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In 4D printing, an additively manufactured component is given the ability to change its shape or function in an intended and useful manner over time. The technology of 4D printing is still in an early stage of development. Nevertheless, interesting research and initial applications exist in the literature. In this work, a novel methodical approach is presented that helps transfer existing 4D printing research results and knowledge into solving application tasks systematically. Moreover, two different smart materials are analyzed, used, and combined following the presented methodical approach to solving the given task in the form of recovering an object from a poorly accessible space. This is implemented by self-positioning, grabbing, and extracting the target object. The first smart material used to realize these tasks is a shape-memory polymer, while the second is a polymer-based magnetic composite. In addition to the presentation and detailed implementation of the methodical approach, the potentials and behavior of the two smart materials are further examined and narrowed down as a result of the investigation. The results show that the developed methodical approach contributes to moving 4D printing closer toward a viable alternative to existing technologies due to its problem-oriented nature.
Lithium-ion batteries exhibit slow voltage dynamics on the minute time scale that are usually associated with transport processes. We present a novel modelling approach toward these dynamics by combining physical and data-driven models into a Grey-box model. We use neural networks, in particular neural ordinary differential equations. The physical structure of the Grey-box model is borrowed from the Fickian diffusion law, where the transport domain is discretized using finite volumes. Within this physical structure, unknown parameters (diffusion coefficient, diffusion length, discretization) and dependencies (state of charge, lithium concentration) are replaced by neural networks and learnable parameters. We perform model-to-model comparisons, using as training data (a) a Fickian diffusion process, (b) a Warburg element, and (c) a resistor-capacitor circuit. Voltage dynamics during constant-current operation and pulse tests as well as electrochemical impedance spectra are simulated. The slow dynamics of all three physical models in the order of ten to 30 min are well captured by the Grey-box model, demonstrating the flexibility of the present approach.
Given the looming threats of climate change and the rapid worldwide urbanization, it is a necessity to prioritize the transition towards a carbon-free built environment. This research study provides a holistic digital methodology for parametric design of urban residential buildings with regard to the Mediterranean semi-arid climate zone of Morocco in the early design phase. The morphological parameters of the urban residential buildings, namely the buildings’ typology, the distance between buildings, the urban grid’s orientation, and the window-towall ratio, are evaluated in order to identify the key combinations of passive and active solar design strategies that determine the high energy performing configurations, based on the introduced Energy Performance Index (EPI), which is the ratio between solar BIPV production to maximum available installed BIPV capacity and the normalized thermal energy needs. Through an automated processing of 2187 iterations via Grasshopper, we simulate daylight autonomy, indoor thermal comfort and solar rooftop photovoltaic and building integrated photovoltaic (BIPV) energy potential. Then, we analyze the conflicting objectives of energy efficiency measures, active solar design strategies, and indoor visual comfort in the decision-making process that supports our goal of getting closer to net zero urban residential buildings. The digital workflow showed interesting trends in reaching a balanced equilibrium between performance metrics influenced by the contrasting impact of solar exposure on indoor daylight autonomy and thermal energy demand. Furthermore, the study’s findings indicate that it is possible to achieve an annual load match exceeding 66,56 % while simultaneously ensuring an acceptable visual indoor comfort (sDA higher than 0.4). The findings also highlight the important role of the BIPV system in shifting towards the net zero energy goal, by contributing up to 30 % of the overall solar energy output and covering up to 20 % of the yearly self-consumption. Moreover, the energy balance evaluation on an hourly basis indicates that BIPV system notably enhances the daily load cover factor by up to 5.5 %, particularly in the case of slab SN typology, throughout the different seasons. Graphical representations of the yearly, monthly and hourly load matches and the hourly energy balance of the best performing configurations provide a thorough understanding of the potential evolution of the urban energy system over time as a result of the gradual integration of active solar electricity production.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
In this paper, a temperature-dependent viscoplasticity model is presented that describes thermal and cyclic softening of the hot work steel X38CrMoV5-3 under thermomechanical fatigue loading. The model describes the softening state of the material by evolution equations, the material properties of which can be determined on the basis of a defined experimental program. A kinetic model is employed to capture the effect of coarsening carbides and a new isotropic cyclic softening model is developed that takes history effects during thermomechanical loadings into account. The temperature-dependent material properties of the viscoplasticity model are determined on the basis of experimental data measured in isothermal and thermomechanical fatigue tests for the material X38CrMoV5-3 in the temperature range between 20 and 650 ∘C. The comparison of the model and an existing model for isotropic softening shows an improved description of the softening behavior under thermomechanical fatigue loading. A good overall description of the experimental data is possible with the presented viscoplasticity model, so that it is suited for the assessment of operating loads of hot forging tools.
For the treatment of bone defects, biodegradable, compressive biomaterials are needed as replacements that degrade as the bone regenerates. The problem with existing materials has either been their insufficient mechanical strength or the excessive differences in their elastic modulus, leading to stress shielding and eventual failure. In this study, the compressive strength of CPC ceramics (with a layer thickness of more than 12 layers) was compared with sintered β-TCP ceramics. It was assumed that as the number of layers increased, the mechanical strength of 3D-printed scaffolds would increase toward the value of sintered ceramics. In addition, the influence of the needle inner diameter on the mechanical strength was investigated. Circular scaffolds with 20, 25, 30, and 45 layers were 3D printed using a 3D bioplotter, solidified in a water-saturated atmosphere for 3 days, and then tested for compressive strength together with a β-TCP sintered ceramic using a Zwick universal testing machine. The 3D-printed scaffolds had a compressive strength of 41.56 ± 7.12 MPa, which was significantly higher than that of the sintered ceramic (24.16 ± 4.44 MPa). The 3D-printed scaffolds with round geometry reached or exceeded the upper limit of the compressive strength of cancellous bone toward substantia compacta. In addition, CPC scaffolds exhibited more bone-like compressibility than the comparable β-TCP sintered ceramic, demonstrating that the mechanical properties of CPC scaffolds are more similar to bone than sintered β-TCP ceramics.
Recent advances in spiked shoe design, characterized by increased longitudinal stiffness, thicker midsole foams, and reconfigured geometry are considered to improve sprint performance. However, so far there is no empirical data on the effects of advanced spikes technology on maximal sprinting speed (MSS) published yet. Consequently, we assessed MSS via ‘flying 30m’ sprints of 44 trained male (PR: 10.32 s - 12.08 s) and female (PR: 11.56 s - 14.18 s) athletes, wearing both traditional and advanced spikes in a randomized, repeated measures design. The results revealed a statistically significant increase in MSS by 1.21% on average when using advanced spikes technology. Notably, 87% of participants showed improved MSS with the use of advanced spikes. A cluster analysis unveiled that athletes with higher MSS may benefit to a greater extent. However, individual responses varied widely, suggesting the influence of multiple factors that need detailed exploration. Therefore, coaches and athletes are advised to interpret the promising performance enhancements cautiously and evaluate the appropriateness of the advanced spike technology for their athletes critically.
One of the main problematics of the seals tests is the time and money consuming they are. Up to now, there are few tries to do a digitalisation of a test where the seals behaviour can be known.
This work aims to digitally reproduce a seal test to extract their behaviour when working under different operation conditions to see their impact on the pimp’s efficiency. In this thesis, due to the Lomaking effect, the leakage and the forces applied on the stator will be the base of analysis.
First of all, among all the literature available for very different kind of seals and inner patterns, it has been chosen the most appropriate and precise data. The data chosen is “Test results for liquid Damper Seals using a Round-Hole Roughness Pattern for the Stator” from Fayolle, P. and “Static and Rotordynamic Characteristics of Liquid Annular Seals with Circumferentially/Grooved Stator and Smooth Rotor using three levels of circumferential Inlet-Fluid” from Torres J.M.
From the literature, dimensions of the test rig and the seals will be extracted to model them into a 3D CAD software. With the 3D CAD digitalisation, the fluid volumes for a rotor-centred position, meaning without eccentricity, will be extracted, and used. The following components have been modelled:
- Smooth Annular Liquid Seal (Grooved Rotor)
- Grooved Annular Liquid Seal (Smooth Rotor)
- Round-Hole Pattern Annular Liquid Seal (𝐻𝑑=2 𝑚𝑚) (Smooth Rotor)
- Straight Honeycomb Annular Liquid Seal (Smooth Rotor)
- Convergent Honeycomb Annular Liquid Seal (Smooth Rotor)
- Smooth Rotor / Smooth Annular Liquid Seal (Smooth Rotor)
As there is just one test rig, all the components have been adapted to the different dimensions of the seals by referencing some measures. This allows to test any seal with the same test rig.
Afterwards a CFD simulation that will be used to obtain leakage and stator forces. The parameters that will be changed are the rotational velocity of the fluid (2000 rpm, 4000 rpm, and 6000 rpm) and the pressure drop (2,068 bar, 4,137 bar, 6,205 bar, and 8,274 bar).
Those results will be compared to the literature ones, and they will determine if digitalisation can be validated or not. Even though the relative error is higher than 5% but the tendency is the same and it is thought that by changing some parameters the test results can be even closer to the literature ones.