS) and Vehicle Dynamics Controllers (VDC) which act in standard and limit situations lead to increasing accuracy demands in the description of dynamic reactions of tyre contact forces, e.g. For that purpose, first-order approaches are widely applied in this field of vehicle dynamics and handling, which originate from Schlippe & Dietrich, were modified by Pacejka and later on refined by Rill.
The present paper deals with the experimental validation of tyre dynamics approaches as it is widely applied in tyre models for vehicle dynamics and handling. Firstly it gives a brief derivation of two modelling principles regarding the deflection velocity in the considered direction of the tyre’s deformation. This is than followed by a brief description of the performed measurement procedure. From the measurements, a set of model parameters of the considered tyre, depending on different manoeuvre speeds and frequencies, is identified, where no particular fitting parameters for the tyre dynamics are needed. Based on these model parameters, the related dynamic simulations are carried out. The comparisons show that the applied first-order model describes the behaviour quite well within a certain operation range, whereas the second-order approach cannot deliver better results in spite of the longer computational time. However, for investigations within an enlarged frequency range of the steer input and at high slip angles, a more detailed model is recommended.
For the dynamic simulation of on-road vehicles, the model-element "tire/road" is of special importance, according to its influence on the achievable results. Sufficient description of the interaction between tire and road is one of the most challenging tasks of vehicle modeling. Two groups of tire models can be classified: handling models and structural or high-frequency models. Usually, various assumptions are made in modeling vehicles as multibody systems. Therefore, in the interest of balanced modeling, the precision of the complete vehicle model should stand in reasonable relation to the performance of the applied tire model. Handling tire models are characterized by a useful compromise between user friendliness, model complexity, and efficiency in computation time on the one hand, and precision in representation on the other hand. The present paper describes the general approach of the semi-physical tire model TMeasy for vehicle dynamics and handling simulation and its enhancement for bore torque simulation in Version TMeasy 5. A parameter fitting process realized by TESIS DYNAware and the validation of real tire behavior by simulation with DYNA4 is presented. Even with first guess parameters, the TMeasy tire model behaves in a realistic and plausible manner. Parameter estimation is intuitive and datasets from previous model versions can be easily migrated. After parameter fitting, the simulation results correlate well with both the tire test rig and full vehicle measurements. The enhancement of a three-dimensional slip calculation in the latest version does not modify the model behavior for high slip conditions, but improves the results not only for highly dynamic situations but also for low speed maneuvers such as parking.
Effiziente Methode zur Bestimmung von dynamischen strukturellen Belastungen in Großpresswerkzeugen
(2016)
In the forming tools for pressing car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the forming tool and on the press. Therefore a detailed knowledge about the forming tool dynamics is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of selected automotive forming tool is presented enabling identification of regions of critical stresses. For validation of the simulation results, the kinematic responses of the tool's components are compared with the measurements obtained in an experiment.
Simultaneous Laser Beam Melting of polymers (SLBM) allows the generation of multi-material components,consisting of different thermoplastic polymers, within one additive building process. Besides the common advantagesof conventional Laser Beam Melting (LBM), multi-material components built by SLBM can fulfill different productrequirements like different chemical resistances or haptic material properties within a single part. To achieve suchparts, different powder materials are deposited next to each other and preheated a few degrees below their meltingtemperatures by infrared emitters and laser radiation (λ = 10.60 μm), before in the last step the preheated powdersare molten simultaneously by an additional laser source (λ = 1.94 μm). In this paper, different polymer powders likepolypropylene (PP) and polyamide 12 (PA12) are used for the generation of multi-material specimens. By varyingdifferent building parameters according to a specified design of experiments, their influence on the part properties isanalyzed. Important building parameters are the intensity and the irradiation time of the laser beam used for meltingthe preheated powders. Besides using tensile tests to determine the tensile strength and the elongation at break, theaverage part height in dependence of the energy input is analyzed. The overall aim is to specify the correlationbetween different building parameters regarding the energy deposition on the resulting part properties.
The generation of multi-material components using Laser beam melting (LBM) is a challenge which requires the invention of new coating devices for the preparation of arbitrary powder patterns. One solution is the usage of vibration-controlled nozzles for selective deposition of polymer powders. Powder flow can be initiated by vibration even when using powders with low flowability. In this report, the selective deposition of polymer powder by vibrating nozzles is investigated with respect to their application in LBM machines. Therefore, a steel nozzle attached to a piezo actor is applied, whereas the nozzle itself features internal channels which allow the precise control of the powder temperature using heat transfer oil. The setup is used to study the influence of temperature on the powder mass flow. The results show that, next to the vibration mode, the temperature strongly influences the powder mass flow which is done by affecting the moisture and thus the particle-particle adhesion forces. This shows that a precise control of the powder temperature inside the nozzle is required in order to achieve a constant mass flow and thus a successful application of vibrating nozzles inside LBM machines.
Simultaneous laser beam melting (SLBM) allows the direct realization of multi-material components consisting of different polymer materials by a single Additive Manufacturing (AM) process. To achieve a high compound strength between different materials by adhesive bonding, a common boundary zone based on diffusion of the macromolecules is necessary and thus, both materials needs to be compatible regarding their specific adhesion compatibility. However, by SLBM also incompatible polymers can be processed to multi-material parts. If two incompatible polymers are processed, a positive locking between the different materials is necessary to achieve a connection between the materials. The positive locking results of a random mixture process of the different powder materials during the powder deposition process by a two chamber recoater system, which leads to the forming of undercuts of one material in the other during the melting and recrystallization. In this paper, thermoplastic elastomer (TPE) and polypropylene (PP) powders, which are incompatible, are processed to multi-material specimens. By qualifying basic material properties, their influence on the process and especially on the forming of undercuts in the boundary zone is analyzed. To also allow the analysis of the influence of both material and process parameters on the resulting part properties, tensile test specimens are built and their tensile strength is determined. Additionally, cross sections of the boundary zone are prepared and analyzed by microscope images.
Biomechanik des Alterns
(2016)
Quasi-simultaneous laser transmission welding is a well-known joining technique for thermoplastics and mainly used in the automotive as well as in the medical industry. For process control usually the so called set-path monitoring is used, where the weld is specified as "good" if the irradiation time is inside a defined confidence interval. However, the detection of small-sized gaps or thermal damaged zones is not possible with this technique. The analyzation of the weld seam temperature during welding offers the possibility to overcome this problem. In this approach a 3D-scanner is used instead of a scanner with flat-field optic. By using a pyrometer in combination with a 3D-scanner no color-corrected optic is needed in order to provide that laser- and detection-spot are concentric. Experimental studies on polyethylene T-joints have shown that the quality of the signal is adequate, despite the use of an optical setup with a long working distance and a small optical aperture. The effects on temperature are studied for defects like a gap in the joining zone. Therefore a notch was milled into the absorbent polymer. In case of producing housings for electronic parts the effect of an electrical wire between the joining partners is also investigated. Both defects can be identified by a local temperature deviation even at a feed rate of four meters per second. Furthermore a strategy for signal-processing is demonstrated. By this, remaining defects can be identified. Consequently an online detection of local defects is possible, which makes a dynamic process control feasible.
Tightness is often the main requirement for quasi-simultaneous laser transmission welds. However, remaining gaps cannot be detected by the used set-path monitoring. By using a pyrometer in combination with a 3D-scanner, weld seam interruptions can be localized precisely while welding, due to temperature deviations along the weld contour. To analyze the temperature signal in correlation to the progress of gap-bridging, T-joint samples with predefined gaps are welded. The set-path is measured synchronously. Additionally, the temperature distribution and the influence of the thermal expansion of the polymers are studied by a thermo-mechanical FEM-process simulation. On top of that, the melt blow-out of the welded samples is analyzed using μCT-measurements. The experiments have shown that closing of a gap can be identified reliably by the temperature signal and that the squeezed melt flow into the gap and the thermal expansion in the gap zone accelerates gap-bridging. Furthermore the inserted heat can be adapted in the fault zone, in order to avoid thermal damage.
For the dynamic simulation of on-road vehicles, the model-element “tire/road” is of special importance, according to its influence on the achievable results. Sufficient description of the interaction between tire and road is one of the most challenging tasks of vehicle modeling. Two groups of tire models can be classified: handling models and structural or high-frequency models. Usually, various assumptions are made in modeling vehicles as multibody systems. Therefore, in the interest of balanced modeling, the precision of the complete vehicle model should stand in reasonable relation to the performance of the applied tire model. Handling tire models are characterized by a useful compromise between user friendliness, model complexity, and efficiency in computation time on the one hand, and precision in representation on the other hand.
Um die Lebensqualität und Einsatzfähigkeit von Menschen mit Behinderung oder älteren Menschen zu verbessern, wurde untersucht, inwiefern Gamification-Anwendungen beim Anlernen einer Gestensteuerung geeignet sind. Grundlage des Experiments stellt ein intelligenter Arbeitsplatz (Smart Workbench, SWoB) dar, der Personen bei manuellen Handhabungsaufgaben unterstützt sowie bestimmte Produktionsprozesse teilautomatisiert ausführt. Um die Anlage bedienen zu können, muss im Vorfeld eine Einweisung erfolgen, welche von Menschen oder durch ein Lerntutorial mit Gamification-Elementen zur Motivationssteigerung durchgeführt werden kann. In der Studie wurde untersucht, welche Form des Anleitens aus welchen Gründen von unterschiedlichen Personen eher akzeptiert oder abgelehnt wird.
Structural Dynamic Analysis of Thin Composite Plates Using Noncontact Measurement and Excitation
(2016)
Parameterization Process of the Maxwell Model to Describe the Transient Force Behavior of a Tire
(2017)
The present technical article deals with the modeling of dynamic tire forces, which are relevant during interactions of safety relevant Advanced Driver Assistance Systems (ADAS). Special attention has been paid on simple but effective tire modeling of semi-physical type. In previous investigations, experimental validation showed that the well-known first-order Kelvin-Voigt model, described by a spring and damper element, describes good suitability around fixed operation points, but is limited for a wide working range. When aiming to run vehicle dynamics models within a frequency band of excitation up to 8 Hz, these models deliver remarkable deviations from measured tire characteristics. To overcome this limitation, a nonlinear Maxwell spring-damper element was introduced which is qualified to model the dynamic hardening of the elastomer materials of the tire. However, the advantage of a more realistic description of the transient behavior leads to a more complex parametrization process. Therefore, in the proposed article attention is paid to describe the identification process including defined maneuvers to parameterize the tire model, where the accuracy of the parameter strongly depends on the quality of the available input data from measurement. In order to study this important aspect of parameterization, the reference data from simulation of the full physical tire model FTire is applied like a “virtual measurement” of specified testing maneuvers. The procedure of simulation by means of the enhanced first order dynamics model is implemented by the semi-physical tire model TMeasy. Finally, the improvements of the extended model are discussed and an outlook for future work is given.
This paper discusses modeling and nonlinear control of a joint antagonistically actuated by two pneumatic, artificial muscles. A single model of the whole system is obtained by a combined physical and phenomenological modeling approach. The combined model for the joint, the muscles and the proportional valves results in a nonlinear, affine-in-control system description. The model is used to derive control laws for an input/output linearization approach to linearize the plant. Modeling and parametrization errors are covered via an outer control loop consisting of a state-feedback which is extended by an additional feedback of error integral. Extensive experimental results show the quality of the model and the performance of the respective control laws.
Seamless human-robot collaboration depends on high non-verbal behaviour recognition rates. To realize that in real-world manufacturing scenarios with an ecological valid setup, a lot of effort has to be invested. In this paper, we evaluate the impact of spontaneous inputs on the robustness of human-robot collaboration during gesture-based interaction. A high share of these spontaneous inputs lead to a reduced capability to predict behaviour and subsequently to a loss of robustness. We observe body and hand behaviour during interactive manufacturing of a collaborative task within two experiments. First, we analyse the occurrence frequency, reason and manner of human inputs in specific situations during a human-human experiment. We show the high impact of spontaneous inputs, especially in situations that differ from the typical working procedure. Second, we concentrate on implicit inputs during a real-world Wizard of Oz experiment using our human-robot working cell. We show that hand positions can be used to anticipate user needs in a semi-structured environment by applying knowledge about the semi-structured human behaviour which is distributed over working space and time in a typical manner.
An effective way to reduce greenhouse gas emissions (GHGs) is to use rurally produced straight jatropha oil as a substitute for diesel fuel. However, the different physical and chemical properties of straight vegetable oils (SVOs) require a customized setup of the combustion engine, particularly of the injection timing and quantity. Therefore, this study demonstrates the differences in the injection and combustion processes of jatropha oil compared to diesel fuel, particularly in terms of its compatibility with exhaust gas recirculation (EGR).
A 2.2 l common-rail diesel engine with a two-stage turbocharging concept was used for testing. To examine the differences in injection rate shaping of diesel fuel and jatropha oil, the injector was tested with an injection rate analyzer using both the fuels. To investigate the combustion process, the engine was mounted at an engine test bench and equipped with a cylinder pressure indication system. All limited emissions, as well as fuel consumption, were measured.
Various injection strategies, boost and rail pressure levels were tested at different EGR rates in terms of their impact on the combustion process. EGR in particular offers a great potential in the case of jatropha oil combustion due to its oxygen content. In addition, the investigation of injection rate shaping in combination with cylinder pressure analysis allowed a detailed thermodynamic evaluation of the combustion process. Ignition delay (ID) was also analyzed using a new method to calculate the start of combustion (SOC)
This article discusses the relevance of the motion behavior and adaptation of a collaborative robot for human-robot cooperation. Two experiments on cooperative assembly are shown. First, a human-human experiment with defined test conditions evaluates the aspects of distance, nearest body part, and predictability as significant. Second, a human-robot experiment shows that fixed trajectories and conservative dynamic parameters lead to a quick gain of confidence of the participants. Besides, the data shows that a realistic use case with complex tasks is key to evaluate the impact of motion parameters.
Because of increased stroke rates the loads on forming tools increase too. To ensure a save design of components, durability analyses are intended. For this, simulation results from FE analyses are necessary. Therefore, it is desirable to use elements with quadratic function, because of a good stress approximation.The goal of the described investigation is to show if calculation results created by LS-DYNA [1] can be used for durability analyses. Especially the use of quadratic elements is investigated. For the evaluation, on the one hand explicit FE analyses of a special durability test are carried out. These analyses are validated by available test data. To create results for later durability analyses further FE analyses with implicit time discretisation are carried out. In this paper results of the investigations are presented and evaluated critically.
The use of thermoplastics in lightweight construction is continuing to grow. This implies the need for suitable joining techniques to combine thermoplastics with other materials, such as metals, to gain tailored multi-material parts. In this paper latest results of experimental investigations on laser-based hot-melt bonding and injection molding for laser-structured metal plastic hybrids are presented. As materials stainless steel and short-fiber reinforced polyamide are used. The stainless steel surface is structured with a nanosecond pulse laser before joining to improve the mechanical adhesion between the dissimilar materials. Thereby, different structure depths in the range between 16.6 ± 1.2 µm and 66.5 ± 2.5 µm as well as different hatch distances between 70 and 300 µm are realized. The laser-based joining process is carried out irradiating the metallic surface multiple times. Positioned below the metal in T-joint configuration, the thermoplastic melts as a result of heat transfer and acts as hot-melt cohesive. Besides, hybrid joints are manufactured using injection molding. For experiments, the mold temperature as well as the melt temperature are varied. Regardless of the joining process, the hybrid joints are mechanically characterized by tensile tests. The results demonstrate that for both joining processes strong laser-structured metal plastic hybrids can be realized.
In this paper, first results regarding the realization of laser-based hot-melt bonding of additive manufactured plastics parts to metal sheets for strong and tight multi-material joints are presented. Compared to earlier investigations, in which nearly solely extruded plastic materials were applied, the use of additive manufactured plastics complements the research field with a promising approach. Besides the typical advantages of multi-material joints regarding weight reduction and high strengths, such parts can meet the needs of constructional freedom and the avoiding of tool costs. Materials used for this paper are aluminum (AlMg3), stainless steel (1.4301) and polyamide 12 (PA12). The performed experiments resulting in multi-material joints between metal and polyamide. The realized specimens undergo a tensile shear test and a tightness test, in which the characteristics of the joints are determined.
Common Schanz screw systems can be used to stabilize pelvic ring fractures. In order to accommodate for different patient’s requirements, implants can be placed in cranio-caudal direction into the os ilium (T1), or into the supraacetabular bone canal, and thus, in dorso-ventral direction (T2). Whereas both techniques are currently used, no data of the biomechanical behavior is available up to this date. The aim of this study is to analyze, whether T2 shows biomechanical advantages with respect to tissue and implant stresses due to the enlarged bone-implant interface. Forces acting on the pelvis were analyzed using motion capture data of a gait cycle obtained by the utilization of a musculoskeletal simulation program. A three dimensional finite element (FE) model of the pelvis with grayscale-based material properties was generated. The muscle and joint reaction forces at toe-off were applied to the FE model and instable pelvis fractures were implemented. The osteosynthesis systems were positioned within the model in order to enable the comparison between the two different surgical techniques. Stresses and displacements were analyzed for bone tissue, fracture zone and implant.
T2 lead to approx. 30% larger displacements in the fracture zone. Von-Mises stresses were larger for T2 in the implant (80 MPa vs. 227 MPa), whereas T1 leads to larger stresses in the bone tissue (200 MPa vs. 140 MPa).
Both implantation techniques showed a good biomechanical behavior. Differences could be found with respect to tissue strains and deformations in the fracture zone. If bone quality or fracture healing are of concern, T2 or T1 should be used, respectively. However, both techniques seem to be applicable for cases with no special requirements. Further analyses aim to investigate the behavior under cyclic loading.
Work places and conditions strains the human body, both psychologically and biomechanically. In order to analyse working conditions and in the following to improve them, detailed knowledge about the effect of the different stressors on the body is needed. This manuscript discusses methods on how to evaluate biomechanical and mental loading and its effect on the musculoskeletal system. A possible workflow for the analysis is presented.
The gold standard for the analysis of human kinematics and kinetics is a camera-based motion capture system in combination with force measurement platforms. Alternatively, inertial measurement units can be utilized to obtain human kinematics, while ground reaction forces are computed from full body dynamics. This setup represents a system independent from the spatial confinement of a gait laboratory. The aim of this study is the comparison of the two methods by the investigation of lower limb kinematics and the resulting joint reaction forces within the ankle-, knee- and hip joints. For this purpose, human motion during gait was captured simultaneously by both measurement techniques. 13 trials from 8 different test subjects were evaluated in total. IMU data was processed with a quaternion based Kalman Filter. The data sets were implemented into a musculoskeletal simulation program in order to drive a virtual human body model. Each sensor was aligned to the gravitational and magnetic field vectors of the earth. The angles of flexions, extensions and rotations were analyzed to determine kinematic differences. Joint reaction forces defined kinetic dissimilarities. The overall kinematic differences of both models yielded root mean square errors of 7.62°, 6.02°, 4.95°, 2.79°, 2.38° and 3.56° for ankle flexion, subtalar eversion, knee flexion, hip external rotation, hip abduction and hip flexion, respectively. The proximo-distal differences in force peaks between the models yielded overall for the ankle, 57.33 %Bodyweight(BW) ± 46.86 %BW (16.66 %(Maximum peak to peak) ± 13.62 %) for the knee 37.09 %BW ± 29.33 %BW (17.65 % ± 15.44 %) and 32.03 %BW ± 24.33 %BW (15.6 % ± 12.54 %) for the hip. The overall outcome of this work investigated an approach independent of the common setup of the gait laboratory, thus enabling a cheaper and more flexible technology as an alternative. However, kinematic and thus kinetic differences remain rather large. Future work aims to improve the contact criterion for the calculation of the ground reaction forces and the implementation of a full-body calibration algorithm for the IMU system in order to counteract magnetic field disturbances.