workshop intermech.more_r2b

Emilia-Romagna High Technology Network

Via Vignolese 905 - I 41125 Modena ITALY - tel: +39 059 2056150 - fax: +39 059 2056126 www.intermech.unimore.it

Tech-pole for Mechanics

Emilia Romagna Excellence in Research

Intermech Mo.Re. Dir.: Angelo O. Andrisano

Mechanics – Material Platform

R2B, June 8-9, 2011



5 Universities on 11 sites Main research Centers

Over 150,000 Students

Over 6,000 Researchers

Emilia-Romagna Region Research System




Evolution

First Step

Net-Labs/Hi-Mech District

High Technology Network

Second Step

Third Step

2000

Next Future

2008

Towards Technopoles



Tech-poles aim: put together competences, technologies,

scientific knowledge and industrial know-how to support

growing up, innovation, development.

Tech-Poles boosts and makes easier the technology

knowledge diffusion between University-Research

Centers/Labs-Industry.

A look within the Modena and Reggio Tech-Poles

WHO TAKES PART

• University of Modena and Reggio Emilia

• Local Administrations

• Supporters and Sponsors



LABS

Centre for Rigenerative Medicine “Stefano Ferrari”

INTERMECH-MO.RE.

5

A look within Modena Tech-Pole

PLATFORM LIFE SCIENCE

PLATFORM MECHANICS-MATERIALS

PLATFORM ICT & DESIGN



LABS

INTERMECH-MO.RE.

BIOGEST.SITEIA

CRPA LAB

EN & TECH

A look within Reggio Emilia Tech-Pole

PLATFORM

FOOD PROCESSING

PLATFORM

MECHANICS-MATERIALS

PLATFORM

COSTRUCTION

PLATFORM

ENERGY-ENVIRONMENT



– 5 University Departments involved at Modena and Reggio Emilia (DIMeC, DIMA, DII, DISMI, FISMORE).

– Financial autonomy, internal and independent administration.

– Bureau:

• Director

• Centre Council

• Scientific Committee

Centre for Applied Research and Services for Advanced Mechanics and Automotive

Technology - INTERMECH University of Modena and Reggio Emilia



Centre for Applied Research and Services for Advanced Mechanics and Automotive

Technology - INTERMECH

• Applied Research, diffusion and transfer of technology and knowledge

– Research Unit Advanced Mechanics = 4 Operative Research Units

• ORU 1: SIMECH Mechanics: automotive/ gear transmission/

automation production systems and integration with robotics/fire

protection/pollutant emissions

• ORU 2: SIMECH Industrial Design and Manufacturing

• ORU 3: MATERIALS

• ORU 4: SUP&RMAN Material properties/Coatings

• ORU 5: MECTRON Mechatronics



UOR 1 SIMECH

Mechanics



Automotive 1

Engine thermofluids 1

Ferrari Auto e GeS; VM Motori; Ducati; Lombardini; Alfa Romeo; Casappa; CNH

Imperial College (UK); Chalmers University of Technology (SWE)

•Full engine system analysis

•Sub-system analysis

•Combustion&turbulence

•Injection systems

[email protected]

mailto:[email protected]



Automotive 2


Development of a new type of small capacity HSDI (High-Speed Direct

Injection) 2-Stroke Diesel engine prototype (HSD2)

HSD2 prototype parameters

Number of cylinders 3

Bore [mm] x Stroke [mm] 70 x 91

Total displacement [l] 1.05

Compression Ratio 19.5:1

IPC [CAD ABDC] 62.0

EPC [CAD BBDC] 76.0

[email protected]




Automotive 3


Development of a new type of small capacity HSDI 2-Stroke Diesel engine

prototype (HSD2)

Temperature field – Radial plane

Full load @ 3000 rpm

•Full Optimization of the combustion

chamber geometry and of the main

injection strategies

•Assess the effectiveness of the

combustion system

•Predict and compare exhaust gas

emissions

•KIVA3V – Rel. 2 3D CFD numerical

simulations. Diesel Oil Surrogate

(DOS) Model

[email protected]




Automotive 4

Engine test bed Main components and characteristics:

• Soundproof room (6m x 4m x 3m)

• Eddy Current double rotor dynamometer (290

kW – 500 Nm – 13.000 rpm)

• Fuel storage device and automatic feeding

system for gasoline and diesel oil controlled

with Coriolis flow-meter

• External evaporative cooling tower (500 kW)

• Control units both for Eddy Current

dynamometer and throttle actuator and host

controlled operation are possible)

• Data acquisition system (rotational speed,

torque, power, fuel consumption, combustion

air flow, pressures, temperatures, Air to Fuel

Ratio, environmental conditions)

• Steady state load test • Transient load test • Endurance test • Fuel consumption test • Research and development test

[email protected] [email protected]




Automotive 5 Engine components analysis and design

Motorbike frame,

instrumented with

strain gauges, for

stiffness estimate

FEM analysis of a connecting rod. The

eye is made with two parts, to allow the

assembly of a monolithic crankshaft

Photoelasticity: eye

of a connection rod;

stress concentrations

occur at the bore

sides

[email protected]




Automotive 6

Thermomechanics

LOMBARDINI Diesel Engine - cooling

circuit velocity contours

Experiment vs. FEM for crack prediction

in the cooling circuit

Head of a four valve

combustion chamber.

Both stress and

temperature affect the

material

[email protected]




Power used by

pump during a

duty cycle with a

frontal loader

Hydraulic load sensing

Electronic load sensing

Electronic flow matching

Load the

loader

Lift and tilt of

the loader

Unload the loader, lower and tilt it to

initial configuration

36% Of Power Saved for

Electronic Flow Matching

Independent Metering Arch.

25% Of Of Power Saved for

Electronic Load Sensing

Independent Metering Arch.

Automotive 7 – off road

Energy Saving in Mobile Hydraulicsalternative architectures to manage

auxiliary utilities in agricoltural tractor vs. hydraulic load sensing

[email protected]

Partners: PRIN07-CRF-CNH-EATON




Analysis of the lubrication mechanism within the gaps of hydraulic

machines to determine volumetric and mechanical efficiencyto have a design tool

for the optimization of efficiency

Numerical procedure to determine the

gaps height, tilt and the pressure distribution

in the gap viscous forces, and leakages

Energy Saving in Mobile Hydraulicsalternative architectures to manage

auxiliary utilities in agricoltural tractor vs. hydraulic load sensing

[email protected]

Axial Piston Swashplate

Pump/Motor

Automotive 8 – off-road

Partners: PRIN07-POCLAIN




Automotive 9

Thermofluid dynamics

Numerical and experimental research

• Navier-Stokes RANS simulation of vehicle,

vehicle subsystems and fluid circuits

• Time resolved High frequency Stereo PIV and

conventional fluid dynamic analyses

• IR thermography studies

MINARDI F1 heat

exchanger: IR

termography and

numeric simulations

MINARDI F1 lubrication

circuit: numeric analysis

[email protected]




Automotive 10

Aerodynamics and Fluid Flow aspects

Numerical and experimental studies

• Navier-Stokes RANS and LES aerodynamic

simulation

• PIV, anemometry and pressure experiments

TATUUS F

Renault

front wing:

CFD analysis

CFD analysis of a

Rally car intake

opening

High Frequency

Stereo PIV:

apparatus and

velocity field

reconstruction

[email protected]




Automotive 11

Millechili Lab 1

In collaboration with Ferrari SpA we aim at finding new solutions for car chassis

design in order to reduce the weight of the car complying with the company quality

standards for the vehicle in terms of: torsional and bending stiffness, fatigue

resistance, modal analysis, crash test resistance

[email protected]

Referent:

Patrizio

Moruzzi




Automotive 12

Autocar 09 june, 24th

Millechili Lab 2



Automotive 13

Millechili Lab 3

Examples of innovative chassis designs



Automotive 14

Millechili Lab 4

Crash test resistance



Automotive 15

Millechili Lab 5

Tutorial from top-opt.dk: Topology

optimisation for a simple bridge

Topology optimisation for car

chassis design:

TO is an iterative procedure in

which at each iteration of a FEM

analysis a different density is

assigned to each element

according to its structural

relevance

Tutorial from top-opt.dk: Topology

optimisation for a simple bridge

Software OPTISTRUCT

by Altair

[email protected] - [email protected]





Composite Materials 1

Carbon Fiber

Steel

or

Aluminum

Glass Fiber

Aramid Fiber

[email protected] - [email protected]





[email protected]

www.ribacomposites.it

SHUFFLE

Single element

optimization of

dimension,

position and shape

Stacking

sequence

Optimization

Number of plies

and thickness

optimization

FREE - SIZE

SIZE

In collaboration with

Simplified Boom Model

Boom Optimization



http://www.ribacomposites.it/



Carbon composite

tube for a hydraulic

cylinder

Analysis of

bonding joints

Buckling analysis

Weight reduction

of the jacket liner

-45 %


[email protected]

www.ribacomposites.it

In collaboration with


http://www.ribacomposites.it/



•Development of methods for Static and

Dynamic modelling of gear transmissions (in

cooperation with Case New Holland)

•Automatical FEM modelling of helical

gear pairs

•Dynamic models of spur gear pairs

•Models of planetary gears

•Optimization of gear pairs

•Endurance testing of gear transmissions (in

cooperation with Rossi Motoriduttori)

•Experimental checking of computed

stresses

•Pitting failure check

•Re-circulating power test rig

• Development of gear bearings (in coop.

with WAM)

0.2 0.25 0.3 0.35 0.4 0.45−10

−8

−6

−4

−2

0

2

4

6

8

10Contact pressure [MPa]

Roll angle [rad]

Z p

ositio

n [

mm

]

0

250

500

750

Mechanisms 1

Vibration Lab

[email protected]




Mechanisms 2

Vibration Lab

• Development of new theories for thin walled

structures (SPACE APPLICATIONS)

• Nonlinear Dynamics, Stability, Fluid-Structure

interaction

• Development of software for Gear modelling

• Stress, vibration reduction, optimization

• Dynamic tests on shaking table

• Modal analysis (numerical and experimental)

• Vibration measurements

• Complex gear train analyses

[email protected]




Fire Protection 1

Water Mist Systems

Discharge and dispersion analysis of water mist sprays

Characterization of the atomization process of a water jet exiting a high-pressure single injector :

• laser-based experimental device

• data on the drop size distribution are collected by experiments at high pressure (80 bar)

• a theoretical model has been developed

to predict velocity at the injector outlet

• CFD predictions by FDS code are carried out for the

distribution of mass flux at different heights from the outlet

[email protected]




Civil & Environmental 1

Atmospheric Pollution 1

Recent applications :

• estimation of the area impacted by the

plume from an industrial coastal area

(Porto Marghera, Venice Lagoon, terni)

• simulation of the dispersion of dust

particles from a waste landfill in a

complex terrain

Simulation of pollutant distribution in

atmosphere by means of Lagrangian

dispersion models

[email protected]

COLLABORATIONS:

IREN (multiutility company)

ISPESL (national institute for workplace safety and prevention)

CPL Concordia group (energy engineering company)




Unit head: Prof. Grazia Ghermandi

[email protected]

ACTIVITY:

Number size distribution for 10 – 700 nm

particles with a 120 sec temporal resolution

Multielemental analysis for segregated

particles with diameters ranging 0.04 – 10 mm

Volatiles-corrected on-line mass concentration

(PM1,PM2.5 and PM10) by TEOM-FDMS

Environmental pollution: direct measurement of

nanoparticles in air or combustion fumes


PARTNERSHIPS:

ISAC-CNR

LGGE - Université de Grenoble

GEES - University of Birmingham



Experimental monitoring of:

• particle mass concentration (PM1,

PM2.5 and PM10), by TEOM with

FDMS

• total concentration of particles and

particle size distribution, in the

diameter range 10 -700 nm, by

Differential Mobility Analyzer (DMA).

The aim of the research is to verify

removal and accumulation

processes, condensation of finer

particles and particle generation by

nucleation of gaseous components


[email protected]




Thermofluids 1

Concept, Design, Construction And Testing Of An Experimental Facility

For Multi-Point Longitudinal Airflow Measurements In Tunnels

P. Levoni, D. Angeli, E. Stalio, G.S. Barozzi, M. Cipollone

Tunnel Mont Blanc (TMB) – Italian gate

Concept and design of the experimental facility

CFD preliminary aerodynamic tests on the influence experimental facility



Thermofluids 2

Preparatory phase and final check

Transport of the experimental facility inside the Mont Blanc Tunnel



Thermofluids 3

Measurements inside the Tunnel Mont Blanc (TMB)

LT00

LT04

LT08LT12

LT16

LT18LT20

LT22

LT26

LT30

LT34

LT37

-5,00

-4,00

-3,00

-2,00

-1,00

0,00

1,00

2,00

3,00

4,00

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

velocity (m/s)

METRIC POINT

TMB Anemometers

Present Results



Thermofluids 4 Experimental Characterization Of A Tunnel Jet Fan By Direct Measurement Of

The Velocity Components At The Inflow And Outflow Section P. Levoni, D. Angeli, E. Canepa, G.S. Barozzi, M. Cipollone

Testing facility for the fan Howden APR 710/330



UOR 2 SIMECH

DESIGN AND MANUFACTURING



• Product and Process Integrated Design: DFMA,

Digital Manufacturing & Virtual Commissioning

PV

CFD

FEM

Fatica

MBD

Fogli

Calcolo

Fogli

Calcolo per verifica

Continuous or step-by-

step simulation

Virtual 3D system model

Operator

panel

PLC

software

Signals

monitor

Design and Manufacturing 1 [email protected]




• New Product development: Styling and Engineering,

QFD, CAD/CAE, Design for X, DOE

Partner: GRAF SpA





• Integrated Design of Robotic System: – Compact and modular robotic

solutions, that can integrate mechanical, electronic and IT functions; suitable for specific manufacturing requirements;

– Innovative computer-vision based robot solutions, adaptive compensation of the tools and offline programming, that can receive and transmit data and information over the network, capable of carrying out different strategies of control and audit quality in terms of specific processes.

Partn

er: S

ITI G

rou

p –

SIR

Sp

A

Monoscopic Vision Stereoscopic Vision Active triangulation

Design and Manufacturing 3

[email protected]




• Green design and green automation: energy saving,

resource optimization, ergonomics

Partner: ALCOA – FERRARI SpA – SIR SpA





• Green design and green automation: energy saving, resource optimization, ergonomics – Energy consumption

reduction (preliminary study -16%)

– Operation parameter optimization: for free, that is even without cycle time modifications!

– Sequence optimization: sequencing is done upon optimization contraints

– International patent (PCT US based) with Chalmers University of Technology, SE, and Research and Development General Motors Technology, USA





Biomechanics,Biomedical

& Implantology

Multiple dental prosthesis

Finite element studies

Simulation of wear of total hip

replacement

Study and design of hip

prosthesis

Design of biomedical systems.

Torsion equalized Twist inhibited

Lower screw: max. vertical deformation -3,35mm

Upper screw: max. vertical deformation -3,07mm


[email protected]






• Innovative product development methodologies that integrate Concurrent

Engineering and Industrial Design.

• Emphasis to Experience Design, User Centered Design and immersive

design

• Implementation of a service centre with a cave for virtual and augmented

reality (VR / AR) and tools for Real Time Rendering, Tracking and Motion

Capture.





Partner: CNH – CbEM Lab Bologna




Operations Management

• Modelling and analysis of production, handling and

logistic systems

• Development of discrete event simulation models

• Layout design and optimization

• Resource scheduling and operation planning

• Business Process Reengineering (BPR) (from

Forecasting process to Planning and Operations)

• Total Productive Maintenance

Response Surfaces and function for the

inventory level under relevant parameter

Simulating model for a transport and

storage system

[email protected] Design and Manufacturing 11




Manufacturing Technologies

Study of the primary and secondary anisotropy in parts built by Laser

Consolidation In cooperation with X-AT

Exeter University (UK)

EDM micro-drilling on advanced

materials: process modelling

μ- wave sintering of SLS metal

parts and nanostructured powders

In cooperation with

Politecnico di Torino

[email protected]

[email protected]






UOR 3

MATERIALS



Materials 1

Study of optimised

pack mix formulations

Diffusion coatings L. Lusvarghi, G. Bolelli, B. Bonferroni, F. Bozza

[email protected]

Diffusion treatment in

laboratory model furnace

Diffusion coating (e.g. aluminising,

chromising)

PROTECTION AGAINST HIGH TEMPERATURES

- Gas turbines, boilers, etc.




Materials 2 Thermal spray coatings L. Lusvarghi, G. Bolelli, B. Bonferroni, F. Bozza

[email protected]

Wear protection

& hard chrome replacement

POWDER SPRAY

PROCESS

COATING

Biomedical coatings




Method 1

good adhesion

low surface roughness

excellent finishing and gloss

low faradic efficiency (<2%)

Method 2

good adhesion

high efficiency, superior to deposition

from Cr(VI) (20-36%)

higher surface roughness

matt appearance

4μm 159 μm

Materials 3 Cr electrodeposition from Cr(III) solutions R. Giovanardi: [email protected]




antimicrobial agents covalently bonded to the polymer matrix

control doped-coating

by inclusion of antimicrobial agents into the polymer

control doped-coating

antimicrobial activity in contact with the coating

antimicrobial activity in contact and around the coating

ACTIVE BY CONTACT ACTIVE BY DIFFUSION

zone of NON-growth

Materials 4 Antimicrobial coatings M. Degli Esposti: [email protected]




• Inertization, recovery and valorization

of inorganic wastes and biomass and

engineering of the valorization and

recovery systems.

• Formulation and production of

ceramics, glasses, glass-ceramics,

bricks, composites, cement and

pigments starting from residues and

wastes (ashes from incinerator plants,

ceramics sludges, glass cullet, wastes

from electrical and electronic

equipments, wastes from agroindustrial

field...) alternative and/or competitive

to products on the market.

brick

glaze

cement

glass-ceramic

[email protected]

Materials 5




Connection pin

F

e

Ni

A

u

Connectors (boards)

Gold = 135 ppm

Connectors (pin)

Gold = 11 ppm

Microprocessors

Gold = 15 000 ppm

Chemical and physical methods for the

extraction of valuable components from wastes.

Au

20µm

Ni

Fe, Ni, Co

Metallic lid

Ores

Gold = 0.5 – 13.7 ppm

[email protected] Materials 6




Materials 7

• Preparation of green polymer by using as precursor the phenolic component found in agrowastes.

ESEM images of cross section

Agrowastes

Phenolic components

New materials by green process

[email protected]




Materials 8

• Evaluation of Life Cycle Assessment of materials and processes.

Human Health Ecosystem Quality Resources

-54.7%

-42.6%

-28.8%

-31.1%

0.00752 0.00265 0.00694 0.00599

Comparison between environmental impact of the use of primary

and secondary raw materials for the glazed formulation

[email protected]




Materials 9 Rheology of ceramic suspension

Modeling and optimisation of

body formulations by Design

of Experiment

[email protected]




UOR 4

SUP&RMAN



Sup&rman 1 Surface multi-scale texturing

Control of FRICTION

and ADHESION

in micro-nano devices

LASER MICROTEXTURING

FIB NANOTEXTURING

[email protected]

[email protected]

[email protected]

0.80

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00

Fri

cti

on

Co

eff

icie

nt

1.00.80.60.40.2

Laps [x 105]

"SINGLE DROP LUBRICATION"

textured surface untextured surface

ENDURANCE TEST

Hydrodinamic lift support:

↓ -80% friction

2R = 100 μm

H = 50 μm

Ltot = 4 μm






Sup&rman 2 Coatings



UOR 5

MECTRON



Mectron 1

FLUID-TRONICS [email protected]

Modeling, Design & Testing of Hydraulic Machines & Components



Mectron 2

Modeling, Design & Testing of Hydraulic Industrial Systems

FLUID-TRONICS [email protected]



Mectron 3

Magneto-Rheological Fluids

1 cm

MECHATRONICS MATERIALS [email protected]

Piezo-Electric Ceramics Shape- Memory Alloys

Reversible Physical Characteristics

(shape, stiffness, viscosity)

… once submitted to “stimulation” …

(temperature, electric and/or magnetic field,

…)

… electrically induced …



Mectron 4

MECHATRONICS MANTAINANCE [email protected]

Complex Mechatronics Systems Diagnosis

Systems Modeling e Reliability Measurements

Maintenance Protocols and Strategies

TESTING EFFICIENCY INDICATORS



Mectron 5

Maintenance Planning &

Organization Tools

Development

MECHATRONICS MANTAINANCE [email protected]



Mectron 6 CONTROL & OPTIMIZATION IN ROBOTICS

[email protected]

- Modeling the optimal control of industrial

machineries and production lines (UML,

SYSML, discrete events, hybrids &

continuous, …)

- New methods for the design of enhanced

HMI interfaces

- Mobile and stationery industrial robots

autonomous control



Mectron 7

Optimization

• packaging

• production load

• production rate

• production path

Modeling & Control

Automatic Production Lines

Logistics

CONTROL & OPTIMIZATION IN ROBOTICS [email protected]



Mectron 8

INDUSTRIAL ELECTRONIC SYSTEMS [email protected]

Control Sensors &

Networks

Energy Harvesting

Systems

Tele-Communications

& Distributed ICT

Design & Control of

Electric Drives



Mectron 9

INTEGRATING TECHNOLOGIES

Thanks to my colleagues and the University staff

for providing the original material

Thank you so much for your attention

workshop intermech.more_r2b

Documents

mobile hydraulicsalternative

applied research

gear transmissions

green design

itenergy saving

agricoltural

manageauxiliary

41125 modena