NURBS Modelling in Virtual Reality

Simulation of the Behaviour of a New Semitrailer with Structural Load-Carrying Platform in Composite Material

Design of a new tibial intramedullary nail

Approccio Metodico alla Riprogettazione di un Semirimorchio

Economic competition leads to continuous development of new products and processes, but it is opposed by the decrease of speed of characteristics improvement and by the consequent tendency of the market to saturation. Redesign assumes in this context a particular remark because it cans allowing the acceleration of process of performances increase. This objective needs a methodical and structured approach that can leading, even, to the modification of product concept. In this work it has been studied the possibility of reducing the mass of a road semitrailer, by intervening on its structural elements. Some solutions, characterized by new topology and/or materials, have been examined and a st…

Influence of the evolutionary optimization parameters on the optimal topology

Topological optimization can be considered as one of the most general types of structural optimization. Between all known topological optimization techniques, the Evolutionary Structural Optimization represents one of the most efficient and easy to implement approaches. Evolutionary topological optimization is based on a heuristic general principle which states that, by gradually removing portions of inefficient material from an assigned domain, the resulting structure will evolve towards an optimal configuration. Usually, the initial continuum domain is divided into finite elements that may or may not be removed according to the chosen efficiency criteria and other parameters like the spee…

Progettazione di un dispositivo paraincastro posteriore ad elevata dissipazione di energia per veicoli industriali

Mechanical behavior of a sandwich with corrugated GRP core: numerical modeling and experimental validation

In this work the mechanical behaviour of a core reinforced composite sandwich structure is studied. The sandwich employs a Glass Reinforced Polymer (GRP) orthotropic material for both the two external skins and the inner core web. In particular, the core is designed in order to cooperate with the GRP skins in membrane and flexural properties by means of the addition of a corrugated laminate into the foam core. An analytical model has been developed to replace a unit cell of this structure with an orthotropic equivalent thick plate that reproduces the in plane and out of plane behaviour of the original geometry. Different validation procedures have been implemented to verify the quality of t…

Towards a fully integrated CAD system in virtual reality environment

Assessment of paradoxical anterior translation in a CR total knee prosthesis coupling dynamic RSA and FE techniques

Purpose: The study aims were to assess the kinematic data, Internal-External (IE) rotation, and Antero-Posterior (AP) translation of the contact points between the femoral condyles and polyethylene insert and to develop a combined dynamic RSA-FE (Radiostereometric – Finite Element) model that gives results congruent with the literature. Methods: A cohort of 15 patients who underwent cemented cruciate-retaining highly congruent mobile-bearing total knee arthroplasty were analyzed during a sit-to-stand motor task. The kinematical data from Dynamic RSA were used as input for a patient-specific FE model to calculate condylar contact points between the femoral component and polyethylene insert. …

Improving the Downwind Sail Design Process by Means of a Novel FSI Approach

The process of designing a sail can be a challenging task because of the difficulties in predicting the real aerodynamic performance. This is especially true in the case of downwind sails, where the evaluation of the real shapes and aerodynamic forces can be very complex because of turbulent and detached flows and the high-deformable behavior of structures. Of course, numerical methods are very useful and reliable tools to investigate sail performances, and their use, also as a result of the exponential growth of computational resources at a very low cost, is spreading more and more, even in not highly competitive fields. This paper presents a new methodology to support sail designers in ev…

TOPOLOGY OPTIMIZATION OF A CONNECTING ROD FOR AN INTERNAL COMBUSTION ENGINE

The topology optimization of a structure is a process that allows to establish if in a point of an assigned domain there should be some material. No assumption is made with regard to the number and the distribution of the contours and the final topology, that can be very different compared to that one initially hypothesized. In this paper a study related to the topology optimization of a connecting rod for an internal combustion engine is presented. The used technique for the optimization is the density (or distribution of material) method. The developed application, besides giving an innovative solution of the topology of the connecting rod with a lower mass in comparison with the initial …

On the Finite Element Modeling of the Lumbar Spine: A Schematic Review

Finite element modelling of the lumbar spine is a challenging problem. Lower back pain is among the most common pathologies in the global populations, owing to which the patient may need to undergo surgery. The latter may differ in nature and complexity because of spinal disease and patient contraindications (i.e., aging). Today, the understanding of spinal column biomechanics may lead to better comprehension of the disease progression as well as to the development of innovative therapeutic strategies. Better insight into the spine’s biomechanics would certainly guarantee an evolution of current device-based treatments. In this setting, the computational approach appears to be a remarkable …

Analysis of different geometrical features to achieve close-to-bone stiffness material properties in medical device: A feasibility numerical study

Background and objective: In orthopedic medical devices, elasto-plastic behavior differences between bone and metallic materials could lead to mechanical issues at the bone-implant interface, as stress shielding. Those issue are mainly related to knee and hip arthroplasty, and they could be responsible for implant failure. To reduce mismatching-related adverse events between bone and prosthesis mechanical properties, modifying the implant's internal geometry varying the bulk stiffness and density could be the right approach. Therefore, this feasibility study aims to assess which in-body gap geometry improves, by reducing, the bulk stiffness. Methods: Using five finite element models, a unia…

Design of a Low Cost 3D Printable Single-Component Compliant Mechanism for FWMAV’s Wing Actuation

Considering a modern approach to design, one of the viable options for developing innovative projects is the possibility of integrating the effectiveness of the solutions offered by nature and living beings with the latest design methods. With this in mind, the following research exploits the idea of reproducing the natural flexibility inherent in biological structures by combining the advantages of compliant mechanisms with the adaptability of additive manufacturing processes. In the specific, the authors intend to highlight the potential and critical aspects of a possible approach for the application of compliant mechanisms in the development of single-component structures suitable for th…

A new methodology to evaluate the flying shape of a sail

VirDe: A new virtual reality design approach

Virtual reality (VR), even if it does not represent any more a novel technology, is one of the most powerful tool to help designers during the development of new projects. This is proved by very numerous research activities related to this field. In this research, we have studied a new way to approach the development of a product. We present the ongoing development of a system, called VirDe, acronym of virtual design, which can allow the designers to perform the whole design process, from the modelling phase to the finite element method (FEM) simulation analysis, in a virtual reality environment. This new method allows remarkable time and money saving in the overall product design process, …

A New Approach to Evaluate the Biomechanical Characteristics of Osseointegrated Dental Implants

Tooth loss is a common pathology that affects many people. Dental osseointegrated implants are the ideal solution to restore normal functionality in partially or completely edentulous patients. The not perfect osseointegration and the fixture fracture are the main causes of failure for these kinds of implant. To avoid these drawbacks, several studies have been conducted to analyse the behaviour of dental implants. Aim of this work is to analyse the biomechanical behaviour of three different endosseous dental implants. For this purpose, a new numerical model has been developed to simulate different levels of osseointegration and to evaluate the stress values on the bone at different times. I…

Numerical simulations on periprosthetic bone remodeling: a systematic review

Abstract Background and objective The aim of the present study was to review the literature concerning the analysis of periprosthetic bone remodeling through finite element (FE) simulation. Methods A systematic review was conducted on 9 databases, taking into account a ten-year time period (from 2009 until 2020). The inclusion criteria were: articles published in English, publication date after 2009, full text articles, articles containing the keywords both in the abstract and in the title. The articles were classified through the following parameters: dimensionality of the simulation, modelling of the bone-prosthesis interface, output parameters, type of simulated prosthesis, bone remodeli…

Redesign of a reverse shoulder prosthesis: Kinematic and mechanical study

In this work a commercial reverse shoulder prosthesis has been redesigned to improve performances in terms of range of movements of the implant and stability to dislocation. A kinematic and mechanic study has been performed using a realistic solid model of the prothesised shoulder: in particular, all the components of the prosthesis have been acquired via a 3D laser scanner and inserted in a virtual humerus-glenoid system by reproducing the common surgical procedure. The final model has been used to measure the maximum angles of abduction and rotation of the arm and the shear forces that cause dislocation. Modifications proposed to the commercial prosthesis are: a different orientation of t…

A new haptic-based tool for training in medicine

A new method to evaluate the influence of the glenosphere positioning on stability and range of motion of a reverse shoulder prosthesis

Abstract Purpose Shoulder instability and reduced range of motion are two common complications of a total reverse shoulder arthroplasty. In this work, a new approach is proposed to estimate how the glenoid component positioning can influence the stability and the range of motion of a reverse shoulder prosthesis. Materials and methods A standard reverse shoulder prosthesis has been analysed. To perform virtual simulation of the shoulder-prosthesis assembly, all the components of the prosthesis have been acquired via a 3D laser scanner and the solid models of the shoulder bones have been reconstructed through CT images. Loads on the shoulder joint have been estimated using anatomical models d…

Thermal stress analysis of different full and ventilated disc brakes

During the braking phase, the heat produced by friction between pads and disc cannot be entirely dissipated. Consequently, the brake disc, especially if very hard braking occur, can accumulate large amounts of heat in a short time so producing high gradients of temperature on it. Under these conditions, functionality and safety of the brake system can be compromised. The object of this study is to investigate, under extreme working conditions, the thermomechanical behaviour of different brake rotors in order to evaluate their efficiency and stability and to identify any compromising weakness on them. In particular, by means of FEM thermo-mechanical coupled analyses, one full disc and three …

Optimal positioning of the humeral component in the reverse shoulder prosthesis.

Total reverse shoulder arthroplasty is becoming more and more the standard therapeutic practice for glenohumeral arthropathy with massive lesions of the rotator cuff. The biomechanical principle of this prosthesis is represented by the reversion of the normal anatomy of the shoulder joint. This non-anatomical prosthesis leads to a medialization of the rotation centre of the glenohumeral joint and also to a distalization of the humeral head. All that causes a deltoid tension increasing so allowing a larger abduction of the arm. Main complications of the reverse shoulder prosthesis are due to the joint instability, the scapular notching and the wear of the polyethylene insert. The main goal o…

Influence of sutures configuration on the strength of tendon-patch joints for rotator cuff tears treatment

Abstract Purpose Massive rotator cuff tears are common in the aging population. The incidence of failed rotator cuff repairs is still quite high, especially in the treatment of full-thickness tears or revision repairs. In this context, natural and synthetic meshes can be used as augmentation scaffolds or as devices to close the gap between a retracted tendon and the bone. The purpose of this work is to evaluate the ultimate tensile strength of different tendon-patch joints in order to consider their use in the treatment of massive cuff tears. Materials and methods Porcine tendons and a synthetic low-density polypropylene mesh have been used. A preliminary study on the tensile strength of te…

A new user interface for human-computer interaction in virtual reality environments

This paper concerns the result of a research activity about the problems related to the human-computer interaction (both hardware and software) in virtual reality systems. In particular, a virtual reality application package, called VIRDE and used for the design review in immersive environment, has been used as a case study. After a detailed analysis of the hardware and software systems, and the examination of the main functional requirements, a new user interface has been developed. This new interface being composed of two input devices (tracked by an optical system) permits the two-hands interaction, instead of the most commonly single-hand interaction. The measurement of the software usa…

A tool for the interactive mesh refinement in virtual environments

Simulation of a Milling Process with Virtual Reality

2D size, position and shape definition of defects by B-scan image analysis

The non-destructive evaluation of defects by automatic procedures is of great importance for structural components. Thanks to the developments of the non-contact ultrasonic techniques, the automation of the inspections is gaining a progressively important role. In this work, an automatic inspection technique for the evaluation of defects by the analysis of B-scan images obtained by a laser ultrasonic system is presented. The data are extracted directly from a B-scan map obtained for a panel with internal defects, and are used to build an image of the cross section of the panel. The proposed automatic procedure allows the definition of size, position and shape of defects in panels of known t…

Contact between the components of a knee prosthesis: numerical and experimental study

The aim of this work is the analysis of the contact area in a knee prosthesis using two different approaches. In particular, the interface between the femoral component and the polyethylene insert has been studied both numerically and experimentally. The interest in studying the contact area is related to the fact that the wear of the polyethylene insert, due to the high contact pressures, represents one of the major causes of failure of the total knee prosthesis. The possibility to evaluate the contact area at different loads and mutual position between femur and tibia is, therefore, of fundamental importance to study the service life of a prosthesis and to improve its performance. The fin…

A Population-Based 3D Atlas of the Pathological Lumbar Spine Segment

The spine is the load-bearing structure of human beings and may present several disorders, with low back pain the most frequent problem during human life. Signs of a spine disorder or disease vary depending on the location and type of the spine condition. Therefore, we aim to develop a probabilistic atlas of the lumbar spine segment using statistical shape modeling (SSM) and then explore the variability of spine geometry using principal component analysis (PCA). Using computed tomography (CT), the human spine was reconstructed for 24 patients with spine disorders and then the mean shape was deformed upon specific boundaries (e.g., by ±3 or ±1.5 standard deviation). Results dem…

Numerical study of the components positioning influence on the stability of a reverse shoulder prosthesis

Aim of this paper is to setup a novel procedure able to analyze performances of a reverse shoulder prosthesis when different geometrical configurations are assumed. Nowadays, such a prosthesis is widely used but, because of its novelty, data in literature give poor information about performances and limits to its applicability. The activity has been divided into the following steps. At the beginning the shape of the prosthesis has been digitally acquired via a 3D scanner. Then, CAD models of all prosthetic components have been geometrically optimized in a way to obtain final entities suitable for numerical simulations. After that, CAD assemblies have been created between prosthetic componen…

Fractional Calculus as a New Perspective in the Viscoelastic Behaviour of the Intervertebral Disc

The spinal column is the load-bearing structure of the human being along with its components, which together build a strong, resistant, and stable structure, but there are a few different pathologies from which it can suffer, such as herniated discs. The intervertebral disc acts as a shock absorber and ensures the spine’s great capacity to support high loads and different states of stress, thanks to its viscoelastic properties. Some studies have attempted to describe the viscoelastic behaviour of the intervertebral disc using classical rheological models, such as the Kelvin-Voigt, or multi-parameter models. Even if these models partially describe the viscoelastic response of disc, all visco…

Numerical methods in the design process of a sailing yacht

Design of a new high energy rear underrun protective device

In recent years the vehicle design field has followed a progressive evolution by focusing its main interest on passive and active safety levels. One of the most injurious cases for the safety of passengers is the crash between a car and a heavy vehicle (truck). Generally, in fact, when such an occurrence happens, the greatest damage is suffered by the passengers of the car. This is because of the considerable structural difference between the two vehicles and the lack of devices to reduce the injuries of the car passengers. In this work, as a consequence of the previous considerations, we deal with the design of a new protective system for heavy vehicles over 3.5 tons. The new rear underrun…

Process parameters influence in additive manufacturing

Additive manufacturing is a rapidly expanding technology. It allows the creation of very complex 3D objects by adding layers of material, in spite of the traditional production systems based on the removal of material. The development of additive technology has produced initially a generation of additive manufacturing techniques restricted to industrial applications, but their extraordinary degree of innovation has allowed the spreading of household systems. Nowadays, the most common domestic systems produce 3D parts through a fused deposition modeling process. Such systems have low productivity and make, usually, objects with no high accuracy and with unreliable mechanical properties. Thes…

B-Scan image analysis for position and shape defect definition in plates

Definition of size, shape and location of defects into a mechanical component is of extreme importance in the manufacturing industry in general and particularly in high-tech applications, and in applications that can become dangerous due to the structural failure of mechanical components. In this paper, a laser-UT system has been used to define position and shape of internal defects in aluminum plates. An infrared pulsed laser is used to generate ultrasonic waves in a point of the plate and a CW laser interferometer is used as receiver to acquire the out-of-plane displacements due to the ultrasonic waves in another point of the plate. The method consists of acquiring a B-Scan map on which s…

Influence of the Screw Positioning on the Stability of Locking Plate for Proximal Tibial Fractures: A Numerical Approach

Tibial fractures are common injuries in people. The proper treatment of these fractures is important in order to recover complete mobility. The aim of this work was to investigate if screw positioning in plates for proximal tibial fractures can affect the stability of the system, and if it can consequently influence the patient healing time. In fact, a more stable construct could allow the reduction of the non-weight-bearing period and consequently speed up the healing process. For that purpose, virtual models of fractured bone/plate assemblies were created, and numerical simulations were performed to evaluate the reaction forces and the maximum value of the contact pressure at the screw/bo…

STRUCTURAL ANALYSIS OF A POSTERIOR STABILITY TOTAL KNEE JOINT REPLACEMENT

Aim of this work is to compare two different total knee prostheses that differ in the shape of the Polyethylene (PE) insert, trying to optimize the shape of the best one, in order to reduce the stress peaks. The study procedure has been divided into the following steps. First step has been the three-dimensional shape acquisition of the two prostheses by means of a COMET5 3D scanner. The morphology of two prototypes of the prostheses has been acquired by elaborating multiple Moirè fringe pattern projected on their surfaces. Second step consisted of the manipulation of these data in a CAD module, that is the interpolation of raw data into parametric surfaces, reducing singularities due to the…

Virtual prototyping of a new intramedullary nail for tibial fractures

In this work a new distal interlocking system has been developed which is easy to use, allows a reduction of the operating time and consequently the exposure to radiations both for surgeon and patient. The main goal of this study has been the design of a new intramedullary nail for tibial fractures able to simplify and speed up the distal locking operation phases. After a preliminary stage during which several candidate concepts have been proposed and analysed, the best solution has been developed and deeply investigated. The new system, called “expansion nail”, has been firstly modelled by setting up a full parametric CAD model and, then, tested by running non linear FEM analyses to evalua…

L’implementazione del processo di redesign

A new design approach to the use of composite materials for heavy transport vehicles

In order to keep or to reach a high level of competitiveness and performance of a product, it is necessary to explore all the possible solutions that allow the best compromise between costs and project requirements. By this point of view the study of alternative designs and/or materials to use, is an important aspect that can identify a new concept or way of thinking about a product. This paper presents how to make use of composite materials in the field of heavy vehicles transportation. A new semitrailer in composite material has been designed, using a methodical redesign approach and an optimisation process. The main innovation in this project is, besides the use of the Glass Fibre Reinfo…

New customized elbow orthosis made by additive manufacturing

Orthoses are additional devices that help people with disabilities. The focus of this work is the design and manufacture of a new customized elbow orthosis completely made by Additive Manufacturing (AM). One of the innovative characteristic of the device is the use of torsion springs that simulate the action of physiotherapists during exercises for patient rehabilitation. Parametric modeling approach based on generative algorithms was used to design the device. Finally, FEM analyses have been performed to validate the design.

New algorithms to evaluate the real shape of a hull

In this study, a new method to compare rebuilt surfaces of hulls of sailing yachts is presented. In particular, the considered rebuilt surfaces are created through classic reverse engineering approaches. The new method has been developed by means of Grasshopper, a free generative algorithms editor that can be used as plugin of Rhinoceros, one of the most widespread free-form modelling software. In particular, two different algorithms have been developed: the first one allows controlling the quality of the rebuilt surfaces, the second one, instead, allows to measure the deviations between the original CAD Model and the rebuilt surface of the hull. A case study related to the hull of a small …

THE TOPOLOGY OPTIMIZATION IN THE PRODUCT DESIGN PROCESS

The design process represents, already for a long time now, a very interesting research field for the scientific community that has tried, through its own activity of research and development, to make it faster, more reliable and efficient. Thanks to this continuous development, during the last years, the product design process has suffered a remarkable improvement, both regarding the methodological aspect, become mostly structured, objective and rational, and as regards the helping tools for the design like, for example, the software CAD, FEM, CFD, that have been improved in their efficiency and functionality. In this context, the development of more and more reliable and simple to use met…

L’ottimizzazione topologica come strumento di innovazione

A reverse engineering approach to measure the deformations of a sailing yacht

In this work, a multidisciplinary experience, aimed to study the permanent deformations of the hull of a regatta sailing yacht is described. In particular, a procedure to compare two different surfaces of the hull of a small sailing yacht, designed and manufactured at the University of Palermo, has been developed. The first one represents the original CAD model while the second one has been obtained by means of a reverse engineering approach. The reverse engineering process was performed through an automatic close-range photogrammetry survey, that has allowed to obtain very accurate measures of the hull, and a 3D modelling step by the well-known 3D computer graphics software Rhinoceros. The…

Virtual simulation of an osseointegrated trans-humeral prosthesis: A falling scenario

Abstract Introduction Traditional prosthetic solutions expose the amputee to numerous problems that limit his ability to safely perform the normal activities of daily life. In order to eliminate the problems related to the use of the traditional prosthesis with socket, a new technique was developed for fixing the prosthesis to the amputees based on the principle of osseointegration. The aim of this paper is to study and analyze the stress distribution on the interface between a trans-humeral osseointegrated prosthetic implant and the residual bone, identifying the most stressed areas and thus foreseeing possible failure phenomena of the entire prosthetic system and, after, to compare the st…

Un nuovo strumento per lo studio dei risultati di analisi FEM

A new ESO-based method to find the optimal topology of structures subject to multiple load conditions

In the field of topology optimization problems, the Evolutionary Structural Optimization (ESO) method is one of the most popular and easy to use. When dealing with problems of reasonable difficulty, the ESO method is able to give very good results in reduced times and with a limited request of computational resources. Generally, main applications of this method are addressed to the definition of the optimal topology of a component subjected to a single load condition.In this work, a new methodology, based on the ESO approach, is introduced for the study of the optimal topology of a component subjected to multiple load conditions. The new procedure, entirely developed in the APDL programming…

A New ESO-Based Method to Find the Optimal Topology of Structures Subject to Multiple Load Conditions

In the field of topology optimization problems, the Evolutionary Structural Optimization (ESO) method is one of the most popular and easy to use. When dealing with problems of reasonable difficulty, the ESO method is able to give very good results in reduced times and with a limited request of computational resources. Generally, main applications of this method are addressed to the definition of the optimal topology of a component subjected to a single load condition. In this work, a new methodology, based on the ESO approach, is introduced for the study of the optimal topology of a component subjected to multiple load conditions. The new procedure, entirely developed in the APDL programmin…

Advances on mechanics, design engineering and manufacturing

The theme of the present editorial is dedicated to the“Advances on Mechanics, Design Engineering and Manufac-turing” that emerge in different engineering and architecturalfields.The theme has been chosen as leitmotiv of a series ofevents that have been organized by three societies operatingin Italy, Spain and France, respectively: ADM (Associ-azione nazionale Disegno e Metodi dell’ingegneria indus-triale), INGEGRAF (Asociación Española de IngenieríaGráfica and AIP-PRIMECA (Ateliers Inter-établissementsde Productique—Pôles de Resources Informatiques pour laMECAnique). Since 2014, a series of JCM conferences havebeen organized. JCM is the acronym of “Joint Conference onMechanics, Design Engin…

Kansei Engineering and Virtual Reality in Conceptual Design

A New Approach for CAD Modelling of Customised Orthoses by Generative Design

The standard method of design and manufacturing customised orthoses is still very time-consuming due to their often very complex shape. Different authors have tried to solve this problem but, unfortunately, the proposed approaches cannot be easily used in clinical practice because they require substantial interaction among medical staff and engineers or technicians. The aim of this work is to present the framework of a new design approach that could allow clinicians to easily model a customised orthosis, without a skilled technician develops the entire procedure. In particular, an automatic process based on Generative Design has been implemented. The obtained results have demonstrated that …

Numerical Optimization of a Composite Sandwich Panel with a Novel Bi-directional Corrugated Core Using an Animal-Inspired Optimization Algorithm

Composite sandwich panels with honeycomb, corrugated, tetrahedral, trapezoidal, 3D periodic and hybrid lattice cores have long been studied for their use in various industrial fields. In this study, several numerical analyses were conducted in ANSYS APDL environment in order to analyze the effect of a novel bi-directional corrugated core configuration on the flexural performance of a CFRP sandwich panel. In particular, the sandwich core is obtained by repeating a regular unit cell in two different directions to form a three-dimensional lattice structure. In order to determine the optimal values of the geometrical parameters of the core unit cell and to evaluate how the layout of the composi…

Additively manufactured textiles and parametric modelling by generative algorithms in orthopaedic applications

Purpose The purpose of this paper is to implement a new process aimed at the design and production of orthopaedic devices fully manufacturable by additive manufacturing (AM). In this context, the use of generative algorithms for parametric modelling of additively manufactured textiles (AMTs) also has been investigated, and new modelling solutions have been proposed. Design/methodology/approach A new method for the design of customised elbow orthoses has been implemented. In particular, to better customise the elbow orthosis, a generative algorithm for parametric modelling and creation of a flexible structure, typical of an AMT, has been developed. Findings To test the developed modelling a…

OTTIMIZZAZIONE TOPOLOGICA DI BIELLA PER MOTORE A COMBUSTIONE INTERNA

Progettazione di un chiodo endomidollare tibiale

DESIGN AND OPTIMIZATION OF A CHASSIS FOR A FORMULA SAE RACE CAR

In this paper, the design process of a new chassis for a Formula SAE car is presented. The chassis is undoubtedly one of the most important parts of the car, both for the influence that it has on the vehicle dynamic behaviour, and because it is the main component that assures the driver safety. The new designed chassis is composed of many structural tubular bars and has been equipped with systems for the joining of all the auxiliary members. After the definition of the masses distribution and the choice of the main dimensions, preliminary CAD and FEM models have been carried out for the evaluation of the structural behaviour of this kind of vehicle. Successively, in order maximizing the tor…

A comparison of simplex and simulated annealing for optimization of a new rear underrun protective device

In this paper, two optimization approaches to improve the product design process have been analysed. Through the analysis of a case study, concerning the designing of a new High Energy Absorption Rear Underrun Protective Device (HEARUPD), two different optimization approaches (simplex and simulated annealing) have been compared. In the implemented optimization processes, the crash between an economy car and the rear part of a truck has been simulated by dynamic numerical (FEM) analyses. Moreover, authors have proposed the use of a suitable linear function of four variables with the purpose of reducing the multi-objective optimization processes to mono-objective ones. That has been made to s…

On the Left Ventricular Remodeling of Patients with Stenotic Aortic Valve: A Statistical Shape Analysis

The left ventricle (LV) constantly changes its shape and function as a response to pathological conditions, and this process is known as remodeling. In the presence of aortic stenosis (AS), the degenerative process is not limited to the aortic valve but also involves the remodeling of LV. Statistical shape analysis (SSA) offers a powerful tool for the visualization and quantification of the geometrical and functional patterns of any anatomic changes. In this paper, a SSA method was developed to determine shape descriptors of the LV under different degrees of AS and thus to shed light on the mechanistic link between shape and function. A total of n=86 patients underwent computed tomography (…

FEM and experimental analysis of a total knee prosthesis

In this study, a comparison between two different approaches used to study a total knee prosthesis is presented. In particular, the contact area of the components of knee prosthesis has been evaluated using both a numerical and an experimental approach. The numerical analysis has been performed by FEM Models, whereas the experimental study has been conducted using an ultrasonic-based method. To setup the FEM simulations, CAD Models of the components of the prosthesis have been reconstructed using a classic reverse engineering approach. Obtained results has allowed evaluating the contact area of the components of the prosthesis and demonstrated a very good level of correlation between numeri…

Ottimizzazione topologica di un cerchione per ruota di autovettura

NUMERICAL FATIGUE LIFE EVALUATION OF AN INNOVATIVE INTERNAL COMBUSTION ENGINE SHAFT

A novel self-balanced internal combustion engine is presented. The new engine has a modular structure composed of two cylinders arranged in opposite way. It is characterized by an innovative system of linking between the pistons and the shaft, which has three toggles. One of these is on the middle of the shaft, whereas the others two are placed symmetrically. Thanks to this particular shape of the shaft, the pistons can rotate with the same timing and so the new engine comes back to be perfectly auto-balanced. Moreover, the fatigue life prediction of the shaft has been studied through numerical methods. In particular, two different approaches have been compared to estimate the maximum numbe…

CFD parametric analysis and experimental results on a hydraulic actuator

Metodologie di progettazione innovative In campo navale

A new design approach for customised medical devices realized by additive manufacturing

AbstractThe aim of this work is the design of a new customised elbow orthosis completely realized by Additive Manufacturing and the development of generative algorithms for parametric modelling and creation of 3D patterns to be adapted to the CAD model. This work describes a method to perfect the design of a custom elbow orthosis. A reverse engineering approach has been used to digitalize the patient’s arm and the subsequent CAD modelling of the structure of the custom elbow orthosis has been performed. In particular, two algorithms have been implemented for the creation of 3D patterns and Voronoi tessellations. Subsequently, FEM analyses have been carried out to validate the design. Finall…

A multi-technique simultaneous approach for the design of a sailing yacht

In this paper, most significant steps involved during the whole process of designing a sailing yacht are outlined. In particular, a novel simultaneous approach has been proposed to optimize the design process of a sailing yacht. Analytical resistance prediction models are simultaneously used with CAD systems and computational fluid dynamics tools to find, in the more effective way, the best solution for the chosen design conditions. As a general rule, in fact, once the target point has been decided, task of the designer is the definition of those systems of aerodynamic and hydrodynamic forces that are in equilibrium when the boat sails at its target. Unfortunately, a multi-purpose yacht doe…

VR studio: Solid modelling in a Virtual Reality Environment

Today one of the most important industrial needs is to improve the design process, making it faster and more robust; of course such a requirement can be obtained by using virtual reality. In the field of mechanical design, in fact, there is a great demand for more intuitive and natural modelling systems to speed up the modelling process. All that can be reached by stereocopic visualization tecnology and 3D input systems. In this paper we present a software for 3D solid modelling in a virtual reality system. The CAD models, carried out by this software, can be studied in their natural scale thanks to a large screen display. Moreover the user is free to move his hands to sketch the models tha…

Influence of the metaphysis positioning in a new reverse shoulder prosthesis

Aim of this work is to investigate the behaviour of a new reverse shoulder prosthesis, characterized by a humeral metaphysis with a variable offset, designed to increase the range of movements and to reduce the impingement. In particular, by means of virtual prototypes of the prosthesis, different offset values of the humeral metaphysis have been analysed in order to find the best positioning able to maximize the range of movements of the shoulder joint. The abduction force of the deltoid, at different offset values, has been also estimated. The study has been organized as follows. In the first step, the point clouds of the surfaces of the different components of the prosthesis have been ac…

Behaviour of a speargun with a novel muzzle - Comportamento di un fucile subacqueo con testata innovativa

The paper presents the results of a numerical and experimental investigation performed on a barrel of a speargun equipped with two kinds of muzzle. In particular, a standard muzzle for speargun (having an elastic propulsion) has been compared with an innovative one called ‘roller’. This new muzzle is equipped with two rollers and special bands. The rubber bands, fixed at the lower side of the barrel, run through the rollers and are engaged in suitable seats of the shaft. These bands are, therefore, longer than the traditional ones and, consequently, with equal force applied by the diver, the roller speargun has a longer range. Thanks to the particular geometry of the new muzzle, one of the …

Two different posterior-stabilized mobile-bearing TKA designs: navigator evaluation of intraoperative kinematic differences

Purpose: The purpose of this study was to compare two types of posterior-stabilized (PS) mobile-bearing (MB) total knee arthroplasties (TKAs). The hypothesis was that no major differences were going to be found among the two TKA designs. Methods: Two cohorts of patients who were divided according to implant design (Cohort A, new design gradually reducing radius PS MB TKA; Cohort B, traditional dual-radius PS MB TKA) were analyzed by means of intraoperative navigation. All operations were guided by a non-image-based navigation system that recorded relative femoral and tibial positions in native and implanted knees during the following kinematic tests: passive range of motion (PROM), varus–va…

Generative Design for Additively Manufactured Textiles in Orthopaedic Applications

AbstractThe aim of this work is to implement a new process for the design and production of orthopaedic devices to realize entirely by Additive Manufacturing (AM). In particular, a generative algorithm for parametric modelling of flexible structures to use in orthopaedic devices has been developed. The developed modelling algorithm has been applied to a case study based on the design and production of a customized elbow orthosis made by Selective Laser Sintering. The results obtained have demonstrated that the developed algorithm overcomes many drawbacks typical of traditional CAD modelling approaches. FEM simulations have been also performed to validate the design of the orthosis. The new …

Redesign of a Reverse Shoulder Prosthesis: Kinematic and Mechanical Study

In this work a commercial reverse shoulder prosthesis has been redesigned to improve performances in terms of range of movements of the implant and stability to dislocation. A kinematic and mechanic study has been performed using a realistic solid model of the prothesised shoulder: in particular, all the components of the prosthesis have been acquired via a 3D laser scanner and inserted in a virtual humerus-glenoid system by reproducing the common surgical procedure. The final model has been used to measure the maximum angles of abduction and rotation of the arm and the shear forces that cause dislocation. Modifications proposed to the commercial prosthesis are: a different orientation of t…

Fluid–structure interaction of downwind sails: a new computational method

The spreading of high computational resources at very low costs led, over the years, to develop new numerical approaches to simulate the fluid surrounding a sail and to investigate the fluid–structure interaction. Most methods have concentrated on upwind sails, due to the difficulty of implementing downwind sailing configurations that present, usually, the problem of massive flow separation and large displacements of the sail under wind load. For these reasons, the problem of simulating the fluid–structure interaction (FSI) on downwind sails is still subject of intensive investigation. In this paper, a new weak coupled procedure between a RANS solver and a FEM one has been implemented t…

Integrazione di Tecnologie CAE in Ambienti VR

Applying virtual reality (VR) to numerical analyses (finite element –FE or fluid dynamics - CFD) produces considerable advantages, both for costs and for quality, in the mechanical engineering design process. Generally, during the stage of structural tests, after having carried out the CAD model, the designer runs FE and/or CFD analyses. Clearly, hardly ever, the obtained results are satisfactory during the first iteration, so that the designer, after having analysed the first data, needs to modify some parts of the model and to carry out a new analysis. Such re-analysis process is very improved and faster if it is carried out in a virtual reality environment; that because using the virtual…

CAD Modeling for Evaluating LVOT Obstruction in Transcatheter Mitral Valve Replacement

The current generation of transcatheter heart valves (THV), as the Edwards SAPIEN 3 Ultra (S3), is not specifically designed for mitral position implantation and has intrinsic design geometry that may make mitral implantation suboptimal. This study aimed to develop a computed-tomography (CT) based CAD workflow for the preoperative planning of transcatheter mitral valve replacement (TMVR) by evaluating the resulting obstruction in the left ventricular outflow tract (LVOT). Specifically, the computational framework to reconstruct heart anatomy and virtually deploy the THV into mitral valve annulus was developed and successively applied to the cases of two patients who experienced annuloplasty…

DESIGN OPTIMIZATION AND ANALYSIS OF A NEW REAR UNDERRUN PROTECTIVE DEVICE FOR TRUCK

In this paper the optimization process of a new High Energy Absorption Rear Underrun Protective Device called HEARUPD is discussed. The main objectives of the HEARUPD design optimization process have been related to the reduction in car decelerations (high crashworthiness) and avoiding the car underrun (high structure stability). In the implemented optimization process, the crash between an economy car (GEO Metro) and the rear part of a truck has been simulated by numerical models. A linear function of the decelerations measured on the car has been used as objective to minimize, the main dimensional values of the rear underrun protective device, instead, have been chosen as design variables…

Parametric Hull Design with Rational Bézier Curves and Estimation of Performances

In this paper, a tool able to support the sailing yacht designer during the early stage of the design process has been developed. Cubic Rational Bézier curves have been selected to describe the main curves defining the hull of a sailing yacht. The adopted approach is based upon the definition of a set of parameters, say the length of waterline, the beam of the waterline, canoe body draft and some dimensionless coefficients according to the traditional way of the yacht designer. Some geometrical constraints imposed on the curves (e.g., continuity, endpoint angles, curvature) have been conceived aimed to avoid unreasonable shapes. These curves can be imported into any commercial Computer Aide…

Finite element reanalysis in virtual reality environments

Progettazione ed ottimizzazione di un telaio per vettura di Formula SAE

Finite element analysis of two total knee joint prostheses

Aim of this work is to compare two different total knee prostheses that differ mainly in the shape of the polyethylene (PE) component inserted between the femoral and tibial plates. The best solution between them has been originally reshaped in order to reduce stress peaks. The study procedure has been divided into the following steps. First step is the digitalisation of the shape of the prostheses by means of a 3D laser scanner. The morphology of two prototypes of the prostheses has been acquired by elaborating multiple Moire fringe patterns projected on their surfaces. Second step consisted on the manipulation of these data in a CAD module, that is the interpolation of raw data into NURBS…

REDESIGN OF AN AUTO-LEVELLING BASE FOR SUBMARINE SEISMIC SENSOR

The OBS (acronym of Ocean Bottom Seismometer) is a system to monitor the submarine seismic activity. To properly work, an OBS system needs a suitable auto-levelling base to maintain a fixed (horizontal) position during the measurement phases. In this work a new auto-levelling base for submarine seismic sensors has been designed. During the redesign process a preliminary phase of analysis of the state of art has been made. Afterwards, the technological solutions chosen by different manufactures have been critically analysed, and a full description of their functionalities, working principles and system performances has been carried out. Later, some innovative concepts have been proposed. Amo…

Biomechanical analysis of two types of osseointegrated transfemoral prosthesis

In the last two decades, osseointegrated prostheses have been shown to be a good alternative for lower limb amputees experiencing complications in using a traditional socket-type prosthesis

Study of a constrained finite element elbow prosthesis: the influence of the implant placement

Abstract Background The functional results of total elbow arthroplasty (TEA) are controversial and the medium- to long-term revision rates are relatively high. The aim of the present study was to analyze the stresses of TEA in its classic configuration, identify the areas of greatest stress in the prosthesis–bone–cement interface, and evaluate the most wearing working conditions. Materials and methods By means of a reverse engineering process and using a 3D laser scanner, CAD (computer-aided drafting) models of a constrained elbow prosthesis were acquired. These CAD models were developed and their elastic properties, resistance, and stresses were studied through finite element analysis (fin…

A new methodology for the optimal design of crash-boxes

A virtual Concept of City Car

In this paper a virtual concept of a city car is proposed with the aim of approaching rationally the use of private and public means of transport, by combining the advantages of the traditional systems and the new technologies. The concept suggests the Drive by Wire interface for all the commands on board; this is based on electric signals, direction and moving operated by joystick. The simpleness of driving and the small dimensions could allow the use of the car to the disabled person without any additional device.

Biomechanical analysis of the humeral tray positioning in reverse shoulder arthroplasty design

Despite the widespread use of reverse total shoulder arthroplasty, the fundamental effects of implant configuration on certain biomechanical outcomes have not been completely elucidated especially for the most innovative prostheses. Aim of this work is to investigate the behaviour of a new reverse shoulder prosthesis, characterized by a humeral tray with a variable offset, designed to increase the range of motion and to reduce the impingement. The purposes of this study were to evaluate the effect of reverse shoulder implant design parameters on the deltoid muscle forces, required to produce abduction, and on the shoulder range of motion, in order to provide a more systematic understanding …