A numerical methodology for the multi-objective optimization of the DI Diesel engine combustion

DI Diesel engine are widely used both for industrial and automotive applications due to their durability and fuel economy. Nonetheless, increasing environmental concerns force that type of engine to comply with increasingly demanding emission limits, so that, it has become mandatory to develop a robust design methodology of the DI Diesel combustion system focused on reduction of soot and NOx simultaneously while maintaining a reasonable fuel economy. In recent years, genetic algorithms and CFD three-dimensional combustion simulations have been successfully applied to that kind of problem. However, combining GAs optimization with actual CFD three-dimensional combustion simulations can be too onerous since a large number of calculations is usually needed for the genetic algorithm to converge, resulting in a high computational cost and, thus, limiting the suitability of this method for industrial processes. In order to make the optimization process less time-consuming, CFD simulations can be more conveniently used to generate a training set for the learning process of an artificial neural network which, once correctly trained, can be used to forecast the engine outputs as a function of the design parameters during a GA optimization performing a so-called virtual optimization. In the current work, a numerical methodology for the multi-objective virtual optimization of the combustion of an automotive DI Diesel engine, which relies on artificial neural networks and genetic algorithms, was developed.

Politiche attive del lavoro e ammortizzatori sociali in deroga: misure difensive o di promozione delle capacità?

Il tema generale del dottorato di ricerca è l'analisi delle politiche di attivazione in Italia durante la crisi economica. La combinazione di politiche attive e passive del lavoro viene interpretata ricorrendo al quadro teorico proposto da Amartya Sen e basato sul concetto di capability. Abbiamo considerato le misure nazionali e regionali nel quadro delle linee guida europee e analizzato le tendenze verso l'empowerment dei beneficiari di politiche del lavoro attraverso il concetto di capability proposto da Sen. La ricerca empirica ha utilizzato diversi strumenti per la raccolta dei dati: focus group, un questionario inviato ad un campione di 1.200 lavoratori, e interviste.

Progettualità e interventi educativi nella dislessia. Il progetto ProDSA e le prospettive future di ricerca.

Il presente lavoro è strutturato in quattro parti analizzando e comparando le pubblicazioni del settore scientifico italiano, anglofono e tedesco di riferimento. Nel primo capitolo della tesi viene proposta una riflessione sulle parole che ruotano attorno al tema dei DSA e della disabilità. Nel secondo capitolo vengono presentati, a partire dalla letteratura scientifica di riferimento, gli indicatori di rischio che segnalano possibili disturbi specifici di apprendimento e le caratteristiche di apprendimento dei DSA mettendo in luce potenzialità e talenti spesso intrinseci. Nel terzo capitolo viene vagliata la normativa di riferimento, in particolare la recente Legge 170/2010 e le relative Linee Guida. Nel quarto capitolo, partendo dal tema della diffusione delle tecnologie dell’informazione e della comunicazione (da ora in poi TIC) nel mondo della scuola, sono ampiamente trattati i principali strumenti compensativi (sintesi vocale, libri digitali, mappe concettuali, Lavagna Interattiva Multimediale) e le misure dispensative adottabili. Nel quinto capitolo viene analizzato in tutte le sue parti il Piano Didattico Personalizzato (da ora in poi PDP) e viene proposto un possibile modello di PDP pubblicato sul sito dell'Ufficio per l’Ambito Territoriale di Bologna. Nel sesto capitolo della tesi viene presentato il Progetto Regionale ProDSA. Il Progetto, rivolto a studenti, con diagnosi di DSA, delle scuole secondarie di primo grado e del primo biennio delle secondarie di secondo grado dell’Emilia-Romagna, ha visto, grazie a un finanziamento della Regione, la consegna in comodato d'uso gratuito di tecnologie compensative agli alunni che hanno aderito. La sezione empirica del presente lavoro indaga l’uso reale che è stato fatto degli strumenti proposti in comodato d’uso e le motivazioni legate alla scelta di non utilizzarli in classe. Nel settimo capitolo vengono proposti strumenti progettati per rispondere concretamente alle criticità emerse dall'analisi dei dati e per sensibilizzare il mondo della scuola sulle caratteristiche dei DSA.

Giunzione mediante laser di materiali difficili, ibridi ed a struttura cellulare

Lo studio presentato in questa sede concerne applicazioni di saldatura LASER caratterizzate da aspetti di non-convenzionalità ed è costituito da tre filoni principali. Nel primo ambito di intervento è stata valutata la possibilità di effettuare saldature per fusione, con LASER ad emissione continua, su pannelli Aluminum Foam Sandwich e su tubi riempiti in schiuma di alluminio. Lo studio ha messo in evidenza numerose linee operative riguardanti le problematiche relative alla saldatura delle pelli esterne dei componenti ed ha dimostrato la fattibilità relativa ad un approccio di giunzione LASER integrato (saldatura seguita da un post trattamento termico) per la realizzazione della giunzione completa di particolari tubolari riempiti in schiuma con ripristino della struttura cellulare all’interfaccia di giunzione. Il secondo ambito di intervento è caratterizzato dall’applicazione di una sorgente LASER di bassissima potenza, operante in regime ad impulsi corti, nella saldatura di acciaio ad elevato contenuto di carbonio. Lo studio ha messo in evidenza come questo tipo di sorgente, solitamente applicata per lavorazioni di ablazione e marcatura, possa essere applicata anche alla saldatura di spessori sub-millimetrici. In questa fase è stato messo in evidenza il ruolo dei parametri di lavoro sulla conformazione del giunto ed è stata definita l’area di fattibilità del processo. Lo studio è stato completato investigando la possibilità di applicare un trattamento LASER dopo saldatura per addolcire le eventuali zone indurite. In merito all’ultimo ambito di intervento l’attività di studio si è focalizzata sull’utilizzo di sorgenti ad elevata densità di potenza (60 MW/cm^2) nella saldatura a profonda penetrazione di acciai da costruzione. L’attività sperimentale e di analisi dei risultati è stata condotta mediante tecniche di Design of Experiment per la valutazione del ruolo preciso di tutti i parametri di processo e numerose considerazioni relative alla formazione di cricche a caldo sono state suggerite.

Studio e ottimizzazione del processo di fabbricazione additiva (SLM) per applicazioni in ambito biomedicale: produzione di protesi e strutture reticolari

Il progetto di dottorato che verrà presentato in questa tesi è focalizzato sullo sviluppo di un metodo sperimentale per la produzione di protesi personalizzate utilizzando il processo di fabbricazione additiva di Selective Laser Melting (SLM). L’obiettivo è quello di definire una condizione di processo ottimizzata per applicazioni in ambito chirurgico che possa essere generalizzabile, ovvero che ne garantisca la riproducibilità al variare dell’anatomia del paziente e che rappresenti la base per estendere il metodo ad altre componenti protesiche. Il lavoro si è sviluppato lungo due linee principali, la cui convergenza ha permesso di realizzare prototipi di protesi complete utilizzando un solo processo: da una parte la produzione di componenti a massima densità per il raggiungimento di elevate resistenze meccaniche, buona resistenza ad usura e corrosione e controllo di tensioni residue e deformazione delle parti stampate. Dall’altra si sono studiate strutture reticolari a geometria e porosità controllata per favorire l’osteointegrazione della componente protesica post impianto. In questo studio sono stati messe a confronto le possibili combinazioni tra parametri di processo e sono state individuate le correlazioni con le proprietà finali dei componenti stampati. Partendo da queste relazioni si sono sviluppate le strategie tecnologiche per la progettazione e la produzione dei componenti. I test sperimentali svolti e i risultati ottenuti hanno dimostrato la fattibilità dell’utilizzo del processo SLM per la produzione di protesi personalizzate e sono stati fabbricati i primi prototipi funzionali. La fabbricazione di protesi personalizzate richiede, però, anche la progettazione e la produzione di strumentario chirurgico ad hoc. Per questo motivo, parallelamente allo studio della lega di Cromo Cobalto, sono stati eseguiti i test anche su campioni in INOX 316L. Anche in questo caso è stato possibile individuare una finestra operativa di processo che garantisse proprietà meccaniche comparabili, e in alcuni casi superiori, a quelle ottenute con processi convenzionali.

Design, development, and analysis of hybrid metal-composite tube for industrial application

In the aerospace, automotive, printing, and sports industries, the development of hybrid Carbon Fiber Reinforced Polymer (CFRP)-metal components is becoming increasingly important. The coupling of metal with CFRP in axial symmetric components results in reduced production costs and increased mechanical properties such as bending, torsional stiffness, mass reduction, damping, and critical speed compared to the single material-built ones. In this thesis, thanks to a novel methodology involving a rubbery/viscoelastic interface layer, several hybrid aluminum-CFRP prototype tubes were produced. Besides, an innovative system for the cure of the CFRP part has been studied, analyzed, tested, and developed in the company that financed these research activities (Reglass SRL, Minerbio BO, Italy). The residual thermal stresses and strains have been investigated with numerical models based on the Finite Element Method (FEM) and compared with experimental tests. Thanks to numerical models, it was also possible to reduce residual thermal stresses by optimizing the lamination sequence of CFRP and determining the influence of the system parameters. A novel software and methodology for evaluating mechanical and damping properties of specimens and tubes made in CFRP were also developed. Moreover, to increase the component's damping properties, rubber nanofibers have been produced and interposed throughout the lamination of specimens. The promising results indicated that the nanofibrous mat could improve the material damping factor over 77% and be adopted in CFRP components with a negligible increment of weight or losing mechanical properties.

Automotive Antennas for V2X Communications

The main topic of this thesis is about the design and prototyping of automotive antennas that allows Vehicle to Everything (V2X) communications, that is the communication between the vehicle and all what else is relevant. In particular 5G will be an enabling technology for these communications. Vehicular connectivity is a mandatory feature in nowadays car. Typical applications are that one related to the infotainment, i.e. radio or mobile telephone, or security ones, i.e. radars. The antennas that support this type of communications can be divided in two frequency range: the sub-6GHz range and the millimeter wave (mmW) range. Also the 5G standard can be divided in this two frequency ranges. In this work different automotive antennas solutions are presented for both the frequency bands. For the sub-6GHz range two different antennas are presented: a tin sheet 5G-sub6 radiating element and a complete 5G-GNSS-V2X shark fin module. For the mmW frequency band, an automotive PCB planar solution is presented. Since these frequencies are a novelty for the automotive market, satellite communications (SatCom) field has been considered. In SatCom applications mmW solutions are a well-established technology. Thus, also mmW antennas solutions for SatCom applications are here presented.

Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Joints and innovative components for automotive applications

The research activities described in this thesis were focused on two main topics: the study of shaft-hub joint performance, with particular regard to interference-fitted and adhesively bonded connection, and the fatigue characterization of additively processed metal alloys. The research on interference-fitted shaft-hub joints dealt with some studies in the field of fretting fatigue. Rotating bending fatigue tests were performed on different materials by not conventional specimens to determine the fatigue properties of interference-fitted joints and to investigate the fretting fatigue phenomenon, which led to novel and original results. In adhesively bonded and interference-fitted shaft-hub connections (called hybrid joints) the synergic effect of anaerobic adhesive and interference has the capability of improving the joint strength. However, the adhesive contribution depends on several factors. Therefore, its behavior was investigated for different coupling pressure, coupling procedure, operating temperature and joint design. The study on additively manufactured metal alloy deals with rotating banding fatigue tests. AlSi10Mg and Maraging Stainless Steel CX were involved in the campaign for their wide applicability in Automotive. Build direction, heat and surface treatments were considered as input parameters. Fatigue results were interpreted by statistical method and microscopy analyses in order to determine the effectiveness and the beneficial or detrimental effects of the considered factors. Fracture mode and microstructure were investigated by fractographic and micrographic analyses

Processi e pratiche di Innovazione Responsabile: il ruolo dell' Advanced Design nella trasformazione collaborativa dei territori

La ricerca indaga il rapporto tra Design e Innovazione Responsabile calandolo all’interno della relazione tra territorio e pratiche collaborative guidate dal design, ma anche legate al patrimonio culturale immateriale e a un sistema di conoscenza a quintupla elica. La necessità emergente di cura del futuro porta a rivedere il contesto del territorio come campo strumentale per la trasformazione degli individui e della comunità e a domandarsi in che modo il design possa supportare questo cambiamento, abilitando la produzione di conoscenza collaborativa. La ricerca parte dal dimostrare come il modello di innovazione recentemente proposto dalla Comunità Europea attraverso il concetto di Responsible Research Innovation (RRI), poi ripreso nella nozione di Responsible Innovation (RI), sia un campo aperto e responsivo: se integrato con altre discipline, in particolare con il design, può supportare lo sviluppo di processi, politiche, prodotti, servizi e comportamenti che rispettino la relazione tra società, ambiente, identità individuale e collettiva e i ritmi ad essi connessi. Partendo dal contesto sopra descritto, ci si chiede come il design e il designer possano integrare le dimensioni RI nei processi di progettazione, per innovare in modo collaborativo i territori. Si individua quindi nell’Advanced Design la metodologia che, grazie alla sua natura anticipatrice, collaborativa, trasformativa, riesce a coniugarsi virtuosamente con l’approccio RI e supportare il cambiamento in atto. L’intersezione di questi elementi porta alla creazione del Modello Advanced Design per/con l’Innovazione Responsabile (ADIR): un sistema multidimensionale per gruppi di innovazione (quintupla elica) che hanno l’obiettivo di rigenerare in modo collaborativo e inclusivo i territori. L’esperienza sul campo ha confermato come la struttura del modello, formata da un corpus di semi-lavorati, permetta di creare un proprio ritmo, una compenetrazione tra azioni e forme progettuali volti a mantenere il senso di comunità e il coinvolgimento degli attori, a creare relazioni, a sviluppare una trasformazione continua.

Development of a Computer-Based methodology for tolerance selection and optimization applied to the automotive sector

The design optimization of industrial products has always been an essential activity to improve product quality while reducing time-to-market and production costs. Although cost management is very complex and comprises all phases of the product life cycle, the control of geometrical and dimensional variations, known as Dimensional Management (DM), allows compliance with product and process requirements. Hence, the tolerance-cost optimization becomes the main practice to provide an effective application of Design for Tolerancing (DfT) and Design to Cost (DtC) approaches by enabling a connection between product tolerances and associated manufacturing costs. However, despite the growing interest in this topic, a profitable application in the industry of these techniques is hampered by their complexity: the definition of a systematic framework is the key element to improving design optimization, enhancing the concurrent use of Computer-Aided tools and Model-Based Definition (MBD) practices. The present doctorate research aims to define and develop an integrated methodology for product/process design optimization, to better exploit the new capabilities of advanced simulations and tools. By implementing predictive models and multi-disciplinary optimization, a Computer-Aided Integrated framework for tolerance-cost optimization has been proposed to allow the integration of DfT and DtC approaches and their direct application for the design of automotive components. Several case studies have been considered, with the final application of the integrated framework on a high-performance V12 engine assembly, to achieve both functional targets and cost reduction. From a scientific point of view, the proposed methodology provides an improvement for the tolerance-cost optimization of industrial components. The integration of theoretical approaches and Computer-Aided tools allows to analyse the influence of tolerances on both product performance and manufacturing costs. The case studies proved the suitability of the methodology for its application in the industrial field, providing the identification of further areas for improvement and refinement.

Design and testing of innovative, artificial intelligence-based techniques to model and control the combustion process and to reduce the Co2 emissions in modern, high-performance, gasoline direct injection engines

This work deals with the development of calibration procedures and control systems to improve the performance and efficiency of modern spark ignition turbocharged engines. The algorithms developed are used to optimize and manage the spark advance and the air-to-fuel ratio to control the knock and the exhaust gas temperature at the turbine inlet. The described work falls within the activity that the research group started in the previous years with the industrial partner Ferrari S.p.a. . The first chapter deals with the development of a control-oriented engine simulator based on a neural network approach, with which the main combustion indexes can be simulated. The second chapter deals with the development of a procedure to calibrate offline the spark advance and the air-to-fuel ratio to run the engine under knock-limited conditions and with the maximum admissible exhaust gas temperature at the turbine inlet. This procedure is then converted into a model-based control system and validated with a Software in the Loop approach using the engine simulator developed in the first chapter. Finally, it is implemented in a rapid control prototyping hardware to manage the combustion in steady-state and transient operating conditions at the test bench. The third chapter deals with the study of an innovative and cheap sensor for the in-cylinder pressure measurement, which is a piezoelectric washer that can be installed between the spark plug and the engine head. The signal generated by this kind of sensor is studied, developing a specific algorithm to adjust the value of the knock index in real-time. Finally, with the engine simulator developed in the first chapter, it is demonstrated that the innovative sensor can be coupled with the control system described in the second chapter and that the performance obtained could be the same reachable with the standard in-cylinder pressure sensors.

Design and characterization of automated agricultural vehicle systems

Nowadays, technological advancements have brought industry and research towards the automation of various processes. Automation brings a reduction in costs and an improvement in product quality. For this reason, companies are pushing research to investigate new technologies. The agriculture industry has always looked towards automating various processes, from product processing to storage. In the last years, the automation of harvest and cultivation phases also has become attractive, pushed by the advancement of autonomous driving. Nevertheless, ADAS systems are not enough. Merging different technologies will be the solution to obtain total automation of agriculture processes. For example, sensors that estimate products' physical and chemical properties can be used to evaluate the maturation level of fruit. Therefore, the fusion of these technologies has a key role in industrial process automation. In this dissertation, ADAS systems and sensors for precision agriculture will be both treated. Several measurement procedures for characterizing commercial 3D LiDARs will be proposed and tested to cope with the growing need for comparison tools. Axial errors and transversal errors have been investigated. Moreover, a measurement method and setup for evaluating the fog effect on 3D LiDARs will be proposed. Each presented measurement procedure has been tested. The obtained results highlight the versatility and the goodness of the proposed approaches. Regarding the precision agriculture sensors, a measurement approach for the Moisture Content and density estimation of crop directly on the field is presented. The approach regards the employment of a Near Infrared spectrometer jointly with Partial Least Square statistical analysis. The approach and the model will be described together with a first laboratory prototype used to evaluate the NIRS approach. Finally, a prototype for on the field analysis is realized and tested. The test results are promising, evidencing that the proposed approach is suitable for Moisture Content and density estimation.

Power converters in WBG device technology for automotive applications and characterization setups for GaN power transistors

This PhD dissertation envisages the design of innovative power converters exploiting WBG devices to get state-of-the-art performance in products intended for industrial applications of automotive field. The collaborations with different specialized companies, provided the opportunity to access commercially-available state-of-the-art SiC and GaN technologies and the possibility to realize innovative converter prototypes. Concerning SiC technology, the complete design of a $350kW$ Battery Emulator instrument in collaboration with a company leader in the automotive testing sector, was carried out from scratch exploiting state-of-the-art SiC power-modules, planar magnetics and top-notch MCU technologies. Discrete high-voltage GaN switches were exploited in the Power Supplies design for automotive charger application to target improved performances compared to the market state-of-the-art. Specifically, two high-efficiency prototypes, an AC/DC converter and a DC/DC converter of $7.5kW$, have been realized for this purpose. To further investigate the characteristics of state-of-the-art GaN power devices two measurement set-ups have been designed. In particular, the trapping phenomenon causing the collapse of drain current during ON-state with a consequent degradation of ON-resistance has been analyzed.

Hardware-software design of embedded systems for intelligent sensing applications

This Thesis wants to highlight the importance of ad-hoc designed and developed embedded systems in the implementation of intelligent sensor networks. As evidence four areas of application are presented: Precision Agriculture, Bioengineering, Automotive and Structural Health Monitoring. For each field is reported one, or more, smart device design and developing, in addition to on-board elaborations, experimental validation and in field tests. In particular, it is presented the design and development of a fruit meter. In the bioengineering field, three different projects are reported, detailing the architectures implemented and the validation tests conducted. Two prototype realizations of an inner temperature measurement system in electric motors for an automotive application are then discussed. Lastly, the HW/SW design of a Smart Sensor Network is analyzed: the network features on-board data management and processing, integration in an IoT toolchain, Wireless Sensor Network developments and an AI framework for vibration-based structural assessment.