Angelo O. Andrisano

Emilia-Romagna High Technology Network

Via Vignolese 905 - I 41125 Modena ITALY - tel: +39 059 2056150 - fax: +39 059 2056126 www.intermech.unimore.it

MECHANICS – MATERIALS

PLATFORM

Angelo O. Andrisano Università degli Studi di Modena e Reggio Emilia



Unemployment rate: 3.1% (2008)

GDP per Capita Index: 132.5 (EU 27 average equal to 100)

Gross Domestic Product per Capita: 31,75 €

Gross Domestic Product: 113,824 M€ (8.8 % Italy)

Population Density: 192/Km2

Surface: 22,123 Km2

Inhabitants: 4,223,264 (7% Italy)

Sources: Eurostat, Istat 20079- Unioncamere 2009

N. Companies: 433,412 (2008)

N. Manufacturing Companies: 58,389 (2009)

Emilia-Romagna Region Overview



Biomedical Equipment

Packaging

Machining & Tools

Ceramic Tiles

Mechatronics

Automotive and Motorcycles

Food Industry

Agricultural Machinery

Woodworking Machinery

Emilia-Romagna Region Industry

Leisure Crafts



5 Universities on 11 sites Main research Centers

Over 150,000 Students

Over 6,000 Researchers

Emilia-Romagna Region Research System




Evolution

First Step

Net-Labs/Hi-Mech District

High Technology Network

Second Step

Third Step

2000

Next Future

2008

Towards Technopoles

DESIGN AND MANUFACTURING

Design & Manufacturing 1

New product/process development and re-engineering

Robust Design, DFMA and Digital Manufacturing [email protected]

mailto:[email protected]


Industrial Robotics and Automation

Artificial Vision and Adaptive Manufacturing

Simulation and Offline Programming

Human Machine Interface

Dextrous Grippers

Integrated design of Intelligent Manufacturing Systems (IMS)

[email protected]



Operations Management

• Modelling and analysis of production, handling and

logistic systems

• Development of discrete event simulation models

• Layout design and optimization

• Resource scheduling and operation planning

• Business Process Reengineering (BPR) (from

Forecasting process to Planning and Operations)

• Total Productive Maintenance

Response Surfaces and function for the

inventory level under relevant parameter

Simulating model for a transport and

storage system

[email protected]



Manufacturing Technologies

Study of the primary and secondary anisotropy in parts built by Laser

Consolidation In cooperation with X-AT

Exeter University (UK)

EDM micro-drilling on advanced

materials: process modelling

μ- wave sintering of SLS metal

parts and nanostructured powders

In cooperation with

Politecnico di Torino

[email protected]

[email protected]



MECHANISMS

Mechanisms 1

Biomechanics & implantology

• Multiple tooth replacement

• Finite element stress - strain analysis

• Hip joint wear simulation

• Development of hip joint prostheses

[email protected] & [email protected]




Mechanisms 2

Vibration Lab

• Development of new theories for thin walled

structures (SPACE APPLICATIONS)

• Nonlinear Dynamics, Stability, Fluid-Structure

interaction

• Development of software for Gear modelling

• Stress, vibration reduction, optimization

• Dynamic tests on shaking table

• Modal analysis (numerical and experimental)

• Vibration measurements

• Complex gear train analyses

[email protected]


ENGINES AND AUTOMOTIVE

Engines & Automotive 1

Engine thermofluids 1

Ferrari Auto e GeS; VM Motori; Ducati; Lombardini; Alfa Romeo; Casappa; CNH

Imperial College (UK); Chalmers University of Technology (SWE)

•Full engine system analysis

•Sub-system analysis

•Combustion&turbulence

•Injection systems

[email protected]




Development of a new type of small capacity HSDI 2-Stroke Diesel engine

prototype (HSD2) HSD2 prototype parameters

Number of cylinders 3

Bore [mm] x Stroke [mm] 70 x 91

Total displacement [l] 1.05

Compression Ratio 19.5:1

IPC [CAD ABDC] 62.0

EPC [CAD BBDC] 76.0

[email protected]




Development of a new type of small capacity HSDI 2-Stroke Diesel engine

prototype (HSD2)

Temperature field – Radial plane

Full load @ 3000 rpm

•Full Optimization of the combustion

chamber geometry and of the main

injection strategies

•Assess the effectiveness of the

combustion system

•Predict and compare exhaust gas

emissions

•KIVA3V – Rel. 2 3D CFD numerical

simulations. Diesel Oil Surrogate

(DOS) Model


Engine test bed Main components and characteristics:

• Soundproof room (6m x 4m x 3m)

• Eddy Current double rotor dynamometer (290

kW – 500 Nm – 13.000 rpm)

• Fuel storage device and automatic feeding

system for gasoline and diesel oil controlled

with Coriolis flow-meter

• External evaporative cooling tower (500 kW)

• Control units both for Eddy Current

dynamometer and throttle actuator and host

controlled operation are possible)

• Data acquisition system (rotational speed,

torque, power, fuel consumption, combustion

air flow, pressures, temperatures, Air to Fuel

Ratio, environmental conditions)

• Steady state load test • Transient load test • Endurance test • Fuel consumption test • Research and development test


Engine components analysis and design

Motorbike frame,

instrumented with

strain gauges, for

stiffness estimate

FEM analysis of a connecting rod. The

eye is made with two parts, to allow the

assembly of a monolithic crankshaft

Photoelasticity: eye

of a connection rod;

stress concentrations

occur at the bore

sides

[email protected]



Thermomechanics

LOMBARDINI Diesel Engine - cooling

circuit velocity contours

Experiment vs. FEM for crack prediction

in the cooling circuit

Head of a four valve

combustion chamber.

Both stress and

temperature affect the

material

[email protected]



Hydraulic Components and Systems

Load Sensing proportional Valves - analysis of the metering characteristics, of the

transient behaviour, design optimization in order to improve energy consumption

Test bed

Proportional

Valves Test Rig

Volumetric

Machines Test Rig

[email protected]



Hydraulic Components and Systems

Analysis of the lubrication mechanism within the gaps of hydraulic

machines to determine volumetric and mechanical efficiency

Numerical procedure to determine the

gaps height, tilt and the pressure distribution

in the gap viscous forces, and leakages

[email protected]



Thermofluid dynamics

Numerical and experimental research

• Navier-Stokes RANS simulation of vehicle,

vehicle subsystems and fluid circuits

• Time resolved High frequency Stereo PIV and

conventional fluid dynamic analyses

• IR thermography studies

MINARDI F1 heat

exchanger: IR

termography and

numeric simulations

MINARDI F1 lubrication

circuit: numeric analysis

[email protected]



Aerodynamics and Fluid Flow aspects

Numerical and experimental studies

• Navier-Stokes RANS and LES aerodynamic

simulation

• PIV, anemometry and pressure experiments

TATUUS F

Renault

front wing:

CFD analysis

CFD analysis of a

Rally car intake

opening

High Frequency

Stereo PIV:

apparatus and

velocity field

reconstruction


Millechili Lab 1

In collaboration with Ferrari SpA we aim at finding new solutions for car chassis

design in order to reduce the weight of the car complying with the company quality

standards for the vehicle in terms of: torsional and bending stiffness, fatigue

resistance, modal analysis, crash test resistance

[email protected]



Autocar 09 june, 24th

Millechili Lab 2


Millechili Lab 3

Examples of innovative chassis designs


Millechili Lab 4

Crash test resistance


Millechili Lab 5

Topology optimisation for car chassis design:

TO is an iterative procedure in which at each iteration of a FEM analysis a different

density is assigned to each element according to its structural relevance

Tutorial from top-opt.dk: Topology

optimisation for a simple bridge

Software OPTISTRUCT

by Altair

[email protected]



Formula Student 1

General Supervisor: G.S. Barozzi

Technl. Supervisor: V. Bellentani


Formula Student 2


Formula Student 3

2009 Specifications • Torsional stiffness 2300 Nm/deg

• Chassis weight: 29 kg

• Push-road suspensions

• Carbon bodywork

• Electrical-actuated gearbox

• Engine: Yamaha XT660 modified

THERMOFLUIDS

Thermofluids 1

Natural Convection in enclosures 1 G.S. Barozzi M.A. Corticelli, P. Levoni, D. Angeli, M. Cavazzuti

DNS simulations and PIV & UPDV measurements

Thermofluids 2

Natural Convection in enclosures 2

Transitional Flows

Objective: To investigate flow

transitions and routes to chaos

of natural convection flows

originated by enclosed thermal

sources

Reference case: square-

sectioned enclosure containing

a horizontal heated cylinder

Tools: Direct Numerical

Simulation, PIV, UPDV

[email protected]


Natural Convection in enclosures 3

Transient convection from a heated cylinder

Objectives: to investigate the

mechanisms of the initial

transient of convection from

suddenly heated cylinders, and

to determine scaling laws for the

delay time associated with the

onset of convective transport

Tools: numerical Simulation,

scale analysis.

Thermofluids 3

Natural convection in chimneys

Effect of horizontal ribs and multi-objective rib-shape optimization

Thermofluids 4

stream

function

Velocity contours

Pareto front diagram

[email protected]


Turbulent heat transfer over riblets

Thermofluids 5

Riblets are used for drag reduction in many

applications, but their effectiveness for heat

transfer enhancement is still not proven.

Turbulent heat transfer over riblets is studied

by means of direct numerical simulation

(DNS)

Instantaneous drag and temperature fluctuations on the corrugated wall (Re = 12E3); red spots correspond to drag and heat transfer increase.

[email protected]


Thermofluids 6

Compact Heat exchanger E.Stalio, M.A. Corticelli, M. Cavazzuti

Corrugated channels

DNS-3D for sinusoidal corrugations 2D RANS simulation of shape

optimisation of freely corrugated

channels (mode-Frontier)

Instantaneous plots of the

velocity and temperature

fields:

- trajectories of particles and

contours of velocity on three

spanwise planes;

- isosurfaces of temperature

and temperature fluctuation

contours.

Thermofluids 7

Hemodynamics M. A. Atherton, A. W. Khir, M. Cavazzuti, G. S. Barozzi, M. W. Collins, Vascular

device interaction with the endothelium, Biomedicine & Pharmacoteraphy, 2008, 62(8):504-505

VISC06 (Virtual Intracranial Stenting Challenge)

VISC06 committee asked for steady state simulations using a Newtonian fluid; for better

accuracy we also simulated unsteady non-Newtonian fluid flow in the aneurysm region

CFD simulations of blood flow in an intracranial aneurysm in presence of a stent: time-dependent wall shear-stress distributions for the VISC’06 aneurism with no stent, and the 3 VISC stent models

no stents # 1 #2 #3

[email protected]


Thermofluids 8

Angstroem Method

A development for the measure of thermal diffusivity

The thermal diffusivity is retrieved from amplitude decay and phase shift of thermal waves

traveling along the specimen, as measured by IR thermography .

A novel approach was used to generate the thermal waves, based on a Peltier source, in

order to obtain pure sine waves with null net heat input.

[email protected]


Thermofluids 9

Other industrial CFD applications

Marine & Yacht design

Biomedical

Electronics

Hydraulics

HVAC

Aerospace

[email protected]


Thermofluids 10

Advanced Peltier devices

Patented devices:

Cooled surface (IR sequence)

Wearable body cooler for cold therapy (patent

requested)

Wearable micro-icebox for insulin and medicines

(patent requested)

Heated and cooled steering wheel (international

patent Momo/Key Safety Inc.)

Peltier micro-generator for self-powered heat

counters (to be applied to house radiators)

[email protected]


Experiments on landmine scale-models to develop data analysis and automatic

detection algorithms

Thermofluids 11

IR landmine detection

12 p.m. 8 p.m. 4 p.m. 12 a.m. 8 a.m.

[email protected]


Thermofluids 12

Droplet cooling of hot surfaces

The interface temperature is measured

from below, through a BaF2 solid crystal

(very high spectral transmittance), by an

AVIO TVS-620 thermographic camera.

Temperature distribution on the

disk surface

75

80

85

90

95

100

0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00

t*

Te

mp

era

ture

[°C

]

T 1 - sprayT 2 - dropletsT 3 - sprayT 4 - dropletsT 5 - spray

Average temperature vs. dimensionless

time on the disk surface

Droplets-wall interaction: measurement of the interface temperature through

infrared-transparent media.

[email protected]


Research in Thermofluids 13

Fire Protection: Water Mist Systems Prof. P. Tartarini

Discharge and dispersion analysis of water mist sprays

Characterization of the atomization process of a water jet exiting a high-pressure single injector :

• laser-based experimental device

• data on the drop size distribution are collected by experiments at high pressure (80 bar)

• a theoretical model has been developed

to predict velocity at the injector outlet

• CFD predictions by FDS code are carried out for the

distribution of mass flux at different heights from the outlet

[email protected]


MATERIALS

Inertization, recovery and valorization of

inorganic wastes and biomass and

engineering of the valorization and

recovery systems.

Formulation and production of

ceramics, glasses, glass-ceramics,

bricks, composites, cement and

pigments starting from residues and

wastes (ashes from incinerator plants,

ceramics sludges, glass cullet, wastes

from electrical and electronic

equipments, wastes from agroindustrial

field...) alternative and/or competitive

to products on the market.

brick

glaze

cement

glass-ceramic

Materials 1

Materials Engineering 1

[email protected]


Connection pin

F

e

Ni

A

u

Connectors (boards)

Gold = 135 ppm

Connectors (pin)

Gold = 11 ppm

Microprocessors

Gold = 15 000 ppm

Chemical and physical methods for the

extraction of valuable components from wastes.

Au

20µm

Ni

Fe, Ni, Co

Metallic lid

Ores

Gold = 0.5 – 13.7 ppm


Materials 2

[email protected]


Preparation of green polymer by using as precursor the phenolic component found in agrowastes.

ESEM images of cross section

Agrowastes

Phenolic components

New materials by green process


Materials 3

[email protected]


Evaluation of Life Cycle Assessment of materials and processes.

Human Health Ecosystem Quality Resources

-54.7%

-42.6%

-28.8%

-31.1%

0.00752 0.00265 0.00694 0.00599

Comparison between environmental impact of the use of primary

and secondary raw materials for the glazed formulation


Materials 4

[email protected]


Rheology of ceramic suspension

Modeling and optimisation of

body formulations by Design

of Experiment

3D Plot a typical graphical result from a mixture design Viscosity vs. Shear rate for a ceramic suspension

Viscosity vs. time for a ceramic suspension


Materials 5

[email protected]


ENERGY

• CFD analysis of indoor air flow, heat transfer

by convection and radiation, thermal bridges

• Optimization of building insulation and

Heating Ventilation Air Conditioning systems

• Development of innovative materials and

components for building insulation

• Development of advanced and innovative

HVAC systems

• Standard and tailored rating of energy

performance of buildings

Assessment and optimization of energy performance of buildings

2.3

-8

-4

0

4

8

12

16

20

24

0 1 2 3 4 5 6 7 8 9 10 11 12

Month

q' H

[W/m2u]

heat loss through insulationheat loss for ventilationinternal gainsolar gaintotal heat needhot water heat need

Energy 1

outconvwallcondinconv RRRRU

,,,

11

Wall U-values - Thermographic Analysis

Energy 2a

Energy 2b

Wall U-values - Thermographic Analysis

W

A

L

L

WARM ROOM

+ 20 °C

COLD ROOM

- 5 °C

Sensors monitor

heat flux,

q

Sensors monitor

surface

temperatures, Ts

W

Km

q

TTR

cshsparete

2,,

Km

W

RRRU

outconvwallcondinconv2

,,,

1

Energy 2c

Wall U-values - Experimental Analysis

Energy 3a

Thermal Bridges - Numerical Analysis

Left: non-insulated thermal bridge = possible surface condensation

Right: insulated thermal bridge

Thermal Bridges - Numerical Analysis

Energy 3b

“Component based program”:

many independent subroutines

(types)

Modular structure: complex

system = connection of simple

systems

TRNSYS 16.01 – Transient analysis

Energy 4a

Comparisons between commercial codes and TRNSYS

Otto

bre

Dicem

bre

Febbr

aio

Aprile

TRNSYS

EC501

0

1000

2000

3000

4000

5000

6000

7000

8000

kW

h

Apporti Gratuiti

Otto

bre

Nov

embr

eDicem

bre

Gen

naio

Feb

brai

o

Mar

zo

Apr

ile

TRNSYS

EC501

-10,0

0,0

10,0

20,0

30,0

40,0

50,0

[kW

h/m

2m

es

e]

Fabbisogno specifico dell'involucro

TRNSYS 16.01 – Transient analysis

Otto

bre

Nov

embr

eDicem

bre

Gen

naio

Febbr

aio

Mar

zo

Aprile

TRNSYS

EC501

0

5000

10000

15000

20000

25000

[kW

h/m

ese]

Dispersioni

Gennaio

Febbraio

Marzo

TotaleContabilizzazione

TRNSYS

EC5010

20000

40000

60000

80000

100000

120000

MJ

Energia primaria

Gennaio

Febbraio

Marzo

TotaleContabilizzazione

TRNSYS

EC5010

2000

4000

6000

8000

10000

12000

MJ

Consumi elettrici

Energy 4b

Feasibility study and development of a biomass Combined

Heat Power system for a new residential sector

• Preliminary analysis

of the energy

demand of the

sector.

• Choice of the most

suitable plant

solution.

• Investment cost

analysis

Energy 5a

• Heat generation through vegetal biomass

- Agricultural and forest residues

- Dedicated crops

- Wood processing waste

• Organic Rankine Cycle -cycle based CHP unit

- Electric energy is sold to the network with incentive fee

- Thermal energy is used for the climatization and the biomass drying

• District heating network

Biomass Combined Heat Power - Chosen solutions

Energy 5b

Energy 6

Wind Energy The problem of icing on the blades of a wind turbine

Energy 8

Cool Roofs

Development of building

surfaces with colours

similar to the traditional

ones (e.g. terracotta tiles)

but with higher solar

reflectance

CR are paintings for building surfaces to avoid summer overheating thanks to high

and durable values of solar reflectance and IR thermal emittance

[email protected]


CIVIL AND ENVIRONMENTAL

Civil & Environmental 4

Atmospheric Pollution 1

Recent applications :

• estimation of the area impacted by the

plume from an industrial coastal area

(Porto Marghera, Venice Lagoon)

• simulation of the dispersion of dust

particles from a waste landfill in a

complex terrain

Simulation of pollutant distribution in

atmosphere by means of Lagrangian

dispersion models

[email protected]


Experimental monitoring of:

• particle mass concentration (PM1,

PM2.5 and PM10), by TEOM with

FDMS

• total concentration of particles and

particle size distribution, in the

diameter range 10 -700 nm, by

Differential Mobility Analyzer (DMA).

The aim of the research is to verify

removal and accumulation

processes, condensation of finer

particles and particle generation by

nucleation of gaseous components

Civil & Environmental 5

Atmospheric Pollution 2

[email protected]


MechLav TechnoPole Advanced Mechanics Laboratory

Ferrara (Italy)

Mechanics and ICT Area 3D Scanning and rapid prototyping of machines Fluid dynamic design of turbomachines

MechLav TechnoPole - Ferrara (Italy)

Area website:

www.centec.it

Mechanics and ICT Area Advanced high-performance FEM and CFD computation (Open Source)

ICT solutions to support design, manufacturing, and other business processes

Area website:

www.centec.it


Acoustics and Vibration Area

Mechanical system modeling for vibro-acoustic optimization

Vibration-based diagnostics and quality control

0 50 100 150 200 250 300 350

Sperimentale 5000 rpm Virtual.Lab -Flessibilità

Area website:

www.unife.it/tecnopolo/lav


Acoustics and Vibration Area

Porous materials: characterization and modelling Noise control of machinery Numerical modelling: FEM, BEM, SEA, Raytracing simulation of vibroacoustic systems

Area website:


Area website:



Facilities

• Anechoic and hemi-anechoic chamber

(50 Hz cut-off frequency)

•Complete instrumentation for acoustic

and vibration measurements and modal

analysis

•MB, FEM, BEM software for simulation

and optimization

•Model-Test correlation

•Test bench for rotating components

(gears, bearings, joints)

•Laser Doppler vibrometers


Facilities • Fully instrumented test rig for fluid

machine testing

• Fatigue testing

• Reverse engineering tools

• Portable 3D Scanner

• Rapid Prototyping

• Quality control and assessment

• Scientific cluster for high performance

FEM/CFD computations


Thanks to my colleagues and the University staff

for providing the original material

Thank you so much for your patient attention

Documents

Angelo O. Andrisano