Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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Phase field modeling of fracture has been in the focus of research for over a decade now. The field has gained attention properly due to its benefiting features for the numerical simulations even for complex crack problems. The framework was so far applied to quasi static and dynamic fracture for brittle as well as for ductile materials with isotropic and also with anisotropic fracture resistance. However, fracture due to cyclic mechanical fatigue, which is a very important phenomenon regarding a safe, durable and also economical design of structures, is considered only recently in terms of phase field modeling. While in first phase field models the material’s fracture toughness becomes degraded to simulate fatigue crack growth, we present an alternative method within this work, where the driving force for the fatigue mechanism increases due to cyclic loading. This new contribution is governed by the evolution of fatigue damage, which can be approximated by a linear law, namely the Miner’s rule, for damage accumulation. The proposed model is able to predict nucleation as well as growth of a fatigue crack. Furthermore, by an assessment of crack growth rates obtained from several numerical simulations by a conventional approach for the description of fatigue crack growth, it is shown that the presented model is able to predict realistic behavior.
In the field of liquid filtration, the realization of gas throughput-free cake filtration has been investigated for a long time. Cake filtration without gas throughput would lead to energy savings in general and would reduce the mechanically achievable residual moisture in filter cakes in particular. The reason why gas throughput-free filtration could not be realized with fabrics so far is that the achievable pore sizes are not small enough, and that the associated capillary pressure is too low for gas throughput-free filtration. Microporous membranes can prevent gas flow through open pores and cracks in the filter cake at a standard differential pressure for cake filtration of 0.8 bar due to their smaller pore size. Since large-scale implementation with membranes was not yet successful due to their inadequate mechanical strength, this work focuses on the development and testing of a novel composite material. It combines the advantages of gas throughput-free filtration using membranes with the mechanical stability of fabrics. For the production of the composites, a paste dot coating with adhesive, which is a common method in the textile industry, was used. Based on filtration experiments, delamination and tensile tests, as well as CT analysis, it is shown that this method is suitable for the production of composite filter materials for gas throughput-free cake filtration.
Since their introduction, robots have primarily influenced the industrial world, providing new opportunities and challenges for humans and machinery. With the introduction of lightweight robots and mobile robot platforms, the field of robot applications has been expanded, diversified, and brought closer to society. The increased degree of digitalization and the personalization of goods and products require an enhanced and flexible robot deployment by operating several multi-robot systems along production processes, industrial applications, assembly and packaging lines, transport systems, etc.
Efficient and safe robot operation relies on successful task planning followed by the computation and execution of task-performing motion trajectories. This thesis addresses these issues by developing, implementing, and validating optimization-based methods for task and trajectory planning in robotics, considering certain optimality and performance criteria. The focus is mainly on the time optimality of the presented approaches with respect to both execution and computation time without compromising safe robot use.
Driven by a systematic approach, the basis for the algorithm development is established first by modeling the kinematics and dynamics of the considered robots and identifying required dynamic parameters. In a further step, time-optimal task and trajectory planning algorithms for a single robotic arm are developed. Initially, a hierarchical approach is introduced consisting of two decoupled optimization-based control policies, a binary problem for task planning, and a continuous model predictive trajectory planning problem. The two layers of the hierarchical structure are then merged into a monolithic layer, resulting in a hybrid structure in the form of a mixed-integer optimization problem for inherent task and trajectory planning.
Motivated by a multi-robot deployment, the hierarchical control structure for time-optimal task and trajectory planning is extended for the case of a two-arm robotic system with highly overlapping operational spaces, leading to challenging robot motions with high inter-robot collision potential. To this end, a novel predictive approach for collision avoidance is proposed based on a continuous approximation of the robot geometry, resulting in a nonlinear optimization problem capable of online applications with real-time requirements. Towards a mobile and flexible robot platform, a model predictive path-following controller for an omnidirectional mobile robot is introduced. Here, a time-minimal approach is also applied, which consists of the robot following a given parameterized path as accurately as possible and at maximum speed.
The performance of the proposed algorithms and methods is experimentally analyzed and validated under real conditions on robot demonstrators. Implementation details, including the resulting hardware and software architecture, are presented, followed by a detailed description of the results. Concrete and industry-oriented demonstrators for integrating robotic arms in existing manual processes and the indoor navigation of a mobile robot complete the work.
Schneckengetriebe werden meist aus einer Stahlschnecke und einem Bronze-Schneckenrad gefertigt. Diese werden zur einstufigen Übertragung von Drehbewegungen bei hohen Übersetzungen eingesetzt. Einen Nachteil von Schneckengetrieben stellt der relativ hohe Verschleiß infolge der hohen Gleitreibung im Zahneingriff dar. Durch eine geeignete Schmierung können Reibung und Verschleiß reduziert werden. Dies reduziert den Temperaturanstieg
im Betrieb und führt somit zu einer längeren Lebensdauer des Getriebes. Aufgrund der ausgeprägten Kühlwirkung erfolgt die Schmierung von Schneckengetrieben in der Praxis überwiegend mit Schmierölen. Fettartige Schmierstoffe werden ebenfalls verwendet, weisen jedoch eine geringere Kühlwirkung als flüssige Schmierstoffe auf. Bei Vakuumanwendungen oder unter extremen Betriebsbedingungen, wie z.B. Hoch- oder Tieftemperaturanwendungen
sowie bei niedrigen hydrodynamischen Geschwindigkeiten, verlieren die oben genannten konventionellen Schmierstoffe ihre Schmierwirkung. Als Alternative
werden Festschmierstoffe eingesetzt.
Festschmierstoffe können im Allgemeinen auf verschiedene Weise in den Kontaktstellen von Maschinenelementen verwendet werden. In dieser Arbeit wird das Prinzip der Transferschmierung durch ein Opferbauteil eingesetzt. Hierbei werden Compounds aus strahlenmodifiziertem Polytetrafluorethylen (PTFE) und Polyamid (PA) als Opferbauteil im Schneckengetriebe verwendet, sodass die Stahlschnecke zeitgleich mit dem Bronze-Schneckenrad und dem Opferrad aus PA-PTFE-Compound im Zahneingriff steht. Durch die Belastung des Opferrades mit einem relativ kleinen Drehmoment verschleißt das Opferrad, wodurch der PTFE-Festschmierstoff freigesetzt und an der Stahloberfläche deponiert wird. Dies führt zur Bildung eines Transferfilms, welcher zur Schmierung des Kontakts
zwischen der Stahlschnecke und dem Bronze-Schneckenrad führt. Die Mechanismen des Auf- und Abbaus solcher Transferfilme in Schneckengetrieben sind derzeit unbekannt und werden in dieser Arbeit anhand experimenteller Untersuchungen erforscht. Hierzu wurden tribologische Versuche an Modellprüfständen durchgeführt, wodurch das reib- und Verschleißverhalten an Stahl-Bronze-Kontakten untersucht wurde. Als Modellprüfstände kamen der Block-auf-Ring-, der Block-Zwei-Scheiben- und der Drei-Scheiben-Prüfstand zum Einsatz. Anschließend wurden Bauteilversuche auf einem Schneckengetriebeprüfstand durchgeführt, um die aus den Modellversuchen gewonnenen Erkenntnisse zu validieren. Mit Hilfe von oberflächenanalytischen Techniken wurden die Prüfkörper auf der Mikroskala untersucht, um die Qualität und Quantität des aufgebauten Transferfilms zu bestimmen.
Cancer, a complex and multifaceted disease, continues to challenge the boundaries of biomedical research. In this dissertation, we explore the complexity of cancer genesis, employing multiscale modeling, abstract mathematical concepts such as stability analysis, and numerical simulations as powerful tools to decipher its underlying mechanisms. Through a series of comprehensive studies, we mainly investigate the cell cycle dynamics, the delicate balance between quiescence and proliferation, the impact of mutations, and the co-evolution of healthy and cancer stem cell lineages. The introductory chapter provides a comprehensive overview of cancer and the critical importance of understanding its underlying mechanisms. Additionally, it establishes the foundation by elucidating key definitions and presenting various modeling perspectives to address the cancer genesis. Next, cell cycle dynamics have been explored, revealing the temporal oscillatory dynamics that govern the progression of cells through the cell cycle.
The first half of the thesis investigates the cell cycle dynamics and evolution of cancer stem cell lineages by incorporating feedback regulation mechanisms. Thereby, the pivotal role of feedback loops in driving the expansion of cancer stem cells has been thoroughly studied, offering new perspectives on cancer progression. Furthermore, the mathematical rigor of the model has been addressed by deriving wellposedness conditions, thereby strengthening the reliability of our findings and conclusions. Then, expanding our modeling scope, we explore the interplay between quiescent and proliferating cell populations, shedding light on the importance of their equilibrium in cancer biology. The models developed in this context offer potential avenues for targeted cancer therapies, addressing perspective cell populations critical for cancer progression. The second half of the thesis focuses on multiscale modeling of proliferating and quiescent cell populations incorporating cell cycle dynamics and the extension thereof with mutation acquisition. Following rigorous mathematical analysis, the wellposedness of the proposed modeling frameworks have been studied along with steady-state solutions and stability criteria.
In a nutshell, this thesis represents a significant stride in our understanding of cancer genesis, providing a comprehensive view of the complex interplay between cell cycle dynamics, quiescence, proliferation, mutation acquisition, and cancer stem cells. The journey towards conquering cancer is far from over. However, this research provides valuable insights and directions for future investigation, bringing us closer to the ultimate goal of mitigating the impact of this formidable disease.
Laser-based powder bed fusion (L-PBF) is a promising technology for the production of near net–shaped metallic components. The high surface roughness and the comparatively low-dimensional accuracy of such components, however, usually require a finishing by a subtractive process such as milling or grinding in order to meet the requirements of the application. Materials manufactured via L-PBF are characterized by a unique microstructure and anisotropic material properties. These specific properties could also affect the subtractive processes themselves. In this paper, the effect of L-PBF on the machinability of the aluminum alloy AlSi10Mg is explored when milling. The chips, the process forces, the surface morphology, the microhardness, and the burr formation are analyzed in dependence on the manufacturing parameter settings used for L-PBF and the direction of feed motion of the end mill relative to the build-up direction of the parts. The results are compared with a conventionally cast AlSi10Mg. The analysis shows that L-PBF influences the machinability. Differences between the reference and the L-PBF AlSi10Mg were observed in the chip form, the process forces, the surface morphology, and the burr formation. The initial manufacturing method of the part thus needs to be considered during the design of the finishing process to achieve suitable results.
A detailed study of a cylinder activation concept by efficiency loss analysis and 1D simulation
(2020)
Cylinder deactivation is a well-known measure for reducing fuel consumption, especially when applied to gasoline engines. Mostly, such systems are designed to deactivate half of the number of cylinders of the engine. In this study, a new concept is investigated for deactivating only one out of four cylinders of a commercial vehicle diesel engine (“3/4-cylinder concept”). For this purpose, cylinders 2–4 of the engine are operated in “real” 3-cylinder mode, thus with the firing order and ignition distance of a regular 3-cylinder engine, while the first cylinder is only activated near full load, running in parallel to the fourth cylinder. This concept was integrated into a test engine and evaluated on an engine test bench. As the investigations revealed significant improvements for the low-to-medium load region as well as disadvantages for high load, an extensive numerical analysis was carried out based on the experimental results. This included both 1D simulation runs and a detailed cylinder-specific efficiency loss analysis. Based on the results of this analysis, further steps for optimizing the concept were derived and studied by numerical calculations. As a result, it can be concluded that the 3/4-cylinder concept may provide significant improvements of real-world fuel economy when integrated as a drive unit into a tractor.
We present a model predictive control (MPC) algorithm for online time-optimal trajectory planning of cooperative robotic manipulators. Robotic arms sharing a common confined operational space are exposed to high interrobot collision
risks. For collision avoidance, a smooth robot geometry approximation by Bézier curves is applied, utilizing velocity constraints and tangent separating planes, enabling an efficient generation of robot trajectories in real-time. The proposed optimization algorithm is validated on an experimental setup consisting of two collaborative robotic arms performing synchronous pick-and-place tasks.
Physical vapor deposition (PVD) coatings are vital for enhancing wear resistance. However this technology faces challenges when coating inaccessible surfaces due to its line-of-sight characteristic. A potential remedy is utilizing triboactive CrAlMoN coatings. These form a tribofilm in the contact zone when applied to one contact partner along with a suitable lubricant. This tribofilm can subsequently safeguard inaccessible yet tribologically stressed surfaces. One of the main applications for this method is roller chain drives, whose longevity depends on the joint wear and the resulting chain elongation. Large-scale pin coatings have proven effective in curbing wear and prolonging chain life. However, the inaccessibility of bushes complicates standard PVD coating procedures. Triboactive coatings offer the possibility of forming transfer layers on the bushes, thereby enhancing friction reduction and wear protection. Experimental material studies for chain drives can be cost-intensive due to complexity and numerous components. This article demonstrates that CrAlN and CrAlMoN coatings in combination with greases with the additives phosphorus and sulfur can reduce friction and wear in chain joints. Furthermore, it is shown that a reasonable selection of tribometer testing can significantly reduce costs. Comparing the results of tests on a pin-on-disk tribometer and component tests show that model tests cannot completely replace component tests. But the combination offers an efficient way to optimize test matrices. Triboactive coatings like CrAlMoN hold promise for addressing the challenge of inaccessible surfaces. Reasonable tribometer test selection can help mitigate the costs of experimental studies, making these coatings a more practical
solution.
The modified fouling index (MFI) is a crucial characteristic for assessing the fouling potential of reverse osmosis (RO) feed water. Although the MFI is widely used, the estimation time required for filtration and data evaluation is still relatively long. In this study, the relationship between the MFI and instantaneous spectroscopic extinction measurements was investigated. Since both measurements show a linear correlation with particle concentration, it was assumed that a change in the MFI can be detected by monitoring the optical density of the feed water. To prove this assumption, a test bench for a simultaneous measurement of the MFI and optical extinction was designed. Silica monospheres with sizes of 120 nm and 400 nm and mixtures of both fractions were added to purified tap water as model foulants. MFI filtration tests were performed with a standard 0.45 µm PES membrane, and a 0.1 µm PP membrane. Extinction measurements were carried out with a newly designed flow cell inside a UV–VIS spectrometer to get online information on the particle properties of the feed water, such as the particle concentration and mean particle size. The measurement results show that the extinction ratio of different light wavelengths, which should remain constant for a particulate system, independent of the number of particles, only persisted at higher particle concentrations. Nevertheless, a good correlation between extinction and MFI for different particle concentrations with restrictions towards the ratio of particle and pore size of the test membrane was found. These findings can be used for new sensory process monitoring systems, if the deficiencies can be overcome.