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The resonant direct magnetoelectric (ME) effect for a series of multilayer heterostructures comprising a magnetoactive elastomer (MAE) of different thicknesses and a commercially available piezoelectric polyvinylidene fluoride-based vibration sensor has been investigated in detail. The specimens were rigidly fixed at one end as cantilevers. The cantilevers were operated in the transverse-transverse (T-T) mode, where both magnetic and electric fields were perpendicular to the plane of a non-deformed heterostructure. It is shown that the ME voltage coefficient of considered heterostructures in the T-T mode can be about 20-fold higher than in the conventional longitudinal–transverse (L-T) mode. The highest ME voltage coefficient reached about 150 V/(Oe·cm) at the first bending oscillation mode for the sample with MAE layer thickness of 4 mm. Mechanism of the resonant ME effect in T-T mode is explained using theory of critical bending of MAE cantilevers. Magnetic fields, when the ME voltage reaches its maximum, strongly depended on the MAE layer thickness, and could be associated with the critical field, where the structure commences to strongly bend. The non-monotonous dependence of the resonance frequency of the first oscillation mode on magnetic field strength was observed. The shift of the resonance frequency in the maximum magnetic field reached up to roughly 100 % in comparison with zero field.
It has been recently demonstrated that laser micromachining of magnetoactive elastomers is a very convenient method for fabricating dynamic surface microstructures with magnetically tunable properties, such as wettability and surface reflectivity. In this study, we investigate the impact of the micromachining process on the fabricated material’s structural properties and its chemical composition. By employing scanning electron microscopy, we investigate changes in size distribution and spatial arrangement of carbonyl iron microparticles dispersed in the polydimethylsiloxane (PDMS) matrix as a function of laser irradiation. Based on the images obtained by a low vacuum secondary electron detector, we analyze modifications of the surface topography. The results show that most profound modifications occur during the low-exposure (8 J/cm^2) treatment of the surface with the laser beam. Our findings provide important insights for developing theoretical models of functional properties of laser-sculptured microstructures from magnetoactive elastomers.
Im Betrieb von Förderbändern auftretende Phänomene sind das Bandwandern in Achsrichtung der Walzen und die Bandverformung in der Bandebene [1, S. 142]. Das Bandwandern ist bisher detailliert untersucht [2,3,4], während die Bandverformung Gegenstand weniger Veröffentlichungen ist. Deshalb wird in diesem Artikel eine Methode zur Berechnung der sich im dynamischen Betrieb einstellenden Verformung eines elastischen Förderbandes vorgestellt. Dazu wird ein Mehrkörpersimulations-Modell basierend auf der Lumped-Mass-Modellierung verwendet. Als Untersuchungsbeispiel dient ein Zwei-Walzensystem mit flexiblen und zylindrischen Walzen, sowie ein flexibles Förderband. Es zeigt sich, dass mit der Lumped-Mass-Modellierung eine dynamische Bandverformung, die von der gewählten Diskretisierung abhängt, berechnet werden kann. Aufgrund dieser Abhängigkeit ist es notwendig eine Konvergenzanalyse durchzuführen. Zusätzlich ist darauf zu achten, dass die künstliche Anregung aufgrund der Lumped-Mass-Modellierung nicht mit einer Eigenfrequenz des Modells zusammenfällt.
Magnetic nanoparticles (MNPs), particularly iron oxide nanoparticles (IONPs), play a pivotal role in biomedical applications ranging from magnetic resonance imaging (MRI) enhancement and cancer hyperthermia treatments to biosensing. This study focuses on the synthesis, characterization, and application of IONPs with two different size distributions for frequency mixing magnetic detection (FMMD), a technique that leverages the nonlinear magnetization properties of MNPs for sensitive biosensing. IONPs are synthesized through thermal decomposition and subsequent growth steps. Our findings highlight the critical influence of IONP size on the FMMD signal, demonstrating that larger particles contribute dominantly to the FMMD signal. This research advances our understanding of IONP behavior, underscoring the importance of size in their application in advanced diagnostic tools.
Many currently available dynamic hand orthoses use articulated connections that have one degree of freedom, such as hinge joints. These orthoses are therefore only able to replicate the multiaxial range of motion of the human hand to a limited extent. A possible solution for replecating the multiaxial movements of the hand is the use of pre-stressed compliant structures as a basis for the orthoses. After a brief description of this concept, the two main first steps by the development, the so called form-finding and the wrist-joint force characterization by hand movements are explained with theoretical analysis based on the static Finite Element Method. The influence of the orthosis parameters, global stiffness and geometric dimensions as well as the influence of the wrist-joint position relative to the orthosis are discussed. Finally, the next planned development steps towards to the first prototype are outlined.
We analyze the repercussions of different kinds of uncertainty on cash demand, including uncertainty of cashless infrastructures, confidence crises of the financial system, natural disasters, political uncertainties, and inflationary crises. Based on a comprehensive literature survey and complemented by case studies, we derive a classification scheme how cash holdings typically evolved in each of these types of uncertainty over the past 30 years by separating between demand for domestic and international cash as well as between transaction and store of value balances. Hereby, we focus on the stabilizing macroeconomic properties of cash and recommendguidelines for cash supply by central banks and the banking system. Finally, we exemplify ouranalysis with five case studies from the developing world, namely Venezuela, Zimbabwe, Afghanistan, Iraq, and Libya.
The minitrack contains contributions with a focus on simulation modeling and digital twins and decision making in the context of Industry 4.0. The use of simulation models and digital twins is manifold, from planning to virtual commission and real-time operational decision support. Cyber-physical systems integrate the real world and the virtual world to enable decision making in the age of Industry 4.0. For example, customer decisions and supply disruptions which directly influence manufacturing and logistics systems require immediate decisions. Thus, models must have the capability to support decision making in manufacturing as well as in internal and external logistics in real-time. Methods include discrete-event simulation, discrete-rate simulation, hybrid simulation, system dynamics simulation, the combination of simulation modeling with machine learning or optimization heuristics, prescriptive analytics, and adaptive systems. Furthermore, this minitrack addresses simulation education and simulation models used for education and training in manufacturing and logistics.
In order to determine the influence of the ondulations in fabrics on the damping properties of fiber-reinforced plastics, the structural dynamic properties of fabric- and unidirectionally reinforced plastics are investigated. The free decay behavior of flat beam-like specimens is investigated under fixed-free boundary conditions. As the material damping is consistently higher in fabric-reinforced specimens compared to unidirectionally reinforced ones, a contribution of an additionally acting mesomechanic kinematic in fabric weaves is implied. Based on a degree of ondulation, it is possible to classify the enhancement of the material damping and determine the corresponding energy dissipation. The study provides valuable quantitative relations of the additional damping effect due to the mesomechanic kinematic. Compared to the unidirectionally reinforced material, plain weave enhances the material damping by 37…52% at ˜OPL=0.0133 , whereas twill weave 2/2 enhances it by 31…40% at ˜OT2=0.0098 . The consideration of the findings contributes to a deeper understanding of the visco-elastic dynamic behavior of fabric-reinforced plastics and allows further applications in research, development, and industry.
In this paper a compliant tensegrity structure based on spatially curved compressed members is presented. Due to an internal variation of the prestress state the shape of the structure can be controlled. In particular, a modification of a cylindrical outer shape to a conical form is achieved. Regarding to the applications in mobile robotics this approach enables a steerable two-dimensional rolling locomotion system. Beside the consideration of the underlying non-holonomic constraints a simplified mechanical model an the corresponding equations of motion are derived for a predefined actuation principle. Various numerical simulations are evaluated focusing on the corresponding locomotion behavior. Based on these results a reliable actuation strategy to navigate in two dimensions is proposed.
Effect of Temperature on the Growth of Cu(I)O Nanocubes: The Impact of the Copper Precursor Species
(2024)
Cuprous oxide (Cu2O) nanoparticles were synthesized using a wet chemical surfactant free method at different synthesis temperatures from 25 ◦C to 60 ◦C. Morphology, size, and chemical composition of the prepared Cu2O nanoparticles were analyzed by SEM, PXRD, and ATR-IR. We discovered that the chemical composition of the Cu2O nanoparticles remained unaffected by the synthesis temperature. However, morphology and size of the nanoparticles showed a strong temperature dependency. This could be attributed to the temperature induced formation of cupric oxide (CuO) species from the copper hydroxide (Cu(OH)2 ) precursor which also functions as copper precursor for the Cu2O nanoparticle growth. The cupric oxide species was determined to be the main cause for the formation of micrometer sized particles, whereas with the Cu(OH)2 precursor species for the Cu2O nanoparticles nanocubes with smaller edge lengths as well as octahedrons were obtained.
Fused filament fabrication (FFF) is a widely used additive manufacturing process for producing functional components and prototypes. The FFF process involves depositing melted material layer-by-layer to build up 3D physical parts. The quality of the final product depends on several factors, including the component density and tensile strength, which are typically determined through destructive testing methods. X-ray microtomography (XCT) can be used to investigate the pore sizes and distribution. These approaches are time-consuming, costly, and wasteful, making it unsuitable for high-volume manufacturing. In this paper, a new method for non-destructive determination of component density and estimation of the tensile strength in FFF processes is proposed. This method involves the use of gradual error detection by sensors and convolutional neural networks. To validate this approach, a series of experiments has been conducted. Component density and tensile strength of the printed specimens with varying extrusion factor were measured using traditional destructive testing methods and XCT. The cumulative error detection method was used to predict the same properties without destroying the specimens. The predicted values were then compared with the measured values, and it was observed that the method accurately predicted the component density and tensile strength of the tested parts. This approach has several advantages over traditional destructive testing methods. The method is faster, cheaper, and more environmentally friendly since it does not require the destruction of the product. Moreover, it facilitates the testing of each individual part instead of assuming the same properties for components from one series. Additionally, it can provide real-time feedback on the quality of the product during the manufacturing process, allowing for adjustments to be made as needed. The advancement of this approach points toward a future trend in non-destructive testing methodologies, potentially revolutionizing quality assurance processes not only for consumer goods but various industries such as electronics or automotive industry. Moreover, its broader applications extend beyond FFF to encompass other additive manufacturing techniques such as selective laser sintering (SLS), or electron beam melting (EBM). A comparison between the old destructive testing methods and this innovative non-destructive approach underscores the possible fundamental change toward more efficient and sustainable manufacturing practices. This approach has the potential to significantly reduce the time and cost associated with traditional destructive testing methods while ensuring the quality of FFF-manufactured products.
During the hot pressing of pure titanium and different carbon steels in a temperature range of ϑ = 950–1050 °C, a compound layer up to dL≈10 μm thick is formed at the titanium–steel interface. With a higher carbon content of the used steel, the layer thickness increases. The carbon concentration within the layer is in the range of stoichiometry for TiC. Apart from TiC, no other phases can be detected by X-ray diffraction (XRD) measurements inside the formed layer. The calculation of the activation energy for the TiC layer formation is Q = 126.5–136.7 kJ mol−1 and is independent of the carbon content of the steel. The resulting microstructure has a grain size gradient, wherein the mechanical properties, such as hardness and Young‘s modulus, are almost constant. Statistical analysis using Response Surface Methodology (RSM) indicates that the carbon content of the steel has the most significant influence on layer thickness, followed by annealing temperature and annealing time. By selecting the appropriate carbon steel and the subsequent removal of the steel, it is possible to produce targeted TiC layers on titanium substrates, which holds enormous potential for this material in wear-intensive applications.
We review the developments in life safety and the incorporation thereof in the design and assessment of structures over the last 50 years. Various measures of life safety are presented that have been developed according to the marginal life saving cost principle based on individual, societal and economic considerations. Target probabilities of failure, or target reliabilities, are central to modern structural design and assessment. These are derived either through back-calibration to existing practice or through life cycle cost minimisation, both of which yield comparable safety levels, and are underpinned by lower bounds from life safety. Life cycle cost minimisation is reviewed here, which considers all direct and indirect costs of failure including loss of life and limb, as well as the costs and efficiency of increasing reliability. We discuss the incorporation of life safety into reliability-based design and assessment through the concept of the Life Quality Index, which uses key societal indicators, namely, the GDP and life expectancy, and health economics as a basis for specifying minimum reliabilities for both new and existing structures. The current state of advancement of reliability- and risk-informed design, and recommendations for future developments in life safety are considered.
AbstractTensegrity structures are prestressed structures consisting of compressed members connected by prestressed tensioned members. Due to their properties, such as flexibility and lightness, mobile robots based on these structures are an attractive subject of research and are suitable for space applications. In this work, a mobile robot based on a tensegrity structure with two curved members connected by eight tensioned strings is analyzed in terms of deformation in the curved members. Further, the difference in locomotion trajectory between the undeformed and deformed structure after the prestress is analyzed. For that, the theory of large deflections of rod-like structures is used. To determine the relationship between acting forces and the deformation, the structure is optimized using minimization algorithms in Python. The results are validated by parameter studies in FEM. The analysis shows that the distance between the two curved members significantly influences the structure’s locomotion. It can be said that the deformation of the components significantly influences the locomotion of tensegrity structures and should be considered when analyzing highly compliant structures.
Operational wear behaviour of 3D-printed lightweight metal gears: EDS and oil analysis comparison
(2024)
Additive manufacturing (AM) has come to the fore in recent years among manufacturing techniques. This technique, which has different advantages than traditional ones such as casting, forging and machining, is expected to be widely used in producing machine parts like gears in the coming years. Therefore, experimental data on AM parameters for lightweight metal gears are important for industrial production. In this study, a wear test was applied to AlSi10Mg and Ti6Al4V gears under operational conditions, and the wear behaviour of conventionally and additively manufactured gears was compared. The amount of abrasion elements was determined by analysing the oil in the gearbox. In addition, gear surfaces were analysed using scanning electron microscopy and an energy-dispersive spectrometer before and after wear. Thus, the wear behaviour of gears produced by conventional and AM under service conditions was demonstrated comparatively.
Absorber-free laser transmission welding enables precise and clean joining of polymer foils without absorbent additives or adhesives. It is well suited for applications in medical technology and food industry, which impose high demands on process reliability. To achieve a large process window and thus a reliable process, a homogeneous weld seam temperature is desirable. For this purpose, the intensity distribution of the laser beam is adapted locally by refractive beam shaping optics. Using a donut-shaped intensity distribution, the weld seam temperature is homogenized. Thus, the process window for welding polypropylene or polyethylene foils is enlarged up to a factor of 4 compared to a conventional, Gaussian-shaped distribution. This enables the reliable welding of even 85 µm thin foils, which could only be welded to a limited extent with a conventional laser intensity distribution.
The use of intrinsically compliant tensegrity structures in manipulation systems is an attractive research topic. In this paper a 3D compliant robotic arm based on a stacked tensegrity structure consisting of x-shaped rigid members is considered. The rigid members are interconnected by a net of prestressed, tensioned members with pronounced intrinsic elasticity and by inelastic tensioned members. The system's motion is achieved by length-change of the inelastic tensioned members. The operating principle of the system is discussed with the help of kinematic considerations and verified by experiments.
The recent REACH regulations require the elimination of bisphenol-A and titanium dioxide from commercially available boron-based polymers. This has led to changes in some of the mechanical characteristics, which strongly influence the properties of magnetoactive borosilicate polymers. This work delivers results on the electrical properties and discusses some implications for future research using bisphenol-A and titanium-dioxide-free substitutes.
Lumped-Mass-Modellierung von Förderbändern am Beispiel eines Zwei-Walzensystems mit flexiblen Walzen
(2024)
A novel method for controlling the rebound behavior of small balls made of Al2O3 with a radius of 2.381 mm is presented. It uses different types of micro-structured surfaces of soft magnetoactive elastomers. These surfaces were fabricated via laser micromachining and include fully ablated surfaces as well as micrometer-sized lamellas with a fixed width of 90 µm, height of 250 µm and three different gap sizes (15, 60 and 105 µm). The lamellas can change their orientation from edge-on to face-on configuration according to the direction of the external magnetic field from a permanent magnet. The orientation of the external magnetic field significantly influences the rebound behavior of the balls, from a coefficient of restitution e of to < 0.1. The highest relative change in the coefficient of restitution between zero field and face-on configuration of is observed for lamellas with a gap of 60 µm. Other characteristics of the ball rebound such as the penetration depth into an Magnetoactive elastomer and the maximum deceleration are investigated as well. The proposed method does not require a constant power supply due to the use of permanent magnets. It may find novel applications in the field of impact engineering.
Im Betrieb von Förderbändern auftretende Phänomene sind das Bandwandern in Achsrichtung der Walzen und die Bandverformung in der Bandebene [1, S. 142]. Das Bandwandern ist bisher detailliert untersucht [2–4], während die Bandverformung Gegenstand weniger Veröffentlichungen ist. Deshalb wird in diesem Artikel eine Methode zur Berechnung der sich im dynamischen Betrieb einstellenden Verformung eines elastischen Förderbandes vorgestellt. Dazu wird ein Mehrkörpersimulations-Modell basierend auf der Lumped-Mass-Modellierung verwendet. Als Untersuchungsbeispiel dient ein Zwei-Walzensystem mit flexiblen und zylindrischen Walzen, sowie ein flexibles Förderband. Es zeigt sich, dass mit der Lumped-Mass-Modellierung eine dynamische Bandverformung, die von der gewählten Diskretisierung abhängt, berechnet werden kann. Aufgrund dieser Abhängigkeit ist es notwendig eine Konvergenzanalyse durchzuführen. Zusätzlich ist darauf zu achten, dass die künstliche Anregung aufgrund der Lumped-Mass-Modellierung nicht mit einer Eigenfrequenz des Modells zusammenfällt.
Bei der Untersuchung und Optimierung der Getriebedynamik, im Sinne der Akustik und Lastverteilung, wird oftmals der Drehwegfehler als Bewertungskriterium herangezogen. Zahlreiche Forschungsvorhaben haben sich in diesem Zusammenhang intensiv mit dem Drehwegfehler als parametererregte Schwingungsanregung auseinandergesetzt, um diesen im Hinblick auf das Systemverhalten zu optimieren. Dabei bleibt der Zahnfußbereich, welcher außerhalb der Evolvente liegt, und dessen Einfluss auf den Drehwegfehler oftmals unberücksichtigt.
Dieser Artikel untersucht daher den Einfluss des Zahnfußbereiches auf den statischen Drehwegfehler, indem relevante Größen wie das spezifische Kopfspiel und der Fußrundungsradius an einer typischen und real eingesetzten Stirnradverzahnung variiert werden.
Ferner wird betrachtet, inwiefern der Drehwegfehler durch unterschiedliche Geometriedefinitionen (Fertigungssimulation, Zahngeometrie mit vereinfachter sowie stark vereinfachter Modellierung des Zahnfußbereichs) beeinflusst wird. Die Autoren nutzen hierfür zwei FE-Ansätze (adaptives und nicht-adaptives Netz) und bewerten diese hinsichtlich ihrer Gültigkeit, Modellgüte und Praktikabilität.
Die Ergebnisse der Untersuchungen werden hinsichtlich einer minimal erforderlichen Geometrie des Zahnfußbereiches interpretiert. Für den Praxistransfer wird einerseits der maximale Fehler bei Nichtberücksichtigung des gesamten Zahnfußbereichs beziffert.
Andererseits wird eine Empfehlung zur Anpassung einer vereinfachten Geometrie, an eine Geometrie, ähnlich der aus einer Fertigungssimulation, gegeben. Weiterhin wird der Artikel diskutieren, ob man ein vereinfachtes Zahnmodell zur Berechnung der Getriebedynamik nutzen kann, wenn der Fertigungsprozess noch nicht definiert ist.
The present paper takes a novel approach to production of fibre-reinforced thermoplastic tubes. The method begins with the raw materials, reinforcing fibre and thermoplastic granulate which are processed to tapes through a newly developed direct impregnation process. It is followed by consolidation of fibre-reinforced thermoplastic tubes using infrared (IR) emitters in the filament winding process. This process employs various angles and utilizes a rotatable consolidation axis. The winding process operates at a constant speed, addressing the challenge of bending the fibre-reinforced tapes in the angle reversal areas near the tube ends. Experiments have confirmed that the process can run at speeds reaching approximately 470 mm/min. The design of the impregnation line takes into account the properties of the thermoplastic and the roving, allowing for a speed of up to 1 m/s.
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 and should therefore 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.
Transient surrogate modeling of modally reduced structures with discontinuous loads and damping
(2024)
In this work, a surrogate model for structural, transient and discontinuously excited finite element method simulations is developed. This allows to reduce the computational effort of repeated calculations of identical models under different load cases. The architecture of the surrogate combines fully connected neural network layers with long short-term memory layers. For the reproduction of different damping ratios, a categorical variable is added to the continuous input data. Based on a recursive flow of the predicted data back to the input layer, long-term dependencies do not vanish due to short-input sequences. The system dimension is reduced by applying the model-order reduction technique for modal decomposition. The high accuracy of the surrogate and the reduction of computational costs are shown on an academic example of a cantilever beam and a real-world example of a robot. The advantages of our approach are illustrated in comparison with state-of-the-art surrogates for transient finite element analysis. By using the surrogate proposed in this study, oscillations due to discontinuous excitation of mechanical structures can be reproduced. For this purpose, only short-input sequences are necessary since the excitation of the oscillations does not have to be part of the input sequence during the whole duration of the oscillations. Due to the categorical variable for the damping ratio, the surrogate can account for the influence of different damping in parameter studies.
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.
Significant deformations of bodies made from compliant magnetoactive elastomers (MAE) in magnetic fields make these materials promising for applications in magnetically controlled actuators for soft robotics. Reported experimental research in this context was devoted to the behaviour in the quasi-static magnetic field, but the transient dynamics are of great practical importance. This paper presents an experimental study of the transient response of apparent longitudinal and transverse strains of a family of isotropic and anisotropic MAE cylinders with six different aspect ratios in time-varying uniform magnetic fields. The time dependence of the magnetic field has a trapezoidal form, where the rate of both legs is varied between 52 and 757 kA/(s·m) and the maximum magnetic field takes three values between 153 and 505 kA/m. It is proposed to introduce four characteristic times: two for the delay of the transient response during increasing and decreasing magnetic field, as well as two for rise and fall times. To facilitate the comparison between different magnetic field rates, these characteristic times are further normalized on the rise time of the magnetic field ramp. The dependence of the normalized characteristic times on the aspect ratio, the magnetic field slew rate, maximum magnetic field values, initial internal structure (isotropic versus anisotropic specimens) and weight fraction of the soft-magnetic filler are obtained and discussed in detail. The normalized magnetostrictive hysteresis loop is introduced, and used to explain why the normalized delay times vary with changing experimental parameters.
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.
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.
Commercially available contact angle (CA) measuring devices usually do not allow for the application of magnetic fields to the sample under test. A setup for measuring the CA of liquids on magnetosensitive surfaces has been developed specifically for investigating the surfaces of magnetoactive elastomers (MAEs). The addition of a programmable linear stage, which moves a permanent magnet, allows for fine control of the magnetic field applied to the MAE without the need for large and power-consuming electromagnets. Paired with a custom control and evaluation software, this measurement setup operates semiautomatically, limiting operator error and increasing precision, speed, as well as repeatability of static and dynamic CA measurements for different magnetoactive materials. The software is equipped with robust droplet fitting algorithms to avoid experimental challenges arising with soft magnetoactive materials, such as the curling of sample edges or diffuse non-reflective surfaces. Several application examples on MAE surfaces, both processed and unprocessed, are presented.
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.
In an industrial product development process, the Bill of Materials (BOM) is a hierarchical, multi-level representation of all components, parts and quantities of a product. With increasing complexity of industrial products, also BOMs become more complex and thus prone to errors, for example when the individual parts of a product are changed during the product development process. Frequently, these Bill of Materials errors have to be identified manually or by using simple, rule-based schemes. In this paper, we provide a technical background of BOMs, showing the intricacy of temporal BOMs errors in an industrial product development process. The work of other authors, which focused on association mining and tree reconciliation to detect Bill of Materials errors, is analysed. We found that there is currently no system being able to prescribe where in a Bill of Materials and when in the product development process, errors are probable to occur. Also, Machine Learning (ML) methods have not been applied yet. Based on these findings, we formalize the notions Bill of Materials and Bill of Materials errors. Furthermore, we present a deterministic distance measure for BOMS. We provide an answer to the main question of how to represent a Bill of Materials for Machine Learning tasks by solving the orthogonal Procrustes problem for dynamic, hierarchical datasets. Then, we describe an isolation forest based approach to temporal anomaly detection, which points at potential errors in a Bill of Materials at a specific timestamp. Furthermore, we apply Machine Learning and present a multi-output Multi Layer Perceptron for the prediction of temporal Bill of Materials errors. The model predicts where and at which point of time Bill of Materials errors are probable to occur, which renders it a prescriptive system. Eventually, we optimize the performance of our model using contextualization via -means clustering. Finally, we apply our prescriptive pipeline to a real world dataset and show its superiority to existing methods using a qualitative comparison.
Thermal cyclers are used to perform polymerase chain reaction runs (PCR runs) and Peltier modules are the key components in these instruments. The demand for thermal cyclers has strongly increased during the COVID-19 pandemic due to the fact that they are important tools used in the research, identification, and diagnosis of the virus. Even though Peltier modules are quite durable, their failure poses a serious threat to the integrity of the instrument, which can lead to plant shutdowns and sample loss. Therefore, it is highly desirable to be able to predict the state of health of Peltier modules and thus reduce downtime. In this paper methods from three sub-categories of supervised machine learning, namely classical methods, ensemble methods and convolutional neural networks, were compared with respect to their ability to detect the state of health of Peltier modules integrated in thermal cyclers. Device-specific data from on-deck thermal cyclers (ODTC®) supplied by INHECO Industrial Heating & Cooling GmbH (Fig 1), Martinsried, Germany were used as a database for training the models. The purpose of this study was to investigate methods for data-driven condition monitoring with the aim of integrating predictive analytics into future product platforms. The results show that information about the state of health can be extracted from operational data - most importantly current readings - and that convolutional neural networks were the best at producing a generalized model for fault classification.
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.
Unternehmen sind häufig mit Situationen konfrontiert, in denen schnell Entscheidungen bezüglich der Auswahl mehrerer Handlungsalternativen gefunden werden müssen. Mathematische Verfahren können hierbei unterstützen, z. B. für die Ermittlung einer ersten Diskussionsbasis. Verfügbare Softwarelösungen errechnen zwar häufig optimale Ergebnisse, zeigen jedoch Schwächen bei der praktischen Anwendbarkeit. So ist eine Einarbeitung in komplexe Optimierungssoftware für die teilweise sporadisch auftretenden Probleme in der Regel für Unternehmen nicht möglich, unter anderem auch unter Anbetracht der teilweise hohen Kosten der Standardsoftware und dem benötigten hohen Einarbeitungsaufwand. Gerade Problemstellungen in Fachbereichen, die nicht auf mathematische Problemlösung spezialisiert sind, münden daher regelmäßig in Ineffizienzen. Basierend auf den in der Literatur diskutierten Lösungsansätzen wurde ein praxisorientierter Ansatz zur Entscheidungsunterstützung für Rucksackprobleme bzw. 0–1 Probleme mithilfe von Genetischen Algorithmen (GA) entwickelt und technisch in Microsoft Excel® umgesetzt. Ein Praxistest bei einem chinesischen Textilunternehmen belegt erhöhte Effektivität und Effizienz. Die Software kann kostenfrei nach MIT Lizenz unter http://www.solvega.de/ heruntergeladen werden.
Purpose
Tooling is a common component of an industrial product’s manufacture. Specific tooling is devised to serve the fabrication of a particular product, while generic tooling can be used in the manufacture of multiple products. In the latter case, companies are confronted with the problem of fairly allocating the indirect costs of the tooling. This article studies how to allocate costs of generic tooling to single production orders.
Methodology
Ten allocation methods (AMs) are described that are in principle suited to the distribution of generic tooling costs to production orders. Since the presented methods have for the most part been discussed in differing contexts, we apply them to a specified generic tooling problem for comparison. Evaluation of the various methods is based on 16 criteria. Reasoning is supported by a computational Monte Carlo simulation. Furthermore, we suggest using the Analytical Hierarchy Process (AHP) to elaborate one final proposition concerning the most preferable allocation scheme.
Findings
The article reports the single allocation rules’ performances for different allocation scenarios. The described characteristics refer to fairness, efficiency, and simplicity as well as to empty-core performance. Using AHP analysis allows for the aggregation of the rules’ criteria ratings. Thus, especially suitable allocation schemes for the problem at hand are identified.
Practical implications
An allocation is required for budgeting reasons and also for the definition of projects’ bottom-up sales prices. Selecting the “right” AM is important, as a suboptimal AM can result in unfair allocation vectors, which will act as incentives to stop using the common resource, potentially leading to higher total costs.
Originality/value of the article
Research on the comparison of AMs is typically performed for certain purposes, such as enterprise networks, horizontal cooperative purchasing scenarios, or municipal service units. This article will augment the research evaluating AMs by introducing a novel set of evaluation criteria and by providing an in-depth comparison of AMs suited for the allocation of generic tooling costs.
CO-Emissionen sind ein wichtiger Indikator für die Beurteilung der ökologischen Nachhaltigkeit von Unternehmen. In der Praxis sind sie jedoch schwierig zu bestimmen. Insbesondere für Logistik-und Transportaktivitäten, auf die ein Großteil der Emissionen entfällt, sind zuverlässige Methoden zur Ermittlung und Reduktion des Schadstoffausstoßes erforderlich.
The 0-1 multidimensional knapsack problem (MKP) is a well-known combinatorial optimization problem with several real-life applications, for example, in project selection. Genetic algorithms (GA) are effective heuristics for solving the 0-1 MKP. Multiple individual GAs with specific characteristics have been proposed in literature. However, so far, these approaches have only been partially compared in multiple studies with unequal conditions. Therefore, to identify the “best” genetic algorithm, this article reviews and compares 11 existing GAs. The authors' tests provide detailed information on the GAs themselves as well as their performance. The authors validated fitness values and required computation times in varying problem types and environments. Results demonstrate the superiority of one GA.
Prior research studies on supplier selection factors assess vendor reputation as a low ranked criterion. Reputation in these articles, however, only refers to the position in the industry, without considering the role of the final customer. Our results from a survey with 565 individuals suggest that the end user as a stakeholder should be also considered when analyzing a vendor’s prestige. We demonstrate that a supplier’s standing has negative as well as positive reputational effects on the buyer. Depending on the relevance of the purchased good as well as the reputation of the supplier and the buyer, low/high-ranked ingredients significantly decrease/increase the final customer’s perception of the buyer.
Die Projektauswahl stellt eine Herausforderung insbesondere für mittelständische Industrieunternehmen dar. Abhängigkeiten verschiedener Alternativen und vorgegebene Investitionsbudgets führen bei Anwendung von in der Praxis standardmäßig eingesetzten Verfahren regelmäßig zu suboptimalen Projektkombinationen. In enger Abstimmung mit einem Automobilzulieferer wurde ein Ansatz zur Projektauswahl unter Berücksichtigung von Ressourcen und laufenden Projekten entwickelt sowie technisch umgesetzt. Implementierte Praxistests belegen Verbesserungen bei der Projektauswahl, aber auch bei der Budgeteinhaltung, der Fixkostenreduzierung sowie der Angebotspreisbestimmung.
In a three-guide coupler with multimode central waveguide, more than two modes of the entire structure participate in the coupling between the outer waveguides. Using a three-mode approximation we found simple conditions for complete power transfer between the outer waveguides: the device length has to match certain multiples of the con- ventionally defined coupling length. The specific form of the relevant modes allows us to design a magneto-optic isolator or circulator with significantly reduced device length (as compared to the conventional nonreciprocal coupler). The performance of the proposed devices is simulated by propagating-mode calculations. Estimates for admissible fabrication tolerances for the layer thicknesses are presented.
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)
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.
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.
We investigate a system of two waveguides with leaky modes sharing a common substrate (radiatively coupled waveguides). The main advantage of such a system is the possibility of remote coupling. A perturbation theory is developed for both TE and TM polarization. Numerical calculations of dispersion curves and of the coupling length allow us to determine the limitations of the perturbation theory. We study the influence of multimode interference on the process of beating by considering the propagation of a given initial field. Finally, we propose a new design for an effective, integrated optical TE-TM polarization splitter.
Three-guide couplers with multimode central waveguides allow for remote coupling between optical channels. A simple three mode approximation turns out to be sufficient for the description of the main features of the power transfer behavior. The specific form of the relevant modes suggests the design of integrated optical isolators and circulators based on magnetic garnet materials. These novel devices are superior to conventional nonreciprocal couplers with respect to the total length and admissible fabrication tolerances. We characterize the isolation performance and the transmission loss for the proposed devices by propagating mode simulations and estimate the influence of geometry parameter deviations.
Each particular implementation of the beam propagation method (BPM) requires a special procedure allowing for radiation to leave the computational window. We propose a new approach to constructing the finite difference schemes of the BPM at the boundary of the computational window. These schemes are independent of the computed fields and allow for a similar treatment of both interior and boundary points. The new approach can be further improved by correcting the field values at the boundary points according to Hadley's method. The algorithm is easy to implement for both two- and three-dimensional structures. The new method considerably reduces computation times because the propagation matrices remain constant in longitudinally invariant sections, thus avoiding repeated LU-decompositions. The basic idea-establishing the finite difference scheme such that locally exact, approximate, or plausible solutions are recovered-may be of interest for other efforts to solve partial differential equations by the finite difference method.
Effective coupling between two remote optical waveguides without branching sections can be achieved in a three-guide system with multimode central waveguide. We investigate the nonlinear power switching of c.w. laser radiation by such radiatively coupled waveguides. It is shown that effective all-optical switches with spatially well separated input/output channels can be realized although the influence of multimode interference on the switching characteristics becomes more pronounced for increasing thickness of the central guide. Different coupling regimes are specified, and the changes in switching characteristics during the transformation from one regime to another is studied. Numerical calculations for the critical power are compared with an approximate analytical expression. It is also shown that, at a moderate input power, a small number of modes determines the switching behavior.
The performance of nanoelectronic and molecular electronic devices relies strongly on the employed functional units and their addressability, which is often a matter of appropriate interfaces and device design. Here, we compare two promising designs to build solid-state electronic devices utilizing the same functional unit. Optically addressable Ru-terpyridine complexes were incorporated in supramolecular wires or employed as ligands of gold nanoparticles and contacted by nanoelectrodes. The resulting small-area nanodevices were thoroughly electrically characterized as a function of temperature and light exposure. Differences in the resulting device conductance could be attributed to the device design and the respective transport mechanism, that is, thermally activated hopping conduction in the case of Ru-terpyridine wire devices or sequential tunneling in nanoparticle-based devices. Furthermore, the conductance switching of nanoparticle-based devices upon 530 nm irradiation was attributed to plasmon-induced metal-to-ligand charge transfer in the Ru-terpyridine complexes used as switching ligands. Finally, our results reveal a superior device performance of nanoparticle-based devices compared to molecular wire devices based on Ru-terpyridine complexes as functional units.
Produktionswirtschaft
(2020)
Dieses Buch gibt einen umfassenden Überblick über wichtige Bereiche der Produktionswirtschaft. Der Schwerpunkt liegt auf dem operativen Produktionsmanagement. Es zeigt den Einsatz der Produktionsfaktoren Mensch, Betriebsmittel und Material, erklärt die Bedeutung von Informationen für die betriebliche Führung und bietet anhand zahlreicher Beispiele einen breiten Einblick in die Planung und Steuerung industrieller Produktion. Ausführlich werden neben produktionswirtschaftlichen Grundlagen der Ablauf und Inhalt von Planungs- und Steuerungsprozessen erläutert. Auch das aktuelle Thema Industrie 4.0 sowie cyber-physische Systeme werden dargestellt.
In der 2. Auflage wurden umfangreiche Überarbeitungen hinsichtlich Sprache und Aufbau vorgenommen sowie anschauliche Beispielaufgaben, neue Unternehmensbeispiele und hilfreiche Hintergrunderklärungen ergänzt.
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.
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.
Transfer kann als Beziehungsgeschehen zwischen Transferakteuren, die im Dialog stehen, aufgefasst werden. Beziehungsgeschehen gestaltet sich in erster Linie durch Sprache aus. Sprache wiederum erzeugt Wirklichkeit sowohl auf der auf der Inhalts- wie auch auf der Beziehungsebene. Sprache verbindet Dialogpartner oder trennt sie – je nach Sprachgebrauch. Die fachliche Ausdrucksweise, die Verwendung von Fachterminologien sowie die Kommunikation der fachlichen und überfachlichen Werte sind dabei prägend für den Sprachgebrauch und auch für das Sprachverständnis. Soll Transfer und das damit verbundene Transfergeschehen erfolgreich sein, muss die genutzte Sprache für alle Transferpartner im Dialog definiert, verständlich und motivierend, also direkt handlungsanregend, sein. Das bedeutet letztendlich, dass es klar sein muss, worüber man spricht und auf welcher Grundlage ein (Transfer-)Dialog stattfindet. Was Transfer aber genau beinhaltet, wie er strukturiert ist, wo und wie Transfer verortet ist und wie Transfer gemessen wird, darüber herrscht keineswegs Einigkeit. Damit schmälern sich die grundlegenden Voraussetzungen für einen erfolgreichen Transfer. Umso wichtiger erscheint es deshalb, einen eindeutigen Sprachgebrauch zu pflegen, der auf Definitionen und Begriffsabgrenzungen referenziert. Diese müssen Bestandteile eines konkludent durchdachten und wissenschaftstheoretisch basierten Systemmodells sein und ein gemeinsam getragenes Transferverständnis sicherstellen.
It is common practice to use maximum FAST time-weighted sound pressure levels to assess transient impact noise, as these levels correlate well with human perception of impact noise. Maximum FAST time-weighted levels are known to be dependent on the reverberation time of the receiving room. In previous studies, an analytical correction term was developed using a Dirac impulse. The correction term is used to calculate the maximum FAST time-weighted levels from peak sound pressure levels. Peak levels are independent of the reverberation time of the room. Applying the correction term makes it possible to compare measurement results from different rooms. The correction term has been validated in several studies for the standard rubber impact ball. In this paper, the influence of the source signal (Dirac impulse) on the correction term is studied. Analytical and numerical models are employed to investigate the consequences of stretching the impulse in time and of changing its shape. The results are compared with empirical solutions developed in other studies.
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.
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.
Efficient transportation of droplets (∽10 ¹ ̶̶̶̶ 10 ² µl) and small solid objects (∽10 ¹ ̶ 10 ² mm ³ ) have important applications in many fields, such as microfluidics, lab‐on‐a‐chip devices, drug delivery, etc. A novel multifunctional surface consisting of a periodic array of micro‐lamellae from a soft magnetoactive elastomer (MAE) on a plastic substrate is reported for these purposes. The physical origin of the propulsion is the bending of soft magnetic lamellae in non‐uniform magnetic fields, which is also observed in uniform magnetic fields. The magnetoactive surface is fabricated using a facile and rapid method of laser ablation. The propulsion of items is realized using a four‐pole rotating magnet. This results in a cyclic lamellar fringe motion over the micro‐structured surface and brings an advantage of easy reciprocation of transport by rotation reversal. Two modes of object transportation are identified: “pushing” mode for precise control of droplet and solid positioning and “bouncing” mode for heavier solid objects transportation. A water droplet of 5 μl or a glass sphere with a 2.1 mm diameter can be moved at a maximum speed of 60 mm s ⁻¹ . The multifunctionality of the proposed mechatronic platform is demonstrated on the examples of selective solid‐liquid separation and droplet merging.
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.
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.
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.
This paper focuses on Artificial Intelligence (AI) in robotic surgery. The question of safety and autonomy follows through the whole paper. Guidelines like Safety Integrity Levels which apply to dependable systems in general are described shortly. Overall, this work does not explicitly supply advantages of AI and instructional guidelines to build autonomous robots, instead, concentrates on challenges in the use of AI. In conclusion, there are still many open issues in the use of AI which cause potential gaps in reliability.
In this paper, the results of Thermally Stimulated Depolarization Currents (TSDC)-measurements of a complex system of stacked dielectric layers, like typically appearing in semiconductor packages, is presented. Characteristics of the individual isolation layers are presented solely and the results are compared to the stack. The investigated layers are comprising polyimide film, alkali-free glass, polyolefin film and epoxy based mold compound. Measurements have been carried out in the temperature range from 19 - 195°C at varying polarization fields for every material. Various relaxation peaks, originated by different polarization mechanisms within the materials could be observed. A comparison between the TSDC-peaks of the layer stack and the individual materials is shown. Our results demonstrate, that the super positioned spectrum is getting dominated by a single portion, the mold compound.
Anhand zweier Beispiele wird ein interaktives System vorgestellt, mit welchem Live-Messungen an elektronischen Bauteilen und Schaltungen im Hörsaal durchgeführt werden können. Das System basiert auf dem USB-Messgerät „Analog Discovery 2“ der Firma Digilent, erweitert um eine Adapterplatine mit Steckbrett und eine Webcam.
Zunächst werden drei Aspekte erläutert, in welchen ein solches System positive Auswirkungen auf den Kompetenzerwerb haben kann: Praxisbezug, Aktivierung und Vernetzung. Anschließend werden die zwei Beispiele ausgeführt. In Beispiel 1 wird die persönliche Alltagserfahrung mit Akkus über interaktive Clicker-Fragen und begleitende Messungen mit dem Modell der linearen Quelle verknüpft. Die Studierenden lernen, oberflächliche Lösungen wie die Messung der Leerlaufspannung zu hinterfragen und das Verhalten realer Quellen anhand der gemessenen I-U-Kennlinien zu verstehen. Beispiel 2 zeigt kurz die Möglichkeiten auf, den abstrakten Formalismus der komplexen Wechselstromrechnung am Beispiel des Serienschwingkreises im Zeit- und Frequenzbereich
messtechnisch erlebbar zu machen.
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.
It is shown that the advancing (ACA) and receding (RCA) contact angles of water on extremely soft (shear modulus of the order of 10 kPa) magnetoactive elastomer (MAE) films significantly depend on the applied magnetic field. The difference between these angles, known as the contact angle hysteresis, is examined. The roles of the filler concentration and material softness are elaborated. The highest change in the contact angle hysteresis (CAH) from 34° in the absence of magnetic field to 76° in a magnetic field of 0.4 T is achieved for the softest sample with the lowest mass fraction of iron particles (70 wt%). The dependence of the CAH on magnetization history (“magnetic hysteresis”) is observed. This magnetic hysteresis is clearly pronounced for the ACA and has little effect on the RCA. Magnetic field-induced changes of the surface roughness exhibit qualitatively the same hysteresis behavior with regard to the external magnetic field as the ACA. The results are promising for the development of smart surfaces for applications where the dynamic wetting has to be controlled.
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.
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.
An effective method for on-demand control over the impact dynamics of droplets on a magnetoresponsive surface is reported. The surface is comprised of micrometer-sized lamellas from a magnetoactive elastomer on a copper substrate. The surface itself is fabricated using laser micromachining. The orientation of the lamellae is switched from edge-on (orthogonal to the surface) to face-on (parallel to the surface) by changing the direction of a moderate (<250 mT) magnetic field. This simple actuation technique can significantly change the critical velocities of droplet rebound, deposition, and splashing. Rebound and deposition regimes can be switched up to Weber number We < 13 ± 3, while deposition and splashing can be switched in the range of 32 < We < 52. Because a permanent magnet is used, no permanent power supply is required for maintaining the particular regime of droplet impact. The presented technology is highly flexible and enables selective fabrication and actuation of microstructures on complex devices. It has great potential for applications in soft robotics, microfluidics, and advanced thermal management.