Reconfigurable Machines

Reconfigurable Machines form a new class of machines that are designed around a specific part family of products and allow rapid change in their structure. They are designed to allow changes in production requirements by changes in the machine mechanical configuration and structure. Reconfigurable machines might be designed for various types of production operations such as machining, inspection and assembly. This paper introduces characteristics and design principles of reconfigurable machines, and describes their features using an example of our new full-scale industrial prototype of a Reconfigurable Bore Surface Inspection Machine (RBSIM). In addition, the paper also describes briefly other three prototypes of Reconfigurable Machines that were developed during recent years in our center: (1) the Reconfigurable Machine Tool (RMT), (2) the Reconfigurable Inspection Machine (RIM), and (3) the Reconfigurable Assembly Machine (RAM).

A Reexamination of the Extraction of Material Properties Using Nanoindentation

The paper reexamines the extraction of material properties using nanoindentation for linearly elastic and elastic-plastic materials. The paper considers indentation performed using a rigid conical indenter, as follows. Linearly elastic solids: The reduction of nanoindentation test data of elastic solids is usually processed using Sneddon’s relation [1], which assumes a linearly elastic infinite half space and an infinitely sharp indenter tip. These assumptions are violated in practical indentation experiments. Since most of the research on the extraction of material properties relies heavily on numerical simulations, we used them to investigate the specimen dimensions required for it to qualify as an infinite body, and the indentation conditions for finite tip radius effect to be negligible. The outcome of this part is firstly, the definition of a “converged” 2D geometry so that additional magnification of the numerical model does not influence the load-displacement curve, and secondly, an explicit relationship between the measured load and displacement that takes into account the finite tip radius. Elastic-plastic solids: Here, the main data reduction technique was proposed by Pharr et al. [2], assuming elastic unloading of a plastic nanoindentation. We investigated the effects of finite tip radius in elastic-plastic indentations and found that the accuracy of the prediction is currently limited by the accurate determination of the projected contact area. This point will be discussed and a new experimental technique to measure the projected contact area will be proposed. The Poisson’s ratio effect in elastic-plastic indentations is found to be different from the linearly elastic case. This leads to the discussion on the applicability of the correction factor (for Poisson’s ratio effect) derived in linear elastic indentations, on elastic-plastic indentations. Finally, a technique to obtain an upper bound estimate of the yield stress for the indented elastic-plastic material (which is an exact estimation for non-hardening materials), will be presented.

Virtual Evaluation for Machine Tool Design

This paper presents the virtual machine tool environment Mori Seiki established for the evaluation of static, dynamic, and thermal performance of Mori Seiki machine tools. In this system environment, machining accuracy and quality are the main focus for each individual analysis discipline. The structural analysis uses the Finite Element Method (FEM) to monitor and optimize the static rigidity of the machine tool. Correlation between physical experiments and digital simulation is conducted to validate and optimize the static simulation accuracy. To accurately evaluate and effectively optimize dynamic performance of the machine tool in the virtual environment, the critical modal parameters such as damping and stiffness are calibrated based on experimental procedures which results in precise setup of the frequency response models. Computational Fluid Dynamic (CFD) analysis model is built in the environment so that the thermal perspective of the machine tool is evaluated and thermal deformation is monitored. This paper demonstrates compatibility of the digital simulation with physical experiments and success in integrating theoretical simulation processes with practical Mori Seiki machine tool development.

CMM Measurement Variability Analysis: A Comparison Between Two Metrological Laboratories Measuring Three Industrial Workpieces

Quality may be defined as a set of requirements a system should satisfy in order to meet customer’s needs. Control of these requirements assures satisfaction of relevant standards, and consequently the performance levels of a manufacturing/transactional stream. In this context it is fundamental to define control procedures and reliable measurement systems adequate for adopting improvement action as soon as anomalies and dysfunctions are detected. This paper deals with a study of measurement variability occurring during practical exploitation of CMMs (Coordinate Measuring Machines). These measurement systems are designed to probe selected points of workpiece surface, and compare the relevant coordinates or derived quantities with specified values; capability and versatility of CMMs justify their widespread use in industry. Evaluation of CMM measurement variability is however often awkward owing to a number of factors, such as e.g. measurement task, environment, operator and measurement procedures. A round robin exercise involving two industrial laboratories was planned in order to address these issues. Three typical machine tool parts were circulated among participants, who were asked to measure linear dimensions as well as tolerances at specified locations, according to an agreed upon schedule. Results of measurements, performed by experienced CMM industrial users, were analyzed in order to bring out discrepancies, and suggest remedial actions in the light of information gathered. Several factors involving metrological as well as other aspects were observed to cause major discrepancies, yielding in turn information on where to look for potential sources of trouble. Conclusions were drawn in terms of operating procedure, leading to improved information on origin and components of variability.

Deformation Behavior of a Shape Memory Alloy: Nitinol

Nickel-Titanium, commonly referred to as Nitinol, is a shape-memory alloy with numerous applications due to its superelastic nature and its ability to revert to a previously defined shape when deformed and then heated past a set transformation temperature. While the crystallography and the overall phenomenology are reasonably well understood, much remains unknown about the deformation and failure mechanisms of these materials. These latter issues are becoming critically important as Nitinol is being increasingly used in medical devices and space applications. The talk will describe the investigation of the deformation and failure of Nitinol using an in-situ optical technique called Digital Image Correlation (DIC). With this technique, full-field quantitative maps of strain localization are obtained for the first time in thin sheets of Nitinol under tension. These experiments provide new information connecting previous observations on the micro- and macro-scale. They show that martensitic transformation initiates before the formation of localized bands, and that the strain inside the bands does not saturate when the bands nucleate. The effect of rolling texture, the validity of the widely used resolved stress transformation criterion, and the role of geometric defects are examined.

Aluminum Shield Under Hypervelocity Impact of Mylar Flyer

The near-earth space environment is cluttered with man-made debris and naturally occurring meteoroids, which is a big menace to the safety of satellites and spacecrafts. This paper is addressed on the failure response of aluminum shields under hypervelocity impact of milligrame level flyer. A compacted electric gun is employed to accelerate a mylar flyer up to 10 km/s. Failure response of Ly12 aluminum shields with different thickness and layers impacted by mylar flyer with different velocities is under investigation. The spallation is observed in the rear free surface of 4 mm thick monolithic aluminum shield, and its fracture mechanism changes from plastic to brittle when loading pressure is above 13 GPa. A perforation with a diameter 8 mm in the impacted area of the 4mm thick Ly12 shield is observed after which is impacted by 0.1 mm thick mylar flyer 8mm in diameter with velocity 8.2 km/s. When three layers of shields are impacted, the debris clouds (DC) are observed in the first and the second spaces respectively during the impact process by high speed camera, and its leftover can be observed on the surface of the third plate. The shape of the first debris cloud head is a little flat, and its speed of lateral expansion is very slow, which is different from those impacted by spherical projectile, and its formation mechanics mainly attributes to multi-spallations based on the analysis of simulation.

Performance Comparison for a Constructal-Based Flow Field Pattern in a Single PEMFC

The present work shows a three-dimensional numerical simulation of a Single Proton Exchange Membrane Fuel Cell (PEMFC) with a constructal-based pattern as a gas distributor. The models are classified according to the proposed angle and bifurcation level. The numerical model considers a complete solution of the Navier-Stokes equations, the species transport equation and two potential field equations; the model is solved using a finite-volume technique assuming isothermal and steady state conditions. The three-dimensional simulation includes nine control volumes: two current collectors, two flow channels, two gas diffusion layers, two catalyst layers and a membrane between the two catalyst layers. The results show that larger values of current density can be obtained in order if the bifurcation levels are increased. This suggests that a better performance is reached when the structure is closer to those structures found in the natural world.

Operation of the Siemens SOFC Generators CHP100 and SFC5 in a Mechanical Factory

Solid Oxide Fuel Cells (SOFCs) are a promising technology for distributed electricity generation and cogeneration. Most of the installations of SOFC are small size fuel cells (of the order of decades of watts or few hundred watts) in laboratories. There are very few installations of commercial scale SOFC plants. In this paper the operating results obtained with two SOFC plants are presented. These plants, whose nominal electric power is 100 kW and 5 kW respectively, produce heat and power to contribute to the energy requirements of the Turbocare factory in Torino, Italy.

Extended Geometric Filter for Reconstruction as a Basis for Computational Inspection

Inspection of machined objects is one of the most important quality control tasks in the manufacturing industry. Contemporary scanning technologies have provided the impetus for the development of computational inspection methods, where the computer model of the manufactured object is reconstructed from the scan data, and then verified against its design computer model. Scan data, however, is typically very large scale (i.e. many points), unorganized, noisy and incomplete. Therefore, reconstruction is problematic. To overcome the above problems the reconstruction methods may exploit diverse feature data, that is, diverse information about the properties of the scanned object. Based on this concept, the paper proposes a new method for de-noising and reduction of scan data by Extended Geometric Filter (EGF). The proposed method is applied directly on the scanned points and is automatic, fast and straightforward to implement. The paper demonstrates the integration of the proposed method into the framework of the computational inspection process.

Advanced Ferroelectric MFC Actuators: The Effect of Ferro-Elastic Domain Switching

Macro Fiber Composite (MFC) actuators, which are commonly integrated in modern smart structures, may be subjected to high levels of mechanical loads. Opposed to the electrical actuation, these loads are not always controlled or anticipated by the user. Thus, they may yield a response that is beyond the linear range due to a stress induced ferro-elastic domain switching. In this paper, the phenomenon of domain switching and mechanical depolarization in the MFC actuator and the resulting degradation of the actuation capabilities are investigated. As an illustrative numerical example, the response of MFC layers in an active beam element is analyzed. Emphasis is placed on the location of the fiber segment along the active beam with a distinction between the compressed and the tensed layers. The results highlight the range of effects associated with the potential nonlinear response of the active structure under high levels of mechanical load.