Day 2 :
Keynote Forum
Jože Duhovnik
University of Ljubljana, Slovenia
Keynote: Golden loop inside the design methodology for total production engineering
Time : 09:55-10:30
Biography:
Jože Duhovnik is a Professor in University of Ljubljana and he has established LECAD Laboratory. He has many lectures in Universities around EU and USA and has more than 600 professional projects around the world. He has more than 200 publications and 12 books about the design and CAD Technik.
Abstract:
Production engineering can come on highest level of productivity if in the whole process involved in very beginning time Research-development and designing phase. One of the known methodologies is golden loop, which was present firstly on TU Delft on 2002. Later was developed in LECAD on the University of Ljubljana. Laboratory LECAD was known about fully cooperation with the industry and novelties of the product. In paper will be present first loop where the problem recognition was performed. The second loop is important for team consolidation and clearing the problems at all. On the third loop, we find out the function capability according the request. Finally, in the golden loop we proposed the detail design with high level of detail searching. With that golden loop the product, become visible in good prepared for production and especially for total production engineering. With some example as e-drive bicycle, it is we as if present few interesting details, which can be improved if we used golden loop methodology in the whole process.
Keynote Forum
Michal Krzyzanowski
Birmingham City University, UK
Keynote: Towards design and manufacturing of biomedical implants with biological fixation: Development of an integrated numerical model
Time : 10:30-11:05
Biography:
Michal Krzyzanowski is currently a Professor of Engineering and Materials Science at Birmingham City University, UK. He has served and is currently on many International Conference Scientific/Executive Committees and is also a Fellow Member of the Institute of Materials and Mining, UK. He has co-authored of over 150 publications including one book, research monograph and several book chapters. His current research interests include also processing of nanocrystallized multilayered metallic structures and development of physically based modelling methodologies for investigation of multiphysical phenomena in additive manufacturing.
Abstract:
In recent years, orthopaedic implant research has been driven by biological fixation. In this type of fixation, a layer of biologically active material on the implant surface generates interfacial bonding between the implant and bone. The presence of bio-active material with appropriate level of porosity and crystallinity influences host bone regeneration by creating an environment allowing for cell spreading, proliferation and subsequent bone formation integrating the implant into the body. Their clinical applications are limited to non-load bearing implants due to brittleness and relatively poor mechanical properties. Multilayered coating of a mechanically tough substrate is an alternative route to reduce the risk of early implant failure. Faster and cheaper fabrication of such implants is expected with laser-assisted densification of multiple materials via additive manufacturing (AM) technology. The process is being developed to fabricate implants made of multiple materials in one operation without part-specific tooling and human intervention. Such implants having increased longevity provide more secure fixation using tailored properties, which cannot be achieved by conventional manufacturing techniques. There are many factors that can influence a laser assisted AM of the implants reflecting in enhancement of their biological fixation. There appears to be no clear understanding of the cooperative relationships between different physical phenomena taking place in the manufacturing process on different scales of consideration. There is also lack of mathematical models, which could predict and link them with the macro- response of the multi-layered structures. This lack of relevant knowledge is the serious obstacle on the way towards reliable manufacturing and successful clinical use of such multi-layered implants made by AM methods. The paper presents resent advances on development of an integrated model including specific mechanical, optical, thermal, thermo-mechanical, metallurgical and chemical phenomena taking place in the laser-assisted multi-material AM. Most importantly, the development of such multiscale numerical model, which can support the design and manufacture of such novel implants, is multidisciplinary enterprise involving material design, implant design and fabrication, biological and clinical assessment among others. An establishment of an appropriate platform for cooperation between relevant institutions including universities, hospitals and enterprises to facilitate research, development, preclinical and clinical studies is crucial.
Keynote Forum
Josep M Bergada
ESEIAAT-UPC, Spain
Keynote: Fluidic oscillators for active flow control applications
Biography:
Josep M Bergada pursued his PhD in Mechanical Engineering (1996) from University Polytechnic of Catalonia (UPC), Barcelona, Spain. He is currently an Associate Professor in Fluid Mechanics Department at UPC. He has published more than 18 key-papers in reputed journals and over 55 papers in international conferences. He is also serving as an Editorial Board Member of a reputed SCI journal and has reviewed over 250 papers from more than 15 SCI journals. His books on fluid mechanics is gaining international relevance. His research interest include: active flow control, piston pumps, tribology, compressible flow, CFD etc.
Abstract:
Active flow control (AFC) applications are increasing every day, the use of (AFC) technologies allows, among other applications, reducing drag forces in bluff bodies, increasing lift in airfoils reducing cavity noise and enhancing mixing in combustion chambers. There exist several (AFC) methodologies to modify the boundary layer thickness and its separation point in a given bluff body, all of them being based on the use of slots, grooves, or holes, through which fluid is injected or sucked. The use of constant blowing, constant sucking or periodic forcing, are the three common methods to interact with the boundary layer. Periodic forcing appears to be the most efficient one regarding the energy requirements, yet for each application it is necessary to employ a particular pulsation frequency and amplitude. Among the different devices used to generate pulsating flow, the most common ones are the zero net mass flow actuators (ZNMFA), also called synthetic jets and the fluidic oscillators (FO). The main advantage of (FO) versus (ZNMFA), resides in the lack of moving parts, which a priory gives confidence regarding its reliability. In the present paper one of the most common configurations of (FO) will be carefully analyzed via using 3D computational fluid dynamics (CFD). The origin of the fluctuations, based on the Coanda effect, will be studied, the relation incoming flow-outgoing frequency and amplitude as a function of the Reynolds number shall be clarified, a parametric analysis is also to be performed in order to understand the effect of the different internal dimensions on the (FO) overall performance. The advantage of the present paper versus previous publications, see for example resides in the evaluation of the momentum acting on the jet entering the mixing chamber.
Keynote Forum
Monique Calvo Dahlborg
University Rouen Normandy - CNRS, France
Keynote: Design of multi-major-component (high entropy) alloys of suitable magnetic and mechanical properties based on a Hume-Rothery approach
Time : 11:55-12:30
Biography:
Monique Calvo Dahlborg completed her PhD in the year 1985 from Caen University, France. She is CNRS Senior Scientist at University of Rouen Normandy (France) and Honorary Research Fellow of Swansea University (UK). She has published more than 40 papers in reputed journals and more than 45 in proceedings with reviewing procedure. She has expertise in rapid solidification, disordered metallic systems and high entropy alloys and has contributed to many international research projects.
Abstract:
Multi major component alloys (also called high entropy alloys (HEAs)) appeared around 2004. They are based on 4 or more elements in close to equimolar composition. The equal footing of each element on solidification leads to an interesting new metallurgy providing materials with promising properties. The design of HEAs is thus a challenge to improve traditional compositions with possibly cheaper or greener components. The present work reports a strategy for the design of HEAs with suitable magnetic and mechanical properties based on a Hume-Rothery approach, namely on the calculation of the number of itinerant valence electrons and the average atomic radius for 12 atoms neighborhood. Prediction algorithms based on self-ordering maps permit to improve the composition choice.
Keynote Forum
Adam M. Philo
Swansea University, UK
Keynote: The crucible method: A new technique of generating process maps for laser powder-bed fusion
Biography:
Adam M. Philo is a Post-Doctoral Research Assistant in the College of Engineering at Swansea University. He has a background in Aerospace Engineering and Mathematics and hold an Engineering Doctorate which was completed with Renishaw’s Additive Manufacturing Products Division. His research interests are predominately in the field of computational modelling of the laser powder bed fusion process. These are multiscale and multi-physical in nature and involve a variety of fluidic, thermal and structural analyses.
Abstract:
Laser powder-bed fusion (LPBF) is an additive manufacturing process fusing metal powder layer-by-layer to form complex 3D components. LPBF is seen as a rapid evolution of machine design (more and higher power lasers, improved laser control and build preparation software) giving increased density of built parts, better inter- and intra-build repeatability, all leading to better mechanical properties. The traditional method to create process maps via post-mortem examination of solidified single line tracks aims to understand how the laser interacts with the powder to form single line tracks directly onto a baseplate. Control of process parameters such as speed, power and beam diameter are integral to choosing optimal laser penetration whilst avoiding evaporation, keyhole melting or balling defects. This method is limited as the substrate may be of a similar composition but microstructurally dissimilar and controlling additional parameters such as the powder layer thickness is difficult. A new crucible method is described and compared to the traditional method using Ti-6Al-4V and 316L with advantages, which include: i) high-throughput, high-quality topographical and cross-sectional metallography to be easily obtained. ii) tracks to be built in-situ on a previously deposited substrate is more representative of the process at all layers. iii) tight control on the powder depth and additional parameters. The crucible method predicted a much less severe transition between conductive and keyhole modes of melting than direct deposition of single tracks onto a baseplate, with shallower re-melting of lower layers. The crucible method also predicted a more forgiving transition between continuous and discontinuous tracks.
- Design Engineering | Industrial Design | Manufacturing Process | Materials Science | Mechatronics Robots Applications of Automation | Human Robot Interaction | Control Systems
Location: Scala
Chair
Jose M Pardor Gortor
The University Carlos III of Madrid, Spain
Co-Chair
Michal Krzyzanowski
Birmingham City University, UK
Session Introduction
Johanna Ender
Liverpool John Moores University, UK
Title: Design of an intelligent workplace system for human-machine-interaction in the digitized industry
Biography:
Johanna Ender passed her graduation as a Diploma Designer (FH) for Product Design (2017) with distinction from the Hochschule Wismar University of Applied Sciences Technology, Business and Design. She has started her international and interdisciplinary PhD research in June 2017 at the Faculty of Engineering and Technology of Liverpool John Moores University in cooperation with the Hochschule Wismar University. She received the Gottlob Frege Price 2017 for her final thesis, which was developed in cooperation with the Fraunhofer IGP, Rostock (Germany). A study project about a robot integration into a kitchen furniture was awarded with the Anja Schaible Price 2017 at the Living Kitchen (event), Cologne (Germany). She spent a pre-study practical in Tasmania. While studying, she developed a patent for a household appliance (DE 102015210996A1) for the Corporate Brand Siemens/Design of the BSH Hausgeräte GmbH within an internship. For her work as a designer, she was awarded as German Design Award Nominee 2018.
Abstract:
Modern industry workplaces include operators working intensely using computers, robots and autonomously operating machines. Tasks including human-machine interaction (HMI) are increasingly integrated into the work process. The work ranges of robots and operators in manual assembly and maintenance are progressively fusing – the coexistence will move towards human-robot collaboration (HRC). Consequently, the higher dynamics of processes in the digitized industry include additional stress factors and offers new challenges: HMI can result in cognitive overload of the worker due to the interpretation of multiple signals and therefore lead to a high risk of exhaustion. Furthermore, there are strong barriers to working with a robot colleague. To increase the acceptance of HRC and to reduce the strain of the worker, user-centered needs have to be sufficiently considered. However, workplaces for HMI are widely developed from a technology-centric perspective. The design research will close this gap by developing a novel holistic method for the design of industrial workplaces. Accordingly, the study places great emphasis on understanding of human factors in terms of its physical, cognitive and organizational limitations and their applications to industrial design. The workbench system includes a novel interface directing working tasks to the worker within the networked plant. Derived from the existing Pick-by-Light framework – where operators are directed to particular stock areas via light signals – the approach, named Work-by-Light, utilizes light displays to support the operators solving particular working tasks in collaboration with a robot. In particular, areas of interaction, like the supply and removal of work pieces through the robot, are highlighted as well as instructions for the assembly are communicated. Light signals inside the surface of the table are reduced to the minimum of information to support the rapid processing of the instruction through the worker. Consequently, the intuitive utilization of the interface reduces strain in HRC. It will be exemplified how the system can support the worker during maintenance and manufacturing of airplanes. Therefore, explorative testing of a conceptual prototype by potential users is planned.
Tobias Masiak
Zentrum für Mechatronik und Automatisierungstechnik gemeinnützige, Germany
Title: Implementation of a human-machine-interaction control system in a human-robotcollaborative riveting process in aircraft assembly
Time : 14:25-14:45
Biography:
Abstract:
Assembly processes in aircraft production are difficult to automate due to technical risks. Examples of such technical challenges are small batch sizes, large product dimensions and limited work space. Full automation of complex processes is expensive as it requires much effort with respect to service and maintenance. A semi-automated process, utilizing human-robot-collaboration, is the most effective approach for optimizing aircraft production in relation to aircraft section assembly. In the assembly process of the aft section of aircrafts, the pressure bulk head is assembled with the section barrel using hundreds of rivets. This assembly process is a non-ergonomic and demanding task in which two people are working together collaboratively. Working conditions can be improved through collaboration between the operator and the robot system. The approach is based on the process requirements as well as dynamic and skill based task sharing between the operator and the robot. This is demonstrated by positioning a robot within section 19. The robot's task is to position the anvil tool, while the operator performs the more complex task of inserting the rivet and operating the riveting tool. An intuitive operating is implemented to increase operator acceptance and to enable interaction with production equipment. Within the framework of natural and intuitive human machine interaction, smart devices are integrated to control process specific production equipment. Graphical user interfaces in smart phones or smart watches and the integration of mixed reality technology offers new possibilities for visualization and assistance. The developed systems allow intuitive configuration and operation of the station using an open control concept and dynamic task sharing. The operator is therefore supported with a collaborative robot in combination with additional assistance systems in order to improve production quality and ergonomics during the riveting process. The results are part of the EU’s Horizon 2020 research and innovation programme in the four by three projects at ZeMA.
Carmine Pirozzi
CIRA, Italy
Title: Study on porosity defects of EBMed Ti64 components by tomographic analysis
Biography:
Carmine Pirozzi graduated with Honors in Industrial Engineering in 2004 with a PhD in Systems and Technology of Production. He is a Researcher in additive manufacturing since 2011, involved in projects as HYPROB, TIMA-RITAM, ANGELA, SAT-AM as material science and additive manufacturing engineer specialist. He does cooperate with several research centers, universities and firms being authors of more than 10 scientific articles on specialized journals and conferences.
Abstract:
The electron beam melting (EBM) is one of the most promising ALM technologies, which utilizes a high-energy electron beam, as a moving heat source, in order to melt and fuse (by rapid self-cooling) metal powder and produce parts in a layer-building fashion. Anyway many technical aspects concerning the quality of EBM produced components are still industrial open items and studies need to be carried out. The objective of this study is to evaluate the distribution and the features of porosity defects generated during the EBM process by using tomographic analysis, at this aim a simple test case, consisting in rectangular parallelepiped (50x10x10 mm) samples manufactured in Ti6Al4V, was chosen. A suitable DOE was developed in order to investigate the effect of the following intra-build process parameters on porosity: Samples orientation: samples were built according to n.4 different orientations: x, y, z (90°) and 45°. The x and y oriented samples were built horizontally and they were, respectively, parallel and perpendicular to the rake movement direction and the 90° oriented samples were built vertically. Height in the build chamber: the group of samples shown in 2b was built at n.3 different levels in the build chamber which are named hereafter: h1, h2 and h3. More in detail, h1 level starts at z=40 mm, h2 level starts at z=170 mm and h3 level starts at z=300 mm.
Zaheer Abbas
National University of Science and Technology, Pakistan
Title: Design optimization of spot welds for optimal strength of structure
Biography:
Zaheer Abbas pursued his BE in Aerospace from College of Aeronautical Engineering at the National University of Engineering & Technology in 2010. He is currently pursuing MS in Aerospace Engineering from National University of Engineering & Technology.
Abstract:
Resistance spot welding (RSW) is particularly employed for high volume and rapid welding applications in automotive assembly process for joining multiple metal sheets and parts. The failure of spot welded joints are linked to several factors like, weld nugget size, edge distance, spacing between spot welds, sheet thickness, material properties of heat affected zone, residual stresses and material inhomogeneity. Finite element analysis (FEA) of multiple spot welded joints under tensile-shear load are investigated to attain optimum strength and desired factor of safety. The analysis shows that spacing between the adjacent spot welds, edge distance and thickness of the sheets are primary factors affecting the strength of the joints for a given material. The optimal edge distance increases the strength of the weld by providing clearance of spot welds from plate edge. The optimal spacing of spot welds is the thin line between the stress superimposition and supporting effect of spot welds. The variation of sheet thickness effects the strength of spot welds as the optimal edge distance changes with thickness. For asymmetric thickness of sheets, strength is defined by thinner sheet and for symmetric sheet edge optimal edge distance varies with thickness.
Grazvydas Kazokaitis
Kaunas University of Technology, Lithuania
Title: Spherical magnetic drive for attitude control on nano satellites
Biography:
Grazvydas Kazokaitis has experience in design and R&D fields developing small and precise mechanisms for ultra-fast laser beam control and machining apparatus. This experience allows providing solid foundation and knowledge creating possible solutions for laser beam orientation mechanisms between small units in space, attitude control and other control tasks.
Abstract:
Small satellites are great tools for various research and analysis tasks. They can work like standalone units or to be modular and combined together to the clusters. Depending on their missions and provided exercises, various orientation and positioning systems are needed. Attitude control systems can be with active or passive elements. Typically, these systems are driven by: gravitational forces, permanent or electromagnets, reactions wheels or thrusters. Small satellites have limited capabilities and many restrictions for size, composition, energy consumptions. Nowadays most popular systems consume significant amounts of energy, takes a lot of volume. As a possible option for alternative attitude control mechanism spherical magnetic drive was submitted. Spherical permanent magnet has stable dipole and when it orientates with the Earth’s magnetic field, attitude control can be achieved. This developed drive combines advantages of active and passive systems. The drive is fairly simple: permanent magnetic sphere is inserted between two ring-shaped piezoelectric actuators. Electrodes of the piezoelectric rings are divided into three equal sectors and are excited by separate harmonic signal. The out-of-plane bending and radial vibration modes of the piezoelectric rings are excited to obtain elliptical motion of the contacting points and rotate magnetic sphere about three axes. Amplitude and duration of the applied signal depends on rotation or motion trajectory of the sphere. In addition, it must be mentioned that actuator can be driven by burst type signal in order to achieve very high resolution. Using this technique, controlled movement of magnetic sphere is achieved. Numerical and experimental studies were performed to verify operating principle and output characteristics of the actuator. The aim of study was to investigate vibration modes of the piezoelectric actuators and identify resonance frequencies at which these piezoelectric actuators generate 3-DOF rotational motion of a spherical rotor with high resolution, determinate further development steps.