lecture "are traditional engineers in the cage of old technologies?"

MOSCOW STATE UNIVERSITY

OF MECHANICAL ENGINEERING (MAMI)

UNIVERSITY OF MECHANICAL ENGINEERING

Are traditional engineers in the

cage of old technologies?

Dr.-Ing. mult. Michael A. Petrov

Department "Machines and metal forming technologies“ &

Department "Computer modelling and additive technologies"

12.07.2016, Moscow




corresponding address: [email protected]




I)

II)

III)

COMPONENTS

MATERIALS

CAx

TECHNOLOGIES

2/45




MATERIALS

low strength

(B= 0,31 0,7 GPa)

middle strength

(B= 0,7 1,8 GPa)

high strength

(B= 1,8 2 GPa)

polymers

(B= up to 0,1 GPa)

stones

(B= 0,025 0,27 GPa)

fiber/layer reinforced

(B= 0,5 1,8 GPa)

combined

(B= 0,35 3 GPa)

particle reinforced

(B= 0,28 1,2 GPa)

METALS NON-METALS COMPOSITES

ceramics

(B= up to 2,6 GPa)

CLASSIFICATION

3/45nature inspired (B= up to ? GPa)




The most perspective material representations have following specified characteristics:

- for steel outer sheets does not exceed the thickness of 0,2 – 3 mm;

- for aluminium outer sheets does not exceed the thickness of 0,05 – 0,5 mm;

- the common thickness value of the coating of the outer sheets – 25 – 50 m;

- the common thickness value of the core adhesive layer – up to 0,5 mm.

steel outer sheets:

B = 410 – 560 MPa

S = 280 – 550 MPa

= 17 – 28%

aluminium outer sheets:

B = 90 – 245 MPa

S = 60 – 200 MPa

= 7 – 16%

core material:

fibre reinforcement increase ultimate material strength up to

B = 1.200 MPa and = 7 %; elastomer core can withstand the

strain values up to 30 – 50%

LAYER REINFORCED

4/45

Metal laminates (ML): three-layer material (sandwich structure)




low formability

delamination during its exploitation

-acoustic insulation

(attenuation coefficient )

vibration insulation

weight reduction of any construction

+

LAYER REINFORCED

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reverse-engineeringdirect 3D-modelling in

any CAD-program

elastic element

hub

hub

teeth

3D-MODELLING

6/45




standards and directives drawing of the end part

TECHNOLOGICAL PROJECT (CALCULATION)

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Volume: 1,7*106 mm3

Mass: 13,24 kg

Volume: 1,67*106 mm3

Mass: 13,03 kg


Mass: 1,69 kg


Mass: 0,48 kg

Total mass of the tool set: 26,27 kg

Ratio of mass of end part to mass of forging: 0,28

TECHNOLOGICAL PROJECT (END CALCULATION)

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TECHNOLOGICAL PROJECT (NUMERICAL SIMULATION)

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TECHNOLOGICAL PROJECT (DOCUMENTATION FOR TOOL SET)

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Is it so easy to

create the tool

set for every

geometry and material?

QUESTION

11/45

cold forming

isothermal forging

hot forging

casting

http://rp-center.com

corresponding address:

[email protected]




TOOLS FOR FORMING OPERATIONS

cold forming

warm forming

hot forming

isothermal forming

monolith die or punch

assembled die or punch

by any casting

technology

by CNC-milling

by any additive

technology

TYPE OF OPERATION TYPE OF TOOLSTYPE OF ART OF

PRODUCTION

PRODUCTION OF THE TOOLS (CLASSIFICATION)

12/45




COMPLICITY OF THE TOOLS (METAL WORKING)

13/45Source: information was found in Internet applied Google search engine; Keywords: forging dies, stamping tool, fine blanking tool, PET blow

molds (moulds), injection molds (moulds), штампы для горячей штамповки, штампы для холодной штамповки




TECHNOLOGICAL PARAMETERS (SURFACE QUALITY)

EDM

14/45

linear roughness (2D)

surface topography (3D)

roughness gauges

milling

lapping

Source: R. Contreras-Guerrero, A. Guillen-Cervantes,

Z. Rivera-Alvarez et al., Journal of Crystal growth,

2009, Vol. 311 (7), pp. 1666 – 1670.




VS.

expensive and acceptable only for

mass production;

for fully-automated forging lines.

cheap and acceptable for small and

medium batches;

not fully-automated forging lines.

automated lubrication or/and

homogeneous lubricant

manual lubrication or/and

inhomogeneous lubricant

HOW CAN WE GUARANTEE THE IDEAL LUBRICANT’S DISTRIBUTION ON THE TOOLS’ SURFACE?

TECHNOLOGICAL PARAMETERS (LUBRICATION)

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I – agglomerated particles with spherical surface morphology;

II – non-agglomerated particles with spherical surface morphology;

III – non-agglomerated particles with curvature surface morphology

(1 – grains, that building the particle; 2 – particle)


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- obtained on the REM

- mostly non-spherical surface morphology; particles’ size up to 1,2 m

resolution x 5.000 resolution x 7.500


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geometry of the forgingsisothermal-

like forgingforging temperature range

QUALITY (Q)

topography

(roughness)

PHYSICAL PARAMETERS (PP)

lubrication

activation

LFP

LB

CCL

MDP

lubrication

activation

LFP

hot forgingforging temperature range

ob

jec

tive

facto

rs

su

bje

ctiv

e

facto

rs

what PP give acceptable Q of the forging?

TECHNOLOGICAL PARAMETERS (CHALLENGE of Q vs. PP)

18/45




BIONICAL AD-HOC

19/45




Syphonaptera or Flea

BIONICAL AD-HOC

20/45

Source: www.wikipedia.org




Aglais io or Peacock

(nymphalidae family butterfly)

magnification x 300

BIONICAL AD-HOC

21/45wing

Source: www.wikipedia.org




It will be great to

rethink the engineering

methods of design and

neared it to the nature,

isn’t it?

QUESTION

22/45… and now back again to production technologies!


[email protected]




RAPID PROTOTYPING (abbr. RP), in schemes

SPIF metal spinning

EBF3

HVOF, HVAF

LOMSLA

23/45Source: information was found in Internet applied Google search engine; Keywords: rapid prototyping, SPIF, metal spinning,

high velocity oxyfuel process, HVOF, HVAF, electron beam melting 3D, stereolithography, laminated object manufacturing




RAPID PROTOTYPING (abbr. RP), in products

SPIF metal spinning

EBF3

HVOF, HVAF

SLA LOM

24/45Source: information was found in Internet applied Google search engine; Keywords: rapid prototyping, SPIF, metal spinning,

high velocity oxyfuel process, HVOF, HVAF, electron beam melting 3D, stereolithography, laminated object manufacturing




Parameters Values

3D-printer UPrint

Printed layer thickness, mm 0,25-0,33

Temperature of the extruder’s nozzle, °C 310

MATERIAL’S TESTING, samples’ manufacturing

FDM

25/45

Source: http://www.stratasys.com/

Source: http://www.custompartnet.com/

with supports




Parameters Values

3D-printer Picaso

Printed layer thickness, mm 0,10

Temperature of the extruder’s nozzle, °C 270


FDM

26/45

without supports

Source: http://www.picaso-3d.com

Source: http://www.spiegel.de




low filament density (L) high filament density (H) super high filament density (S)

Filling density (FD) Values, mm

low filament density (designation «L») 2,27

high filament density (designation «H») 0,87

super high filament density (designation «S») 0,65

Computer aided measurements of centre-to-centre distances of the deposited

filaments:

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TEST_ABS

100%_ABS50%_ABS

25%_ABS

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TEST_PLA

100%_PLA50%_PLA

25%_PLA




Parameters Values

Universal testing machine EU-100

Nominal force, MN 10

Environmental temperature, °C 23,5

Ram velocity, mm/s 1

MATERIAL’S TESTING, testing machine

30/45

Time, sF

orc

e,

N

Time – Force machine diagram




ABS – acrylonitrile butadiene styrene, thermoplastic

Chemical formula: (C8H8)x·(C4H6)y·(C3H3N)z

International CAS-number: 9003-56-9

Possible type of structure: amorphous and semi-crystallized structure

Parameters

Parameters’ values according to:

information

from literatureGOSTs* product

information sheet

Density, g/cm3 1,04 – 1,12 1,03 – 1,05 1,04 – 1,05

Young’s modulus, GPa 1,9 – 2 ,7 - 1,6 – 2,3

Ultimate stress, MPa 32 – 56 - 22 – 36

Ultimate relative strain, % 15 – 40 3 – 7 4 – 6

HardnessRockwell (R):

75 – 12098 -

* GOSTs ref. no.: density 15139; ultimate strain 11262; hardness 4670; elasticity

modulus bending 9550-81

MATERIAL’S TESTING, mechanical properties

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Filament thickness, mm: up to 0,58

Center-to center distance, mm: up to 0,9

Microscope captures of the printed test

sample with FD «H» (USB-microscope with

maximal magnification of х 300)

Fracture

surface

circle

pattern

MATERIAL’S TESTING, results

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Machine diagrams obtained after compression tests of the cylindrical specimens

(for FG «L»)

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(for FG «H»)

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(for FG «S»)

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Exhibition «Archimedes 2014»

Exhibition «Vuzpromexpo 2014» 36/45

OUR EXAMPLES: metal hollow spheres manufacturing

Source: http://mami.ru

50% of scaled mechatronical model of the equipment

was additive manufactured

1) Current source

2) Compressor

3) Control unit 1

4) Control unit 2

5) Pneumatic

station

6) Equipment (RP)




scaled model of the large diesel

engine for energy industry; separate

parts were additive manufactured

OUR EXAMPLES: diesel engine

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Source: http://rp-center.com




3D-model of the femur or thighbone

Exhibition «Archimedes 2015»

OUR EXAMPLES: biomedical engineering

prototypes of the human jaws, which

were produced for the needs of the

dental industry

prototypes of the human bones,

obtained either through direct 3D-

modelling of based on the reverse-

engineering CAx-technologies 38/45

Source: http://mami.ru

Source: http://rp-center.com




We need more nature-

like things created by

engineers, don’t we?

QUESTION

39/45


[email protected]




ADDITIVE TECHNOLOGIES: PRESENT

40/45Source: Michiel van den Berg, Breakthrough factories, MIT Technology Review, Vol. 117, №6




ADDITIVE TECHNOLOGIES: FORECAST FOR THE FUTURE

41/45Source: http://forbes.com




flakes on butterfly wing

flakes on butterfly wing

ADDITIVE TECHNOLOGIES & NATURE….IN FUTURE

42/45




flakes on shark skin

structural hierarchy of the

gecko adhesive system


43/45

Source: https://www.flickr.com/photos/fei_company/

Source: K. Autumn, N. Gravish, Gecko adhesion: evolutionary

nanotechnology, Philosophical Transactions of the Royal

Society of London A: Mathematical, Physical and Engineering

Sciences, 2008, Vol. 366, № 1870, pp. 1575 – 1590.




superhydrophobic surfaces: a) magnolia leaf; b) hairs; c) synthetic

obtained microposts after etching; d) fibrous synthetic material


44/45Source: D. Quéré , M. Reyssat, Non-adhesive lotus and other hydrophobic materials, Philosophical Transactions of the Royal Society of London A:

Mathematical, Physical and Engineering Sciences, 2008, Vol. 366, № 1870, pp. 1539 – 1556.




Thank you for attention!

Corresponding address: [email protected]




lecture "are traditional engineers in the cage of old technologies?"

Education