Characterization of design of a product for additive manufacturing

The purpose of conducting this thesis is to gather around information about additive manufacturing and to design a product to be additively manufactured. The specific manufacturing method dealt with in this thesis, is powder bed fusion of metals. Therefore when mentioning additive manufacturing in this thesis, it is referred to powder bed fusion of metals. The literature review focuses on the principle of powder bed fusion, the general process chain in additive manufacturing, design rules for additive manufacturing. Examples of success stories in additive manufacturing and reasons for selecting parts to be manufactured with additive manufacturing are also explained in literature review. This knowledge is demanded to understand the experimental part of the thesis. The experimental part of the thesis is divided into two parts. Part A concentrates on finding proper geometry for building self-supporting pipes and proper parameters for support structures of them. Part B of the experimental part concentrates on a case study of designing a product for additive manufacturing. As a result of experimental part A, the design process of self-supporting pipes, results of visual analysis and results of 3D scanning are presented. As a result of experimental part B the design process of the product is presented and compared to the original model.

Design and implementation of machine vision system for the mobile assembly robot

The review of intelligent machines shows that the demand for new ways of helping people in perception of the real world is becoming higher and higher every year. This thesis provides information about design and implementation of machine vision for mobile assembly robot. The work has been done as a part of LUT project in Laboratory of Intelligent Machines. The aim of this work is to create a working vision system. The qualitative and quantitative research were done to complete this task. In the first part, the author presents the theoretical background of such things as digital camera work principles, wireless transmission basics, creation of live stream, methods used for pattern recognition. Formulas, dependencies and previous research related to the topic are shown. In the second part, the equipment used for the project is described. There is information about the brands, models, capabilities and also requirements needed for implementation. Although, the author gives a description of LabVIEW software, its add-ons and OpenCV which are used in the project. Furthermore, one can find results in further section of considered thesis. They mainly represented by screenshots from cameras, working station and photos of the system. The key result of this thesis is vision system created for the needs of mobile assembly robot. Therefore, it is possible to see graphically what was done on examples. Future research in this field includes optimization of the pattern recognition algorithm. This will give less response time for recognizing objects. Presented by author system can be used also for further activities which include artificial intelligence usage.

Computing the persistent homology of range images with alpha shapes

Laser scanning is becoming an increasingly popular method for measuring 3D objects in industrial design. Laser scanners produce a cloud of 3D points. For CAD software to be able to use such data, however, this point cloud needs to be turned into a vector format. A popular way to do this is to triangulate the assumed surface of the point cloud using alpha shapes. Alpha shapes start from the convex hull of the point cloud and gradually refine it towards the true surface of the object. Often it is nontrivial to decide when to stop this refinement. One criterion for this is to do so when the homology of the object stops changing. This is known as the persistent homology of the object. The goal of this thesis is to develop a way to compute the homology of a given point cloud when processed with alpha shapes, and to infer from it when the persistent homology has been achieved. Practically, the computation of such a characteristic of the target might be applied to power line tower span analysis.

Application of Computational Fluid Dynamics in Modeling Blood Flow in Human Thoracic Aorta

The aim of this study was to simulate blood flow in thoracic human aorta and understand the role of flow dynamics in the initialization and localization of atherosclerotic plaque in human thoracic aorta. The blood flow dynamics in idealized and realistic models of human thoracic aorta were numerically simulated in three idealized and two realistic thoracic aorta models. The idealized models of thoracic aorta were reconstructed with measurements available from literature, and the realistic models of thoracic aorta were constructed by image processing Computed Tomographic (CT) images. The CT images were made available by South Karelia Central Hospital in Lappeenranta. The reconstruction of thoracic aorta consisted of operations, such as contrast adjustment, image segmentations, and 3D surface rendering. Additional design operations were performed to make the aorta model compatible for the numerical method based computer code. The image processing and design operations were performed with specialized medical image processing software. Pulsatile pressure and velocity boundary conditions were deployed as inlet boundary conditions. The blood flow was assumed homogeneous and incompressible. The blood was assumed to be a Newtonian fluid. The simulations with idealized models of thoracic aorta were carried out with Finite Element Method based computer code, while the simulations with realistic models of thoracic aorta were carried out with Finite Volume Method based computer code. Simulations were carried out for four cardiac cycles. The distribution of flow, pressure and Wall Shear Stress (WSS) observed during the fourth cardiac cycle were extensively analyzed. The aim of carrying out the simulations with idealized model was to get an estimate of flow dynamics in a realistic aorta model. The motive behind the choice of three aorta models with distinct features was to understand the dependence of flow dynamics on aorta anatomy. Highly disturbed and nonuniform distribution of velocity and WSS was observed in aortic arch, near brachiocephalic, left common artery, and left subclavian artery. On the other hand, the WSS profiles at the roots of branches show significant differences with geometry variation of aorta and branches. The comparison of instantaneous WSS profiles revealed that the model with straight branching arteries had relatively lower WSS compared to that in the aorta model with curved branches. In addition to this, significant differences were observed in the spatial and temporal profiles of WSS, flow, and pressure. The study with idealized model was extended to study blood flow in thoracic aorta under the effects of hypertension and hypotension. One of the idealized aorta models was modified along with the boundary conditions to mimic the thoracic aorta under the effects of hypertension and hypotension. The results of simulations with realistic models extracted from CT scans demonstrated more realistic flow dynamics than that in the idealized models. During systole, the velocity in ascending aorta was skewed towards the outer wall of aortic arch. The flow develops secondary flow patterns as it moves downstream towards aortic arch. Unlike idealized models, the distribution of flow was nonplanar and heavily guided by the artery anatomy. Flow cavitation was observed in the aorta model which was imaged giving longer branches. This could not be properly observed in the model with imaging containing a shorter length for aortic branches. The flow circulation was also observed in the inner wall of the aortic arch. However, during the diastole, the flow profiles were almost flat and regular due the acceleration of flow at the inlet. The flow profiles were weakly turbulent during the flow reversal. The complex flow patterns caused a non-uniform distribution of WSS. High WSS was distributed at the junction of branches and aortic arch. Low WSS was distributed at the proximal part of the junction, while intermedium WSS was distributed in the distal part of the junction. The pulsatile nature of the inflow caused oscillating WSS at the branch entry region and inner curvature of aortic arch. Based on the WSS distribution in the realistic model, one of the aorta models was altered to induce artificial atherosclerotic plaque at the branch entry region and inner curvature of aortic arch. Atherosclerotic plaque causing 50% blockage of lumen was introduced in brachiocephalic artery, common carotid artery, left subclavian artery, and aortic arch. The aim of this part of the study was first to study the effect of stenosis on flow and WSS distribution, understand the effect of shape of atherosclerotic plaque on flow and WSS distribution, and finally to investigate the effect of lumen blockage severity on flow and WSS distributions. The results revealed that the distribution of WSS is significantly affected by plaque with mere 50% stenosis. The asymmetric shape of stenosis causes higher WSS in branching arteries than in the cases with symmetric plaque. The flow dynamics within thoracic aorta models has been extensively studied and reported here. The effects of pressure and arterial anatomy on the flow dynamic were investigated. The distribution of complex flow and WSS is correlated with the localization of atherosclerosis. With the available results we can conclude that the thoracic aorta, with complex anatomy is the most vulnerable artery for the localization and development of atherosclerosis. The flow dynamics and arterial anatomy play a role in the localization of atherosclerosis. The patient specific image based models can be used to diagnose the locations in the aorta vulnerable to the development of arterial diseases such as atherosclerosis.

3D-suunnittelujärjestelmän ja tuotetiedonhallintajärjestelmän integrointi

3D-suunnittelujärjestelmät ovat tärkeitä työkaluja tuotetiedon luomista ja muokkaamista varten, joten niiden tehokas toiminta yhdessä tuotetiedonhallintajärjestelmien kanssa on erittäin tärkeää. 3D-suunnittelujärjestelmien kehityksen seurauksena 3D-malleihin voidaan sisällyttää entistä enemmän tuotetietoa, jolloin tehokas tiedon tallentaminen ja sen hallinta kasvattaa merkitystään. 3D-malleihin sisältyvää tietoa, kuten esimerkiksi kappaleen painoa tai geometriaa, halutaan myös tarkastella ilman tiettyä 3D-järjestelmää. Tuotetiedon hallinta on ollut jo pitkään tärkeä osa tuotteen suunnitteluprosessia. Tuotetiedon hallintaan sisältyy tiedon luomista, keräämistä ja muokkaamista koko tuotteen eliniän ajan. Näitä tietoja voivat olla esimerkiksi piirustukset, 3D-mallit, mittauspöytäkirjat, kokouspöytäkirjat, mallistoluettelot, lujuuslaskelmat, huoltoraportit jne. Tuotetiedonhallintajärjestelmä pitää huolta kaikesta tästä tiedosta ja sen kautta tuotteisiin liittyvää tietoa voidaan myös muokata ja jakaa tehokkaasti. Tässä diplomityössä tutkittiin näiden kahden järjestelmän integraation toteutusta erilaisilla menetelmillä. Työn tarkoituksena oli valita Valtra Oy:n tarkoituksiin parhaiten sopiva menetelmä tuotetiedon siirtämiseksi järjestelmien välillä tehokkaasti. Työn tuloksena annetaan suositus käytettävistä menetelmistä ja työkaluista.

Tuotteen suunnitteluketjun tehostaminen 3D-ympäristössä

Tämä diplomityö on tehty Andritz Oy:lle Washers & Filters tuoteryhmään. Työ on osa 3D-suunnittelujärjestelmän käyttöönottoprojektia. Tavoitteena on arvioida uuden laitesuunnittelujärjestelmän vaikutuksia yrityksen tietojärjestelmiin ja toimintatapoihin sekä etsiä potentiaalisia tulevaisuuden kehityskohteita. Suunnittelutietoa hyödyntäviä sidosryhmien edustajia haastattelemalla selvitettiin järjestelmille ja ohjelmistoille asetettavia vaatimuksia. Ohjelmistoihin tutustumalla saatiin käsitys niiden nykytilasta ja kehityssuunnista. 3D-geometrian hyödyntämiseen perustuvilla järjestelmillä voidaan poistaa päällekäistä työtä sekä lyhentää läpimenoaikoja suunnittelussa ja valmistuksessa sijoittamalla työvaiheita rinnakkain. Suurimmat 3D-suunnittelun edut saavutetaan tuotekehitysvaiheessa, tuotemuutoksia tehtäessä sekä valmistusprosesseja suunniteltaessa. Ongelmallisimmat osa-alueet tietojärjestelmien kehittämisessä ovat ensi-sijaisesti tiedonsiirto ohjelmistojen välillä, työntekijöiden muutosvastarinta sekä laadukkaiden järjestelmien korkea hinta. Laajojen tietojärjestelmä-projektien läpivienti on hyvin haastavaa ja onnistuminen vaatii kaikkien sidosryhmien mukana olemista ja tarkkaa projektin koordinointia.

Mechanical Design of Hydraulic Vise

The general task of clamping devise is to connect the parts to the machining centers so that the work piece could be fixed on its position during the whole machining process. Additionally, the work piece should be clamped easily and rapidly by the machine users. The purpose of this Master’s thesis project was to develop a product design and find out the dimensioning of a hydraulic vise system for Astex Engineering OY, which was taking care of the general principles of product design and development during the design process. Throughout the process, the needs of manufacturing and assembling were taken into consideration for the machinability and minimization of the cost of manufacturing. The most critical component of the clamping devise was modeled by FEM for the issue of strength requirements. This 3D model was created with Solidworks and FEM-analysis was done with Cosmos software. As the result of this design work, a prototype of the hydraulic vise was manufactured for Astex Engineering OY and the practical test.

Exploration and Design of Power-Efficient Networked Many-Core Systems

Multiprocessing is a promising solution to meet the requirements of near future applications. To get full benefit from parallel processing, a manycore system needs efficient, on-chip communication architecture. Networkon- Chip (NoC) is a general purpose communication concept that offers highthroughput, reduced power consumption, and keeps complexity in check by a regular composition of basic building blocks. This thesis presents power efficient communication approaches for networked many-core systems. We address a range of issues being important for designing power-efficient manycore systems at two different levels: the network-level and the router-level. From the network-level point of view, exploiting state-of-the-art concepts such as Globally Asynchronous Locally Synchronous (GALS), Voltage/ Frequency Island (VFI), and 3D Networks-on-Chip approaches may be a solution to the excessive power consumption demanded by today’s and future many-core systems. To this end, a low-cost 3D NoC architecture, based on high-speed GALS-based vertical channels, is proposed to mitigate high peak temperatures, power densities, and area footprints of vertical interconnects in 3D ICs. To further exploit the beneficial feature of a negligible inter-layer distance of 3D ICs, we propose a novel hybridization scheme for inter-layer communication. In addition, an efficient adaptive routing algorithm is presented which enables congestion-aware and reliable communication for the hybridized NoC architecture. An integrated monitoring and management platform on top of this architecture is also developed in order to implement more scalable power optimization techniques. From the router-level perspective, four design styles for implementing power-efficient reconfigurable interfaces in VFI-based NoC systems are proposed. To enhance the utilization of virtual channel buffers and to manage their power consumption, a partial virtual channel sharing method for NoC routers is devised and implemented. Extensive experiments with synthetic and real benchmarks show significant power savings and mitigated hotspots with similar performance compared to latest NoC architectures. The thesis concludes that careful codesigned elements from different network levels enable considerable power savings for many-core systems.

Pipework data in design system integration

This thesis work describes the creation of a pipework data structure for design system integration. Work is completed in pulp and paper plant delivery company with global engineering network operations in mind. User case of process design to 3D pipework design is introduced with influence of subcontracting engineering offices. Company data element list is gathered by using key person interviews and results are processed into a pipework data element list. Inter-company co-operation is completed in standardization association and common standard for pipework data elements is found. As result inter-company created pipework data element list is introduced. Further list usage, development and relations to design software vendors are evaluated.

Virtual technology and haptic interface solutions for design and control of mobile working machines

Commercially available haptic interfaces are usable for many purposes. However, as generic devices they are not the most suitable for the control of heavy duty mobile working machines like mining machines, container handling equipment and excavators. Alternative mechanical constructions for a haptic controller are presented and analysed. A virtual reality environment (VRE) was built to test the proposed haptic controller mechanisms. Verification of an electric motor emulating a hydraulic pump in the electro-hydraulic system of a mobile working machine is carried out. A real-time simulator using multi-body-dynamics based software with hardware-in-loop (HIL) setup was used for the tests. Recommendations for further development of a haptic controller and emulator electric motor are given.

Design Space Exploration for MPSoC Architectures

Multiprocessor system-on-chip (MPSoC) designs utilize the available technology and communication architectures to meet the requirements of the upcoming applications. In MPSoC, the communication platform is both the key enabler, as well as the key differentiator for realizing efficient MPSoCs. It provides product differentiation to meet a diverse, multi-dimensional set of design constraints, including performance, power, energy, reconfigurability, scalability, cost, reliability and time-to-market. The communication resources of a single interconnection platform cannot be fully utilized by all kind of applications, such as the availability of higher communication bandwidth for computation but not data intensive applications is often unfeasible in the practical implementation. This thesis aims to perform the architecture-level design space exploration towards efficient and scalable resource utilization for MPSoC communication architecture. In order to meet the performance requirements within the design constraints, careful selection of MPSoC communication platform, resource aware partitioning and mapping of the application play important role. To enhance the utilization of communication resources, variety of techniques such as resource sharing, multicast to avoid re-transmission of identical data, and adaptive routing can be used. For implementation, these techniques should be customized according to the platform architecture. To address the resource utilization of MPSoC communication platforms, variety of architectures with different design parameters and performance levels, namely Segmented bus (SegBus), Network-on-Chip (NoC) and Three-Dimensional NoC (3D-NoC), are selected. Average packet latency and power consumption are the evaluation parameters for the proposed techniques. In conventional computing architectures, fault on a component makes the connected fault-free components inoperative. Resource sharing approach can utilize the fault-free components to retain the system performance by reducing the impact of faults. Design space exploration also guides to narrow down the selection of MPSoC architecture, which can meet the performance requirements with design constraints.

Kattilan ja kanaviston eristykset 3D-laitossuunnitteluohjelmassa

Työn tavoitteena oli kehittää kanavistojen ja kattilan eristyksien mallintamista 3D-laitossuunitteluohjelmassa sekä siitä saatavia materiaalilistoja. Kanavistojen eristeitä kuvastavaa geometriaa muokattiin vastaamaan eristyksen todellista tilanvarausta. Kattilan eristyksen mallintaminen on aikaisemmin jouduttu tekemään manuaalisesti, työssä kehitettiin työkalu, jonka avulla eristysten materiaalitiedot ja oikeat tilanvaraukset saadaan lisättyä 3D-malliin. Kaikkia eristyksen mallintamista ei kuitenkaan pystytä mielekkäästi toteuttamaan automaattisesti työkalujen avulla, näitä kohteita ovat tukikehikkorakenteet kuten kattilan vinttikehikko. Lisäksi täytyi selvittää, mitä tietoja eristyksien materiaalimäärälistoille vaaditaan, ja kuinka nämä tiedot saataisiin listoihin mukaan. Jotta kaikki eristettävät kohteet saadaan tuotettaviin materiaalilistoihin, on ohjelmaan lisättävä käytettäväksi uusia komponentteja. Näitä ovat uudet kanavistojen osat sekä muun muassa venturit ja huoltoluukut kanavistoille. Kattilaan asennettavat laitteet kuten näkölasit ja polttimet vaativat tukirakenteen, joka samalla toimii kotelona putkistojen taivutuksille. Näitä kohteita on aikaisemmin tuotu vanhoista projekteista tai ne on tehty suunnittelijan toimesta uusiksi. Työssä esitettiin uusi tapa mallintaa kattilan pinnat, jolloin niihin voidaan liittää koteloita erillisestä komponenttikirjastosta. Kanavistojen eristyksien materiaalimäärälistojen tuottaminen suoraan ohjelmasta auto-matisoitiin. Kattilan ja siihen liittyvien eristyskehysrakenteiden listojen tuotanto kuitenkin vaatii yhteisten toimintamallien kehittämistä. Tämän työn uudet menetelmät mahdollistavat yhä uusien työkalujen kehittämisen, esimerkiksi automaattisen eristysten teknisten piirustusten kuvatuotannon tulevaisuudessa.

3D-tulostustekniikan hyödyntäminen diagnostisten pikatestien tuotekehityksessä

Pikamallinnustekniikat ovat kehittyneet viime vuosina nopeasti. Tämä antaa jo lähes rajat-tomat mahdollisuudet tuottaa 3D-tulostamalla erilaisia tuotteita. 3D-tulostuksen hyödyntä-minen on yleistynyt erityisesti teollisuuden ja teknologian aloilla. Tässä työssä tutkittiin miten 3D-tulostamista voidaan hyödyntää diagnostisten pikatestien tuotekehityksessä. Immunologinen lateral flow-testi on vasta-aineisiin perustuva, nopea ja helppokäyttöinen mittausmenetelmä pienten ainemäärien havaitsemiseen. Tässä työssä kehitettiin lateral flow-testikotelo, jonka suunnitteluun ja rakenteen mallintamiseen käytettiin 3D-tulostustekniikkaa. Testikotelon toimivuus lateral flow- testissä varmistettiin kehittämällä testikoteloon sopiva pikatesti, jonka suorituskykyä analysoitiin sekä visuaalisesti että Actim 1ngeni-lukulaitteella. Työ aloitettiin tutkimalla eri pikavalmistustekniikoita, joista testikotelon tulostamiseen valittiin SLA-tekniikka sen tulostustarkkuuden ja tuotteen pinnan laadun perusteella. Testikotelon suunnittelu aloitettiin määrittämällä millaisia ominaisuuksia testikotelolta haluttiin. Näitä ominaisuuksia olivat lateral flow-testin suojaaminen sekä testissä kulkevan näytteen virtauksen varmistamien. Lateral flow- testin kehityksessä hyödynnettiin osin aiemmin kehitetystä pikatestistä saatuja tietoja. Lateral flow- kasettitestin valmistusprosessi koostui seitsemästä eri prosessivaiheesta jotka olivat: Vasta-aineen/kontrollireagenssin konjugointi, näytetyynyn käsittely, konjugointityynyn käsittely, konjugointityynylle annostelu, membraanille annostelu, tikkujen laminointi ja leikkaus sekä kasettitestin kokoonpano. Kehitetyn lateral flow- kasettitestin toimivuus varmistettiin tutkimalla testin reaktiokinetiikkaa ja analyyttistä herkkyyttä sekä visuaalisesti että lukulaitteen avulla. Tutkimustulosten perusteella 3D-tulostus on erittäin hyödyllinen menetelmä pikatestien tuotekehityksessä suunniteltaessa testikotelorakenteita, näytteen annosteluvälineitä ja näiden yhdistelmiä.

3D-tulostettu tuuliturbiinin vaihteen pienoismalli

Työn aiheena on vaihteen pienoismallin suunnittelu ja toteutus 3d-tulostusta hyväksi käyttäen. Pienoismalli tehdään Moventas Gears Oy:n suunnittelemasta tuuliturbiinin vaihteesta. Vaihteen pienentämisestä johtuen malliin on suunniteltava uudet laakeripesät ja hammaspyörät. 3D-tulostuksen ja pienoismallin pienen koon ansiosta vaihdetta voidaan yksinkertaistaa suuresti ja näin vähentää tulostettavien osien määrää. Lisäksi työssä selvitetään, mitä ongelmia 3D-tulostus tuo valmistukseen ja suunnitteluun. Työn kirjallisessa osassa selvennetään planeettavaihteen toimintaa yleisesti sekä esitellään Exceed Series 3+ vaihdetta. Lisäksi kerrotaan 3D-tulostuksesta, sen periaatteesta, erilaisista tulostusmenetelmistä, tulostinlaitteesta ja mahdollisista ongelmista tulostuksessa. Kokeellinen osa koostuu pienoismallin suunnittelusta ja valmistuksesta. Valmistuksessa olleiden virheiden takia muutama osa jouduttiin tulostamaan uudelleen. Muutamia osia jouduttiin myös hieman jälkikäsittelemään tulostuksen jälkeen, jotta malli saatiin kasattua. Ongelmakohdaksi muodostui tulostimen ohjelmisto ja tulostustiedostot. Tulostusprosessi sujui kuitenkin hyvin. Lopputuloksena saatiin toimiva pienoismalli. 3D-tulostus toimii hyvin monimutkaisten kappaleiden tulostuksessa. Tulostuksen hinta nousi kuitenkin varsin korkeaksi. Tulostuslaitteistosta riippuen tulostuksen voisi mahdollisesti suorittaa myös halvemmallakin.

Näkökulmia 3D-tulostuksen opetukseen ja koulutukseen

Additive manufacturing, or 3D printing, is globally one of most interesting area in developing of manufacturing technologies. This technology is suitable for fabrication off industrial products and it interests actors in fields of computer sciences, economics, medical sciences and design&arts. Additive manufacturing is often referred as third industrial revolution: first revolution was invention of steam engines in 18th century and second was industrial revolution started by Henry Ford in 1920s. Companies should be able to test suitability of their products for additive manufacturing and 3D printing but also how much better products could be when products are totally re-designed so that all potential of this new technology can be utilized. This is where education has its importance; new generations who enter working life should be educated to know of additive manufacturing and 3D printing, its advantages but also of it limits. There has to be also possibility to educate industry and people already working there, so that industrial implementation could be done successfully. This is especially very valid for Finland. Education is strongly needed so that Finnish industry can maintain its competence in global markets. Role of education is extremely important when a new technology is industrially implemented. Additive manufacturing and 3D printing offers freedom to design new products, production and generally ways of doing things. Development, planning and execution of education for additive manufacturing and 3D printing is challenging as this area develops very fast. New innovations are coming almost every month. Planning of education for additive manufacturing and 3D printing requires collection pieces of data from various of sources. Additive manufacturing and 3D printing industry and its development has to be followed frequently, and material for additive manufacturing and 3D printing has to be renewed frequently.