An evaluation of the performance of advanced melded composite joints

Melding is an efficient three step composite joining process that involves the selective cure of composite adherends before the final adhesive joint is created using the adherends own resin system. Melding does not require many of the processes and compromises associated with conventional techniques like adhesive bonding and mechanical fastening.

The Taguchi design of experiments technique was used to optimise three melded joint factors for a unidirectional epoxy prepreg material. The performance of the joint was evaluated using tensile and flexural strength as well as flexural modulus. It was found that not having a step for every ply in the joint was the most influential factor affecting joint performance. This was due to the differing failure modes induced by this factors various levels, which varied the amount of fibre breakage at failure.

Effect of tool speeds during friction stir lap welding on mode of fracture and fracture strength of Al 6060-T5 joints

Friction stir lap welding (FSLW) of an age hardened Al alloy and evaluations of how FS speeds affected hooking and how hooking and softening due to FS affected fracture strength of the lap welds have been conducted. It was found that increasing rotation speed and reducing welding speed (v) increased the stir zone size (AB-SZ) and also hook size (h), although a maximum value of h (hMax) reached. The features of hooks for the observed - AB-SZ-h relationships are presented and explained. It was found that when h increased to a value of ~ 0.9 mm (for the 3 mm alloy sheets), it started to invoke a significant effect on reducing fracture strength. Factors such as FS softening and insufficient joining, limited the fracture strength of the lap welds for small h values and these are presented and discussed.

Adaptive mechanically controlled lubrication mechanism found in articular joints

Articular cartilage is a highly efficacious water-based tribological system that is optimized to provide low friction and wear protection at both low and high loads (pressures) and sliding velocities that must last over a lifetime. Although many different lubrication mechanisms have been proposed, it is becoming increasingly apparent that the tribological performance of cartilage cannot be attributed to a single mechanism acting alone but on the synergistic action of multiple "modes" of lubrication that are adapted to provide optimum lubrication as the normal loads, shear stresses, and rates change. Hyaluronic acid (HA) is abundant in cartilage and synovial fluid and widely thought to play a principal role in joint lubrication although this role remains unclear. HA is also known to complex readily with the glycoprotein lubricin (LUB) to form a cross-linked network that has also been shown to be critical to the wear prevention mechanism of joints. Friction experiments on porcine cartilage using the surface forces apparatus, and enzymatic digestion, reveal an "adaptive" role for an HA-LUB complex whereby, under compression, nominally free HA diffusing out of the cartilage becomes mechanically, i.e., physically, trapped at the interface by the increasingly constricted collagen pore network. The mechanically trapped HA-LUB complex now acts as an effective (chemically bound) "boundary lubricant"-reducing the friction force slightly but, more importantly, eliminating wear damage to the rubbing/shearing surfaces. This paper focuses on the contribution of HA in cartilage lubrication; however, the system as a whole requires both HA and LUB to function optimally under all conditions.

Kinematics analysis of 6-DOF parallel micro-manipulators with offset U-Joints : a case study

This paper analyses the kinematics of a special 6-DOF parallel micro-manipulator with offset RR-joint configuration. Kinematics equations are derived and numerical methodologies to solve the inverse and forward kinematics are presented. The inverse and forward kinematics of such robots compared with those of 6-UCU parallel robots are more complicated due to the existence of offsets between joints of RR-pairs. The characteristics of RR-pairs used in this manipulator are investigated and kinematics constraints of these offset U-joints are mathematically explained in order to find the best initial guesses for the numerical solution. Both inverse and forward kinematics of the case study 6-DOF parallel micro-manipulator are modelled and computational analyses are performed to numerically verify accuracy and effectiveness of the proposed methodologies.

Kinematics analysis of 6-DOF parallel micro-manipulators with offset u-joints : a case study

This paper analyses the kinematics of a special 6-DOF parallel micro-manipulator with offset RR-joint configuration. Kinematics equations are derived and numerical methodologies to solve the inverse and forward kinematics are presented. The inverse and forward kinematics of such robots compared with those of 6-UCU parallel robots are more complicated due to the existence of offsets between joints of RR-pairs. The characteristics of RR-pairs used in this manipulator are investigated and kinematics constraints of these offset U-joints are mathematically explained in order to find the best initial guesses for the numerical solution. Both inverse and forward kinematics of the case study 6-DOF parallel micro-manipulator are modelled and computational analyses are performed to numerically verify accuracy and effectiveness of the proposed methodologies.

High-precision five-axis machine for high-speed material processing using linear motors and parallel-serial kinematics

The paper describes some details of the mechanical and kinematics design of a five-axis mechanism. The design has been utilized to physically realize an industrial-scale five-axis milling machine that can carry a three KW spindle. However, the mechanism could be utilized in other material processing and factory automation applications. The mechanism has five rectilinear joints/axes. Two of these axes are arranged traditionally, i.e. in series, and the other three axes utilize the concept of parallel kinematics. This combination results in a design that allows three translational and two rotational two-mode degrees of freedom (DOFs). The design provides speed, accuracy and cost advantages over traditional five-axis machines. All axes are actuated using linear motors.

Investigation of processing conditions of melded parts to determine process boundaries

Melding, a novel method for producing seamless joints in thermosetting composites utilising the Quickstep™ process, is explored in this paper. The effect of processing conditions on the quality of melded joins is examined and a set of processing boundaries defined so that the strength of melded joints is optimized. HexPly® 914c pre-preg material was exposed to a range of processing temperatures prior to joining via the melding process. Differential Scanning Calorimetry analysis was carried out to investigate the degree of cure of material prior to final joining, and it was found that minimal cure occurs at temperatures below 120°C. After consolidation and cure of the melded parts, short beam shear testing was conducted to evaluate the strength of the melded interface. Exposure temperatures between 65°C and 120°C were found to optimize short beam shear join strength. Mode I double cantilever beam and mode II end notched flexural tests showed no detrimental effect of elevated exposure temperatures prior to joining.

Artificial hand - from a robotic perspective

The human hand provides proof that the anthropomorphic configuration, properly controlled, is successful and gives a target to aim at for artificial hand/robot hand researchers. In this paper we discuss the human hand physiology and grasp capabilities. We then provide design on a double thumb, two finger robotic hand. Architecture of the hand, fingers and their dynamic modelling is discussed. Finally, results are reported on the performance of a finger in the hand.

Fighting fatigue whilst fighting bushfire : an overview of factors contributing to firefighter fatigue during bushfire suppression

Aching muscles and joints, lethargy, and sleepiness are all signs of firefighter fatigue during bushfire suppression. If not managed, fatigue may lead to injury or illness for the individual, which may also compromise the safety and productivity of their crew. Understanding the many sources of firefighter fatigue is, therefore, fundamental for all Australian fire agencies. This article will briefly address  several factors thought to contribute to firefighter fatigue including; sleep loss, firefighter’s work activity, their hydration, and nutrition, the hot and smoky  working environment, firefighter’s physical fitness and their experience. This brief overview draws on findings from firefighting research and the broader scientific literature.

Lateral strength of zero bond masonry walls subjected to wind loads

Masonry walls are usually laid with the individual masonry units along a course overlapping units in the course below. Commonly, the perpend joints in the course occur above the mid-points of the units below to form a ‘half-bond’ or above a third point to form a ‘third-bond’. The amount of this overlap has a profound influence on the strength of a wall supported on three or four sides, where lateral pressures from wind cause combined vertical and horizontal flexure. Where masonry units are laid with mortar joints, the torsional shear bond resistance between the mortar and overlapping units largely determines the horizontal flexural strength. If there is zero bond strength between units, then the horizontal flexural strength is derived from the frictional resistance to torsion on the overlapping bed-faces of the units. This thesis reports a theoretical and experimental investigation into the frictional properties of overlapping units when subjected to combinations of vertical and horizontal moments and vertical axial compression. These basic properties were used to develop a theory to predict the lateral strength of walls supported on two, three or four sides. A plastic theory of behaviour was confirmed by experiment. The theory was then used to determine maximum unbraced panel sizes for particular boundary conditions. Design charts were developed to determine temporary bracing requirements for panels during construction.

Characterization and development of the Quickstep✹ melding process

Melding is a new approach to joining advanced composite materials and components. The research focused on characterizing the nature of composite materials joined by the melding process. The outcomes of the thesis demonstrate that melding produces joints that are equivalent to monolithic material.