Investigation on laser shock peening capability by FE simulation

Laser shock peening is a technique similar to shot peening that imparts compressive residual stresses in materials for improving fatigue resistance. The ability to use a high energy laser pulse to generate shock waves, inducing a compressive residual stress field in metallic materials, has applications in multiple fields such as turbo-machinery, airframe structures, and medical appliances. The transient nature of the LSP phenomenon and the high rate of the laser's dynamic make real time in-situ measurement of laser/material interaction very challenging. For this reason and for the high cost of the experimental tests, reliable analytical methods for predicting detailed effects of LSP are needed to understand the potential of the process. Aim of this work has been the prediction of residual stress field after Laser Peening process by means of Finite Element Modeling. The work has been carried out in the Stress Methods department of Airbus Operations GmbH (Hamburg) and it includes investigation on compressive residual stresses induced by Laser Shock Peening, study on mesh sensitivity, optimization and tuning of the model by using physical and numerical parameters, validation of the model by comparing it with experimental results. The model has been realized with Abaqus/Explicit commercial software starting from considerations done on previous works. FE analyses are “Mesh Sensitive”: by increasing the number of elements and by decreasing their size, the software is able to probe even the details of the real phenomenon. However, these details, could be only an amplification of real phenomenon. For this reason it was necessary to optimize the mesh elements' size and number. A new model has been created with a more fine mesh in the trough thickness direction because it is the most involved in the process deformations. This increment of the global number of elements has been paid with an "in plane" size reduction of the elements far from the peened area in order to avoid too high computational costs. Efficiency and stability of the analyses has been improved by using bulk viscosity coefficients, a merely numerical parameter available in Abaqus/Explicit. A plastic rate sensitivity study has been also carried out and a new set of Johnson Cook's model coefficient has been chosen. These investigations led to a more controllable and reliable model, valid even for more complex geometries. Moreover the study about the material properties highlighted a gap of the model about the simulation of the surface conditions. Modeling of the ablative layer employed during the real process has been used to fill this gap. In the real process ablative layer is a super thin sheet of pure aluminum stuck on the masterpiece. In the simulation it has been simply reproduced as a 100µm layer made by a material with a yield point of 10MPa. All those new settings has been applied to a set of analyses made with different geometry models to verify the robustness of the model. The calibration of the model with the experimental results was based on stress and displacement measurements carried out on the surface and in depth as well. The good correlation between the simulation and experimental tests results proved this model to be reliable.

Stability analysis of linear thin shells

Shell structure is widely used in engineering area. The purpose of this dissertation is to show the behavior of a thin shell under external load, especially for long cylindrical shell under compressive load, I analyzed not only for linear elastic problem and also for buckling problem, and by using finite element analysis it shows that the imperfection of a cylinder could affect the critical load which means the buckling capability of this cylinder. For linear elastic problem, I compared the theoretical results with the results got from Straus7 and Abaqus, and the results are really close. For the buckling problem I did the same: compared the theoretical and Abaqus results, the error is less than 1%, but in reality, it’s not possible to reach the theoretical buckling capability due to the imperfection of the cylinder, so I put different imperfection for the cylinder in Abaqus, and found out that with the increasing of the percentage of imperfection, the buckling capability decreases, for example 10% imperfection could decrease 40% of the buckling capability, and the outcome meet the buckling behavior in reality.

Structural verification of the ESEO spacecraft: from launch loads analysis to composite panels verification

The present thesis work was performed in the frame of ESEO (European Student Earth Orbiter) project. The activities that are described in this document were carried out in the Microsatellites and Space Micro systems Lab led by Professor Paolo Tortora and in ALMASpace company facilities. The thesis deals with ESEO structural analysis, at system and unit level, and verification: after determining the design limit loads to be applied to the spacecraft as an envelope of different launchers load profiles, a finite element structural analysis was performed on the model of the satellite in order to ensure the capability to withstand the loads encountered during the launch; all the analyses were performed according to ESA standards and using the software MSC NASTRAN SIMXPERT. Amplification factors were derived and used to determine loads to be considered at unit level. In particular structural analyses were carried out on the GPS unit, the payload developed for ESEO by students of University of Bologna and results were used in the preparation of GPS payload design definition file. As for the verification phase a study on the panels and inserts to be used in the spacecraft was performed: different designs were created exploiting methods to optimize weight and mechanical behavior. The configurations have been analyzed and results compared to select the final design.

Dynamic mechanical-thermal, microstructural and mechanical analysis of ultra-light polymer-metal composites: influence of forming

A really particular and innovative metal-polymer sandwich material is Hybrix. Hybrix is a product developed and manufactured by Lamera AB, Gothenburg, Sweden. This innovative hybrid material is composed by two relatively thin metal layers if compared to the core thickness. The most used metals are aluminum and stainless steel and are separated by a core of nylon fibres oriented perpendicularly to the metal plates. The core is then completed by adhesive layers applied at the PA66-metal interface that once cured maintain the nylon fibres in position. This special material is very light and formable. Moreover Hybrix, depending on the specific metal which is used, can achieve a good corrosion resistance and it can be cut and punched easily. Hybrix architecture itself provides extremely good bending stiffness, damping properties, insulation capability, etc., which again, of course, change in magnitude depending in the metal alloy which is used, its thickness and core thickness. For these reasons nowadays it shows potential for all the applications which have the above mentioned characteristic as a requirement. Finally Hybrix can be processed with tools used in regular metal sheet industry and can be handled as solid metal sheets. In this master thesis project, pre-formed parts of Hybrix were studied and characterized. Previous work on Hybrix was focused on analyze its market potential and different adhesive to be used in the core. All the tests were carried out on flat unformed specimens. However, in order to have a complete description of this material also the effect of the forming process must be taken into account. Thus the main activities of the present master thesis are the following: Dynamic Mechanical-Thermal Analysis (DMTA) on unformed Hybrix samples of different thickness and on pre-strained Hybrix samples, pure epoxy adhesive samples analysis and finally moisture effects evaluation on Hybrix composite structure.

Task analysis for HMI design. Level of automation study of aircraft navigation functions

Advancements in technology have enabled increasingly sophisticated automation to be introduced into the flight decks of modern aircraft. Generally, this automation was added to accomplish worthy objectives such as reducing flight crew workload, adding additional capability, or increasing fuel economy. Automation is necessary due to the fact that not all of the functions required for mission accomplishment in today’s complex aircraft are within the capabilities of the unaided human operator, who lacks the sensory capacity to detect much of the information required for flight. To a large extent, these objectives have been achieved. Nevertheless, despite all the benefits from the increasing amounts of highly reliable automation, vulnerabilities do exist in flight crew management of automation and Situation Awareness (SA). Issues associated with flight crew management of automation include: • Pilot understanding of automation’s capabilities, limitations, modes, and operating principles and techniques. • Differing pilot decisions about the appropriate automation level to use or whether to turn automation on or off when they get into unusual or emergency situations. • Human-Machine Interfaces (HMIs) are not always easy to use, and this aspect could be problematic when pilots experience high workload situations. • Complex automation interfaces, large differences in automation philosophy and implementation among different aircraft types, and inadequate training also contribute to deficiencies in flight crew understanding of automation.

Analysis and Evaluation of Tiny Machine Learning applications

The aim of TinyML is to bring the capability of Machine Learning to ultra-low-power devices, typically under a milliwatt, and with this it breaks the traditional power barrier that prevents the widely distributed machine intelligence. TinyML allows greater reactivity and privacy by conducting inference on the computer and near-sensor while avoiding the energy cost associated with wireless communication, which is far higher at this scale than that of computing. In addition, TinyML’s efficiency makes a class of smart, battery-powered, always-on applications that can revolutionize the collection and processing of data in real time. This emerging field, which is the end of a lot of innovation, is ready to speed up its growth in the coming years. In this thesis, we deploy three model on a microcontroller. For the model, datasets are retrieved from an online repository and are preprocessed as per our requirement. The model is then trained on the split of preprocessed data at its best to get the most accuracy out of it. Later the trained model is converted to C language to make it possible to deploy on the microcontroller. Finally, we take step towards incorporating the model into the microcontroller by implementing and evaluating an interface for the user to utilize the microcontroller’s sensors. In our thesis, we will have 4 chapters. The first will give us an introduction of TinyML. The second chapter will help setup the TinyML Environment. The third chapter will be about a major use of TinyML in Wake Word Detection. The final chapter will deal with Gesture Recognition in TinyML.

Performance Analysis of Topological Quantum Error Correcting Codes

In the last few years there has been a great development of techniques like quantum computers and quantum communication systems, due to their huge potentialities and the growing number of applications. However, physical qubits experience a lot of nonidealities, like measurement errors and decoherence, that generate failures in the quantum computation. This work shows how it is possible to exploit concepts from classical information in order to realize quantum error-correcting codes, adding some redundancy qubits. In particular, the threshold theorem states that it is possible to lower the percentage of failures in the decoding at will, if the physical error rate is below a given accuracy threshold. The focus will be on codes belonging to the family of the topological codes, like toric, planar and XZZX surface codes. Firstly, they will be compared from a theoretical point of view, in order to show their advantages and disadvantages. The algorithms behind the minimum perfect matching decoder, the most popular for such codes, will be presented. The last section will be dedicated to the analysis of the performances of these topological codes with different error channel models, showing interesting results. In particular, while the error correction capability of surface codes decreases in presence of biased errors, XZZX codes own some intrinsic symmetries that allow them to improve their performances if one kind of error occurs more frequently than the others.