Design Tools and Methods in Industrial Engineering II
Proceedings of the Second International Conference on Design Tools and Methods in Industrial Engineering, ADM 2021, September 9–10, 2021, Rome, Italy
- 2022
- Book
- Editors
- Prof. Caterina Rizzi
- Prof. Francesca Campana
- Dr. Michele Bici
- Dr. Francesco Gherardini
- Prof. Tommaso Ingrassia
- Dr. Paolo Cicconi
- Book Series
- Lecture Notes in Mechanical Engineering
- Publisher
- Springer International Publishing
About this book
This book gathers original papers reporting on innovative methods and tools in design, modelling, simulation and optimization, and their applications in engineering design, manufacturing and other relevant industrial sectors. Topics span from advances in geometric modelling, applications of virtual reality, innovative strategies for product development and additive manufacturing, human factors and user-centered design, engineering design education and applications of engineering design methods in medical rehabilitation and cultural heritage. Chapters are based on contributions to the Second International Conference on Design Tools and Methods in Industrial Engineering, ADM 2021, held on September 9–10, 2021, in Rome, Italy, and organized by the Italian Association of Design Methods and Tools for Industrial Engineering, and Dipartimento di Ingegneria Meccanica e Aerospaziale of Sapienza Università di Roma, Italy. All in all, this book provides academics and professionals with a timely overview and extensive information on trends and technologies in industrial design and manufacturing.
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Table of Contents
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Frontmatter
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Geometric Modelling and Analysis
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Frontmatter
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On the Geometrical Complexity Index as a Driver for Selecting the Production Technology
Alessandro Greco, Pasquale Manco, Salvatore GerbinoThe chapter discusses the importance of the Geometrical Complexity Index in selecting appropriate production technologies during the fourth industrial revolution. It reviews the multidimensional aspects of product complexity and explores various methods for evaluating geometrical complexity. The text introduces a novel approach that combines objective metrics with subjective expert judgments to create a more accurate Geometrical Complexity Index. This index, when combined with assembly complexity and cost analysis, serves as a driver for selecting the most suitable production technology. The chapter includes a case study demonstrating the effectiveness of this framework in evaluating the convenience of traditional manufacturing versus additive manufacturing for different production volumes.AI Generated
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AbstractEmerging production technologies, in particular Additive Manufacturing (AM), nowadays are extremely suitable for creating highly complex products, tending towards the concept of ‘complexity for free’, which is often associated with AM. However, there are no adequate guidelines to provide decision support for the correct selection of the most economically appropriate technology. Indeed, from literature it has been highlighted the need to develop a technology selection methodology based no longer on production volume but on product complexity. This paper investigates this need by presenting an approach to determine the geometrical (or shape) complexity index of a part, which, combined with the assembly complexity, represents the driver for helping to decide the best production technology (traditional or additive). The geometrical complexity index has been determined based on complexity judgments, provided by CAD modelling experts, for a sample of CAD models. In this way, it has been possible to define a preliminary complexity index model, strictly linked to the CAD model information. The results showed that the geometrical complexity metrics from the literature, if individually considered, are not comprehensive. However, a combination of them makes it possible to obtain an index that best reflects the subjective judgement of the experts. In addition, by combining the geometrical and assembly complexity with a cost analysis it is possible to obtain convenience zones for better selecting the production technology. -
A Voxel-Based 2.5D Panel Method for Fluid-Dynamics Simulations
Antonio Bacciaglia, Alessandro Ceruti, Alfredo LiveraniThe chapter introduces a voxel-based 2.5D panel method for fluid-dynamics simulations, addressing the limitations of traditional methods like wind tunnel testing and CFD simulations. This innovative approach uses voxelization to automate the panelization process, reducing the need for manual intervention and computational time. The method is validated through case studies involving different geometries, demonstrating its accuracy and efficiency in estimating aerodynamic forces. The research highlights the potential of this method in the conceptual and preliminary design stages, offering a valuable tool for engineers to quickly and accurately assess aerodynamic performance.AI Generated
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AbstractThe Panel method is an approach for the estimation of the lift of 3D models which is faster than CFD. This can be useful especially in the conceptual design stage where several configurations should be evaluated in a reduced time with a limited computational cost. However, the meshing of the 3D body surface with rectangular panels can be a time-consuming activity because the designer should define from scratch a cloud of points that matches the external surfaces of the tested object to obtain consistent panelling. Therefore, a voxelization-based methodology has been developed to obtain the panels’ position, speeding up and automating the model preparation process. The obtained discretization has been integrated into a panel method available in the literature. Four case studies, of increasing complexity, have been analyzed to investigate the capability of the innovative voxel-based panel methodology. A parametric study has been carried out to study the effect of the voxel grid dimension on the accuracy of the results. Benchmarking values of lift coefficient obtained from literature or xFoil software have been used to evaluate the precision that can be achieved with this approach. The results show a good agreement between the voxel-based panel method and the literature when the overall pressure distributions and aerodynamic coefficient values are considered. Higher errors are noticed with drag. -
Enhanced Statistical Shape Model: A Statistical-Based Tool to design Custom Orthopaedic Devices
Antonio Marzola, Francesco Buonamici, Lorenzo Guariento, Lapo GoverniThe chapter delves into the application of enhanced Statistical Shape Models (eSSM) to design custom orthopaedic devices, with a focus on the pelvis. It introduces a method to expand the information enclosed in the statistical model to include significant landmarks and semantic segmentation, aiming to streamline the design process. The eSSM is trained with a dataset of healthy pelvises and is used to semi-automatically reconstruct the pelvic anatomy and retrieve essential information for implant design, such as the location of the Center of Rotation (COR). This approach promises to save time and effort in the design of patient-specific implants, potentially improving the accuracy and efficiency of the process. The chapter also discusses the potential future applications and enhancements of the eSSM, including the incorporation of bone density information and the use of eSSMs in finite element modeling for implant design.AI Generated
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AbstractDealing with the design of personalized medical devices, mass production is not an option that can be hypothesized. Indeed, a cumbersome production process must be considered in such cases, mainly to account for a delicate design phase that needs to take into consideration, as input, an anatomy that vary each time. This article discusses the development of a statistical tool able to support the design of patient-specific devices. By expanding the classical formulation of the Statistical Shape Model (SSM) with the introduction of multiple levels of information within the same model, the authors have experimented with the concept of an “enhanced SSM”. While the traditional SSM only provides information on the variations that a class of shapes can manifest, the eSSM may include more levels of information. The article discusses two possible mathematical formulations of such statistical tool. Its application to the design of custom-made pelvic implants is discussed. Such application scenario is described starting from the generation of the eSSM for the pelvis. The features of interest considered in this paper are the centers of the acetabular regions of the pelvis, the segmentation of the anatomy in a series of semantical regions that must be considered when developing a load-bearing implant. Finally, the conclusions of this research are drawn and discussed together with possible future development of eSSMs. -
Design of a Low Cost 3D Printable Single-Component Compliant Mechanism for FWMAV’s Wing Actuation
Giovanni Carollo, Tommaso Ingrassia, Antonio PantanoThe chapter discusses the development of low-cost, 3D printable single-component compliant mechanisms for FWMAVs, drawing inspiration from the muscular structure of insects. It delves into the analysis of wing actuation mechanisms, the use of Fused Deposition Modeling (FDM) for manufacturing, and the mechanical properties of suitable materials. Two different layouts of compliant mechanisms are designed and investigated through FEM analyses, showcasing promising results in terms of stress distribution and kinematics. Future work is outlined to address fatigue testing and further optimization of the mechanisms.AI Generated
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AbstractConsidering a modern approach to design, one of the viable options for developing innovative projects is the possibility of integrating the effectiveness of the solutions offered by nature and living beings with the latest design methods. With this in mind, the following research exploits the idea of reproducing the natural flexibility inherent in biological structures by combining the advantages of compliant mechanisms with the adaptability of additive manufacturing processes. In the specific, the authors intend to highlight the potential and critical aspects of a possible approach for the application of compliant mechanisms in the development of single-component structures suitable for the actuation of bio-inspired Flapping Wing Micro Air Vehicles (FWMAVs), which can be produced via low cost 3D printing. Some designs conceived by interpreting the movement of insects’ wings have been developed with the aim of reproducing the functionality and morphology of their thorax through single-component flexible mechanisms. The results of this research demonstrate the high potentiality of realizing bio-inspired single-component compliant mechanisms through 3D printing. -
A Bespoke Neck Orthosis for Additive Manufacturing with Improved Design Method and Sustainable Material
Rita Ambu, Salvatore Massimo Oliveri, Michele CalìThis chapter delves into the innovative design and manufacturing of a customized neck orthosis using additive manufacturing (AM) techniques. The primary goal is to enhance patient comfort by reducing weight and improving breathability. The authors employ a ventilation pattern based on Voronoi cells, which is optimized for both structural integrity and thermal comfort. The methodology includes accurate and non-invasive 3D scanning of the neck area, followed by CAD modeling and structural assessment using Finite Element simulations. The orthosis is manufactured using a sustainable composite filament, Hemp Bio-Plastic® (HBP), which offers superior mechanical and thermal properties. Preliminary thermal analysis demonstrates the effectiveness of the ventilation pattern in maintaining optimal temperature, highlighting the potential for further improvements in orthotic design. The study underscores the feasibility and advantages of using AM for creating customized medical devices, setting a benchmark for future clinical applications.AI Generated
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AbstractThe use of additive manufacturing (AM) has widespread over the years in different areas, including the biomedical field. In particular, the design of customized orthoses, external medical devices used in the treatment of specific pathologies, was proposed in different studies mainly concerning upper limbs, while few investigations are reported relatively to the cervical area. In this paper a new design of a bespoke neck orthosis is reported. The manufacturing of a light device with a good transpiration allows to increase the patient’s comfort and, compatibly with the structural requirements, is a main goal to pursue. With this aim, various aspects were considered in the design and manufacturing of the orthosis. At the design stage, the geometry was conceived with a ventilation pattern based on Voronoi cells, which generally allows a better performance in terms of breathability with respect to a pattern made with uniform geometrical features, keeping at the same time structural requirements, as assessed by numerical finite elements simulations. At the manufacturing stage, a new composite material was used, namely Hemp Bio-Plastic® (HBP) filament, composed by polylactic acid (PLA) and hemp shives which provided lightweight, improved superficial finish and antibacterial properties. In order to assess the thermal comfort, an experimental analysis was finally conducted on a prototype of the orthosis, worn by a volunteer subject, with a thermal imaging camera. The beneficial effect of the ventilation pattern considered in terms of temperature and, accordingly, for the patient’s comfort, was highlighted also in relation to a neck orthosis previously designed. -
Battens Modelling and Optimization in Air-Sail Interaction Analysis
Michele Calì, Ignazio Sapienza, Salvatore Massimo OliveriThe chapter delves into the complex aerodynamics of sails, emphasizing the critical role of stiffening battens in maintaining sail shape and performance. It presents a detailed methodology for modeling and optimizing sail performance, including experimental characterization of sailcloth and battens. The study utilizes advanced computational fluid dynamics (CFD) and finite element analysis (FEA) to investigate fluid-structure interaction, validating results with experimental data. Key findings include the influence of batten position, dimensions, and stiffness on sail deformations and lift coefficients. The chapter also highlights the phenomenon of thread detachment and its impact on sail performance, offering insights into optimizing sail design for improved aerodynamic efficiency.AI Generated
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AbstractNumerical codes can play an important function in the nautical design when advanced simulation tools are increasingly adopted for prediction purposes, and in particular for the calculation of the interaction between boat parts and surrounding fluids. Fluid-structure interaction analysis (FSI) can help engineers to set the optimum design of a sail and also the influence of panels and battens sail arrangement. The paper describes a methodology that enhances the understanding of panel and battens arrangement, as well as their stiffness on sail performance. Specifically, through the battens position, shape and stiffness parametrization, the sail non-developable shape was optimized, in order to compensate the variation in the angle of attack that occurs following variations in the speed of the wind at different sail heights. For an efficient and robust implementation of integrated Reynolds Averaged Navier Stokes (RANS) equations with Shear Stress Transport (SST) turbulence model and Computational Structural Mechanics (CSM) analysis, the constitutive sailcloth and battens characterization was conducted experimentally. The case study of a mainsail in Dacron© TNF 240 of a Vaurien dinghy boat, offered tangible results to support the methodology by validating it with experimental data.
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Industrial Design and Ergonomics
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Frontmatter
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A Detailed Analysis of the Most Promising Concepts of Soft Wearable Robots for Upper–Limb
Dario Panariello, Stanislao Grazioso, Teodorico Caporaso, Giuseppe Di Gironimo, Antonio LanzottiThe chapter delves into the innovative realm of soft wearable robots designed for upper-limb assistance, distinguishing them from rigid exoskeletons. It meticulously analyzes the design concepts, actuation methods, sensing systems, control strategies, and various applications of these robots. Key features such as wearability, safety, and human-robot symbiosis are emphasized, along with a detailed classification of wearable robots for shoulder, elbow, wrist, and multi-joint support. The text also explores the advantages and limitations of these robots, discussing their potential in rehabilitation, assistive tasks, and industrial contexts. Moreover, it highlights the need for advanced design and simulation tools, transportability, and enhanced wearability to fully integrate these robots into daily life and various industries. The chapter concludes by underscoring the current technological readiness of soft wearable robots and the future directions for their development and implementation.AI Generated
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AbstractIn this study we propose a brief analysis of recent soft wearable robots for upper–limb which could have a major impact on future developments and applications. The systems are analysed with respect to: design concepts, actuation systems, sensing systems, control strategies and applications. Finally, a discussion and open issues are presented. -
A New Sedan Concept Car in Stylistic Design Engineering (SDE) Enhanced with Augmented Reality
Gian Maria Santi, Leonardo Frizziero, Giampiero Donnici, Daniela Francia, Marco Neri, Alfredo LiveraniThe chapter delves into the critical initial phase of car design, emphasizing the importance of market analysis and customer needs. It introduces the Industrial Design Structure (IDeS) method and its application to a new sedan concept car, enhanced with Augmented Reality (AR). The use of AR is shown to provide cost-effective solutions for virtual prototyping, significantly improving the design process. The chapter also incorporates Quality Function Deployment (QFD) to align customer requirements with design specifications. A benchmarking analysis is conducted to identify innovative features, and the chapter concludes with a detailed description of the prototype development and aerodynamic testing, showcasing the potential of AR in reducing design errors and costs.AI Generated
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AbstractMany industrial technologies are developed to optimize products and bring innovation. In particular, the automotive sector is renewing itself according to the rules of green energy and consumption. This huge change requires a reinterpretation of the models on the market updating them to the present and the future needs of automotive industry. In this paper the best compromise between innovation and tradition is found for the Ford brand that has not yet presented electric cars in the sedan segment. Following the SDE method enriched with Quality Function Deployment (QFD), Benchmarking (BM) and Top Flop Analysis (TPA), it is possible to carry out an innovative project. All these technologies must, however, be ordered according to a specific product allowing the best result for the design process. It is therefore necessary identifying the most common stylistic trends in order to draw the external styling of the vehicle using virtual prototyping techniques. To achieve an innovative result, Augmented Reality (AR) is considered to complete the method substituting the static and expensive procedure of making maquettes. -
User Experience Design in Software and Hardware Components Studied in Human-Computer Interaction
Aurora Berni, Yuri BorgianniThe chapter delves into the evolution of User Experience (UX) design in software and hardware components within Human-Computer Interaction (HCI). It discusses the shift from task-related aspects to conceptual approaches in UX studies and the need for comprehensive evaluation methods for complex systems. The authors classify and compare various UX approaches, methods, and instruments used in empirical research, revealing a predominance of qualitative analysis and a wide range of support tools. The chapter also highlights the overlooked emotional experience in HCI research and the importance of combining qualitative and quantitative approaches for a complete analysis. The findings suggest that transferring HCI approaches to consumer goods and engineering products may be limited due to the deficiency in emotional approaches.AI Generated
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AbstractUser Experience (UX) is a concept based on the human-product interaction. An increase of UX studies in the Human-Computer interaction (HCI) field was observed in the last decade. Empirical studies based their experimental activity on HCI products, which are characterized by two components: Software and intangible (digital interfaces and web apps) and Hardware and physical (devices). Trough an explorative study, the authors propose a research direction to compares UX studies targeting software and hardware components of HCI products. A preliminary sample of papers was considered. The authors collected contributions where UX in HCI design is investigated through case studies involving devices with software and hardware components. Objectives, methods, and tools of each case study were compared. It emerged that complex systems require both quantitative and qualitative analysis approaches, as the wide variety of tools for data acquisition and processing show. Since Hardware components are more closely related to products such as consumer goods and engineering products, it is possible that methods and tools used to study hardware components could also be applicable to other physical and tangible products, i.e., the main reference for product, engineering, and mechanical design.
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- Title
- Design Tools and Methods in Industrial Engineering II
- Editors
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Prof. Caterina Rizzi
Prof. Francesca Campana
Dr. Michele Bici
Dr. Francesco Gherardini
Prof. Tommaso Ingrassia
Dr. Paolo Cicconi
- Copyright Year
- 2022
- Publisher
- Springer International Publishing
- Electronic ISBN
- 978-3-030-91234-5
- Print ISBN
- 978-3-030-91233-8
- DOI
- https://doi.org/10.1007/978-3-030-91234-5
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