620 Ingenieurwissenschaften und Maschinenbau
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Bamboo is an environmentally friendly alternative to conventional materials in mechanical engineering such as steel or aluminium. Bamboo is the fastest growing plant in the world. Instead of releasing CO2 during the manufacturing process, bamboo absorbs CO2 as it grows.
In addition to the sustainability aspect, bamboo tubes also offer excellent properties as a lightweight construction material, which have been optimised through evolution. Bamboo tubes have high strength and stiffness at low weight when used as tension-compression bars or bending beams. Bamboo has strong, high-density fibres at the boundary area, where bending stresses are greatest. Towards the inside, where the stresses are lower, the bamboo becomes porous to optimise weight. This, together with knots arranged in regular intervals, counteracts buckling.
In mobile applications such as cars and bicycles, lightweight construction is sought for energy efficiency reasons. Because of its excellent lightweight properties, the project investigated whether bamboo could be used in mobile, automotive or agricultural engineering. For example, a bamboo bicycle frame has been developed with the aim to be as light as possible. There are bamboo bicycles on the market, but they can only be made one at a time by hand. The bamboo tubes are joined together and functional elements such as the bottom bracket and headset are integrated by wrapping them in resin-impregnated natural or carbon fibres. This makes the joints very heavy. A different approach is taken here: the bamboo tubes are drilled out slightly to achieve a defined internal diameter, and then short aluminium tubes are glued into the bamboo canes from the inside. To prevent the cane from breaking in the circumferential direction, i.e. perpendicular to the fibre direction, the bamboo tubes are wrapped in a thin layer of natural or carbon fibre impregnated with synthetic resin. The aluminium tubes and functional elements are welded or soldered together beforehand.
The design of the bicycle frame, i.e. the dimensioning of the bamboo tubes and joints, was based on extensive bending and tensile tests to determine the strength properties of the natural material bamboo. The bonding between the bamboo cane and the aluminium tube was also investigated experimentally. Finally, several prototype bicycle frames were made and tested for durability according to DIN-EN-14764. The frames passed the tests.
The result is a bamboo bicycle that is manufactured with standardised connectors and joints. The assembly concept developed allows both fully automated and semi-automated series production of bamboo bicycles.
This paper investigates four different mobile robots with respect to their drivingcharacteristics and soil preservation properties in an agricultural environment.Thereby, robots of classical design from agriculture as well as systems from spacerobotics with advanced locomotion concepts are considered to determine theindividual advantages of each rover concept with respect to the application domain.Locomotion experiments were conducted to analyze the general driving behavior,tensile force, and obstacle‐surmounting capability and ground interaction of eachrobot. Various soil conditions typical for the area of application are taken intoaccount, which are varied in terms of moisture and density. The presented workcovers the specification of the conducted experiments, documentation of theimplementation as well as analysis and evaluation of the collected data. In theevaluation, particular attention is paid to the change in driving characteristics underdifferent soil conditions, as well as to the soil stress caused by driving, since soilquality is of critical importance for agricultural applications. The analysis shows thatthe advanced locomotion concepts, as used in space robotics, also have positiveimplications for certain requirements in agricultural applications, such as maneuver-ability in wet conditions and soil conservation. The results show potential for designinnovations in agricultural robotics that can be used, to open up new fields ofapplication for instance in the context of precision farming.
Oleamide is used as a lubricant in the manufacturing and application of polypropylene (PP) medical devices. Samples of PP were prepared with 0, 1500, and 15 000 ppm oleamide content as lubricant. The samples were either left non-sterile, sterilized with ethylene oxide (ETO), γ-radiation (γ) or autoclaved (A) and stored for up to 4 weeks. To determine the oleamide bulk-to-surface distribution depending on sterilization method and storage time an extraction method and a washing technique were applied. The oleamide content was determined by gas chromatography (GC-FID) and compared with the coefficient of friction (COF). The COF dependent on the measured lubricant content at the surface. The content of lubricant on the surface depends on the type of sterilization: ETO increased the lubricant content to some extent, γ-sterilization and autoclaving reduced it. After storage, no migration of the lubricant to the surface could be detected.
A systematic study was performed to understand the effects of the devulcanizing agent dibenzamido diphenyl disulfide (DBD) on the vulcanization and devulcanization process of a sulfur-cured ethylene-propylene-diene monomer (EPDM) rubber. The influence of DBD on vulcanization was investigated by mixing DBD with virgin rubber and curative system. The devulcanization of rubber waste was achieved with varying amounts of DBD ranging from 0.4 to 13.8 wt% and temperatures from 150 to 200°C. The quality of vulcanizates and devulcanizates was evaluated by rheometer tests, temperature scanning stress relaxation measurements, and analysis of mechanical properties. During vulcanization, DBD acts as an accelerator in the presence of sulfur. When accelerators are added, the scorch time increases, and the cure rate decreases. Thus, DBD acts as a retarder. In the presence of activators, DBD leads to a significant reduction of crosslink density. This results in composites with high elongation at break and poor compression set values. The efficiency of the devulcanization of rubber waste depends strongly on DBD concentration and temperature. The monosulfidic crosslinks are cleaved by low concentrations of DBD, while polysulfidic crosslinks require higher concentrations. These results show that DBD is effective as a devulcanizing agent and degrades the network below 200°C.
The deployment of containers as building modules has grown in popularity over the past years due to their inherent strength, modular construction, and relatively low cost. The upcycled container architecture is being accepted since it is more eco-friendly than using the traditional building materials with intensive carbon footprint. Moreover, owing to the unquestionable urgency of climate change, existing climate-adaptive design strategies may no longer respond effectively as they are supposed to work in the previous passive design. Therefore, this paper explores the conceptual design for an upcycled shipping container building, which is designed as a carbon-smart modular living solution to a single family house under three design scenarios, related to cold, temperate, and hot–humid climatic zones, respectively. The extra feature of future climate adaption has been added by assessing the projected future climate data with the ASHRAE Standard 55 and Current Handbook of Fundamentals Comfort Model. Compared with the conventional design, Rome would gradually face more failures in conventional climate-adaptive design measures in the coming 60 years, as the growing trends in both cooling and dehumidification demand. Consequently, the appropriate utilization of internal heat gains are proposed to be the most promising measure, followed by the measure of windows sun shading and passive solar direct gain by using low mass, in the upcoming future in Rome. Future climate projection further shows different results in Berlin and Stockholm, where the special attention is around the occasional overheating risk towards the design goal of future thermal comfort.
Semi-solid metal alloys, as used in industrial thixoforming, have a special microstructure of globular grains suspended in a liquid metal matrix. The complex rheological properties are strongly influenced by the local solid fraction, particle shape, particle size and state of agglomeration. It was analysed how the microstructure develops in dependence of the shear rate and cooling rate during the solidification and it was observed that the average particle size increased with increasing shear rate and decreasing cooling rate. In order to account for those phenomena, the rate of crystal growth and the relationship between average particle diameter and viscosity was modelled by applying the Sherwood two-film model for the mass transport. The dependence of the viscosity from the particle size were modelled with a modified Krieger–Dougherty model. Based on the rheological and microstructural observations an evaluation method was elaborated that allows for the construction of objective master curves that are independent of the particle growth during the experimentation. The isothermal experiments for the characterisation of the rheological behaviour consisted of step-change of shear-rate and yield-stress experiments. From the experimental data the steady-state flow curves could be determined as well as the time-dependent relaxation of the shear stress after a change of shear rate. The steady-state rheological behaviour was found to be shear thinning. Nevertheless, immediately after a shear-rate change an overshoot was observed that resulted from a short-time shear-thickening behaviour. The yield stress was found to strongly depend on the microstructure and the degree of agglomeration of the solid phase. With increasing rest time the yield stress was increasing strongly, because of the agglomeration of the solid particles. Based on the step-change of shear-rate experiments a single-phase flow has been developed that consists of a modified Herschel–Bulkley approach and accounts for the thixotropic as well as for the yield-stress behaviour of the alloys.
A recently published study of high temperature nitridation of iron chromium aluminum alloys (FeCrAl) at 900°C in N2–H2 has redundantly shown the formation of locally confined corrosion pockets reaching several microns into the alloy. These nitrided pockets form underneath chromia islands laterally surrounded by the otherwise protective alumina scale. Chromia renders a nitrogen‐permeable defect under the given conditions and the presence of aluminum in the alloy. In light of these findings on FeCrAl, a focused ion beam–scanning electron microscope tomography study has been undertaken on an equally nitrided FeNiCrAl sample to characterize its nitridation corrosion features chemically and morphologically. The alloy is strengthened by a high number of chromium carbide precipitates, which are also preferential chromia formation sites. Besides the confirmation of the complete encapsulation of the corrosion pocket from the alloy by a closed and dense aluminum nitride rim, very large voids have been found in the said pockets. Furthermore, metallic particles comprising nickel and iron are deposited on top of the outer oxide scale above such void regions.
The simulation of the residual stress field achieved by shot peening cannot be carried out on component-large models. Hence, an efficient unit cell model for the simulation of the shot peening process is developed. The model allows both, the simple inclusion of a pre-stress and the evaluation of the up-arching of the Almen strip. For this purpose, generalized coupling constraints for the periodic boundaries of the unit cell are developed. These allow for displacement and rotation of the coupled boundaries relative to each other. In the coupling constraints, this is accomplished by respective variables, which can either be prescribed to the analysis or read out as a result from the analysis. Hence, the unit cell can expand, shear, bend and twist under driving forces like, e. g., residual stresses or thermal effects. At the same time, deformations of the cell’s periodic boundary pairs are kept congruent by the generalized coupling. The ability to cover expansion is novel regarding known periodic boundary conditions. Also, the application of a generalized unit cell to shot peening is new.
Results obtained with the generalized unit cell are displayed, demonstrating its capabilities: A fundamental analysis of the residual stress field from shot peening shows inhomogeneities at a fatigue relevant level to be inevitable. A validation of the model was done by comparison with experimental Almen strip shot peening tests reported in literature. Shot peening under pre-stress is demonstrated and its results in terms of residual stress are evaluated. The application of the generalized unit cell is not limited to shot peening.
Vanadium carbide (VC) reinforced FeCrVC hardfacings have become important to improving the lifetime of tools suffering abrasive and impressive loads. This is because the microstructural properties of such hardfacings enable the primary VCs to act as obstacles against the penetrating abrasive. Because dilution is supposed to be the key issue influencing the precipitation behaviour of primary carbides during surfacing, the development of deposit welding processes exhibiting a reduced thermal impact, and hence lower dilution to the base material, is the primary focus of the current research. By inserting an additional hot wire in the melt, an approach was developed to separate the material and energy input during gas metal arc welding (GMAW) and hence realised low dilution claddings. The carbide content could be increased, and a grain refinement was observed compared with conventional GMAW. These effects could be attributed to both the reduced dilution and heterogeneous nucleation.
A suspension of PMMA spheres in a density matched saccharose solution is investigated with a classical Searle rheometer and a NMR (Nuclear Magnetic Resonance) spectrometer. Here the NMR is used to measure the radial distribution of the PMMA spheres in the rotating cell, in addition to the local velocity profile of the suspension. The influence of particle concentration on the wall depletion is studied. Further analysis are carried out with computational fluid dynamics software. The velocity field as well as the solid distribution in the couette flow is simulated with a two-phase model including the Darcy law and compared to the experimental data.