focus specialization in design, mechanics and materials€¦ · focus specialization in design,...
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Focus Specialization in Design, Mechanics and MaterialsProf. Kristina Shea & Friends3 April 2017
Focus Design, Mechanics and Materials 1
Outline
§ Introduction and Motivation§ Lectures§ Bachelor Theses and Research§ Industry and after the Bachelor Degree
Focus Design, Mechanics and Materials 2
The design, analysis, simulation, optimization and evaluation of modern mechanical and mechatronic systems is one of the main tasks of a
mechanical engineer.
The Focus offers a broad selection of courses covering the main aspects of mechanical systems.
Engineering Design
Materials & Manufacturing Analysis Experimental
Methods
Function
Performance
Reliability & Quality Environmental Aspects
Costs
Focus Design, Mechanics and Materials 3
The Team
§ K. Shea, D. Mohr, J. Dual, P. Ermanni, D. Kochmann, P. Hora, E. Mazza, M. Meboldt
Focus Design, Mechanics and Materials 4
Renewable Energy
water, wind, sun, etc.
Sufficiency
less mobility, less living-
room, less etc.
How to satisfy the demand for energy in an affordable, safe and sustainable way ?
climate changeHow to reduce CO2
emissions?
peak oilHow to replace
missing crude oil ?
nuclear risksHow to keep people
safe?
limited clean water and food
How to feed everyone?
One Grand Challenge in Engineering: Sustainable Energy
Efficiencyimproved engines
& drive-trains
reduced losses (aerodynamic, friction, etc)
lightweight structures
(accelerated masses)
Focus Design, Mechanics and Materials 5
Design
Mechanics
ComputingTechnologies
Materials
Mechanical Systems are Highly Interdisciplinary
Focus Design, Mechanics and Materials 6
Outline
§ Introduction and Motivation§ Lectures§ Bachelor Theses and Research§ Industry and after the Bachelor Degree
Focus Design, Mechanics and Materials 7
Bachelor Focus
Computational Methods
LabsApplication in Research and Industry Projects Bachelor Thesis
Analysis Methods
Materials and Processes
Dynamics
Engineering Design Experimental Methods
Methods and ToolsComputational Methods, Analysis Methods, Dynamics, Engineering Design,
Materials und Processes, Experimental Methods
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Lecture Overview: You select five lectures freely
*) Master course
Focus Design, Mechanics and Materials 9
Elective Courses LE-Nr. ETCS HS 16
ETCS FS 17
Procedures for the Analysis of Structures 151-0360-00 4
Lightweight Structures Laboratory 151-0364-00 4
Microscale Acoustofluidics 151-0509-00 4
Continuum Mechanics 1 151-0524-00 4
Nonlinear Dynamics and Chaos I 151-0532-00 4
Forming Technology I – Basic Knowledge 151-0731-00 4
Dynamic Behavior of Materials and Structures* 151-0735-00 4
Studies on Engineering Design 151-3201-00 3
Grand Challenges in Engineering Design 151-3203-00 1
Lightweight 151-3207-00 4
Engineering Design Optimization* 151-3209-00 4
Metals I 327-0501-00 3
Materials at Work I 327-1204-00 4
Lecture Overview: You select five lectures freely
*) Master course
Focus Design, Mechanics and Materials 10
Elective Courses LE-Nr. ETCS HS 16
ETCS FS 17
Engineering Design II 151-0304-00 4
Visualization, Simulation and Interaction – Virtual Reality I 151-0306-00 4
Engineering Design with Polymers and Polymer Composites 151-0324-00 4
Interdisciplinary Product Development: Definition, Realisation and Validation of Product Concepts 151-0332-00 4
An Introduction to the Finite-Element Method* 151-0361-00 4
Experimental Mechanics 151-0540-00 4
Dynamic Behavior of Materials and Structures 151-0735-00 4
Engineering Design Methods 151-3202-00 4
Coaching, Leading and Organising Innovation Projects 151-3204-00 4
Systemic Design for Sustainability 151-3206-00 4
Grand Challenges in Engineering Design Studies on Engineering DesignFall SemesterK. Shea, P. Ermanni, M. Meboldt
11Focus Design, Mechanics and Materials
§ Grand Challenges in Engineering Design§ Introduces students to the
engineering design research and practice in a multitude of mechanical engineering disciplines
§ Guest lectures by academics and industry
§ Studies on Engineering Design§ Identify a topic in engineering
design for further investigation.
Integrative Ski Design and Fabrication Workshop
ETH News: https://www.ethz.ch/de/news-und-veranstaltungen/eth-news/news/2017/01/mit-selbstgebauten-skis-auf-die-piste.html
Integrative Ski Design and Fabrication Workshop
ETH News: https://www.ethz.ch/de/news-und-veranstaltungen/eth-news/news/2017/01/mit-selbstgebauten-skis-auf-die-piste.html
Engineering Design MethodsSpring SemesterK. Shea and T. Stankovic
14Focus Design, Mechanics and Materials
§ Learn fundamental topics in engineering design and product development.
§ Learn a product development and design process and its benefits.
§ Introduction to a variety of design methods and models used in product development and design.
§ Focus on the early design phases and conceptual design.
§ Apply the methods immediately to a team design project carried out in the exercises.
§ Develop design reasoning and critical thinking skills.
source: http://www.tes.comsource: http://www.plantui.com
source: http://www.modernfarmer.com
Design Project 2017: Urban Farming
Engineering Design OptimizationFall SemesterK. Shea and T. Stankovic
15Focus Design, Mechanics and Materials
§ Learn the fundamentals of optimization in the context of engineering design.
§ Express engineering design problems as formal optimization problems.
§ Learn about different optimization methods and how to select, apply and implement them.
§ Understand the links to design more efficient and performance optimized products.
§ Exercises are MATLAB based. Optimization of a butterfly valve disc and housing using simulated annealing (with Georg Fischer).
Systemic Design for SustainabilitySpring SemesterT. Luthe
16Focus Design, Mechanics and Materials
§ Fundamentals of sustainability and systemic design: theory, methods, frameworks.
§ Develop systems thinking and specific sustainable design skills.
§ Learn and apply systemic design concepts, e.g. cradle-to-cradle, life cycle analysis, upcycling, biomimicry, permaculture, passive house, blue/circular economy, etc.
§ Design and build a product applying the learnt systemic design approaches.
§ Case studies, field visits, exercises motivated by sustainability challenges.
https://bureo.co
Coaching, Leading and Organising Innovation ProjectsSpring SemesterM. Meboldt, R. Haas, I. Goller
Innovation und Entwicklung ist geprägt von Teamarbeit, neben Ingenieur-wissenschaftlichen Grundlagen ist das Leiten und Coachen von Projektteams eine Schlüsselkompetenz.§ Die Vorlesung behandelt das
Strukturieren von Entwicklungs-projekten und Leiten von Teams
§ Im Praxisteil: arbeiten sie als Coach im Innovationsprojekt um dort Leadership Erfahrung zu sammeln und zu reflektieren
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Metals I Fall SemesterR. Spolenak
18Focus Design, Mechanics and Materials
§ Dislocation theory:§ Properties of dislocations, motion and kinetics of dislocations, dislocation-dislocation
and dislocation-boundary interactions, consequences of partial dislocations, sessile dislocations
§ Hardening theory:§ a. solid solution hardening: case studies in copper-nickel and iron-carbon alloys§ b. particle hardening: case studies on aluminium-copper alloys§ c. Taylor hardening, Hall-Petch hardening
§ High temperature plasticity:§ thermally activated glide§ power-law creep§ diffusional creep: Coble, Nabarro-Herring§ deformation mechanism maps
Procedures for the Analysis of StructuresFall SemesterG. Kress
19Focus Design, Mechanics and Materials
§ Erweiterung der Grundlagen zur Behandlung strukturmechanischer Auslegungsproblemen.
§ Einführung in die Dimensionierung von Flächentragwerken.
§ Stabilitätsanalyse. Verständnis des Zusammenhangs zwischen
§ Materialverhalten, Strukturtheorien und Auslegungskriterien
Continuum Mechanics 1Fall SemesterE. Mazza
20Focus Design, Mechanics and Materials
§ Models to predict the mechanical response of a wide range of materials.
§ Anisotropic linear elastic, viscoelastic, plastic, viscoplasticmaterial behavior.
§ Theoretical fundamentals for small strain continuum mechanics
§ Examples of engineering applications
Dynamic Behavior of Materials and StructuresSpring SemesterD. Mohr
§ Acquire knowledge and skills needed to predict the deformation and failure response of modern engineering structures under extreme loading conditions
§ Learn about temperature and rate-dependent plasticity and fracture of polymers and metals
§ Become familiar with the development and implementation of user material subroutines for non-linear finite element analysis
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Lightweight Structures LaboratoryHerbstsemesterM. Zogg, P. Ermanni
§ Konkrete Aufgabe wird in Gruppen bearbeit.
§ Ziel: möglichst einfache und leichte Konstruktion
§ Inhalte: Design, Auslegung, Herstellung, Test
§ Bauteil wird anschliessendmechanisch getestet, und im Hinblick auf konstruktive und strukturmechanische Aspekte diskutiert und verbessert.
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Experimental MechanicsSpring SemesterJ. Dual
§ Verständnis, Modellierung und praktische Anwendung von:§ Schwingungsmessung,§ optische Methoden,§ Piezoelektrizität§ Ultraschall,§ Sensoren und Aktoren
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Introduction to the Finite-Element Method Spring SemesterG. Kress
§ Verbindung von Theorieverständnis mit der Fähigkeit Strukturanalysen
§ mit einem Anwenderprogramm durchführen zu können.
§ Ergebnisqualität der Strukturanalysen
§ Eigene FEM-Programmierung.
Modell mit linearen Flächenelementen
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Elementbeiträge zur Systemmatrix
Element 1 + Element 2 + Element 3 + Element 4
+ Element 5 + Element 6 + Element 7 + Element 8
+ Element 9 = System: Bandmodus
Focus Design, Mechanics and Materials 24
Forming Technology I – Basis KnowledgeFall SemesterP. Hora
§ UmformspezifischeBeschreibung von Materialeigenschaften und ihreexperimentelle Erfassung
§ Stoffgesetze, Eigenspannungen, Wärmebilanz, Tribologie von Umformsystemen
§ Werkstück- und Werkzeugversagen
§ Einführung in umformtechnischeVerfahren
Focus Design, Mechanics and Materials 25
Outline
§ Introduction and Motivation§ Lectures§ Bachelor Theses and Research§ Industry and after the Bachelor Degree
Focus Design, Mechanics and Materials 26
§ Motivation for superformula:§ compact surface modelling representation § easily represents complex and natural shapes
§ Shape synthesis of a mono-hull cargo ship
Computational: Shape Synthesis with the Superformula(K. Shea)
Generate
Response Analyze
Simulated Annealing
Start Finish
Loop
Focus Design, Mechanics and Materials 27
Andrea Nessi, Bachelor Thesis, 2015
Design and Testing: 3D Printer RAPTYPE (K. Shea)§ Investigating the relation between speed and print quality:
§ Goal: same quality at similar speed compared to uPrint§ Faster printing possible of simple parts or for reduced quality prints§ Comparison of alternative motors for improved accuracy
vs.
Focus Design, Mechanics and Materials 28
Alexander Nieland, Bachelor Thesis, 2014
Simulation/Process
Manufacturing
Robustness/QualityDesign
Material
Material modeling: An interdisciplinary research field (P. Hora)§ Mathematical description of the material behavior for large plastic deformations
§ Determination of model parameters based on experiments: linear/non-linear strain paths
§ Validation of material models on real forming processes (FEM simulation)§ Optical measurements of the surface strains (DIC - Digital Image Correlation) § Thickness distribution (DIC)
29Focus Design, Mechanics and Materials
Material Labs IVP
Zugversuch Torsionsversuch Bulge-Versuch Goniometer
19 April 2016 30Focus Design, Mechanics and Materials
Experimental: Biomechanical Gait Cycle Analysis Of Different Ski Touring Systems (K. Shea)
Focus Design, Mechanics and Materials 31
Rudolf Maculan, Bachelor Thesis, 2014
Results:• A specific pattern in ski touring motion is
found (larger range of motion in hip and pelvis joint)
• Longer stride length with TourBo system
Analysis of different ski systems on treadmill:• motion of markers on shoes and human
subjects are recorded by 13 infrared cameras and analyzed according to five parameters
Industrial: Mechanics of high voltageconductors (E. Mazza)
32Focus Design, Mechanics and Materials
§ Lifetime prediction of high voltage conductors§ Finite element modeling of helical structure,
considering internal stresses from manufacturingprocess
§ Experimental verification of long term creepresponse at elevated temperatures
§ Specific task for the bachelor project: the studentinvestigates the influence of the creep modelformulation on the long term stress-strainevolution and uses the model to rationalizeexperimental data from strain gauges appliedalong the conductor
Collaboration with Sefag AG, Swisselectric and Swissgrid
Helical arrangement of wires
Simulation of manufacturingprocess
Whole conductor creep test (at Empa)
3D FE model: conductor in wedgeclamp
Please see the websites of each professor for currentavailable student projects and theses!§ K. Shea, C. Daraio, J. Dual, P. Ermanni, D. Kochmann, P.
Hora, E. Mazza, M. Meboldt
Focus Design, Mechanics and Materials 33
Outline
§ Introduction and Motivation§ Lectures§ Bachelor Theses and Research§ Industry and after the Bachelor Degree
Focus Design, Mechanics and Materials 34
Diverse Industry Domains
Consumer Products Automotive Aerospace
Structures and Buildings Rail Systems Manufacturing
Focus Design, Mechanics and Materials 35
Mechatronicsand Robotics
Biomedical and HealthTechnology
Additive Manufacturing
Focus Specialization in Design, Mechanics and Materials
MechanicsAdv. Structures and MaterialsEngineering Design Manufacturing
Focus Design, Mechanics and Materials 36
Energy Systems
Micro- andNano-systems