Modellgestützte und hierarchische Prozesskettenbetrachtung für die additive Fertigung

Additive Fertigungsverfahren eignen sich für die wirtschaftliche Herstellung von Bauteilen im Bereich kleiner bis mittlerer Stückzahlen, da keine Formen oder Spezialwerkzeuge notwendig sind. Die erzielbaren Eigenschaften sind oftmals bereits ausreichend, um einen Einsatz auch in Serienanwendungen zu ermöglichen. Verbunden mit den Vorteilen der Technologie bezüglich einer hohen Flexibilität, sowohl während der Konstruktion als auch der Fertigung, können sich durch eine konsequente Nutzung finanzielle Einsparmöglichkeiten entlang des gesamten Produktlebenszyklus ergeben. Bezüglich der Wirtschaftlichkeit der Verfahren herrscht oftmals noch Unklarheit, da geeignete Methoden fehlen, um diese zu bewerten. Bestehende Methoden und Werkzeuge zur Bewertung der Wirtschaftlichkeit konventioneller Fertigungsverfahren sind dabei für die additive Fertigung nicht direkt nutzbar. In dem Artikel wird eine Methode zur modellgestützten Abbildung einer gesamten additiven Fertigungskette vorgestellt, welche auch die Wechselwirkungen zwischen den einzelnen Prozesskettengliedern berücksichtigen soll. Eine konkrete Aussage bezüglich der Wirtschaftlichkeit der additiven Fertigung soll somit ermöglicht werden.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Auslegung, Konstruktion und Fertigung von strömungsmechanischen Funktionsprototypen mittels Rapid Manufacturing

Bei der Fertigung von Funktionsbauteilen für Strömungsversuche spielt das Design und die Komplexität der Bauteilgeometrie eine wesentliche Rolle. Ziel der interdisziplinären Zusammenarbeit der Lehrstühle Strömungsmaschinen, Rechnereinsatz in der Konstruktion und Fertigungstechnik mit dem Rapid Technology Center (RTC) an der Universität Duisburg-Essen ist es, das Potenzial der additiven Fertigungsverfahren bei der Herstellung von Funktionsprototypen für strömungsmechanische Anwendungen effektiv zu nutzen. An verschiedenen, auf dieser Kooperation beruhenden, Best Practise Beispielen wird gezeigt wie das Laser-Sintern in die Prozesskette zur Herstellung von Laufrädern u. Ä. in unterschiedlichen Größenordnungen integriert werden kann. In diesem Zusammenhang werden auch die Vorüberlegungen (z. B. durch Simulation), Wechselwirkungen und Folgeprozesse, die mit dieser Fertigungstechnologie verbunden sind, aufgezeigt.

Planning of a make-to-order production process in the printing industry

Offset printing is a common method to produce large amounts of printed matter. We consider a real-world offset printing process that is used to imprint customer-specific designs on napkin pouches. The production equipment used gives rise to various technological constraints. The planning problem consists of allocating designs to printing-plate slots such that the given customer demand for each design is fulfilled, all technological and organizational constraints are met and the total overproduction and setup costs are minimized. We formulate this planning problem as a mixed-binary linear program, and we develop a multi-pass matching-based savings heuristic. We report computational results for a set of problem instances devised from real-world data.

Three-dimensional printing for perioperative planning of complex aortic arch surgery

Purpose In this study, we show the use of three-dimensional printing models for preoperative planning of surgery for patients with complex aortic arch anomalies. Description A 70-year-old man with an extensively arteriosclerotic aneurysm reaching from the ascending aorta to the descending aorta was referred to our center for complete aortic arch replacement. We visualized and reconstructed computed tomography data of the patient and fabricated a flexible three-dimensional model of the aortic arch including the aneurysm. Evaluation This model was very helpful for the preoperative decision making and planning of the frozen elephant trunk procedure owing to the exact and lifelike illustration of the native aortic arch. Conclusions Three-dimensional models are helpful in preoperative planning and postoperative evaluation of frozen elephant trunk procedures in patients with complex aortic anatomy.

Calculation Methodology and Fabrication Procedures for Particle Accelerator Strip-Line Kickers: Application to the CTF3 Combiner Ring Extraction Kicker and TL2 Tail Clippers

A particle accelerator is any device that, using electromagnetic fields, is able to communicate energy to charged particles (typically electrons or ionized atoms), accelerating and/or energizing them up to the required level for its purpose. The applications of particle accelerators are countless, beginning in a common TV CRT, passing through medical X-ray devices, and ending in large ion colliders utilized to find the smallest details of the matter. Among the other engineering applications, the ion implantation devices to obtain better semiconductors and materials of amazing properties are included. Materials supporting irradiation for future nuclear fusion plants are also benefited from particle accelerators. There are many devices in a particle accelerator required for its correct operation. The most important are the particle sources, the guiding, focalizing and correcting magnets, the radiofrequency accelerating cavities, the fast deflection devices, the beam diagnostic mechanisms and the particle detectors. Most of the fast particle deflection devices have been built historically by using copper coils and ferrite cores which could effectuate a relatively fast magnetic deflection, but needed large voltages and currents to counteract the high coil inductance in a response in the microseconds range. Various beam stability considerations and the new range of energies and sizes of present time accelerators and their rings require new devices featuring an improved wakefield behaviour and faster response (in the nanoseconds range). This can only be achieved by an electromagnetic deflection device based on a transmission line. The electromagnetic deflection device (strip-line kicker) produces a transverse displacement on the particle beam travelling close to the speed of light, in order to extract the particles to another experiment or to inject them into a different accelerator. The deflection is carried out by the means of two short, opposite phase pulses. The diversion of the particles is exerted by the integrated Lorentz force of the electromagnetic field travelling along the kicker. This Thesis deals with a detailed calculation, manufacturing and test methodology for strip-line kicker devices. The methodology is then applied to two real cases which are fully designed, built, tested and finally installed in the CTF3 accelerator facility at CERN (Geneva). Analytical and numerical calculations, both in 2D and 3D, are detailed starting from the basic specifications in order to obtain a conceptual design. Time domain and frequency domain calculations are developed in the process using different FDM and FEM codes. The following concepts among others are analyzed: scattering parameters, resonating high order modes, the wakefields, etc. Several contributions are presented in the calculation process dealing specifically with strip-line kicker devices fed by electromagnetic pulses. Materials and components typically used for the fabrication of these devices are analyzed in the manufacturing section. Mechanical supports and connexions of electrodes are also detailed, presenting some interesting contributions on these concepts. The electromagnetic and vacuum tests are then analyzed. These tests are required to ensure that the manufactured devices fulfil the specifications. Finally, and only from the analytical point of view, the strip-line kickers are studied together with a pulsed power supply based on solid state power switches (MOSFETs). The solid state technology applied to pulsed power supplies is introduced and several circuit topologies are modelled and simulated to obtain fast and good flat-top pulses.

Efficient Model-based 3D Tracking by Using Direct Image Registration

This thesis deals with the problem of efficiently tracking 3D objects in sequences of images. We tackle the efficient 3D tracking problem by using direct image registration. This problem is posed as an iterative optimization procedure that minimizes a brightness error norm. We review the most popular iterative methods for image registration in the literature, turning our attention to those algorithms that use efficient optimization techniques. Two forms of efficient registration algorithms are investigated. The first type comprises the additive registration algorithms: these algorithms incrementally compute the motion parameters by linearly approximating the brightness error function. We centre our attention on Hager and Belhumeur’s factorization-based algorithm for image registration. We propose a fundamental requirement that factorization-based algorithms must satisfy to guarantee good convergence, and introduce a systematic procedure that automatically computes the factorization. Finally, we also bring out two warp functions to register rigid and nonrigid 3D targets that satisfy the requirement. The second type comprises the compositional registration algorithms, where the brightness function error is written by using function composition. We study the current approaches to compositional image alignment, and we emphasize the importance of the Inverse Compositional method, which is known to be the most efficient image registration algorithm. We introduce a new algorithm, the Efficient Forward Compositional image registration: this algorithm avoids the necessity of inverting the warping function, and provides a new interpretation of the working mechanisms of the inverse compositional alignment. By using this information, we propose two fundamental requirements that guarantee the convergence of compositional image registration methods. Finally, we support our claims by using extensive experimental testing with synthetic and real-world data. We propose a distinction between image registration and tracking when using efficient algorithms. We show that, depending whether the fundamental requirements are hold, some efficient algorithms are eligible for image registration but not for tracking.

X-ray microtomography analysis of the damage micromechanisms in 3D woven composites under low-velocity impact

3D woven composites reinforced with either S2 glass, carbon or a hybrid combination of both and containing either polyethylene or carbon z-yarns were tested under low-velocity impact. Different impact energies (in the range of 21–316 J) were used and the mechanical response (in terms of the impact strength and energy dissipated) was compared with that measured in high-performance, albeit standard, 2D laminates. It was found that the impact strength in both 2D and 3D materials was mainly dependent on the in-plane fiber fracture. Conversely, the energy absorption capability was primarily influenced by the presence of z-yarns, having the 3D composites dissipated over twice the energy than the 2D laminates, irrespective of their individual characteristics (fiber type, compaction degree, porosity, etc.). X-ray microtomography revealed that this improvement was due to the z-yarns, which delayed delamination and maintained the structural integrity of the laminate, promoting energy dissipation by tow splitting, intensive fiber breakage under the tup and formation of a plug by out-of-plane shear.

Microfabrication processes for microfluidic devices on a single laser Workstation: direct writing lithography on SU-8, laser ablation on polymers and mask manufacturing

We demonstrate the capability of a laser micromachining workstation for cost-effective manufacturing of a variety of microfluidic devices, including SU-8 microchannels on silicon wafers and 3D complex structures made on polyimide Kapton® or poly carbonate (PC). The workstation combines a KrF excimer laser at 248 nm and a Nd3+:YVO4 DPSS with a frequency tripled at 355 nm with a lens magnification 10X, both lasers working at a pulsed regime with nanoseconds (ns) pulse duration. Workstation also includes a high-resolution motorized XYZ-tilt axis (~ 1 um / axis) and a Through The Lens (TTL) imaging system for a high accurate positioning over a 120 x 120 mm working area. We have surveyed different fabrication techniques: direct writing lithography,mask manufacturing for contact lithography and polymer laser ablation for complex 3D devices, achieving width channels down to 13μ m on 50μ m SU-8 thickness using direct writing lithography, and width channels of 40 μm for polyimide on SiO2 plate. Finally, we have tested the use of some devices for capillary chips measuring the flow speed for liquids with different viscosities. As a result, we have characterized the presence of liquid in the channel by interferometric microscopy.

Construcción de una maquina de control numérico " CNC" para prototipado rápido de piezas 3D en diferentes polímeros "impresora 3D"

El objetivo principal del presente Proyecto Fin de Carrera es la construcción , montaje y calibración de una impresora 3D auto replicable modelo Prusa Mendel capaz de trabajar en coordenadas polares, lo cual abre las puertas a la investigación de calidades, tolerancias, resistencias estructurales… de estas piezas en comparación con las fabricadas por impresoras cartesianas. Encontraras una guía de montaje paso a paso, además de un listado de todos los componentes, imprimibles y no imprimibles, que componen la impresora 3D. También se analizan y comparan las opciones a la hora de introducir la electrónica necesaria, extrusor y de los posibles errores y soluciones que se pueden encontrar durante la fabricación de una de estas máquinas. Finalmente dispondrás de una guía de calibración de skeinforce 41,para poder conseguir una impresión de gran calidad. Abstract The main objective of this Thesis is the construction, installation and calibration of a self-replicating 3D printer model Prusa Mendel able to work in polar coordinates, which opens the door to research quality, tolerances, these structural resistance ... parts compared to those manufactured by Cartesian printers. In this project you will find a guide step by step assembly, and a list of all components, and 3D printer components printable and unprintable. We also analyze and compare the options when entering the necessary electronics, extruder and possible errors and solutions that may occur during manufacturing of these machines finally have an installation guide calibration skeinforge 41 to get a high quality print

Mechanical behavior and failure micromechanisms of hybrid 3D woven composites in tension

The deformation and failure micromechanisms of a hybrid 3D woven composite were studied in tension. Plain and open-hole composite coupons were tested in tension until failure in the fill and warp directions, as well as fiber tows extracted from the dry fabric and impregnated with the matrix. The macroscopic evolution of damage in the composite coupons was assessed by means of periodic unloading–reloading (to obtain the elastic modulus and the residual strain), whereas the microscopic mechanism were established by means of X-ray computed microtomography. To this end, specimens were periodically removed from the mechanical testing machine and infiltrated with ZnI-containing liquid to assess the main damage modes as a function of the applied strain. The experimental observations and the predictions of an isostrain model were used to understand the key factors controlling the elastic modulus, strength and notch sensitivity of hybrid 3D woven composites in tension. It was found that the full contribution of the glass fibers to the composite strength was not employed, due to the premature fracture of the carbon fibers, but their presence increased the fracture strain and the energy dissipated during fracture. Thus, hybridization of the 3D woven composite led to a notch-insensitive behavior as demonstrated by open-hole tests

Manufacturing DNA microarrays of high spot homogeneity and reduced background signal

Analyses on DNA microarrays depend considerably on spot quality and a low background signal of the glass support. By using betaine as an additive to a spotting solution made of saline sodium citrate, both the binding efficiency of spotted PCR products and the homogeneity of the DNA spots is improved significantly on aminated surfaces such as glass slides coated with the widely used poly-l-lysine or aminosilane. In addition, non-specific background signal is markedly diminished. Concomitantly, during the arraying procedure, the betaine reduces evaporation from the microtitre dish wells, which hold the PCR products. Subsequent blocking of the chip surface with succinic anhydride was improved considerably in the presence of the non-polar, non-aqueous solvent 1,2-dichloroethane and the acylating catalyst N-methylimidazole. This procedure prevents the overall background signal that occurs with the frequently applied aqueous solvent 1-methyl-2-pyrrolidone in borate buffer because of DNA that re-dissolves from spots during the blocking process, only to bind again across the entire glass surface.

Visual perception for the 3D recognition of geometric pieces in robotic manipulation

During grasping and intelligent robotic manipulation tasks, the camera position relative to the scene changes dramatically because the robot is moving to adapt its path and correctly grasp objects. This is because the camera is mounted at the robot effector. For this reason, in this type of environment, a visual recognition system must be implemented to recognize and “automatically and autonomously” obtain the positions of objects in the scene. Furthermore, in industrial environments, all objects that are manipulated by robots are made of the same material and cannot be differentiated by features such as texture or color. In this work, first, a study and analysis of 3D recognition descriptors has been completed for application in these environments. Second, a visual recognition system designed from specific distributed client-server architecture has been proposed to be applied in the recognition process of industrial objects without these appearance features. Our system has been implemented to overcome problems of recognition when the objects can only be recognized by geometric shape and the simplicity of shapes could create ambiguity. Finally, some real tests are performed and illustrated to verify the satisfactory performance of the proposed system.

Manufacturing developments in Argentina.

"Principal sources": p. 25-26.