Development and application of a computer-based methodology for design for additive manufacturing of automotive components

The research project aims to improve the Design for Additive Manufacturing of metal components. Firstly, the scenario of Additive Manufacturing is depicted, describing its role in Industry 4.0 and in particular focusing on Metal Additive Manufacturing technologies and the Automotive sector applications. Secondly, the state of the art in Design for Additive Manufacturing is described, contextualizing the methodologies, and classifying guidelines, rules, and approaches. The key phases of product design and process design to achieve lightweight functional designs and reliable processes are deepened together with the Computer-Aided Technologies to support the approaches implementation. Therefore, a general Design for Additive Manufacturing workflow based on product and process optimization has been systematically defined. From the analysis of the state of the art, the use of a holistic approach has been considered fundamental and thus the use of integrated product-process design platforms has been evaluated as a key element for its development. Indeed, a computer-based methodology exploiting integrated tools and numerical simulations to drive the product and process optimization has been proposed. A validation of CAD platform-based approaches has been performed, as well as potentials offered by integrated tools have been evaluated. Concerning product optimization, systematic approaches to integrate topology optimization in the design have been proposed and validated through product optimization of an automotive case study. Concerning process optimization, the use of process simulation techniques to prevent manufacturing flaws related to the high thermal gradients of metal processes is developed, providing case studies to validate results compared to experimental data, and application to process optimization of an automotive case study. Finally, an example of the product and process design through the proposed simulation-driven integrated approach is provided to prove the method's suitability for effective redesigns of Additive Manufacturing based high-performance metal products. The results are then outlined, and further developments are discussed.

Tolerance optimization with statistical approach in the CAT environment

Nowadays, product development in all its phases plays a fundamental role in the industrial chain. The need for a company to compete at high levels, the need to be quick in responding to market demands and therefore to be able to engineer the product quickly and with a high level of quality, has led to the need to get involved in new more advanced methods/ processes. In recent years, we are moving away from the concept of 2D-based design and production and approaching the concept of Model Based Definition. By using this approach, increasingly complex systems turn out to be easier to deal with but above all cheaper in obtaining them. Thanks to the Model Based Definition it is possible to share data in a lean and simple way to the entire engineering and production chain of the product. The great advantage of this approach is precisely the uniqueness of the information. In this specific thesis work, this approach has been exploited in the context of tolerances with the aid of CAD / CAT software. Tolerance analysis or dimensional variation analysis is a way to understand how sources of variation in part size and assembly constraints propagate between parts and assemblies and how that range affects the ability of a project to meet its requirements. It is critically important to note how tolerance directly affects the cost and performance of products. Worst Case Analysis (WCA) and Statistical analysis (RSS) are the two principal methods in DVA. The thesis aims to show the advantages of using statistical dimensional analysis by creating and examining various case studies, using PTC CREO software for CAD modeling and CETOL 6σ for tolerance analysis. Moreover, it will be provided a comparison between manual and 3D analysis, focusing the attention to the information lost in the 1D case. The results obtained allow us to highlight the need to use this approach from the early stages of the product design cycle.

Lattice-dome design using a knowledge-based system approach

In the design of lattice domes, design engineers need expertise in areas such as configuration processing, nonlinear analysis, and optimization. These are extensive numerical, iterative, and lime-consuming processes that are prone to error without an integrated design tool. This article presents the application of a knowledge-based system in solving lattice-dome design problems. An operational prototype knowledge-based system, LADOME, has been developed by employing the combined knowledge representation approach, which uses rules, procedural methods, and an object-oriented blackboard concept. The system's objective is to assist engineers in lattice-dome design by integrating all design tasks into a single computer-aided environment with implementation of the knowledge-based system approach. For system verification, results from design examples are presented.

The variety of variables in automated real-time refinement

The refinement calculus is a well-established theory for deriving program code from specifications. Recent research has extended the theory to handle timing requirements, as well as functional ones, and we have developed an interactive programming tool based on these extensions. Through a number of case studies completed using the tool, this paper explains how the tool helps the programmer by supporting the many forms of variables needed in the theory. These include simple state variables as in the untimed calculus, trace variables that model the evolution of properties over time, auxiliary variables that exist only to support formal reasoning, subroutine parameters, and variables shared between parallel processes.

Desenvolvimento e implanta????o do sistema Sancad

Recentemente, a expans??o do n??mero de munic??pios conveniados com a FNS fez aumentar a demanda por novos projetos de melhoria dos sistemas de ??gua e esgotos. Ao mesmo tempo, a FNS enfrentava car??ncia de pessoal t??cnico especializado, dificuldades de admiss??o de novos profissionais e limita????o de recursos para a contrata????o de projetos atrav??s de empresas privadas, inviabilizando o atendimento das demandas pela forma tradicional. Diante disso, servidores da FNS desenvolveram um software para projetos de redes de esgotos sanit??rios, utilizando os recursos modernos da computa????o gr??fica (CAD ??? Computer Aided Design). Acoplado ao CAD, prop??s-se a cria????o de um m??dulo de dimensionamento, resultando numa ferramenta completa de elabora????o de projetos, em ambiente computacional Windows, contemplando as v??rias etapas t??picas de um trabalho na ??rea, desde a digitaliza????o do levantamento topogr??fico, lan??amento da rede, c??lculos, planilhas, desenho e montagem final das pranchas geradas. Este sistema foi denominado Sancad. A utiliza????o do Sancad permitiu uma redu????o m??dia de 60 a 70% no tempo de elabora????o de projetos, significando uma forma de atender a um n??mero maior de demandas e de suprir a car??ncia de profissionais na FNS. Al??m disso, a utiliza????o do Sancad tem mostrado ganhos em termos de qualidade, corre????o e confiabilidade do produto final obtido. As previs??es iniciais quanto ?? abrang??ncia de utiliza????o do Sancad foram amplamente superadas, tendo o mesmo se tornado um padr??o para a ??rea de projetos de saneamento da FNS, estando instalado em 12 unidades da Funda????o em todo o Brasil e em processo de instala????o em outras. O Sancad tornou-se objeto de interesse de t??cnicos de saneamento e de estudantes de engenharia e arquitetura de institui????es p??blicas e privadas, que receberam treinamento a fim de conhec??-lo e utiliz??-lo. Finalmente, o sucesso da experi??ncia tem contribu??do para a dissemina????o da cultura de computa????o gr??fica e a ades??o dos profissionais da FNS e das autarquias municipais conveniadas ?? nova tecnologia. Neste mesmo sentido, ressalta-se a utiliza????o de teodolitos eletr??nicos ??? conhecidos como Esta????o Total ??? para a gera????o de plantas topogr??ficas j?? em formato digital, para serem usadas pelo Sancad, com novos ganhos de qualidade e produtividade na elabora????o dos projetos de saneamento

A strategy to extend reactive distillation column performance under catalyst deactivation

This work addresses the effects of catalyst deactivation and investigates methods to reduce their impact on the reactive distillation columns performance. The use of variable feed quality and reboil ratio are investigated using a rigorous dynamic model developed in gPROMS and applied to an illustrative example, i.e., the olefin metathesis system, wherein 2-pentene reacts to form 2-butene and 3-hexene. Three designs and different strategies on column energy supply to tackle catalyst deactivation are investigated and the results compared.

INbreast: Toward a Full-field Digital Mammographic Database

Rationale and Objectives Computer-aided detection and diagnosis (CAD) systems have been developed in the past two decades to assist radiologists in the detection and diagnosis of lesions seen on breast imaging exams, thus providing a second opinion. Mammographic databases play an important role in the development of algorithms aiming at the detection and diagnosis of mammary lesions. However, available databases often do not take into consideration all the requirements needed for research and study purposes. This article aims to present and detail a new mammographic database. Materials and Methods Images were acquired at a breast center located in a university hospital (Centro Hospitalar de S. João [CHSJ], Breast Centre, Porto) with the permission of the Portuguese National Committee of Data Protection and Hospital's Ethics Committee. MammoNovation Siemens full-field digital mammography, with a solid-state detector of amorphous selenium was used. Results The new database—INbreast—has a total of 115 cases (410 images) from which 90 cases are from women with both breasts affected (four images per case) and 25 cases are from mastectomy patients (two images per case). Several types of lesions (masses, calcifications, asymmetries, and distortions) were included. Accurate contours made by specialists are also provided in XML format. Conclusion The strengths of the actually presented database—INbreast—relies on the fact that it was built with full-field digital mammograms (in opposition to digitized mammograms), it presents a wide variability of cases, and is made publicly available together with precise annotations. We believe that this database can be a reference for future works centered or related to breast cancer imaging.

Smart object for 3D interaction

This paper reports on the creation of an interface for 3D virtual environments, computer-aided design applications or computer games. Standard computer interfaces are bound to 2D surfaces, e.g., computer mouses, keyboards, touch pads or touch screens. The Smart Object is intended to provide the user with a 3D interface by using sensors that register movement (inertial measurement unit), touch (touch screen) and voice (microphone). The design and development process as well as the tests and results are presented in this paper. The Smart Object was developed by a team of four third-year engineering students from diverse scientific backgrounds and nationalities during one semester.

In-plane displacement and strain image analysis

Measurements in civil engineering load tests usually require considerable time and complex procedures. Therefore, measurements are usually constrained by the number of sensors resulting in a restricted monitored area. Image processing analysis is an alternative way that enables the measurement of the complete area of interest with a simple and effective setup. In this article photo sequences taken during load displacement tests were captured by a digital camera and processed with image correlation algorithms. Three different image processing algorithms were used with real images taken from tests using specimens of PVC and Plexiglas. The data obtained from the image processing algorithms were also compared with the data from physical sensors. A complete displacement and strain map were obtained. Results show that the accuracy of the measurements obtained by photogrammetry is equivalent to that from the physical sensors but with much less equipment and fewer setup requirements. © 2015Computer-Aided Civil and Infrastructure Engineering.

Optimization studies through simulation of a methanol/water/glycerol distillation column

This paper presents an optimization study of a distillation column for methanol and aqueous glycerol separation in a biodiesel production plant. Considering the available physical data of the column configuration, a steady state model was built for the column using Aspen-HYSYS as process simulator. Several sensitivity analysis were performed in order to better understand the relation between the variables of the distillation process. With the information obtained by the simulator, it is possible to define the best range for some operational variables that maintain composition of the desired product under specifications and choose operational conditions to minimize energy consumptions.

On-line system for faults detection in induction motors based on PCA

Dissertation to obtain the degree of Master in Electrical and Computer Engineering

Fatigue life assessment of endodontic instruments subjected to multi planar curvature

This present study aimed to investigate the fatigue life of unused (new) endodontic instruments made of NiTi with control memory by Coltene™ and subjected to the multi curvature of a mandibular first molar root canal. Additionally, the instrument‟s structural behaviour was analysed through non-linear finite element analysis (FEA). The fatigue life of twelve Hyflex™ CM files was assessed while were forced to adopt a stance with multiple radius of curvature, similar to the ones usually found in a mandibular first molar root canal; nine of them were subjected to Pecking motion, a relative movement of axial type. To achieve this, it was designed an experimental setup with the aim of timing the instruments until fracture while worked inside a stainless steel mandibular first molar model with relative axial motion to simulate the pecking motion. Additionally, the model‟s root canal multi-curvature was confirmed by radiography. The non-linear finite element analysis was conducted using the computer aided design software package SolidWorks™ Simulation, in order to define the imposed displacement required by the FEA, it was necessary to model an endodontic instrument with simplified geometry using SolidWorks™ and subsequently analyse the geometry of the root canal CAD model. The experimental results shown that the instruments subjected to pecking motion displayed higher fatigue life values and higher lengths of fractured tips than those with only rotational relative movement. The finite element non-linear analyses shown, for identical conditions, maximum values for the first principal stress lower than the yield strength of the material and those were located in similar positions to the instrument‟s fracture location determined by the experimental testing results.

Diseño de sistemas de comunicaciones de alta velocidad. Design of high-speed communication systems.

El crecimiento exponencial del tráfico de datos es uno de los mayores desafíos que enfrentan actualmente los sistemas de comunicaciones, debiendo los mismos ser capaces de soportar velocidades de procesamiento de datos cada vez mas altas. En particular, el consumo de potencia se ha transformado en uno de los parámetros de diseño más críticos, generando la necesidad de investigar el uso de nuevas arquitecturas y algoritmos para el procesamiento digital de la información. Por otro lado, el análisis y evaluación de nuevas técnicas de procesamiento presenta dificultades dadas las altas velocidades a las que deben operar, resultando frecuentemente ineficiente el uso de la simulación basada en software como método. En este contexto, el uso de electrónica programable ofrece una oportunidad a bajo costo donde no solo se evaluan nuevas técnicas de diseño de alta velocidad sino también se valida su implementación en desarrollos tecnológicos. El presente proyecto tiene como objetivo principal el estudio y desarrollo de nuevas arquitecturas y algoritmos en electrónica programable para el procesamiento de datos a alta velocidad. El método a utilizar será la programación en dispositivos FPGA (Field-Programmable Gate Array) que ofrecen una buena relación costo-beneficio y gran flexibilidad para integrarse con otros dispositivos de comunicaciones. Para la etapas de diseño, simulación y programación se utilizaran herramientas CAD (Computer-Aided Design) orientadas a sistemas electrónicos digitales. El proyecto beneficiara a estudiantes de grado y postgrado de carreras afines a la informática y las telecomunicaciones, contribuyendo al desarrollo de proyectos finales y tesis doctorales. Los resultados del proyecto serán publicados en conferencias y/o revistas nacionales e internacionales y divulgados a través de charlas de difusión y/o encuentros. El proyecto se enmarca dentro de un área de gran importancia para la Provincia de Córdoba, como lo es la informática y las telecomunicaciones, y promete generar conocimiento de gran valor agregado que pueda ser transferido a empresas tecnológicas de la Provincia de Córdoba a través de consultorias o desarrollos de productos.

Intraobserver and interobserver variability of ascending aorta diameter measurements as assessed by ECG-gated MDCT : automatic versus manual measurements : P15

Purpose: Revolutionary endovascular treatments are on the verge of being available for management of ascending aortic diseases. Morphometric measurements of the ascending aorta have already been done with ECG-gated MDCT to help such therapeutic development. However the reliability of these measurements remains unknown. The objective of this work was to compare the intraobserver and interobserver variability of CAD (computer aided diagnosis) versus manual measurements in the ascending aorta. Methods and materials: Twenty-six consecutive patients referred for ECG-gated CT thoracic angiography (64-row CT scanner) were evaluated. Measurements of the maximum and minimum ascending aorta diameters at mid-distance between the brachiocephalic artery and the aortic valve were obtained automatically with a commercially available CAD and manually by two observers separately. Both observers repeated the measurements during a different session at least one month after the first measurements. Intraclass coefficients as well the Bland and Altman method were used for comparison between measurements. Two-paired t-test was used to determine the significance of intraobserver and interobserver differences (alpha = 0.05). Results: There is a significant difference between CAD and manual measurements in the maximum diameter (p = 0.004) for the first observer, whereas the difference was significant for minimum diameter between the second observer and the CAD (p <0.001). Interobserver variability showed a weak agreement when measurements were done manually. Intraobserver variability was lower with the CAD compared to the manual measurements (limits of variability: from -0.7 to 0.9 mm for the former and from -1.2 to 1.3 mm for the latter). Conclusion: In order to improve reproductibility of measurements whenever needed, pre- and post-therapeutic management of the ascending aorta may benefit from follow-up done by a unique observer with the help of CAD.