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

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…

Defect characterization in Al welded joints by non-contact Lamb wave technique

Abstract The use of air-coupled sensors to detect flaws in Al welded joints and the advantage of Lamb wave for their characterization has been proved. Ultrasonic waves were generated by a pulsed laser and by contact angle-beam transducer, and received by an air-coupled capacitive transducer. Laser-based configuration was used to quickly locate the defect, whereas the angle-beam contact probe configuration to characterize it thanks to the dispersive behavior of Lamb waves. Guided waves allow inspection of the complete thickness with only one scan, permitting to detect and to size both internal and surface defects; their high flexibility in the measurement is due to the various parameters cha…

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…

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 …

Evaluation of Clutch Plate Integrity with Non-Destructive Methods

Abstract Nondestructive evaluation (NDE) represents an important phase in the life cycle of a product to detect defects both in service and in production. NDE techniques most commonly used to detect surface defects are visual inspection and methods based on eddy current and ultrasound. Laser and non-contact sensors have been recently used to inspect ultrasonically without contact. Components with complex geometry are usually inspected combining several NDE techniques, or simply visually where analysis and evaluation of results are performed by an operator based on specific parameters of acceptance. This last method is currently used to inspect the clutch plates since their complex geometry,…

Reverse Engineering and Redesign of the Impeller of a Submersible Centrifugal Pump

In this work a Reverse Engineering based approach has been implemented aiming to reconstruct the 3D shape of a strongly damaged and no longer usable impeller of a submersible centrifugal pump. After obtaining the 3D model, new designs of the impeller were investigated in terms of structural stability and corrosion resistance by changing the geometry and the material. Obtained results show the used approach can be very useful both to reproduce, by Additive Manufacturing, no longer available spare parts, so allowing to extend the useful life of old machineries and to reduce costs resulting from plant shutdowns, but also to improve the performances of old designs, making use of different mater…

A new methodology to evaluate the flying shape of a sail

Previsione numerica delle tensioni residue indotte in fori espansi a freddo

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 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…

Quantitative Evaluation of Defects in Adhesive-Bonded Joints by Non-contact Ultrasonic Techniques

TORSIONAL STRESS CONCENTRATIONS IN SHAFTS: FROM ELECTRICAL ANALOGIES TO NUMERICAL METHODS

This paper presents the historical development of methods used for the study of torsional stresses in shafts. In particular the paper covers both analog methods, in particular those based on electrical analogies proposed since about 1925, and numerical methods, in particular finite difference methods (FDM), finite element methods (FEM) and boundary elements (BEM).

Detection of disbonds in multilayer structures by laser-based ultrasonic technique

Adhesively bonded multi-layer structures are frequently used, mostly in the aerospace industry, for their structural efficiency. Nondestructive evaluation of bond integrity in these types of structures, both after manufacturing and for periodic inspection during service, is extremely important. A laser-based ultrasonic technique has been evaluated for non-contact detection of disbonds in aluminum multi-layer structures. Two configurations have been used to detect disbonded areas: pitch-catch with unidirectional guided wave scan and through-transmission with bidirectional scan. Guided wave scanning was done with a laser line source and air-coupled transducer sensing at 500 kHz, 1 ;MHz, and 2…

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 …

A NEO APPLICATION OF REVERSE ENGINEERING BASED ON THE PROJECTION MOIRé TECHNIQUE

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…

Adhesively bonded joints: evaluation of integrity

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…

Progettazione concettuale di dispositivo paraincastro posteriore per veicoli industriali

Head Injury Criterion: mini review

Head Injury Criterion (HIC) is the most important parameter in terms of human survival; it is indicative of brain injuries due to the impact of the head in numerous cases, with a vehicle. This index can be estimated by integrating the resulting acceleration of the head (measured in its gravity center) in a time window

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…

Improvements of Fatigue Life in Drilling Structures by Both Cold Expansion and Indentation

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…

Aumentare la sicurezza passiva

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…

L’implementazione del processo di redesign

Numerical prediction of ventilated planing flat plates for the design of Air Cavity Ships

In recent years, a great world issue is the respect for the environment. Each researcher, in his competence field, proposes new technologies and new approaches in order to reduce the environmental impact of a product or of an industrial process. In the naval field, the main way in order to reduce the environmental impact of the ship during the navigation is the reduction of the drag resistance and so the reduction of requested power. There are many ways in order to obtain a reduction of drag. This paper investigates, with a preliminary numerical study by means of Computational Fluid Dynamics (CFD), the Air Cavity Ships technology (ACS). A first part of the paper concerns the study of the ri…

Quantitative subsurface defect detection in composite materials using a non-contact ultrasonic system

The results of an experimental study conducted to detect subsurface defects in a thick Gr/PPS composite test sample using a noncontact ultrasonic system are presented. Surface waves are generated by a pulsed laser and detected by an air-coupled capacitance transducer. By controlling the surface wave wavelength through a shadow mask, it is possible to control surface wave penetration depth in the sample. Surface wave peak-to-peak amplitude is related to the near-surface material condition. Results indicate that signal amplitude decreases as the width of the defect increases and an approximately linear relation can be deduced.

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 …

Surface Measurement by Digital Image Correlation Technique

BRAKING PROCEDURE ANALYSIS OF A PEGS-WIN VENTILATED DISK BRAKE ROTOR

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…

DISPOSITIVO PARAINCASTRO POSTERIORE AD ELEVATO ASSORBIMENTO ENERGETICO

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…

Braking procedure analysis of a pegs-wing ventilated disk brake rotor

Fade test results of a ventilated disk brake rotor with pegs-wing performed by means of an inertia dynamometer, consisting of 14 repeated brake applications from an initial brake speed of 160 km/h down to 0 km/h, with constant deceleration are shown. The first brake application test results are compared to the FEM numerical predictions with MSC Visual Nastran on the entire disk. These conform well to the experimental data, although numerical thermal field is slightly higher than the experimental one. Besides, ventilated disk brake rotor shows great dimensional stability and the ability to dissipate a great amount of thermal flow.

DATA FITTING WITH NURBS SURFACES BY A REAL-CODED GENETIC ALGORITHM

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

Conceptual Design by Triz: an Application to a Rear Underrun Protective Device for Industrial Vehicle

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…

A preliminary method for the numerical prediction of the behavior of air bubbles in the design of Air Cavity Ships

Air-cavity ships (ACS) are advanced marine vehicles that use air injection under hull to improve the vessel’s hydrodynamic characteristics. Although the concept of drag reduction by supplying gas under the ship’s bottom was proposed in the 19th century by Froude and Laval, at this time there are not many systematic studies on this subject. This paper is a preliminary work with the purpose of being a basic tool for the design of the ACS with computational fluid dynamic methods. The study aims to conduct a series of computational tests to compare the numerical models of bubble with experimental data. The first step of this study was to investigate the behavior of free bubble in water, conside…

Finite-element simulation of residual stress induced by split-sleeve cold-expansion process of holes

A three-dimensional finite-element simulation was conducted for a split-sleeve cold-expansion process in order to determine the residual stress field around an expanded hole. The commercial FEA software DEFORM-3D™, a Lagrangian implicit code designed for metal forming processes, was used to model the cold-expansion process of a fastener hole. The results show a through-thickness residual stress field in good agreement with the analytical solution developed by Guo. Moreover, the simulation has highlighted the effect of the split sleeve and the plate thickness on the residual stress field. © 2007 Elsevier B.V. All rights reserved.

Yacht performance monitoring in real sailing conditions

Abstract In this paper a multi-method approach is used to setup and validate a monitoring system applied to a small sailing boat during real sailing conditions. This monitoring system is able to transform the data coming from some typical devices installed on board into information about the deformed state of the boat. GPS, Wind Data Logger and cameras have been installed on the boat to measure its route and speed, the apparent wind velocity and direction and the positions of the crew members. These data are processed to determine the equilibrium of the boat and estimate the loads applied on it. Then, a CAD/FEM model calculates the effects of these loads on the boat shape. The resulting def…

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…

Integrated Computer-Aided Innovation: The PROSIT approach

Abstract The paper presents a methodology aimed at the improvement of the product development cycle through the integration of Computer-Aided Innovation (CAI) with Optimization and PLM systems. The interoperability of these tools is obtained through the adoption of Optimization systems as a bridging element between CAI and PLM systems. This methodology was developed within the PROSIT project ( http://www.kaemart.it/prosit ). The paper describes the main issues related to the integration of these complementary instruments and the solutions proposed by the authors. More specifically, the main idea of the PROSIT project to link CAI and Optimization systems is the adoption of the latter tools n…

Un metodo per l’analisi delle tensioni residue nei fori espansi a freddo

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…

Determination of Torsional Stresses in Shafts: From Physical Analogies to Mathematical Models

This paper presents the historical development of methods used for the study of torsional stresses in shafts. In particular, the paper covers both analog methods, especially those based on electrical analogies proposed circa 1925, and numerical methods, especially finite difference methods (FDM), finite element methods (FEM) and boundary element methods (BEM).

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…

A NON-CONTACT ULTRASONIC SYSTEM FOR IN-FIELD RAIL TRACK INSPECTION

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 …

Industry 4.0: smart test bench for shipbuilding industry

AbstractIndustry 4.0 promises to increase the efficiency of production plants and the quality of the final product. Consequently, companies that implement advanced solutions in production systems will have a competitive advantage in the future. The principles of Industry 4.0 can also be applied to shipyards to transform them into “smart shipyards” (Shipyard 4.0). The aim of this research is to implement an interactive approach by Internet of Things on a closed power-loop test bench equipped with sophisticated sensors that is specifically designed to test high-power thrusters before they are installed on high-speed crafts, which are used in passenger transport. The preliminary results of the…

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…

On the history of torsional stress concentrations in shafts: From electrical analogies to numerical methods

This article proposes a retrospective on experimental and numerical methods developed throughout the past century to solve the torsion problem in shafts, with particular emphasis on the determination of shear stress concentration factors in discontinuities of typical use in shaft design. This article, in particular, presents the theory and related solutions distinguishing between two classes of geometries: shafts with constant cross section and axisymmetric shafts with variable diameter. Emphasis is given to approaches based on physical analog methods and, in particular, those based on electrical analogies proposed since about 1925. Experimental methods based on structural physical models …

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…

Real-time non-contact ultrasonic detection of surface defects on objects moving at high speed

Il rilievo di difetti superficiali durante le ispezioni periodiche è importante poiché in genere le sollecitazioni sono maggiori in superficie e possono accelerare la crescita delle discontinuità. I difetti superficiali possono essere rilevati utilizzando alcuni metodi tradizionali di controllo non distruttivo, quali correnti indotte, liquidi penetranti, polveri magnetiche ed ultrasuoni. Alcuni tra questi metodi possono essere usati solo in condizioni statiche; gli altri presentano delle limitazioni per l’ispezione dinamica. I progressi recenti nel campo dei sensori ultrasonori senza contatto ci hanno permesso di sviluppare un sistema semplice per l’ispezione in tempo reale di corpi in movi…

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…

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

Misura della riduzione di spessore per corrosione in lamiere di alluminio mediante tecnica laser

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.

PROPAGAZIONE DI ONDE GUIDATE IN LAMINATI MULTISTRATO INCOLLATI: ANALISI NUMERICA E SPERIMENTALE

Friction Stir Welding Inspection by Non-Contact Ultrasonic Technique

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 …

A Non-Contact Automated Vision and Positioning System for In-Field Rail NDE