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.

Estimation of the satellite ephemerides of Saturn using optical navigation pictures of Cassini

The goal of this dissertation thesis is the estimation of the Saturnian satellites ephemerides using optical data of Cassini. In the first part we describe the software employed for the reduction of the images showing its main features and the accuracy that can be achieved comparing the results with published astrometry. Afterwards we describe the orbit determination problem (ODP) with particular focus on the weights selection for the estimation process. The third chapter describes the dynamical model used and the sources of potential errors in the residuals. The model have been validated trying to replicate JPL's published ephemerides SAT365, SAT375, SAT389 and SAT409. The final part investigates the residuals and the estimated ephemerides with particular focus on the giant moon Titan, the only in the solar system with an atmosphere other than the Earth. No astrometry have been retrieved in literature of Titan using optical observables, thus this represents one of the first investigations of the giant.

Virtual Calibration of CO2 and Pollutant Emissions of a High-Performance PHEV using Model-in-the-Loop Methodology

The study analyses the calibration process of a newly developed high-performance plug-in hybrid electric passenger car powertrain. The complexity of modern powertrains and the more and more restrictive regulations regarding pollutant emissions are the primary challenges for the calibration of a vehicle’s powertrain. In addition, the managers of OEM need to know as earlier as possible if the vehicle under development will meet the target technical features (emission included). This leads to the necessity for advanced calibration methodologies, in order to keep the development of the powertrain robust, time and cost effective. The suggested solution is the virtual calibration, that allows the tuning of control functions of a powertrain before having it built. The aim of this study is to calibrate virtually the hybrid control unit functions in order to optimize the pollutant emissions and the fuel consumption. Starting from the model of the conventional vehicle, the powertrain is then hybridized and integrated with emissions and aftertreatments models. After its validation, the hybrid control unit strategies are optimized using the Model-in-the-Loop testing methodology. The calibration activities will proceed thanks to the implementation of a Hardware-in-the-Loop environment, that will allow to test and calibrate the Engine and Transmission control units effectively, besides in a time and cost saving manner.

Typing your mind away. Comparing keylogged tasks with the Task Segment Framework

One of the main process features under study in Cognitive Translation & Interpreting Studies (CTIS) is the chronological unfolding of the tasks. The analyses of time spans in translation have been conceived in two ways: (1) studying those falling between text units of different sizes: words, phrases, sentences, and paragraphs; (2) setting arbitrary time span thresholds to explore where do they fall in the text, whether between text units or not. Writing disfluencies may lead to comprehensive insights into the cognitive activities involved in typing while translating. Indeed, long time spans are often taken as hints that cognitive resources have been subtracted from typing and devoted to other activities, such as planning, evaluating, etc. This exploratory, pilot study combined both approaches to seek potential general tendencies and contrasts in informants’ inferred mental processes when performing different writing tasks, through the analysis of their behaviors, as keylogged. The study tasks were retyping, monolingual free writing, translation, revision and a multimodal task—namely, monolingual text production based on an infographic leaflet. Task logs were chunked, and shorter time spans, including those within words, were analyzed following the Task Segment Framework (Muñoz & Apfelthaler, in press). Finally, time span analysis was combined with the analysis of the texts as to their lexical density, type-token ratio and word frequency. Several previous results were confirmed, and some others were surprising. Time spans in free writing were longer between paragraphs and sentences, possibly hinting at planning and, in translation, between clauses and words, suggesting more cognitive activities at these levels. On the other hand, the infographic was expected to facilitate the writing process, but most time spans were longer than in both free writing and translation. Results of the multimodal task and some other results suggest venues for further research.

Sustainability analysis in the mining sector: a case study on new recycling technologies for sulphidic mine residues valorisation

Research has demonstrated that mining activities can cause serious impacts on the environment, as well as the surrounding communities, mainly due to the unsafe storage of mine tailings. This research focuses on the sustainability assessment of new technologies for the recovery of metals from mine residues. The assessment consists in the evaluation of the environmental, economic, and social impacts through the Life Cycle based methods: Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Social Life Cycle Assessment (SLCA). The analyses are performed on the Mondo Minerals bioleaching project, which aim is to recover nickel and cobalt from the Sotkamo and Vuonos mine tailings. The LCA demonstrates that the project contributes to the avoided production of nickel and cobalt concentrates from new resources, hence reducing several environmental impacts. The LCC analysis shows that the company’s main costs are linked to the bioleaching process, caused by electricity consumption and the chemicals used. The SLCA analyses the impacts on three main stakeholder categories: workers, local community, and society. The results demonstrated that a fair salary (or the absence of it) impacts the workers the most, while the local community stakeholder category impacts are related to the access to material resources. The health and safety category is the most impacted category for the society stakeholder. The environmental and economic analyses demonstrate that the recovery of mine tailings may represents a good opportunity for mine companies both to reduce the environmental impacts linked to mine tailings and to increase the profitability. In particular, the project helps reduce the amounts of metals extracted from new resources and demonstrates that the use of the bioleaching technology for the extraction of metals can be economically profitable.

Assessing the impact of ammonia content in VFA-rich streams on the PHA-storing MMC acclimatization and the PHA production stage

The use of environmentally friendly products increased the interest in renewable resources as alternatives to petrochemical products. Polyhydroxyalkanoates (PHAs) are examples of such promising products, as they are biodegradable polymers with numerous potential applications. PHA production approach consists of using an open mixed microbial culture (MMC) and inexpensive feedstocks (waste or industry byproducts feedstock). The PHA process generally comprises three stages: (1) acidogenic fermentation (AF) stage (conversion of organic carbon into fermentation products); (2) culture selection stage (enrichment in PHA-storing organisms by applying Feast and Famine regime); and (3) PHA production stage (PHA accumulation up to the culture’s maximum capacity). AF of protein-rich residues results in ammonia-rich fermented streams, which can be presented as a challenge for the PHA production stage. The presence of ammonia during this stage may induce organisms to grow instead of producing PHAs. For this reason, the assessment of the effect of a high content of ammonia on PHA production it is the utmost importance. The main goal of the current project is to select a MMC enriched in PHA-accumulating organisms in conditions of high ammonia content and to evaluate the effects of ammonia presence during PHA accumulation. The culture was selected applying the Feast & Famine strategy, and fed, firstly, using a synthetic mixture of VFAs and later using a fermented stream obtained from the fermentation of protein-rich raw materials. The selected culture could accumulate up to 24% PHA per VSS with the synthetic mixture of VFAs and up to 29% for the real fermented stream. The PHA accumulation resulted in different production in the presence and absence of ammonia. Regarding to the synthetic feed, 59%wt. PHA (VSS basis) in the absence of ammonia, and 55%wt. (VSS basis) in the presence, were obtained. For the real feed, the PHA content was about 40%wt. (VSS basis) in both reactors.

Optimal pose selection for the calibration of an overconstrained Cable-Driven Parallel Robot

In this project an optimal pose selection method for the calibration of an overconstrained Cable-Driven Parallel robot is presented. This manipulator belongs to a subcategory of parallel robots, where the classic rigid "legs" are replaced by cables. Cables are flexible elements that bring advantages and disadvantages to the robot modeling. For this reason, there are many open research issues, and the calibration of geometric parameters is one of them. The identification of the geometry of a robot, in particular, is usually called Kinematic Calibration. Many methods have been proposed in the past years for the solution of the latter problem. Although these methods are based on calibration using different kinematic models, when the robot’s geometry becomes more complex, their robustness and reliability decrease. This fact makes the selection of the calibration poses more complicated. The position and the orientation of the endeffector in the workspace become important in terms of selection. Thus, in general, it is necessary to evaluate the robustness of the chosen calibration method, by means, for example, of a parameter such as the observability index. In fact, it is known from the theory, that the maximization of the above mentioned index identifies the best choice of calibration poses, and consequently, using this pose set may improve the calibration process. The objective of this thesis is to analyze optimization algorithms which aim to calculate an optimal choice of poses both in quantitative and qualitative terms. Quantitatively, because it is of fundamental importance to understand how many poses are needed. Not necessarily a greater number of poses leads to a better result. Qualitatively, because it is useful to understand if the selected combination of poses actually gives additional information in the process of the identification of the parameters.