The 1st Advanced Manufacturing Student Conference (AMSC21) Chemnitz, Germany 15–16 July 2021

The Advanced Manufacturing Student Conference (AMSC) represents an educational format designed to foster the acquisition and application of skills related to Research Methods in Engineering Sciences. Participating students are required to write and submit a conference paper and are given the opportunity to present their findings at the conference. The AMSC provides a tremendous opportunity for participants to practice critical skills associated with scientific publication. Conference Proceedings of the conference will benefit readers by providing updates on critical topics and recent progress in the advanced manufacturing engineering and technologies and, at the same time, will aid the transfer of valuable knowledge to the next generation of academics and practitioners. *** The first AMSC Conference Proceeding (AMSC21) addressed the following topics: Advances in “classical” Manufacturing Technologies, Technology and Application of Additive Manufacturing, Digitalization of Industrial Production (Industry 4.0), Advances in the field of Cyber-Physical Systems, Virtual and Augmented Reality Technologies throughout the entire product Life Cycle, Human-machine-environment interaction and Management and life cycle assessment.:- Advances in “classical” Manufacturing Technologies - Technology and Application of Additive Manufacturing - Digitalization of Industrial Production (Industry 4.0) - Advances in the field of Cyber-Physical Systems - Virtual and Augmented Reality Technologies throughout the entire product Life Cycle - Human-machine-environment interaction - Management and life cycle assessmen

National Educators' Workshop: Update 1989 Standard Experiments in Engineering Materials Science and Technology

Presented here is a collection of experiments presented and demonstrated at the National Educators' Workshop: Update 89, held October 17 to 19, 1989 at the National Aeronautics and Space Administration, Hampton, Virginia. The experiments related to the nature and properties of engineering materials and provided information to assist in teaching about materials in the education community

Development of incrementally formed patient-specific titanium knee prosthesis

Thesis (MScEng)--Stellenbosch University, 2013.ENGLISH ABSTRACT: Osteoarthritis (OA), also known as degenerative joint disease is a progressive disorder of the joints caused by gradual loss of cartilage and resulting in the development of bony spurs and cysts at the margins of the joints. The degradation of the musculoskeletal system, which is mainly caused by joint injury, obesity (leading to musculoskeletal fatigue) and aging can also lead to osteoarthritis. The hands, feet, spine, and large weight-bearing joints, such as the hips and knees are commonly affected. The only medical solution to severe cases of osteoarthritis is the surgical reconstruction or replacement of a malformed or degenerated joint, better known as arthroplasty. Arthroplasty makes use of biomedical implants and replacements to restore functionality of the joints. Biomedical engineering in arthroplasty is an ever increasing field of interest as a result of its innovative improvements to surgical quality. Certain cases of partial osteoarthritis require less surgical action. Partial knee replacement surgery, also known as unicondylar (or unicompartmental) knee arthroplasty involves a covering which is placed over the affected area to resurface the affected bone and protect the patient from further degeneration. Advantages of partial replacement include faster recovery time and less post-operative pain. The biomedical implants used for these operations consist of a standardized implant that is fit onto the bone by modifying (cutting away) the outer structure of the bone. The result is known to cause post-operative discomfort among some patients. The problem with these standard designs includes the requirement of the removal of unaffected (healthy) bone matter, leading to induced trauma and pain for patients during the recovery phase of the operations. A preferred alternative to the standard design would be to create a custom implant for every patient, reducing the need to remove parts of unaffected bone matter. The implementation of this proposed method tends toward Minimally Invasive Surgery (MIS). MIS is normally preferred as it reduces the risk of various negative consequences of normal arthroplasty such as nerve or tendon damage during surgery. It could be argued that the proposed method may cause less damage to the fragile tendon, bloodflow, and nerve networks of the knee. Increasing material costs of metal products introduce great interest in more cost efficient forming processes to reduce the loss of redundant blank material. Incremental Sheet Forming (ISF), a relatively new class of forming process, has the potential to meet the need for this more efficient forming process. The ISF process is highly flexible, can be developed in normal milling machines, and can reduce production cost by up to 90% in comparison to processes such as stamping. The ISF process is a non-patented process, as the existing patents are referred to the designed machines and not the process. The availability of the ISF process contributes greatly to its attractiveness. ISF can be implemented in any facility that has access to a three- or more-axis CNC machine. The advantage of ISF implemented in CNC machines is that CNC technology has already reached a mature stage in development, contributing to the accuracy and methodology (such as feed rate or angular velocity of the tool) of the ISF process. The forming of valuable lightweight materials is well covered by ISF processes. A variety of studies contribute to research on the forming of titanium and titanium based alloys as part of ISF of lightweight materials. The ISF process utilizes the functionality of commercial CNC machines, improving the process availability of many manufacturing companies. The ISF process offers fast setup times and flexibility of the forming process. The purpose of this project is to define a process chain for creating a customized biomedical implant as well as determining the validity of the process chain by applying each step. The design and development procedure of a titanium based biomedical arthroplasty implant using innovative Incremental Sheet Forming (ISF) techniques will be documented, as well as an investigation of the financial cost and potential gain that this implant can offer.AFRIKAANSE OPSOMMING: Osteoartritis is 'n gewrig siekte wat degeneratiewe newe-effekte behels in die gewrigte. Hierdie siekte lei to die geleidelike verlies van kraakbeen en lei tot die onreelmatige ontwikkeling van abnormale beengroei. Osteoartritis kan ook deur beserings in die gewrig veroorsaak word. Die hande, voete, ruggraat, en enige groter gewigdraende gewrigte, soos die heupe en knieë kan geaffekteer word. Die enigste mediese oplossing tot ernstige gevalle van die siekte is chirurgiese rekonstruksie of vervanging van die gewrig, meer bekend as artroplastie. Artroplastie maak gebruik van biomediese implantate om funksionaliteit van die gewrig te herstel. Biomediese ingenieurswese in artroplastie is 'n toenemende navorsingsveld as gevolg van die innoverende aspekte om chirurgiese kwaliteit te verhoog. Sekere gevalle van gedeeltelike osteoartritis vereis veel minder chirurgiese behandeling. Gedeeltelike knie vervanging chirurgie, meer bekend as unikompartementele knie artroplastie, behels 'n bedekking wat slegs die geaffekteerde been bedek, om die pasiënt van verdere degenerasie te beskerm. Voordele van gedeeltelike vervanging sluit vinniger herstel tyd en minder pyn in. Die biomediese implantate wat gebruik word vir hieride operasies bestaan uit standaard ontwerpe wat aan die been gepas word deur die wysiging (of wegsny) van die buitenste beenstruktuur. Die nagevolg van hierdie chirurgie is lang herstel periodes en kan ongemaklikheid in die knie veroorsaak. Die probleem met die bogenoemde standaard is dat die prosedure die verweidering van selfs ongeaffekteerde (of gesonde) been in sluit, wat lei tot verdere kniepyn en ongemak vir pasiënte lei tydens die herstelperiode. 'n Verkiesde alternatief tot die standaard ontwerpe is om 'n persoonlikke implantaat vir elke pasiënt te skep, en so kan die behoefte om dele van ongeaffekteerde been te behou moontlik wees. Die toepassing van die voorgestelde metode neig na Minimale Skade Chirurgie (MSC). MSC word gewoonlik verkies om die risiko van verskeie negatiewe nagevolge te verminder, en skade aan die tendon, bloed- en senunetwerke van die knie te beperk. Die toenemende materiaalkoste vand metal produkte lei tot 'n groot belangstelling in meer koste besparing vormings prosesse, om sodoende die verlies van oortollige materiaalverlies te verminder. Inkrementele Plaat Vervorming (IPV), 'n relatiewe nuwe klas van vervorming, is 'n waardige kanidaat om hierdie doel te bereik. Die IPV proses is baie toepaslik, en kan deur die gebruik van Rekenaar Numeriese Kontrole (RNK) masjienerie toegepas word. Verder sal dit vervaardigingskoste kan verlaag met soveel as 90% in vergelyking met ander prosese soos die stempel metode. Die beskikbaarheid van die IPV proses dra grootliks by tot die proses se aantreklikheid in die industrie. IPV kan geimplementeer word in enige fasiliteit wat toegang tot 'n drie-as RNK masjien het. Die voordeel van dit is die feit dat RNK masjienerie klaar ontwikkel en volwasse is, wat kan bydra tot goeie akkuraatheid in die vormingsproses. Die vervaardiging van laegewig materiale soos titaan of aluminium is gedokumenteer. 'n Verskeidenheid van studies dra waarde tot navorsing van die vormingsproses van titaan as deel hiervan. Die IPV proses bied vinnige opstel tye en goeie buigsaamheid met die vormingsproses, veral met behulp van 'n vyf-as masjien. Die doel van hierdie projek is om 'n proses ketting te ontwerp. Die proses ketting, wat uit vele stappe bestaan, sal die ontwerp en vervaardigingsproses van 'n persoonlike biomediese knie implantaat bevestig deur middel van die IPV vormings tegniek. Validasie van die proses ketting sal dus plaasvind deur die stappe van die voorgestelde proses ketting uit te voer. 'n Finale ondersoek sal die finansiele en regalutoriese aspekte van die projek aanspreek

Tekes projekti SuperMachines loppuraportti

Tutkimuksessa kerättiin best practice aineistoa ja kehitettiin internet alusta kerätyn aineiston tutkimiseen ja hakujen suorittamiseen. Aineisto löytyy internet osoitteesta: http://www.amcase.info/. Rekisteröitymällä kuka vain voi syöttää alustalle lisää aineistoa. Kappaleiden suunnitteluohjeet on julkaistu Suomen pikavalmistusyhdistyksen sivuilla: http://firpa.fi/html/am-tietoa.html. Ohjeesta löytyy mm. suositeltu minimi seinämänvahvuus, suositellun pienimmän yksityiskohdan koko, tyypillinen markkinoilta löytyvä rakennuskammin koko, sekä tyypilliset materiaalit. Valmiiden kokoonpanojen ja mekanismien suunnitteluun muodostettiin Objet 30 ja UPrint SE+ laitteelle ohjeistus josta löytyy pienin radiaalinen välys, aksiaalinen välys, sekä pienin rako riippuen rakennussuunnasta. Tutkimusprojektin aikana seurattiin alan teknologian kehitystä. Kahden vuoden aikana markkinoille ilmaantui noin. 50 uutta laitevalmistajaa, sekä noin 300 erilaista laitetta, sekä lukuisia materiaaleja. Merkittävimmät uudistukset listattiin ja pohdittiin mahdollisia kehityssuuntia. Kaikki uudet toimijat ja laitteet päivitettiin Firpan ylläpitämään tietokantaan: http://firpa.fi/html/am-tietoa.html. Markkinoilla on selvä suuntaus tuotantokomponenttien valmistamiseen, kotitulostimien hintojen laskemiseen, sekä isompien kappaleiden valmistamiseen. Muovilevy komponenttien muovaamista tutkittiin laserin ja alipaineen avulla DDShape laitteella. Laitteella onnistuttiin tekemään testikappaleita ja laitetta saatiin kehitettyä eteenpäin. Laitteiston kehittämiseksi ja kaupallistamisen tueksi Tekes on myöntänyt "Tutkimusideoista uutta tietoa ja liiketoimintaa" (TUTLI) rahoituksen. ISF mini projektissa onnistuttiin kehittämään edullinen pienten kappaleiden painomuovauskone. Samalla kartoitettiin laitteelle soveltuvat parametrit ja rajoitukset. Laseravusteisella muovaamisella päästään kuparilla isompaan seinämän kaltevuuteen ja pinnalaatu pysyy hyvänä. Teräksellä laserista ei ollut juuri hyötyä ja alumiinilla muovattavuus kyllä parani, mutta pinnalaatu huononi. AM kappaleiden viimeistelykoneistuksessa tutkittiin muovisten kappaleiden viimeistely jyrsimällä, sekä metallikappaleiden automaattista hiontaa. Jyrsinnässä vertailtiin eri menetelmillä tehtyjä kappaleita, sekä mitattiin kappaleiden mittatarkkuutta ja geometrisia toleransseja. Huonosta kotitulostimella tehdystä kappaleesta on vaikea saada hyvää kappaletta vaikka se viimeisteltäisiin koneistamalla. Suurimmat ongelmat liittyvät kappaleiden vääntymiseen johtuen lämpöjännityksistä valmistusprosessin aikana. Kappaleiden automaattisessa hionnassa parhaat tulokset saatiin DMLS kappaleille käyttämällä hionta-aineena teräshauleja ja pyörittämällä niitä hiottavat kappaleen kanssa rummussa. Ra arvo parani tällöin noin seitsemästä mikrometristä kolmeen mikrometriin

BIAXIAL STRESS TESTING OF SS-304L MICROTUBES BY AXIAL LOAD AND INTERNAL PRESSURE

The mechanical behavior and material properties of a Stainless Steel SS-304L microtube, with an OD of 2.40 mm and wall thickness of 160 µm, was investigated through uniaxial, isothermal, biaxial, and metallographic testing. The grain structure, microhardness, and tube eccentricity were investigated using optical microscopy. The rate- and temperature-dependence of the material was characterized by isothermal uniaxial tension experiments. A biaxial experimental setup, consisting of a 2 kN electromechanical tensile stage and a 1.4 kbar hydraulic pump, was created to internally pressurize and axially load the microtube in biaxial stress states. Fourteen radial nominal stress path tests were conducted to determine the formability, failure mode, and anisotropy during biaxial stress states. The Yld2000-2D and Yld2004-3D yield functions were fit to the data at the initial yield surface and higher levels of plastic work. The path-dependence of failure stresses and strains was investigated by comparing radial path results to corner paths

Ultrasonic characterisation of rolled aluminium and steel sheet correlated with electron backscatter diffraction measurements

This thesis is based on the characterization of material properties of interest in rolled aluminium and steel sheet, both popular materials used across a wide-range of applications. The forming processes involved in producing rolled sheet metal depend on plastic deformation, inducing elastic anisotropy as a consequence. These changes result in a variation from the simple isotropic and cubic symmetry systems possessed by steel and aluminium prior to cold-working. The most significant changes include the introduction of crystallographic texture and the morphology of the crystallographic grains in size and shape to accommodate the plastic deformation. It is desirable in industries that use rolled product for manufacturing components to quantify such changes. The literature has postulated links between plastic and elastic properties, and hence any quantification of the elasticity, crystallographic texture and grain morphology can aid in the prediction of future formability behaviour. This thesis presents non-destructive, rapid ultrasonic measurements to characterize some of the changes that are evident in rolled aluminium and steel sheet. These ultrasonic results have then been correlated to crystallographic orientation measurements generated from using a microscopic technique called electron backscatter diffraction (EBSD). The level of agreement between the two contrasting methods has been analysed and is presented here. The non-destructive ultrasonic measurements include quantifying crystallographic texture utilising theory linking the S0 Lamb wave velocity and the direction of propagation in a rolled sheet with respect to the rolling direction. This leads to the determination of texture coefficients known as orientation distribution coefficients (ODC). Through-thickness linearly polarized SH waves have then been used to analyse grain morphology using attenuation data, and elasticity measurements from velocity data. EBSD datasets have been manipulated to produce predictions of the effective elastic stiffness constants, which in turn can be used to generate comparable S0 Lamb wave velocity predictions to be directly compared to the ultrasonic measurements. This process has required a novel method to generate such ultrasonic velocity predictions as a function of angle, together with predictions for the nine effective elastic stiffness constants inherent to rolled orthorhombic sheet. The facility to measure grain size and shape accurately from EBSD data has been utilized. The thesis starts with a general introduction in non-destructive testing and microscopy, with focussed discussion on ultrasound, electromagnetic acoustic transducers (EMATs), EBSD and metallurgy in the subsequent chapters. Chapter 6 introduces the development of correlation methods between the ultrasound and EBSD results, with chapters 7 and 8 displaying the empirical ultrasound and EBSD data respectively. Chapter 9 compares the data from the two methods, with the final conclusions given in chapter 10

Thermal protection properties of aerogel-coated Kevlar woven fabrics

This paper investigated the thermal properties of aerogel-coated Kevlar fabrics under both the ambient temperature and high temperature with laser radiation. It is found that the aerogels combined with a Kevlar fabric contribute to a higher thermal insulation value. Under laser radiation with high temperature, the aerogel content plays a vital role on the surface temperature of the fabrics. At laser radiations with pixel time 330 μs, the surface temperatures of the aerogel coated Kevlar fabrics are 400-440°C lower than that of the uncoated fabric. Results also show that the fabric temperature is directly proportional to pixel time. It can be concluded that the Kevlar fabrics coated with silica aerogel provides better thermal protection under high temperature