Continuous generating grinding—Tooth root machining and use of CBN-tools

Profile accuracy, no burning and residual compressive stresses at the tooth root fillet are required for the durability of highly stressed gears. This paper reveals the challenges for continuous generating grinding with corundum and CBN. For this purpose, material removal simulations and experimental investigations were carried out to gain knowledge of the tool–workpiece contact conditions. The potential of CBN tools was analysed due to the fact that the mechanical loads at the grinding worm tip result in high profile wear of the corundum tools. In this context, especially the interrelationship between the dressing strategy and the workpiece quality was investigated in detail.     

A framework for digital sunken relief generation based on 3D geometric models

Sunken relief is a special art form of sculpture whereby the depicted shapes are sunk into a given surface. This is traditionally created by laboriously carving materials such as stone. Sunken reliefs often utilize the engraved lines or strokes to strengthen the impressions of a 3D presence and to highlight the features which otherwise are unrevealed. In other types of relief, smooth surfaces and their shadows convey such information in a coherent manner. Existing methods for relief generation are focused on forming a smooth surface with a shallow depth which provides the presence of 3D figures. Such methods unfortunately do not help the art form of sunken reliefs as they omit the presence of feature lines. We propose a framework to produce sunken reliefs from a known 3D geometry, which transforms the 3D objects into three layers of input to incorporate the contour lines seamlessly with the smooth surfaces. The three input layers take the advantages of the geometric information and the visual cues to assist the relief generation. We have modified the existing techniques of line drawings and relief generation, and then combine them organically for this particular purpose.     

Modeling and optimal control of human platform diving with somersaults and twists

The model-based investigation of fast dynamic motions of anthropomorphic systems is an interesting interdisciplinary field combining research efforts from applied mathematics, robotics, biomechanics, computer graphics and sports. Somersaults and twists of professional platform divers represent a particularly fascinating and extremely difficult type of motion. The purpose of this paper is to show how optimal control methods based on whole-body dynamic models of the diver can be very useful in generating natural platform diving motions. We present 3D somersaults with twists as well as pure somersaults in the sagittal plane for a variety of different take-off configurations and positions to be attained in the aerial phase that all have been produced by optimization of criteria related to energy input. By formulating the dive as a problem with several dynamic phases, we are able to treat contact and flight phase simultaneously, and also to split the flight phase in several sub-phases to correctly model requested positions in the air. Divers are modeled as multibody systems with actuators and damper elements at each joint. For the solution of the optimal control problem we use efficient direct multiple shooting methods based on the boundary value problem approach. The optimization results can be used to generate motions in computer graphics or robotics, but also provide useful insights into biological motion, including joint kinematics and the required torques and forces.     

Performance optimization of polymer electrolyte membrane fuel cells using the Nelder-Mead algorithm

The direct-search simplex method for function optimization has been adapted to performance optimization of polymer electrolyte membrane fuel cells (PEMFCs). The established method is strongly application oriented and uses only experimentally determined data for optimization. It is not restricted to discrete parameters optimums and does not require the use of third-party software or computational resources. Hence, it is easy to implement in fuel cell testing stations. The optimization consists of finding, for a given fuel cell load, an optimum set of values of the 7 fuel cell operating parameters: the fuel cell temperature, the reactants' stoichiometric ratios, the reactants' inlet relative humidity, and the reactants' outlet pressures, resulting in the highest fuel cell performance. The performance is measured using a scalar function of the operating parameters and the load and can be defined according to needs.Two PEMFC performance functions: the fuel cell voltage and the system-related fuel cell efficiency were optimized using the procedure for practically sized PEMFC stacks of two designs. With respect to the nominal operating conditions defined as optimal for each stack design by its manufacturer, the gains from the optimization procedure were up to over 12% and up to over 7% for the stack voltage and efficiency, respectively. The validation of the procedure involved 5 stack specimens and four laboratories and consistent results were obtained.     

Megasonic agitation for enhanced electrodeposition of copper

In this paper we propose an agitation method based on megasonic acoustic streaming to overcome the limitations in plating rate and uniformity of the metal deposits during the electroplating process. Megasonic agitation at a frequency of 1 MHz allows the reduction of the thickness of the Nernst diffusion layer to less than 600 nm. Two applications that demonstrate the benefits of megasonic acoustic streaming are presented: the formation of uniform ultra-fine pitch flip-chip bumps and the metallisation of high aspect ratio microvias. For the latter application, a multi-physics based numerical simulation is implemented to describe the hydrodynamics introduced by the acoustic waves as they travel inside the deep microvias.