Improving robotic machining accuracy through experimental error investigation and modular compensation

Machining using industrial robots is currently limited to applications with low geometrical accuracies and soft materials. This paper analyzes the sources of errors in robotic machining and characterizes them in amplitude and frequency. Experiments under different conditions represent a typical set of industrial applications and allow a qualified evaluation. Based on this analysis, a modular approach is proposed to overcome these obstacles, applied both during program generation (offline) and execution (online). Predictive offline compensation of machining errors is achieved by means of an innovative programming system, based on kinematic and dynamic robot models. Real-time adaptive machining error compensation is also provided by sensing the real robot positions with an innovative tracking system and corrective feedback to both the robot and an additional high-dynamic compensation mechanism on piezo-actuator basis.     

Selective Catalytic Behavior Induced by Crystal-Phase Transformation in Well-Defined Bimetallic Pt-Sn Nanocrystals

The Pt-Sn bimetallic system is a much studied and commercially used catalyst for propane dehydrogenation. The traditionally prepared catalyst, however, suffers from inhomogeneity and phase separation of the active Pt–Sn phase. Colloidal chemistry offers a route for the synthesis of Pt–Sn bimetallic nanoparticles (NPs) in a systematic, well-defined, tailored fashion over conventional methods. Here, the successful synthesis of well-defined ≈2 nm Pt, PtSn, and Pt₃Sn nanocrystals with distinct crystallographic phases is reported; hexagonal close packing (hcp) PtSn and fcc Pt₃Sn show different activity and stability depending on the hydrogen-rich or poor environment in the feed. Moreover, face centred cubic (fcc) Pt₃Sn/Al₂O₃, which exhibited the highest stability compared to hcp PtSn, shows a unique phase transformation from an fcc phase to an L1₂-ordered superlattice. Contrary to PtSn, H₂ cofeeding has no effect on the Pt₃Sn deactivation rate. The results reveal structural dependency of the probe reaction, propane dehydrogenation, and provide a fundamental understanding of the structure−performance relationship on emerging bimetallic systems.     

Application of the Kalai-Smorodinsky approach in multi-objective optimization of metal forming processes

The problem of multi-objective optimization (MOP) is approached from the theoretical background of the Game Theory, which consists in finding a compromise between two rational players of a bargaining problem. In particular, the Kalai and Smorodinsky (K-S) model offers a balanced and attractive solution resulting from cooperative players. This approach allows avoiding the computationally expensive and uncertain reconstruction of the full Pareto Frontier usually required by MOPs. The search for the K-S solution can be implemented into methodologies with useful applications in engineering MOPs where two or more functions must be minimized. This paper presents an optimization algorithm aimed at rapidly finding the K-S solution where the MOP is transformed into a succession of single objective problems (SOP). Each SOP is solved by meta-model assisted evolution strategies used in interaction with an FEM simulation software for metal forming applications. The proposed method is first tested and demonstrated with known mathematical multi-objective problems, showing its ability to find a solution lying on the Pareto Frontier, even with a largely incomplete knowledge of it. The algorithm is then applied to the FEM optimization problem of wire drawing process with one and two passes, in order to simultaneously minimize the pulling force and the material damage. The K-S solutions are compared to results previously suggested in literature using more conventional methodologies and engineering expertise. The paper shows that K-S solutions are very promising for finding quite satisfactory engineering compromises, in a very efficient manner, in metal forming applications.     

A 3D Real‐Scale,Biomimetic, and Biohybrid Model of the Blood‐Brain Barrier Fabricated through Two‐Photon Lithography

The investigation of the crossing of exogenous substances through the blood‐brain barrier (BBB) is object of intensive research in biomedicine, and one of the main obstacles for reliable in vitro evaluations is represented by the difficulties at the base of developing realistic models of the barrier, which could resemble as most accurately as possible the in vivo environment. Here, for the first time, a 1:1 scale, biomimetic, and biohybrid BBB model is proposed. Microtubes inspired to the brain capillaries were fabricated through two‐photon lithography and used as scaffolds for the co‐culturing of endothelial‐like bEnd.3 and U87 glioblastoma cells. The constructs show the maturation of tight junctions, good performances in terms of hindering dextran diffusion through the barrier, and a satisfactory trans‐endothelial electrical resistance. Moreover, a mathematical model is developed, which assists in both the design of the 3D microfluidic chip and its characterization. Overall, these results show the effective formation of a bioinspired cellular barrier based on microtubes reproducing brain microcapillaries to scale. This system will be exploited as a realistic in vitro model for the investigation of BBB crossing of nanomaterials and drugs, envisaging therapeutic and diagnostic applications for several brain pathologies, including brain cancer.     

Nonlinear response topology optimization using equivalent static loads—case studies

Nonlinear structural optimization is fairly expensive and difficult, because a large number of nonlinear analyses is required due to the large number of design variables involved in topology optimization. In element density based topology optimization, the low density elements create mesh distortion and the updating of finite element material with low density elements has a severe effect on the optimization results in the next cycles. In order to overcome these difficulties, the equivalent static loads method for nonlinear response structural optimization (ESLSO) primarily used for size and shape optimization has been applied to topology optimization. The nonlinear analysis is performed with the given loading conditions to calculate equivalent static loads (ESLs) and these ESLs are used to perform linear response optimization. In this paper, the authors have presented the results of five case studies with material, geometric and contact nonlinearities showing good agreement and providing justification of the proposed method.     

Dry coating of solid dosage forms: an overview of processes and applications

Dry coating techniques enable manufacturing of coated solid dosage forms with no, or very limited, use of solvents. As a result, major drawbacks associated with both organic solvents and aqueous coating systems can be overcome, such as toxicological, environmental, and safety-related issues on the one hand as well as costly drying phases and impaired product stability on the other. The considerable advantages related to solventless coating has been prompting a strong research interest in this field of pharmaceutics. In the article, processes and applications relevant to techniques intended for dry coating are analyzed and reviewed. Based on the physical state of the coat-forming agents, liquid- and solid-based techniques are distinguished. The former include hot-melt coating and coating by photocuring, while the latter encompass press coating and powder coating. Moreover, solventless techniques, such as injection molding and three-dimensional printing by fused deposition modeling, which are not purposely conceived for coating, are also discussed in that they would open new perspectives in the manufacturing of coated-like dosage forms.     

Hybrid Copper‐Nanowire–Reduced‐Graphene‐Oxide Coatings: A “Green Solution” Toward Highly Transparent,Highly Conductive,and Flexible Electrodes for (Opto)Electronics

This study reports a novel green chemistry approach to assemble copper‐nanowires/reduced‐graphene‐oxide hybrid coatings onto inorganic and organic supports. Such films are robust and combine sheet resistances (<30 Ω sq^?1) and transparencies in the visible region (transmittance > 70%) that are rivalling those of indium–tin oxide. These electrodes are suitable for flexible electronic applications as they show a sheet resistance change of <4% after 10 000 bending cycles at a bending radius of 1.0 cm, when supported on polyethylene terephthalate foils. Significantly, the wet‐chemistry method involves the preparation of dispersions in environmentally friendly solvents and avoids the use of harmful reagents. Such inks are processed at room temperature on a wide variety of surfaces by spray coating. As a proof‐of‐concept, this study demonstrates the successful use of such coatings as electrodes in high‐performance electrochromic devices. The robustness of the electrodes is demonstrated by performing several tens of thousands of cycles of device operation. These unique conducting coatings hold potential for being exploited as transparent electrodes in numerous optoelectronic applications such as solar cells, light‐emitting diodes, and displays.     

Carbon Nanotube‐Quantum Dot Nanohybrids: Coupling with Single‐Particle Control in Aqueous Solution

A strategy is reported for the controlled assembly of organic‐inorganic heterostructures consisting of individual single‐walled carbon nanotubes (SWCNTs) selectively coupled to single semiconductor quantum dots (QDs). The assembly in aqueous solution was controlled towards the formation of monofunctionalized SWCNT‐QD structures. Photoluminescence studies in solution, and on surfaces at the single nanohybrid level, showed evidence of electronic coupling between the two nanostructures. The ability to covalently couple heterostructures with single particle control is crucial for the design of novel QD‐based optoelectronic and light‐energy conversion devices.     

Stiffness and energy dissipation in polyurethane auxetic foams

Auxetic open cell polyurethane (PU) foams have been manufactured and mechanically characterised under cyclic tensile loading. The classical manufacturing process for auxetic PU foams involves multiaxial compression of the conventional parent foam, and heating of the compressed specimens above the T_m of the foam polymer. Eighty cylindrical specimens were fabricated using manufacturing routes modified from those in the open literature, with different temperatures (135 °C, 150 °C), compression ratios and different cooling methods (water or room temperature exposure). Compressive tensile cyclic loading has been applied to measure tangent modulus, Poisson’s ratios and energy dissipated per unit volume. The results are used to obtain relations between manufacturing parameters, mechanical and hysteresis properties of the foams. Compression, both radial and axial, was found to be the most significant manufacturing parameter for the auxetic foams in this work.     

The effect of silylation on titanium-containing silica catalysts for the epoxidation of functionalised molecules

The epoxidation of functionalised substrates of interest as fine chemicals using mesoporous titanium-containing silicas is here reported and the role of silylation in changing the surface hydrophilic character of these catalysts is investigated. The silylation procedure was carried out on two titanium-grafted silicas with different morphologies. An ordered MCM-41 and a non-ordered commercial mesoporous silica were used as supports. The reactivity of bulky substrates with different characteristics (limonene, -terpineol, carveol and methyl linoleate) is studied and compared. The effect of silylation is more pronounced on Ti–MCM-41 than with low-surface area Ti–SiO₂ and it is shown that the catalytic performances are strongly dependent on the nature of the reactant. Purely alkenic molecules show better reactivity over silylated catalysts than over non-silylated ones. On the other hand, a hydrophilic environment around the titanium active sites has often a beneficial effect in the epoxidation of richly functionalised substrates.