The development of a finite elements based springback compensation tool for sheet metal products

Springback is a major problem in the deep drawing process. When the tools are released after the forming stage, the product springs back due to the action of internal stresses. In many cases the shape deviation is too large and springback compensation is needed: the tools of the deep drawing process are changed so, that the product becomes geometrically accurate after springback. In this paper, two different ways of geometric optimization are presented, the smooth displacement adjustment (SDA) method and the surface controlled overbending (SCO) method. Both methods use results from a finite elements deep drawing simulation for the optimization of the tool shape. The methods are demonstrated on an industrial product. The results are satisfactory, but it is shown that both methods still need to be improved and that the FE simulation needs to become more reliable to allow industrial application

Review of the mathematical foundations of data fusion techniques in surface metrology

The recent proliferation of engineered surfaces, including freeform and structured surfaces, is challenging current metrology techniques. Measurement using multiple sensors has been proposed to achieve enhanced benefits, mainly in terms of spatial frequency bandwidth, which a single sensor cannot provide. When using data from different sensors, a process of data fusion is required and there is much active research in this area. In this paper, current data fusion methods and applications are reviewed, with a focus on the mathematical foundations of the subject. Common research questions in the fusion of surface metrology data are raised and potential fusion algorithms are discussed

Three dimensional extension of Bresenham’s algorithm with Voronoi diagram

Bresenham’s algorithm for plotting a two-dimensional line segment is elegant and efficient in its deployment of mid-point comparison and integer arithmetic. It is natural to investigate its three-dimensional extensions. In so doing, this paper uncovers the reason for little prior work. The concept of the mid-point in a unit interval generalizes to that of nearest neighbours involving a Voronoi diagram. Algorithmically, there are challenges. While a unit interval in two-dimension becomes a unit square in three-dimension, “squaring” the number of choices in Bresenham’s algorithm is shown to have difficulties. In this paper, the three-dimensional extension is based on the main idea of Bresenham’s algorithm of minimum distance between the line and the grid points. The structure of the Voronoi diagram is presented for grid points to which the line may be approximated. The deployment of integer arithmetic and symmetry for the three-dimensional extension of the algorithm to raise the computation efficiency are also investigated

Optimizing the geometrical accuracy of curvilinear meshes

This paper presents a method to generate valid high order meshes with optimized geometrical accuracy. The high order meshing procedure starts with a linear mesh, that is subsequently curved without taking care of the validity of the high order elements. An optimization procedure is then used to both untangle invalid elements and optimize the geometrical accuracy of the mesh. Standard measures of the distance between curves are considered to evaluate the geometrical accuracy in planar two-dimensional meshes, but they prove computationally too costly for optimization purposes. A fast estimate of the geometrical accuracy, based on Taylor expansions of the curves, is introduced. An unconstrained optimization procedure based on this estimate is shown to yield significant improvements in the geometrical accuracy of high order meshes, as measured by the standard Haudorff distance between the geometrical model and the mesh. Several examples illustrate the beneficial impact of this method on CFD solutions, with a particular role of the enhanced mesh boundary smoothness.Comment: Submitted to JC

Improving Building Energy Efficiency through Measurement of Building Physics Properties Using Dynamic Heating Tests

© 2019 the author. Licensee MDPI, Basel, Switzerland.Buildings contribute to nearly 30% of global carbon dioxide emissions, making a significant impact on climate change. Despite advanced design methods, such as those based on dynamic simulation tools, a significant discrepancy exists between designed and actual performance. This so-called performance gap occurs as a result of many factors, including the discrepancies between theoretical properties of building materials and properties of the same materials in buildings in use, reflected in the physics properties of the entire building. There are several different ways in which building physics properties and the underlying properties of materials can be established: a co-heating test, which measures the overall heat loss coefficient of the building; a dynamic heating test, which, in addition to the overall heat loss coefficient, also measures the effective thermal capacitance and the time constant of the building; and a simulation of the dynamic heating test with a calibrated simulation model, which establishes the same three properties in a non-disruptive way in comparison with the actual physical tests. This article introduces a method of measuring building physics properties through actual and simulated dynamic heating tests. It gives insights into the properties of building materials in use and it documents significant discrepancies between theoretical and measured properties. It introduces a quality assurance method for building construction and retrofit projects, and it explains the application of results on energy efficiency improvements in building design and control. It calls for re-examination of material properties data and for increased safety margins in order to make significant improvements in building energy efficiency.Peer reviewedFinal Published versio