machine and vehicle design: research activitiescmv.mecc.polimi.it/files/polimi mecc - machine design...

Machine and Vehicle Design: Research activities (June 2014) POLITECNICO DI MILANO, ITALY DIPARTIMENTO DI MECCANICA

Politecnico di Milano …since 1863…

Department of Mechanical Engineering - Machine and Vehicle Design

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Contacts: Prof. Andrea Bernasconi –[email protected] Prof. Stefano Beretta – [email protected] Prof . Marco Giglio – [email protected]

Selected papers: - A. Bernasconi, S. Beretta, F. Moroni, A. Pirondi. Local stress analysis of the fatigue behaviour of adhesively bonded thick composite laminates. JOURNAL OF ADHESION 86(2010):480-500 - Arm made of composite material and respective production method. MM Cortellini, PD Maini, A Bernasconi, S Beretta EP Patent 2,248,755 - A. Bernasconi et al. Development of a Monitoring System for Crack Growth in Bonded Single-Lap Joints Based on the Strain Field and Visualization by Augmented Reality. The Journal of Adhesion Volume 90, Issue 5-6, 2014 - A Pirondi, G Giuliese, F Moroni, A Bernasconi, A Jamil. Comparative Study of Cohesive Zone and Virtual Crack Closure Techniques for Three-Dimensional Fatigue Debonding. The Journal of Adhesion Volume 90, Issue 5-6, 2014 - A Bernasconi, M Carboni, L Comolli. Monitoring of fatigue crack growth in composite adhesively bonded joints using Fiber Bragg Gratings. Procedia Engineering 10, 207-212

Collaborations: - CIFA - ENI - Università di Parma - M.I.T. (Boston, USA); Projects and funding: - Lombardia regional council STIMA project (270 K€); - ENI - CIFA

STRUCTURAL INTEGRITY AND PROGNOSTICS Fatigue testing and modelling of adhesive joints

Highlights -  Quasi static and fatigue testing of bonded joints of

metal and composite structures -  Assessment of the fatigue strength of bonded joints by

FE analyses -  Assessment of the residual life of bonded structures

under service loads; -  Fatigue crack monitoring in bonded joints by strain field

methods, using FBG sensors Applications -  Lifting equipment; -  Ground vehicles; -  Solar energy collectors Methods: -  Numerical FE simulations (ABAQUS, ANSYS); -  Experimental tests (quasi static, fatigue, fatigue crack

growth); -  Analytical approach.


3 STRUCTURAL INTEGRITY AND PROGNOSTICS Structural integrity of aerospace and mechanical components

Highlights -  Fatigue life prediction and crack propagation behavior

of helicopter components; -  Defect and flow tolerant approach; -  Failure modeling and experimental validation of

mechanical and aerial components; -  High Fidelity non linear modeling, Multiphysics

analyses; -  Extreme loading conditions: failure, large deformations,

explosions, etc -  Simulation and assessment of technological process Applications -  Aerial systems; -  Transports; -  Mechanical systems

Contacts: Prof. Marco Giglio – [email protected] Ph.D. Andrea Manes – [email protected]

Selected papers: - A. Manes, R. Porcaro, H. Ilstad, E. Levoldd, M. Langseth, T. Børvik, "The behaviour of an offshore steel pipeline subjected to bending and stretching" Ships and Offshore Structures, pages 371-387 Volume 7, Issue 4, (2012) - M. Giglio, A. Manes, F. Viganò " Numerical simulation of the slant fracture of a helicopter's rotor hub with ductile damage failure criteria "Fatigue and Fracture of Engineering Materials and Structures, Volume 35, Issue 4, April (2012), pages 317–327 -  F. Viganò, A. Manes, M. Giglio, U. Mariani "Failure analysis of a composite main rotor helicopter hub", Eng. Failure Analysis, Vol. 18, N. 1, January (2011), Pages 97-109 - M. Giglio, S. Beretta, U. Mariani, G. Ratti, “Defect Tolerance Assessment of a Helicopter Component Subjected to Multiaxial Load”, Engineering Fracture Mechanics, Vol. 77, (2010), pp. 2479-2490 - D. Colombo, S. Desiderati, M. Giglio, A. Salerno, “TSA/FEM comparative analysis of a helicopter component under multiaxial load”, Strain, Vol. 43, (2007), pp. 311-318. - D. Colombo, M. Giglio, A. Manes, “3D fatigue crack propagation analysis of a helicopter component”, Int. Journal of Materials and Product Technology, Vol. 30, N° 1/2/3, pp. 107-123, (2007)

Methods: -  Numerical FE simulations (ABAQUS); -  Experimental tests (fatigue and crack propagation

tests, material characterization). Collaborations: -  KTH Stockholm -  Companies: AgustaWestland (Italy), Alenia

Aermacchi (Italy), etc. -  Projects and founding: -  AgustaWestland (2000 K€) -  Italian Ministry of Defence, Project ISSA -  AleniaAermacchi (Italy)


4 STRUCTURAL INTEGRITY AND PROGNOSTICS Impact damage of components and structures

Highlights -  Ball ist ic and low velocity impacts (damage

assessment); -  Assessment of the residual life of aerial and

mechanical components and systems; -  Impact behavior of panels and complex components,

also with composite multilayer construction; -  Mechanical behavior of materials under large plasticity,

high strain rate, high temperature and pressure, fracture and damage criteria, delamination.

Applications -  Aerial systems; -  Ground vehicles; -  Body protections.

Contacts: Prof. Marco Giglio – [email protected] Ph.D. Andrea Manes – [email protected]

Selected papers: - A. Manes, M. Pagani, M. Saponara, D. Mombelli, C. Mapelli, M Giglio, (2014) "Metallographic characterisation of Al6061-T6 aluminium plates subjected to ballistic impact" Materials Science & Engineering A 60, 207–220 - A. Manes, F. Serpellini, M. Pagani, M. Saponara; M. Giglio, (2014) "Perforation and penetration of aluminium target plates by armour piercing bullets", International Journal of Impact Engineering 69 39- 54 - A. Manes, D. Lumassi, L. Giudici, M. Giglio (2013). “An experimental–numerical investigation on aluminium tubes subjected to ballistic impact with soft core 7.62 ball projectiles”, Thin-Walled Struct., 73:68-80 - A. Manes, A. Gilioli, C. Sbarufatti, M. Giglio, (2013) "Experimental and numerical investigations of low velocity impact on sandwich panels" Composite Structures, 99, pp. 8-18 - M. Giglio, A. Manes, (2011) "Terminal ballistic effect on the crack growth assessment of a helicopter rotor drive", Eng. Fract. Mechanics, Vol. 78, N. 8, Pages 1542-1554

Methods: -  Numerical FE simulations (ABAQUS, LS-DYNA); -  Experimental tests (impact, ballistic, residual life); -  Analytical approach.

Collaborations: - N.T.N.U., SIMLab (Trondheim, Norway); - M.I.T. (Boston, USA); - Università di Cassino - Politecnico di Torino

Projects and founding: - Italian Ministry of Defence, Project SUMO(460 K€); - AgustaWestland (380 K€)


5 STRUCTURAL INTEGRITY AND PROGNOSTICS Impact and fatigue damage monitoring of structures

Highlights -  Sensor network design for Load Monitoring and Structural

Health Monitoring (FBGs, Piezo-transducers, CVM, etc.); -  Model-based real-time diagnosis of fatigue damage and

harsh landing damage for aeronautical platforms; -  Real-time prognosis of residual lifetime for components

subject to fatigue crack growth; -  Real-time model identification and updating of material

properties. -  Real-time impact detection, localization and energy

assessment Applications -  Aerial systems; -  High risk environments.

Contacts: Prof. Marco Giglio – [email protected] Ph.D. Claudio Sbarufatti – [email protected]

Selected papers: -  M Corbetta, C Sbarufatti, A Manes, M Giglio, On Dynamic State-Space

models for fatigue-induced structural degradation, International Journal of Fatigue, 61 (2014) 202-219.

-  C. Sbarufatti, G. Manson and K. Worden, A numerically-enhanced machine learning approach to damage diagnosis using a Lamb wave sensing network, Journal of Sound and Vibration (2014), http://dx.doi.org/10.1016/j.jsv.2014.04.059.

-  C. Sbarufatti, A. Manes and M. Giglio (2014), Application of Sensor Technologies for Local and Distributed Structural Health Monitoring, Structural control and health monitoring, 21: 1057-1083, 2014.

-  G. Vallone, A. Manes, C. Sbarufatti, M. Giglio (2013), Helicopter Harsh Landing Events: a Computational Hybrid Methodology to estimate Fuselage Damage, Journal of Aircraft, 50 (6) 1896-1907 (2013).

-  Sbarufatti C, Manes A and Giglio M. (2013), Performance optimization of a diagnostic system based upon a simulated strain field for fatigue damage characterization, Mechanical Systems and Signal Processing, 40 (2), p 667-690.

Methods: -  Numerical FE simulations (ABAQUS); -  Experimental tests (Fatigue crack growth, low/high velocity

impact); -  Machine learning approaches (Artificial Neural Networks)

and statistical analyses (frequentist and Bayesian method).

Collaborations: -  Universities: University of Sheffield (UK), University of

Patras (Greece), AGH (Poland), etc. -  Military agencies: AFIT (Poland), INTA (Spain), EDA (EU) -  Companies: AgustaWestland (Italy), Alenia Aermacchi

(Italy), SINTEF (Norway), etc.

Projects and founding: - EDA Cat. A project, HECTOR (350 K€); - EDA Cat. B project, ASTYANAX (500 K€);


6 STRUCTURAL INTEGRITY AND PROGNOSTICS Hydrogen embrittlement

Highlights -  Method to charge with hydrogen in a controlled,

reproducible and safe way thick steel specimens. Experimental test to characterize the mechanical of steels behaviour in presence of hydrogen.

-  Numerical model to evaluate the sensitivity of steels to hydrogen

Applications -  Pipeline, vessel for hydrogen -  transportation

Contacts: Prof. Laura Vergani – [email protected]

Selected papers: -  1) P. Fassina, L. Vergani et al. Effect of hydrogen and low temperature on

fatigue crack growth of pipeline steels, Engineering Fracture Mechanics, Volume 103, May 2013, Pages 10-25

-  2) P. Fassina, L. Vergani et al. Influence of hydrogen and low temperature on mechanical behaviour of two pipeline steels, Engineering Fracture Mechanics, Volume 81, February 2012, Pages 43-55

-  3) L. Vergani, G. Gobbi, C. Colombo, A NUMERICAL MODEL TO EVALUATE THE EFFECT OF HYDROGEN EMBRITTLEMENT ON LOW-ALLOY STEELS, Atti del congresso IGF XXII, Roma, 1-3 Luglio 2013; ISBN: 978-88-95940-47-2.

-  4) L. Vergani, G. Gobbi, C. Colombo, A NUMERICAL MODEL TO STUDY THE HYDROGEN EMBRITTLEMENT EFFECT ON LOW-ALLOY STEELS, Proceedings of the 12th International Conference on Fracture and Damage Mechanics (FDM), Alghero, Sardinia, Italy, September 17-19, 2013; published on: Key Engineering Materials Vols. 577-578 (2014) pp 541-545; ISSN: 1662-9795

Methods: -  Experimental tests -  Numerical modelling -  Multiscale simulation

Collaborations: -  ENI, -  TENARIS

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7 STRUCTURAL INTEGRITY AND PROGNOSTICS Bio-inspired materials

Highlights -  Multi-scale approach to study the mechanical

behavior of bone -  Bone: hierarchical structure (7 levels of hierarchy),

which affects the material behavior -  Understand how the hierarchical structure

influences the mechanical behavior -  Reproduce this behavior in new materials

Applications -  New materials for biomedical, mechanical,

aerospace applications

Contacts: Prof. Laura Vergani – [email protected]

Selected papers: -  F. Libonati, L. Vergani, M. Buehler Fracture mechanics of hydroxyapatite

single crystals under geometric confinement, J. of the Mechanical Behaviour of Biomedical Materials, Volume 20, April 2013, Pages 184-191

-  F. Libonati, L. Vergani, M. Buehler, Mechanics of collagen-hydroxyapatite model nanocomposites, Mechanics Research Communications, 2013

-  F. Libonati, C. Colombo, L. Vergani, DESIGN AND CHARACTERIZATION OF A BIO-INSPIRED COMPOSITE, Proceedings of the 3rd International Conference of Engineering Against Failure (ICEAF III), Kos, Greece, 26-28 June 2013; ISBN:978-960-88104-3-3.

-  F. Libonati, C. Colombo, L. Vergani, BONE-INSPIRED COMPOSITE: MANUFACTURING AND CHARACTERIZATION, Proceedings of the International Workshop on Aeronautics (EASN), Milan, 9-11 October 2013.

Methods: -  Atomistic simulations

Collaborations: -  Prof. M. Buehler, MIT, Boston


8 STRUCTURAL INTEGRITY AND PROGNOSTICS Gears and Transmissions

Highlights -  Theoretical and experimental research on power

transmissions and gears. Main activities:

-  Geometry and kinematics of gears. -  Gear transmission performance and failure mechanics -  Bending strength and pitting/micropitting phenomena -  Experimental activities on Single Tooth Fatigue pulsator,

testing bench recirculation and mechanical disc-on-disc. -  Diagnostics of transmission error and acoustic emission of

gear drives. -  Theoretical models and bench testing -  Functional performance and energy efficiency of helical

gear. -  Measures of performance, torsional stiffness. -  CFD simulations on lubrication. -  Energy simulations of the system.

Applications -  Aerospace -  Industrial -  Agricultural

Contacts: Prof. Carlo Gorla – [email protected]

Selected papers: -  E. Conrado, S. Foletti, C. Gorla, I.V. Papadopoulos (2011). Use of

multiaxial fatigue criteria and shakedown theorems in thermo-elastic rolling-sliding contact problems WEAR (ISSN:0043-1648), (pp. 344- 354)

-  Y. A. Tesfahunegn, F. Rosa, C. Gorla (2010). The effects of the shape of tooth profile modifications on the transmission error, bending, and contact stress of spur gears PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS. PART C, JOURNAL OF MECHANICAL ENGINEERING SCIENCE (ISSN:0954-4062), (pp. 1749- 1758)

-  G. Gasparini, U. Mariani, C. Gorla, M. Filippini, F. Rosa (2009). Bending Fatigue Tests of Helicopter Case Carburized Gears: Influence of Material, Design and Manufacturing Parameters GEAR TECHNOLOGY (ISSN:0743-6858), (pp. 68- 76), November-December 2009;

-  C. GORLA, P. DAVOLI, F. ROSA, C. LONGONI, F. CHIOZZI, A. SAMARANI (2008). Theoretical and Experimental Analysis of a Cycloidal Speed Reducer JOURNAL OF MECHANICAL DESIGN (ISSN:1050-0472), (pp. 1- 8), 130

Collaborations: -  AgustaWestland, Bonfiglioli, Same, Dana, Samputensili,

Cattini, Rossi Motoriduttori, Galbiati Group, Colmegna, Flame Spray, Bettinelli, FZG


9 STRUCTURAL INTEGRITY AND PROGNOSTICS Structural Integrity and Fitness for Purpose (SI & F4P)

Highlights -  Since 2000, it has developed a particular expertise on the

defect-tolerance analysis and application of innovative methods for the evaluation of fatigue life in welding connections.

-  The skills and competences of the research group on of fatigue crack propagation have been applied in the field of railway components and systems, and the expertise on fatigue behaviour has been developed in the area of high temperature and multi-axial components.

Applications -  Mechanical components, -  Aerospace, -  Energy

Contacts: Prof. Stefano Beretta – [email protected]

Selected papers: -  M. Madia, S. Beretta (2011). An approximation for the cyclic state of stress

ahead of cracks and its implications under fatigue crack growth ENGINEERING FRACTURE MECHANICS (ISSN:0013-7944), (pp. 573- 584), 78;

-  M.G. Tarantino, S. Beretta, S. Foletti, J. Lai (2011). A comparison of Mode III threshold under simple shear and RCF conditions ENGINEERING FRACTURE MECHANICS (ISSN:0013-7944), (pp. 1742- 1755), 78;

-  . Annoni, M. Carboni (2011). Ultrasonic metal welding of AA 6022-T4 lap joints – Part I: technological characterisation and static mechanical behaviour SCIENCE AND TECHNOLOGY OF WELDING AND JOINING (ISSN:1362-1718), (pp. 107- 115), 16;

-  M. Filippini, S. Foletti, G. Pasquero (2010). Combined cycle fatigue of gas turbine blade materials at elevated temperature STRAIN (ISSN:0039-2103), (pp. 374- 381), 46;

-  M. CARBONI, A. CERRINI, P. JOHANNESSON, M. GUIDETTI, S. BERETTA (2008). Load spectra analysis and reconstruction for hydraulic pump components FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES (ISSN:8756-758X), (pp. 251- 261), 31;

Methods: -  Multiaxial fatigue -  Defect tolerance -  LCF and constitutive models -  Welding -  Structural integrity of energy components -  . Collaborations: -  SAES Getters, AVIO, Ansaldo Lucchini

Projects and founding: - EU project E-break (150 k€)


10 STRUCTURAL INTEGRITY AND PROGNOSTICS Structural Integrity of railway components

Highlights -  Since 2005, a know-how was acquired about the

calculation of structural integrity of railway components with particular focus to inspection intervals and durability of axles, but also other components of the bogie. NDT techniques for railways are also heavily studied. The international visibility is, today, excellent.

Applications -  Transports -  Railways

Contacts: Prof. Stefano Beretta – [email protected]

Selected papers: -  Beretta S., Carboni M. (2011), Variable amplitude fatigue crack growth in a

mild steel for railway axles: experiments and predictive models, Eng. Fract. Mech. 78, 848-862.

-  Carboni M., Beretta S., Lo Conte A. (2011), Research on corrosion fatigue of railway axles, Insight 53, 361-367.

-  Madia M., Beretta S., Zerbst U. (2008), An Investigation On The Influence Of Rotary Bending And Press Fitting On Stress Intensity Factors And Fatigue Crack Growth In Railway Axles, Eng. Fract. Mech. 75, 1906-1920.

-  Carboni M., Beretta S. (2007), Effect of probability of detection upon the definition of inspection intervals of railway axles, Proc. Instn Mech. Engrs Vol. 221 Part F: J. Rail and Rapid Transit, 409-417.

-  Beretta S., Carboni M. (2006), Experiments and stochastic model for propagation lifetime of railway axles, Eng. Fract. Mech. 73, 2627-2641.

Methods: -  Experimental -  Numerical -  Analytical

Collaborations: -  ALSTOM (Italy), -  Deltarail (UK), -  Gilardoni (Italy), -  Lucchini RS (Italy), -  DB (Germany), -  ATM (Italy)


11 STRUCTURAL INTEGRITY AND PROGNOSTICS Surface engineering for high-performance materials and structures

Highlights -  The application of mechanical surface treatments

for the generation of a nano-crystalline surface layer and it characterization;

-  Advanced techniques for multifunctional coating with superior properties and reduced environmental impact.

Applications -  Ground and Aerial systems; -  Biomaterials

Contacts: Prof. Mario Guagliano – [email protected]

Selected papers: -  Katarína Miková, Sara Bagherifard, Otakar Bokuvka, Mario Guagliano, Libor

Trško (2013) Fatigue behavior of X70 microalloyed steel after severe shot peening, International Journal of Fatigue, Vol. 55, p. 33-42.

-  Sara Bagherifard, Mario Guagliano Politecnico di (2012). Fatigue behavior of a low-alloy steel with nanostructured surface obtained by severe shot peening. ENGINEERING FRACTURE MECHANICS, vol. 81, p. 56-68.

-  - A. Moridi, S.M. Hassani-Gangaraj, M. Guagliano, “A hybrid approach to determine critical and erosion velocities in the

-  cold spray process” Applied Surface Science 273 (2013) 617– 624

Methods: -  Multiscale simulations (ABAQUS, ABAQUS

Explicit, LAMPPS); -  Experimental tests (fatigue, wear, SEM, XRD..) -  Analytical modelling.

Collaborations: -  University of Oviedo (ES), -  Univeristy of Zilina (SK) -  VenetoNanoTech

Projects and founding: - CORSAIR (FP7, 580 k€) - WINOA (55 k€) - SPX SEITAL (100 k€)


12 GROUND VEHICLES DESIGN AND TESTING Optimal Design

Highlights -  Advanced design methods with reference to

complex systems and structural design (optimal design, multi-objective optimisation, robust design, topology optimisation, ….).

Applications -  Applications to the design of ground vehicle

systems and subsystems. -  Lightweight design.

Contacts: Prof. Massimiliano Gobbi – [email protected] Prof. Gianpiero Mastinu – [email protected]

Selected papers: -  G. Mastinu, M. Gobbi, C. Miano (2006). Optimal Design of Complex

Mechanical Systems with Applications to Vehicle Engineering. p. 1-359, HEIDELBERG:Springer Verlag,

-  M. Gobbi, F. Levi, G. Mastinu (2006). Multi-objective stochastic optimisation of the suspension system of road vehicles. JOURNAL OF SOUND AND VIBRATION, vol. 298, p. 1055-1072.

-  M. Gobbi, I. Haque, G. Mastinu, P. Papalambros (2005). Optimization and integration of ground vehicle systems. VEHICLE SYSTEM DYNAMICS, vol. 43, p. 437-454.

-  M. Gobbi (2013). A k, k-ε optimality selection based multi objective genetic algorithm with applications to vehicle engineering. OPTIMIZATION AND ENGINEERING, vol. 14, p. 345-360.

-  M. Gobbi, G. Mastinu (2001). Analytical description and optimization of the dynamic behaviour of passively suspended road vehicles. JOURNAL OF SOUND AND VIBRATION, vol. 245, p. 457-481,

Methods: -  Development of innovative optimisation methods

and applications. -  Evo lu t i ona ry compu ta t i on (GA) , g loba l

approximation, reliability based optimisation, SIMP, ...

Collaborations: -  CRF, Ferrari, Honda, Magneti Marelli, Brembo,

Univ. Michigan, ADEPT, ……


13 GROUND VEHICLES DESIGN AND TESTING Vehicle design and engineering

Highlights -  Theoretical and experimental methods for the construction

of vehicles and their subsystems: active and passive safety. -  Design for performance and sustainability.

Applications -  Road vehicles, rail vehicles, agricultural machinery,

construction equipment. -  - Wheels, design and testing

- Brakes, NVH - Comfort, testing, and modeling - Green vehicles design and construction - Experimental mechanics, force measurement - Experimental mechanics, measurement of inertial properties of vehicles and subsystems - Development of devices for improving the passive safety of vehicles

Selected papers: -  Giampiero Mastinu, Manfred Ploechl Editors (2013). Road and Off-Road

Vehicle System Dynamics Handbook., CRC Press, ISBN: 9780849333224. -  G. Mastinu, M. Gobbi, G. Previati (2011). A New Six-axis Load Cell. Part I:

Design. EXPERIMENTAL MECHANICS, vol. 51, p. 373-388. -  M. Gobbi, G.Mastinu, G.Previati (2011). A method for measuring the inertia

properties of rigid bodies. MECHANICAL SYSTEMS AND SIGNAL PROCESSING, vol. 25, p. 305-318.

-  M. Pennati, M. Gobbi, G. Mastinu (2009). A dummy for the objective ride comfort evaluation of ground vehicles. VEHICLE SYSTEM DYNAMICS, vol. 47, p. 343-362.

-  M. Gobbi, J. Botero, G. Mastinu (2009). Global chassis control by sensing forces/moments at the wheels. INTERNATIONAL JOURNAL OF VEHICLE AUTONOMOUS SYSTEMS, vol. 7, p. 221-242.

Collaborations: -  Honda R&D Center -  Ferrari, Ansaldo -  Brembo, Streparava -  LMS -  Fiat auto -  SameDeutz-Fahr -  TU Wien -  Univ. Los Andes -  DYSCARF -  GREENFUN -  SLTW -  Sospensioni Leggere

Contacts: Prof. Massimiliano Gobbi – [email protected] Prof. Gianpiero Mastinu – [email protected]

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