Sviluppo di sperimentazioni per la produzione di getti in lega di alluminio a caratteristiche difettologiche e microstrutturali controllate, per la validazione di modelli di previsione delle porosità

Nei processi di progettazione e produzione tramite tecnologie di colata di componenti in alluminio ad elevate prestazioni, risulta fondamentale poter prevedere la presenza e la quantità di difetti correlabili a design non corretti e a determinate condizioni di processo. Fra le difettologie più comuni di un getto in alluminio, le porosità con dimensioni di decine o centinaia di m, note come microporosità, hanno un impatto estremamente negativo sulle caratteristiche meccaniche, sia statiche che a fatica. In questo lavoro, dopo un’adeguata analisi bibliografica, sono state progettate e messe a punto attrezzature e procedure sperimentali che permettessero la produzione di materiale a difettologia e microstruttura differenziata, a partire da condizioni di processo note ed accuratamente misurabili, che riproducessero la variabilità delle stesse nell’ambito della reale produzione di componenti fusi. Tutte le attività di progettazione delle sperimentazioni, sono state coadiuvate dall’ausilio di software di simulazione del processo fusorio che hanno a loro volta beneficiato di tarature e validazioni sperimentali ad hoc. L’apparato sperimentale ha dimostrato la propria efficacia nella produzione di materiale a microstruttura e difettologia differenziata, in maniera robusta e ripetibile. Utilizzando i risultati sperimentali ottenuti, si è svolta la validazione di un modello numerico di previsione delle porosità da ritiro e gas, ritenuto ad oggi allo stato dell’arte e già implementato in alcuni codici commerciali di simulazione del processo fusorio. I risultati numerici e sperimentali, una volta comparati, hanno evidenziato una buona accuratezza del modello numerico nella previsione delle difettologie sia in termini di ordini di grandezza che di gradienti della porosità nei getti realizzati.

Design and development of the new composite-material mainplane of the Dallara T12 race car

Abstract (US) Composite material components design and production techniques are discussed in the present graduation paper. In particular, this paper covers the design process and the production process of a carbon-fiber composite material component for a high performance car, more specifically, the Dallara T12 race car. This graduation paper is split in two. After a brief introduction on existing composite materials (their origins and applications), the first part of the present paper covers the main theoretical concepts behind the design of composite material components: particular focus will be given to carbon-fiber composites. The second part of the present paper covers the whole design and production process that the candidate carried out to create the new front mainplane of the Dallara T12 race car. This graduation paper is the result of a six-months-long internship that the candidate conducted as Design Office Trainee inside Dallara Automobili S.p.A. Abstract (ITA) La presente tesi di laurea discute le metodologie progettuali e produttive legate alla realizzazione di un componente in materiale composito. Nello specifico, viene discussa la progettazione e la produzione di un componente in fibra di carbonio destinato ad una vettura da competizione. La vettura in esame è la Dallara T12. Il lavoro è diviso in due parti. Nella prima parte, dopo una breve introduzione sull’origine e le tipologie di materiali compositi esistenti, vengono trattati i concetti teorici fondamentali su cui si basa la progettazione di generici componenti in materiale composito, con particolare riguardo ai materiali in fibra di carbonio. Nella seconda parte viene discusso tutto il processo produttivo che il candidato ha portato a termine per realizzare il nuovo alettone anteriore della Dallara T12. La presente tesi di laurea è il risultato del lavoro di progettazione che il candidato ha svolto presso l’Ufficio Tecnico di Dallara Automobili S.p.A. nel corso di un tirocinio formativo di sei mesi.

Contributo sperimentale alla ridefinizione della diffusione in parete della camera di prova della galleria del vento Dallara

Joseph Nicolas Cugnot built the first primitive car in 1769 and approximately one hundred year later the first automotive race took place. Thanks to this, for the first time the aerodynamics principles began to be applied to cars. The aerodynamic study of a car is important to improve the performance on the road, or on the track. It purposely enhances the stability in the turns and increases the maximum velocity. However, it is also useful, decrease the fuel consumption, in order to reduce the pollution. Given that cars are a very complex body, the aerodynamic study cannot be conducted following an analytical method, but it is possible, in general, to choose between two different approaches: the numerical or the experimental one. The results of numerical studies depend on the computers’ potential and on the method use to implement the mathematical model. Today, the best way to perform an aerodynamic study is still experimental, which means that in the first phase of the design process the study is performed in a wind tunnel and in later phases directly on track. The automotive wind tunnels are singular mainly due to the test chamber, which typically contains a ground simulation system. The test chamber can have different types of walls: open walls, closed walls, adaptive walls or slotted walls. The best solution is to use the slotted walls because they minimize the interference between the walls and the streamlines, the interaction between the flow and the environment, and also to contain the overall costs. Furthermore, is necessary minimize the boundary layer at the walls, without accelerating the flow, in order to provide the maximum section of homogeneous flow. This thesis aims at redefining the divergent angle of the Dallara Automobili S.P.A. wind tunnel’s walls, in order to improve the overall homogeneity. To perform this study it was necessary to acquire the pressure data of the boundary layer, than it was created the profile of the boundary layer velocity and, to minimize the experimental errors, it was calculated the displacement thickness. The results obtained shows, even if the instrument used to the experiment was not the best one, that the boundary layer thickness could be minor in case of a low diffusion angle. So it is convenient to perform another experiment with a most sensitive instrument to verified what is the better wall configuration.

Design and Control of Robotic Hands

The application of dexterous robotic hands out of research laboratories has been limited by the intrinsic complexity that these devices present. This is directly reflected as an economically unreasonable cost and a low overall reliability. Within the research reported in this thesis it is shown how the problem of complexity in the design of robotic hands can be tackled, taking advantage of modern technologies (i.e. rapid prototyping), leading to innovative concepts for the design of the mechanical structure, the actuation and sensory systems. The solutions adopted drastically reduce the prototyping and production costs and increase the reliability, reducing the number of parts required and averaging their single reliability factors. In order to get guidelines for the design process, the problem of robotic grasp and manipulation by a dual arm/hand system has been reviewed. In this way, the requirements that should be fulfilled at hardware level to guarantee successful execution of the task has been highlighted. The contribution of this research from the manipulation planning side focuses on the redundancy resolution that arise in the execution of the task in a dexterous arm/hand system. In literature the problem of coordination of arm and hand during manipulation of an object has been widely analyzed in theory but often experimentally demonstrated in simplified robotic setup. Our aim is to cover the lack in the study of this topic and experimentally evaluate it in a complex system as a anthropomorphic arm hand system.

Design methods and geometric modelling of scaffolds for bone tissue engineering

Every year, thousand of surgical treatments are performed in order to fix up or completely substitute, where possible, organs or tissues affected by degenerative diseases. Patients with these kind of illnesses stay long times waiting for a donor that could replace, in a short time, the damaged organ or the tissue. The lack of biological alternates, related to conventional surgical treatments as autografts, allografts, e xenografts, led the researchers belonging to different areas to collaborate to find out innovative solutions. This research brought to a new discipline able to merge molecular biology, biomaterial, engineering, biomechanics and, recently, design and architecture knowledges. This discipline is named Tissue Engineering (TE) and it represents a step forward towards the substitutive or regenerative medicine. One of the major challenge of the TE is to design and develop, using a biomimetic approach, an artificial 3D anatomy scaffold, suitable for cells adhesion that are able to proliferate and differentiate themselves as consequence of the biological and biophysical stimulus offered by the specific tissue to be replaced. Nowadays, powerful instruments allow to perform analysis day by day more accurateand defined on patients that need more precise diagnosis and treatments.Starting from patient specific information provided by TC (Computed Tomography) microCT and MRI(Magnetic Resonance Imaging), an image-based approach can be performed in order to reconstruct the site to be replaced. With the aid of the recent Additive Manufacturing techniques that allow to print tridimensional objects with sub millimetric precision, it is now possible to practice an almost complete control of the parametrical characteristics of the scaffold: this is the way to achieve a correct cellular regeneration. In this work, we focalize the attention on a branch of TE known as Bone TE, whose the bone is main subject. Bone TE combines osteoconductive and morphological aspects of the scaffold, whose main properties are pore diameter, structure porosity and interconnectivity. The realization of the ideal values of these parameters represents the main goal of this work: here we'll a create simple and interactive biomimetic design process based on 3D CAD modeling and generative algorithmsthat provide a way to control the main properties and to create a structure morphologically similar to the cancellous bone. Two different typologies of scaffold will be compared: the first is based on Triply Periodic MinimalSurface (T.P.M.S.) whose basic crystalline geometries are nowadays used for Bone TE scaffolding; the second is based on using Voronoi's diagrams and they are more often used in the design of decorations and jewellery for their capacity to decompose and tasselate a volumetric space using an heterogeneous spatial distribution (often frequent in nature). In this work, we will show how to manipulate the main properties (pore diameter, structure porosity and interconnectivity) of the design TE oriented scaffolding using the implementation of generative algorithms: "bringing back the nature to the nature".

Direkte generative Fertigung von Schmiedegesenken eröffnet neue Möglichkeiten

Umformwerkzeuge sind eine neue und bislang nicht erforschte Anwendung generativ gefertigter Werkzeuge. Der Vortrag präsentiert ein Fallbeispiel, bei dem ein typisches Schmiedeteil mit recht komplexer Geometrie erfolgreich unter Verwendung eines generativ gefertigten Schmiedegesenks hergestellt werden konnte. Die Marktanforderungen zur frühestmöglichen Verfügbarkeit echter Schmiedeteile werden dargestellt. Die gesamte Prozesskette von der 3D-CAD-Werkzeugkonstruktion über die Schmiedeprozesssimulation, das Laserstrahlschmelzen der Gesenkeinsätze und die Gesenkmontage bis hin zu den eigentlichen Schmiedeversuchen unter produktionsähnlichen Bedingungen wird dargestellt und mit konventioneller Schmiedegesenkkonstruktion und ‑fertigung verglichen. Die Vorteile und Besonderheiten der generativen Prozesskette werden herausgestellt. Die gefertigten Schmiedeteile werden hinsichtlich Formfüllung, Maßhaltigkeit und Gefüge mit konventionell geschmiedeten Teilen verglichen. Die Lieferzeit der generativ gefertigten Schmiedegesenke wird der von konventionell hergestellten gegenübergestellt, ebenso die Kosten, um die Vorteile des Einsatzes generativer Fertigung herauszustellen. Es werden Randbedingungen beschrieben, unter denen die generative Fertigung von Schmiedegesenken technisch und wirtschaftlich sinnvoll ist.

Intelligent Virtual Patients for Training Clinical Skills

The article presents the design process of intelligent virtual human patients that are used for the enhancement of clinical skills. The description covers the development from conceptualization and character creation to technical components and the application in clinical research and training. The aim is to create believable social interactions with virtual agents that help the clinician to develop skills in symptom and ability assessment, diagnosis, interview techniques and interpersonal communication. The virtual patient fulfills the requirements of a standardized patient producing consistent, reliable and valid interactions in portraying symptoms and behaviour related to a specific clinical condition.

The E-learning Circle – a holistic software design tool for e-learning

The article introduces the E-learning Circle, a tool developed to assure the quality of the software design process of e-learning systems, considering pedagogical principles as well as technology. The E-learning Circle consists of a number of concentric circles which are divided into three sectors. The content of the inner circles is based on pedagogical principles, while the outer circle specifies how the pedagogical principles may be implemented with technology. The circle’s centre is dedicated to the subject taught, ensuring focus on the specific subject’s properties. The three sectors represent the student, the teacher and the learning objectives. The strengths of the E-learning Circle are the compact presentation combined with the overview it provides, as well as the usefulness of a design tool dealing with complexity, providing a common language and embedding best practice. The E-learning Circle is not a prescriptive method, but is useful in several design models and processes. The article presents two projects where the E-learning Circle was used as a design tool.

Uso de DES y RANS no estacionario para la simulación del flujo alrededor de una carena Wigley - Use of Unsteady RANS and DES to simulate flows around a Wigley Hull)

Computer Fluid Dynamics tools have already become a valuable instrument for Naval Architects during the ship design process, thanks to their accuracy and the available computer power. Unfortunately, the development of RANSE codes, generally used when viscous effects play a major role in the flow, has not reached a mature stage, being the accuracy of the turbulence models and the free surface representation the most important sources of uncertainty. Another level of uncertainty is added when the simulations are carried out for unsteady flows, as those generally studied in seakeeping and maneuvering analysis and URANS equations solvers are used. Present work shows the applicability and the benefits derived from the use of new approaches for the turbulence modeling (Detached Eddy Simulation) and the free surface representation (Level Set) on the URANS equations solver CFDSHIP-Iowa. Compared to URANS, DES is expected to predict much broader frequency contents and behave better in flows where boundary layer separation plays a major role. Level Set methods are able to capture very complex free surface geometries, including breaking and overturning waves. The performance of these improvements is tested in set of fairly complex flows, generated by a Wigley hull at pure drift motion, with drift angle ranging from 10 to 60 degrees and at several Froude numbers to study the impact of its variation. Quantitative verification and validation are performed with the obtained results to guarantee their accuracy. The results show the capability of the CFDSHIP-Iowa code to carry out time-accurate simulations of complex flows of extreme unsteady ship maneuvers. The Level Set method is able to capture very complex geometries of the free surface and the use of DES in unsteady simulations highly improves the results obtained. Vortical structures and instabilities as a function of the drift angle and Fr are qualitatively identified. Overall analysis of the flow pattern shows a strong correlation between the vortical structures and free surface wave pattern. Karman-like vortex shedding is identified and the scaled St agrees well with the universal St value. Tip vortices are identified and the associated helical instabilities are analyzed. St using the hull length decreases with the increase of the distance along the vortex core (x), which is similar to results from other simulations. However, St scaled using distance along the vortex cores shows strong oscillations compared to almost constants for those previous simulations. The difference may be caused by the effect of the free-surface, grid resolution, and interaction between the tip vortex and other vortical structures, which needs further investigations. This study is exploratory in the sense that finer grids are desirable and experimental data is lacking for large α, especially for the local flow. More recently, high performance computational capability of CFDSHIP-Iowa V4 has been improved such that large scale computations are possible. DES for DTMB 5415 with bilge keels at α = 20º were conducted using three grids with 10M, 48M and 250M points. DES analysis for flows around KVLCC2 at α = 30º is analyzed using a 13M grid and compared with the results of DES on the 1.6M grid by. Both studies are consistent with what was concluded on grid resolution herein since dominant frequencies for shear-layer, Karman-like, horse-shoe and helical instabilities only show marginal variation on grid refinement. The penalties of using coarse grids are smaller frequency amplitude and less resolved TKE. Therefore finer grids should be used to improve V&V for resolving most of the active turbulent scales for all different Fr and α, which hopefully can be compared with additional EFD data for large α when it becomes available.

Extended Triple-Junction Solar Cell 3D Distributed Model: Application to Chromatic Aberration-Related Losses

An extended 3D distributed model based on distributed circuit units for the simulation of triple‐junction solar cells under realistic conditions for the light distribution has been developed. A special emphasis has been put in the capability of the model to accurately account for current mismatch and chromatic aberration effects. This model has been validated, as shown by the good agreement between experimental and simulation results, for different light spot characteristics including spectral mismatch and irradiance non‐uniformities. This model is then used for the prediction of the performance of a triple‐junction solar cell for a light spot corresponding to a real optical architecture in order to illustrate its suitability in assisting concentrator system analysis and design process.

Design and evaluation of acceleration strategies for speeding up the development of dialog applications

In this paper, we describe a complete development platform that features different innovative acceleration strategies, not included in any other current platform, that simplify and speed up the definition of the different elements required to design a spoken dialog service. The proposed accelerations are mainly based on using the information from the backend database schema and contents, as well as cumulative information produced throughout the different steps in the design. Thanks to these accelerations, the interaction between the designer and the platform is improved, and in most cases the design is reduced to simple confirmations of the “proposals” that the platform dynamically provides at each step. In addition, the platform provides several other accelerations such as configurable templates that can be used to define the different tasks in the service or the dialogs to obtain or show information to the user, automatic proposals for the best way to request slot contents from the user (i.e. using mixed-initiative forms or directed forms), an assistant that offers the set of more probable actions required to complete the definition of the different tasks in the application, or another assistant for solving specific modality details such as confirmations of user answers or how to present them the lists of retrieved results after querying the backend database. Additionally, the platform also allows the creation of speech grammars and prompts, database access functions, and the possibility of using mixed initiative and over-answering dialogs. In the paper we also describe in detail each assistant in the platform, emphasizing the different kind of methodologies followed to facilitate the design process at each one. Finally, we describe the results obtained in both a subjective and an objective evaluation with different designers that confirm the viability, usefulness, and functionality of the proposed accelerations. Thanks to the accelerations, the design time is reduced in more than 56% and the number of keystrokes by 84%.

Bending continuous structures with SMAs: a novel robotic fish design

In this paper, we describe our research on bio-inspired locomotion systems using deformable structures and smart materials, concretely shape memory alloys (SMAs). These types of materials allow us to explore the possibility of building motor-less and gear-less robots. A swimming underwater fish-like robot has been developed whose movements are generated using SMAs. These actuators are suitable for bending the continuous backbone of the fish, which in turn causes a change in the curvature of the body. This type of structural arrangement is inspired by fish red muscles, which are mainly recruited during steady swimming for the bending of a flexible but nearly incompressible structure such as the fishbone. This paper reviews the design process of these bio-inspired structures, from the motivations and physiological inspiration to the mechatronics design, control and simulations, leading to actual experimental trials and results. The focus of this work is to present the mechanisms by which standard swimming patterns can be reproduced with the proposed design. Moreover, the performance of the SMA-based actuators’ control in terms of actuation speed and position accuracy is also addressed.

Amplificador de potencia Clase F en banda L basado en tecnología GaN

This paper reports a high efficiency class-F power amplifier based on a gallium nitride high electron mobility transistor (GaN-HEMT), which is designed at the L band of 1640 MHz. The design is based on source and load pull measurements. During the design process, the parasitics of the package of the device are also taken into account in order to achieve the optimal class-F load condition at the intrinsic drain of the transistor. The fabricated class-F power amplifier achieved a maximum drain efficiency (DE) of 77.8% and a output power of 39.6 W on a bandwidth of 280 MHz. Simulation and measurement results have shown good agreement.

Novel lateral moving tracking optics with the SMS design method

Lateral moving optics along straight path has already been studied in the past. However, their relative small angular range can be a limitation to potential applications. In this work, a new design concept of SMS moving optics is developed, in which the movement is no longer lateral but follows a curved trajectory, which is calculated in the design process. We have chosen an afocal system, which aim to direct the parallel rays of large incident angles to parallel output rays, and we have obtained that the RMS of the divergence angle of the output rays remains below 1 degree within a input angular range of ±45 output. Potential applications of this beam-steering device are: skylights to provide steerable natural illumination, building integrated CPV systems, and steerable LED illumination.

Dreams: A tool for the design of dynamically reconfigurable embedded and modular systems

Dynamically Reconfigurable Systems are attracting a growing interest, mainly due to the emergence of novel applications based on this technology. However, commercial tools do not provide enough flexibility to design solutions, while keeping an acceptable design productivity. In this paper, a novel design flow is proposed, targeting dynamically reconfigurable systems. It is fully supported by a tool called Dreams, which is able to implement flexible systems, starting from a set of netlists corresponding to the modules, as well as a system description provided by the user. The tool automatically post-processes the nets, implementing a solution for the communications between reconfigurable regions, as well as the handling of routing conflicts, by means of a custom router. Since the design process of every module and the static system are independent, the proposed flow is compatible with system upgrade at run-time. In this paper, a use case corresponding to the design of a highly regular and parallel mesh-type architecture is described, in order to show the architectural flexibility offered by the tool.