Activities:

The overall aim of the project was to study and analyze the industrial processes suitable to be monitored by means of Infrared Thermography Technology (IRT). Particular focus was addressed to the material machining and laser welding. For both processes the possibilities to be controlled and monitored through different IRT experimental set-up was investigated. Moreover an analysis of the main defects arising during the processes and their possibility to be detected by means of different IRT techniques was carried out. The laser welding process was deeply analyzed, starting from the investigation of the effect of process parameters on the quality of the welded joint.

Results:

The study was focused on the welding of aluminum profiles and on the possibility to virtually reproduce the welding process. After a preliminary analysis of the technical and numerical issues to be faced, a complex study of the numerical coupling possibilities among thermal, mechanical and metallurgical aspects regarding the process was carried out. Finally, a numerical model, experimentally validated, able to foresee the temperature distribution during the welding process was developed. 

 

Client:  European Commission

Activities:

1. Thermal-structural analysis of the stone splitting equipment 
2. Modeling of Shape Memory Alloys (SMAs) actuators 
3. Steady-state and transient FEM analyses 

Results:

Development and production of a novel stone splitting equipment based on Shape Memory Alloys (SMAs) actuators.

The splitter is composed by two steel shells with the seats for the actuators, the SMA cylinders, and the heating system for the activation. The shells were designed to obtain a homogeneous distribution of the forces produced by the actuators and to obtain an optimal exploitation of the required displacements for rock fracture initiation. Each splitter hosts several actuators characterised by the development of high forces.

The industrial objective of this project was to develop a cost-effective and efficient working tool for the extraction of stone blocks through stitch drilling.

Increased performance levels were predicted to yield a 20 percent cost saving and up to 30 percent increase in production with respect to traditional systems.

Shape memory alloys are novel materials which have the cap ability to return to a predetermined shape when heated, generating large forces and displacements. SMA actuators, consisting of small cylinders, electrically actuated through Joule heating by lightweight portable batteries and recovered to the original shape by means of springs, were designed.

 

Activities:

Full characterization of a test bench for railway pantographs has been carried out. Static structural analyses were carried out to verify the structural integrity of the pantograph test bench under service loading conditions and ultimate loading conditions. Modal analyses were performed to identify the natural frequencies and the associated mode shapes under constrained conditions, in order to ensure the external excitation sources do not lead to resonances. Fatigue analyses were performed to predict the lifetime to failure of the test bench under service loading conditions, taking into account the cyclic variation of specific loads and to assess the influence of eventual imbalance on the lifetime to failure. 

Thermo fluid dynamic analyses were conducted in order to investigate velocity and pressure field in the surroundings of the test bench and temperature distribution within the test bench and its surroundings. Another investigated aspect was the capability of the test bench to auto-dissipate the thermal power generated in the wire due to Joule effect and friction between wire and pantograph: many kinds of wing configurations and profiles were investigated, and the effects of conditioning air flows were also evaluated. Noise generated by turbulence in the neighbourhood of the test bench was evaluated through specific acoustic analyses. Thermal-electric FE were performed to evaluate the electrical current distribution on the disk of the test bench pantograph and thermal field due to joule heat. 

Results

The main result of the project has been the structural FEM and CDF Analysis on a pantograph test bench for railway sector.

Activities:

1. Re-engineering of backplate for brake pads in order to reduce noise and vibration from pad / disk coupling 
2. Development of ten different conceptual designs 
3. Free-free modal analyses 
4. Harmonic analyses to evaluate damping effects in different geometrical configurations 

Results:

The aim of the Project was to develop a new design of automotive brake pads for reducing the noise originated by the pad / disk coupling.

The objective was achieved through modal analyses performed via finite elements (FE) method on several backplates, whose conceptual design was modified on the pad side.

The modifications affect the behavior of the backplate, shifting eigenfrequencies and varying eigenmodes of the pad. Results of numerical analyses performed during validation phase showed good agreement between experimental data and numerical predictions. The numerical model which fitted experimental data with best agreement was adopted to evaluate the different conceptual designs created.

In detail, through some of the conceptual designs created, it was possible to reach the target shift on natural frequencies cause of resonances.

Some simplified analyses to evaluate the dynamic behaviour of the backplates have been also performed.

 

Activities:

The aim of the Project was to evaluate the structural response of an electric motor subjected to earthquake dynamic load, by means of Finite Element (FEM) response spectrum analyses.

The electric motor is a 4 poles induction motor for variable speed industrial application with a rated power of 2500kW. 

Main components of the electric motor are: motor housing, rotor shaft, shields, stator winding, heat exchanger casing, terminal boxes, external fan casing. The shields are connected to the motor housing through bolted connections and the shaft is connected to the shields trough two supports, where bearings are housed. 

Results

The numerical analysis was conducted using the Finite Element Method (FEM) approach, according to international standard. The seismic analysis could be considered constituted by the following two steps: (I) pre-stressed modal analysis (determination of vibration modes and natural frequencies of vibration) followed by a (II) response spectrum analysis (for the determination of the maximum accelerations to which the whole structure is subjected to). 

Activities:

The friction arm is constituted by several components: a base, three connected arms linked by friction joints, and a top, where the tablet-holder is connected. The friction arm can be moved by the pilot into any position; however, the friction joints have to maintain its position under several loading conditions (FORWARD, AFT, UP, DOWN and SIDE accelerations of the aircraft).  

Finite Element (FE) analyses have been performed to predict the capability of the mechanical device to hold a tablet: this, to prevent translational displacements when subject to accelerations. Several numerical analyses were performed to simulate the behavior of the holder, subjected to the accelerations in the longitudinal and vertical directions. 

Results

The purpose of the project was to perform stress analyses on two components: a tablet holder and a friction arm, used to hold a tablet inside an aircraft cockpit.

Activities

• Experimental testing campaign for evaluating the degradation phenomenon inside the vessels subjected to agressive liquid; 
• Development of 3D CAD model of the robotic system and of the whole storage tanks area. 

Results: 

Technical and economic feasibility study to identify the most suitable no destructive technique and procedures for carrying out the investigations, as well as to propose a remotely operated robotic solution that perform the measurements.. 

Activities

The aim of the Project was to perform a thermal-structural analysis of components used for the synthesis gas production (heat exchanger, mixer and catalytic reactor) and numerical FEM analyses were carried out to verify the stress field on mixer and reactor induced by the thermal load. 

The two components were simulated separately; however, in order to properly analyze the connection area, a detailed model was developed.

Different thermal-structural FEM analyses were performed considering the following conditions: 

1. Steady-state condition (operation condition) 
2. Transient conditions (start-up, shut-down and emergency) 

Temperature dependent thermal and mechanical properties of refractory and steel materials were adopted, according to experimental data.

In particular, suitable models were implemented in the FEM analysis for capturing the thermal shock damage of refractory materials.

According to the output of the analysis, a second to simulate phase was activated by the Client, focused on the optimization of the components design of both mixer and reactor. 

Results: 

The main result was a thermal-structural analysis of components used for the synthesis gas production (heat exchanger, mixer and catalytic reactor).

Activities

The SUPCAM concept is based on the development of an endoscopic capsule whose structure and innovative design allow to safely and accurately guiding it along the colonic lumen from the outside, through an electromagnet, completely wireless.

We led the design of the capsule with all the miniaturized subcomponents (i.e., frame, permanent magnet, image system, vision and control boards, illumination board, telemetry board, RFID, recharging coil and battery) integrated within the capsule.

3D animations were developed to show the handling of the camera inside the colon, from outside thanks to magnets. 

Results: 

The main result of the project was the development of new cost effective and minimally invasive endoscopic device able to investigate the colonic mucosa, ensuring a high level of navigation accuracy and enhanced diagnostic capabilities.

Activities

The main activity performed was the Finite Element (FE) analysis on a Load Manager System (LMS), connected to the jacking system (Ener packs) and this latter connected to a double-H-frame.

All these components constitute the system (called “Unit Structure”) that transfers the unit load (dead load weight and pull load), over the double H-frame.

Stress and displacement analysis under static conditions was carried out as well.

Results: 

The main result of the project was the structural assessment on a load manager system.