Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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- Faser-Kunststoff-Verbunde (5)
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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.
Bei der Herstellung hochbelasteter Strukturbauteile aus Faser-Kunststoff-Verbund (FKV) wird verbreitet auf textile Halbzeuge wie Gewebe oder vernähte Biaxial-Gelege zurückgegrif-fen. Diese Halbzeuge zeigen im Verbund mit Kunststoffen periodische out-of-plane Roving-welligkeiten. Die Größe der Welligkeiten hängt unter anderem von den Fertigungsparametern der trockenen Halbzeuge ab. Durch das Verständnis der effektiven Kausalitäten zwischen Rovingwelligkeiten und mechanischem Verhalten soll eine bessere rechnerische Abschätzung der Materialkennwerte erzielt werden.
In dieser Arbeit wurde unter anderem der Einfluss der Welligkeitsparameter Amplitude und Wellenlänge auf die faserparallelen Kennwerte an unidirektional verstärkten Proben unter-sucht. Dafür wurden gezielt unterschiedliche Amplituden und Wellenlängen mit Hilfe von unidirektionalen Geweben in die Probekörper eingebracht. Der Einfluss der Rovingwelligkei-ten auf die Steifigkeiten war kleiner als auf die Festigkeiten. Bei Letzten war zu beobachten, dass die Druckfestigkeiten mehr von den Ondulationen beeinflusst wurden als die Zugfestig-keiten. Außerdem wurden die Welligkeiten und die mechanischen Kennwerte von textilen FKV-Geweben und -Gelegen bestimmt. Bei der Auswahl der untersuchten Halbzeuge war ein wichtiges Kriterium, dass diese auch in der Praxis Anwendung finden.
Im nächsten Schritt wurde ein vereinfachtes Finite-Elemente-Welligkeitsmodell entwickelt, welches es ermöglicht, die faserparallelen Kennwerte ohne zeit- und kostenintensive Materi-alversuche zu bestimmen. Speziell für Gewebe-Materialien mit großen Rovingwelligkeiten ist dieses Modell in der Lage, deutlich bessere Abschätzungen als vorhandene Methoden zu ge-ben. Weiterhin wurde auf dieser Basis ein Regressionsmodell für unidirektional verstärkte Materialien abgeleitet, welches auch dem Konstrukteur ohne Erfahrungen im Umgang mit Finiten-Elemente-Programmen die Anwendung des Welligkeitsmodells ermöglicht.
Der Vorteil des entwickelten Welligkeitsmodells wurde in einem dreistufigen Validierungs-programm nachgewiesen. Dieses beinhaltet den Übergang auf multidirektionale Laminate sowie komplexere Bauteilgeometrien. Die verbesserte Prognose mit Hilfe des Welligkeitsmo-dells zeigte sich vor allem bei Materialien mit großen Rovingwelligkeiten und bei Bauteilen die aufgrund eines Faserbruchs durch eine Druckbelastung versagten.
Nanoparticle-Filled Thermoplastics and Thermoplastic Elastomer: Structure-Property Relationships
(2012)
The present work focuses on the structure-property relationships of
particulate-filled thermoplastics and thermoplastic elastomer (TPE). In this work
two thermoplastics and one TPE were used as polymer matrices, i.e. amorphous
bisphenol-A polycarbonate (PC), semi-crystalline isotactic polypropylene (iPP),
and a block copolymer poly(butylene terephthalate)-block-poly(tetramethylene
glycol) TPE(PBT-PTMG). For PC, a selected type of various Aerosil® nano-SiO2
types was used as filler to improve the thermal and mechanical properties by
maintaining the transparency of PC matrix. Different types of SiO2 and TiO2
nanoparticles with different surface polarity were used for iPP. The goal was to
examine the influence of surface polarity and chemical nature of nanoparticles on
the thermal, mechanical and morphological properties of iPP composites. For
TPE(PBT-PTMG), three TiO2 particles were used, i.e. one grade with hydroxyl
groups on the particle surface and the other two grades are surface-modified with
metal and metal oxides, respectively. The influence of primary size and dispersion
quality of TiO2 particles on the properties of TPE(PBT-PTMG)/TiO2 composites
were determined and discussed.
All polymer composites were produced by direct melt blending in a twin-screw
extruder via masterbatch technique. The dispersion of particles was examined by
using scanning electron microscopy (SEM) and micro-computerized tomography
(μCT). The thermal and crystalline properties of polymer composites were characterized by using thermogravimetric analysis (TGA) and differential
scanning calorimetry (DSC). The mechanical and thermomechanical properties
were determined by using mechanical tensile testing, compact tension and
Charpy impact as well as dynamic-mechanical thermal analysis (DMTA).
The SEM results show that the unpolar-surface modified nanoparticles are better
dispersed in polymer matrices as iPP than polar-surface nanoparticles, especially
in case of using Aeroxide® TiO2 nanoparticles. The Aeroxide® TiO2 nanoparticles
with a polar surface due to Ti-OH groups result in a very high degree of
agglomeration in both iPP and TPE matrices because of strong van der Waals
interactions among particles (hydrogen bonding). Compared to unmodified
Aeroxide® TiO2 nanoparticles, the other grades of surface modified TiO2 particles
are very homogenously dispersed in used iPP and TPE(PBT-PTMG). The
incorporation of SiO2 nanoparticles into bisphenol-A PC significantly increases
the mechanical properties of PC/SiO2 nanocomposites, particularly the resistance
against environmental stress crazing (ESC). However, the transparency of
PC/SiO2 nanocomposites decreases with increasing nanoparticle content and
size due to a mismatch of infractive indices of PC and SiO2 particles. The different
surface polarity of nanoparticles in iPP shows evident influence on properties of
iPP composites. Among iPP/SiO2 nanocomposites, the nanocomposite
containing SiO2 nanoparticles with a higher degree of hydrophobicity shows
improved fracture and impact toughness compared to the other iPP/SiO2
composites. The TPE(PBT-PTMG)/TiO2 composites show much better thermal and mechanical properties than neat TPE(PBT-PTMG) due to strong chemical
interactions between polymer matrix and TiO2 particles. In addition, better
dispersion quality of TiO2 particles in used TPE(PBT-PTMG) leads to dramatically
improved mechanical properties of TPE(PBT-PTMG)/TiO2 composites.
Whole-body vibrations (WBV) have adverse effects on ride comfort and human health. Suspension seats have an important influence on the WBV severity. In this study, WBV were measured on a medium-sized compact wheel loader (CWL) in its typical operations. The effect of short-term exposure to the WBV on the ride comfort was evaluated according to ISO 2631-1:1985 and ISO 2631-1:1997. ISO 2631-1:1997 and ISO 2631-5:2004 were adopted to evaluate the effect of long-term exposure to the WBV on the human health. Reasons for the different evaluation results obtained according to ISO 2631-1:1997 and ISO 2631-5:2004 were explained in this study. The WBV measurements were carried out in cases where the driver wore a lap belt or a four-point seat harness and in the case where the driver did not wear any safety belt. The seat effective amplitude transmissibility (SEAT) and the seat transmissibility in the frequency domain in these three cases were analyzed to investigate the effect of a safety belt on the seat transmissibility. Seat tests were performed on a multi-axis shaking table in laboratory to study the dynamic behavior of a suspension seat under the vibration excitations measured on the CWL. The WBV intensity was reduced by optimizing the vertical and the longitudinal seat suspension systems with the help of computational simulations. For the optimization multi-body models of the seat-dummy system in the laboratory seat tests and the seat-driver system in the field vibration measurements were built and validated.
In recent years, nanofiller-reinforced polymer composites have attracted considerable
interest from numerous researchers, since they can offer unique mechanical,
electrical, optical and thermal properties compared to the conventional polymer
composites filled with micron-sized particles or short fibers. With this background, the
main objective of the present work was to investigate the various mechanical
properties of polymer matrices filled with different inorganic rigid nanofillers, including
SiOB2B, TiOB2B, AlB2BOB3B and multi-walled carbon nanotubes (MWNT). Further, special
attention was paid to the fracture behaviours of the polymer nanocomposites. The
polymer matrices used in this work contained two types of epoxy resin (cycloaliphatic
and bisphenol-F) and two types of thermoplastic polymer (polyamide 66 and isotactic
polypropylene).
The epoxy-based nanocomposites (filled with nano-SiOB2B) were formed in situ by a
special sol-gel technique supplied by nanoresins AG. Excellent nanoparticle
dispersion was achieved even at rather high particle loading. The almost
homogeneously distributed nanoparticles can improve the elastic modulus and
fracture toughness (characterized by KBICB and GBICB) simultaneously. According to
dynamic mechanical and thermal analysis (DMTA), the nanosilica particles in epoxy
resins possessed considerable "effective volume fraction" in comparison with their
actual volume fraction, due to the presence of the interphase. Moreover, AFM and
high-resolution SEM observations also suggested that the nanosilica particles were
coated with a polymer layer and therefore a core-shell structure of particle-matrix was
expected. Furthermore, based on SEM fractography, several toughening
mechanisms were considered to be responsible for the improvement in toughness,
which included crack deflection, crack pinning/bowing and plastic deformation of
matrix induced by nanoparticles.
The PA66 or iPP-based nanocomposites were fabricated by a conventional meltextrusion
technique. Here, the nanofiller content was set constant as 1 vol.%. Relatively good particle dispersion was found, though some small aggregates still
existed. The elastic modulus of both PA66 and iPP was moderately improved after
incorporation of the nanofillers. The fracture behaviours of these materials were
characterized by an essential work fracture (EWF) approach. In the case of PA66
system, the EWF experiments were carried out over a broad temperature range
(23~120 °C). It was found that the EWF parameters exhibited high temperature
dependence. At most testing temperatures, a small amount of nanoparticles could
produce obvious toughening effects at the cost of reduction in plastic deformation of
the matrix. In light of SEM fractographs and crack opening tip (COD) analysis, the
crack blunting induced by nanoparticles might be the major source of this toughening.
The fracture behaviours of PP filled with MWNTs were investigated over a broad
temperature range (-196~80 °C) in terms of notched impact resistance. It was found
that MWNTs could enhance the notched impact resistance of PP matrix significantly
once the testing temperature was higher than the glass transition temperature (TBgB) of
neat PP. At the relevant temperature range, the longer the MWNTs, the better was
the impact resistance. SEM observation revealed three failure modes of nanotubes:
nanotube bridging, debonding/pullout and fracture. All of them would contribute to
impact toughness to a degree. Moreover, the nanotube fracture was considered as
the major failure mode. In addition, the smaller spherulites induced by the nanotubes
would also benefit toughness.
Continuum Mechanical Modeling of Dry Granular Systems: From Dilute Flow to Solid-Like Behavior
(2014)
In this thesis, we develop a granular hydrodynamic model which covers the three principal regimes observed in granular systems, i.e. the dilute flow, the dense flow and the solid-like regime. We start from a kinetic model valid at low density and extend its validity to the granular solid-like behavior. Analytical and numerical results show that this model reproduces a lot of complex phenomena like for instance slow viscoplastic motion, critical states and the pressure dip in sand piles. Finally we formulate a 1D version of the full model and develop a numerical method to solve it. We present two numerical examples, a filling simulation and the flow on an inclined plane where the three regimes are included.
Fucoidans are multifunctional marine macromolecules that are subjected to numerous and various downstream processes during their production. These processes were considered the most important abiotic factors affecting fucoidan chemical skeletons, quality, physicochemical properties, biological properties and industrial applications. Since a universal protocol for fucoidans production has not been established yet, all the currently used processes were presented and justified. The current article complements our previous articles in the fucoidans field, provides an updated overview regarding the different downstream processes, including pre-treatment, extraction, purification and enzymatic modification processes, and shows the recent non-traditional applications of fucoidans in relation to their characters.
Fucoidan is a class of biopolymers mainly found in brown seaweeds. Due to its diverse medical importance, homogenous supply as well as a GMP-compliant product is of a special interest. Therefore, in addition to optimization of its extraction and purification from classical resources, other techniques were tried (e.g., marine tissue culture and heterologous expression of enzymes involved in its biosynthesis). Results showed that 17.5% (w/w) crude fucoidan after pre-treatment and extraction was obtained from the brown macroalgae F. vesiculosus. Purification by affinity chromatography improved purity relative to the commercial purified product. Furthermore, biological investigations revealed improved anti-coagulant and anti-viral activities compared with crude fucoidan. Furthermore, callus-like and protoplast cultures as well as bioreactor cultivation were developed from F. vesiculosus representing a new horizon to produce fucoidan biotechnologically. Moreover, heterologous expression of several enzymes involved in its biosynthesis by E. coli (e.g., FucTs and STs) demonstrated the possibility to obtain active enzymes that could be utilized in enzymatic in vitro synthesis of fucoidan. All these competitive techniques could provide the global demands from fucoidan.
Eine grundlegende Voraussetzung für die Entwicklung von teilautonomer hydraulischen Maschinen ist die automatisierte Bewegung der notwendigen Strukturen. Die Anforderungen an diese Bewegungen sind hoch und aus diesem Grund sind einfache Reglerstrukturen ohne konkrete Streckenkenntnis nicht ausreichend. Die Beschreibung des Streckenkennmodells ist bei hydraulischen Maschinen sehr komplex und zeitaufwendig. Die Modellierung mit theoretischen auf physikalischen Ansätzen beruhenden Methoden ist daher unwirtschaftlich. Aufgrund dessen müssen für die Entwicklung von teilautonomen Maschinen alternative Strategien zur Beschreibung der Dynamik entwickelt werden. Im Rahmen der Diplomarbeit wurde die Machbarkeit von Neuronalen Netzen zur modellbasierten Geschwindigkeitsregelung von hydraulischen Zylindern an einem Bagger untersucht. Dabei wurden unterschiedliche Anregungssignale überprüft und das Regelverhalten des Neuronalen-Reglers auf einem realen Versuchsträger verifiziert. Es hat sich gezeigt, dass sich die datenbasierten Methoden zur Regelung von elektrohydraulischen Baggern eignen. Im Vergleich zu theoretischen Ansätzen konnte eine Steigerung der Regelgüte, bei gleichzeitiger Reduzierung des Arbeitsaufwandes von mehreren Monaten hinzu wenigen Tagen, erreicht werden.
On the Extended Finite Element Method for the Elasto-Plastic Deformation of Heterogeneous Materials
(2015)
This thesis is concerned with the extended finite element method (XFEM) for deformation analysis of three-dimensional heterogeneous materials. Using the "enhanced abs enrichment" the XFEM is able to reproduce kinks in the displacements and therewith jumps in the strains within elements of the underlying tetrahedral finite element mesh. A complex model for the micro structure reconstruction of aluminum matrix composite AMC225xe and the modeling of its macroscopic thermo-mechanical plastic deformation behavior is presented, using the XFEM. Additionally, a novel stabilization algorithm is introduced for the XFEM. This algorithm requires preprocessing only.