Fringe Projection Profilometry in Production Metrology: A Multi-Scale Comparison in Sheet-Bulk Metal Forming.

Fringe projection profilometry in combination with other optical measuring technologies has established itself over the last decades as an essential complement to conventional, tactile measuring devices. The non-contact, holistic reconstruction of complex geometries within fractions of a second in conjunction with the lightweight and transportable sensor design open up many fields of application in production metrology. Furthermore, triangulation-based measuring principles feature good scalability, which has led to 3D scanners for various scale ranges. Innovative and modern production processes, such as sheet-bulk metal forming, thus, utilize fringe projection profilometry in many respects to monitor the process, quantify possible wear and improve production technology. Therefore, it is essential to identify the appropriate 3D scanner for each application and to properly evaluate the acquired data. Through precise knowledge of the measurement volume and the relative uncertainty with respect to the specimen and scanner position, adapted measurement strategies and integrated production concepts can be realized. Although there are extensive industrial standards and guidelines for the quantification of sensor performance, evaluation and tolerancing is mainly global and can, therefore, neither provide assistance in the correct, application-specific positioning and alignment of the sensor nor reflect the local characteristics within the measuring volume. Therefore, this article compares fringe projection systems across various scale ranges by positioning and scanning a calibrated sphere in a high resolution grid.

Hardness Assessment Considering Nitrided Layers Based on Tempering Tests for Numerical Wear Prediction for Forging Processes.

The nitriding of forging tools is an industrially established standard used to increase the hardness of the tool surface layer and reduce wear. However, this modification of the tool surface layer, as well as the microstructural changes that occur during this operation due to the thermo-mechanical load, cannot be considered during wear calculations with the widely used Archard wear model in the context of FE simulations. Based on previous work, this study further develops two tempering tests for the investigation of the hardness evolution of two nitride profiles based on H11 tool steel. Here, significant tempering effects could be observed depending on temperature, mechanical stress superposition and time. The results are used for setting up a new material model that is implemented in an existing numerical wear model. The validation is carried out in two laboratory forging test series. The evaluation shows that the hardness development in terms of tempering effects of a nitrided forging tool can be numerically predicted, especially for high forging cycles. However, due to the unexpected occurrence of adhesion effects, only limited applicability of the wear prediction then carried out is achieved.

Characterization of the Interface between Aluminum and Iron in Co-Extruded Semi-Finished Products.

Within the framework of the Collaborative Research Center 1153, we investigated novel process chains for the production of bulk components with different metals as joining partners. In the present study, the co-extrusion of coaxially reinforced hollow profiles was employed to manufacture semi-finished products for a subsequent die-forging process, which was then used for the manufacture of hybrid bearing bushings. The hybrid hollow profiles, made of the aluminum alloy EN AW-6082 paired with either the case-hardening steel 20MnCr5, the stainless steel X5CrNi18-10, or the rolling bearing steel 100Cr6, were produced by Lateral Angular Co-Extrusion. Push-out tests on hybrid hollow sections over the entire sample cross-section showed shear strengths of 44 MPa ± 8 MPa (100Cr6) up to 63 MPa ± 5 MPa (X5CrNi18-10). In particular, the influence of force and form closure on the joint zone could be determined using specimen segments tested in shear compression. Locally, shear strengths of up to 131 MPa (X5CrNi18-10) were demonstrated in the shear compression test. From these samples, lamellae for microstructural analysis were prepared with a Focused Ion Beam. Detailed analyses showed that for all material combinations, a material bond in the form of an ultra-thin intermetallic phase seam with a thickness of up to 50 nm could be established.

Numerical simulation of strain-adaptive bone remodelling in the ankle joint.

BACKGROUND: The use of artificial endoprostheses has become a routine procedure for knee and hip joints while ankle arthritis has traditionally been treated by means of arthrodesis. Due to its advantages, the implantation of endoprostheses is constantly increasing. While finite element analyses (FEA) of strain-adaptive bone remodelling have been carried out for the hip joint in previous studies, to our knowledge there are no investigations that have considered remodelling processes of the ankle joint. In order to evaluate and optimise new generation implants of the ankle joint, as well as to gain additional knowledge regarding the biomechanics, strain-adaptive bone remodelling has been calculated separately for the tibia and the talus after providing them with an implant. METHODS: FE models of the bone-implant assembly for both the tibia and the talus have been developed. Bone characteristics such as the density distribution have been applied corresponding to CT scans. A force of 5,200 N, which corresponds to the compression force during normal walking of a person with a weight of 100 kg according to Stauffer et al., has been used in the simulation. The bone adaptation law, previously developed by our research team, has been used for the calculation of the remodelling processes. RESULTS: A total bone mass loss of 2% in the tibia and 13% in the talus was calculated. The greater decline of density in the talus is due to its smaller size compared to the relatively large implant dimensions causing remodelling processes in the whole bone tissue. In the tibia, bone remodelling processes are only calculated in areas adjacent to the implant. Thus, a smaller bone mass loss than in the talus can be expected. There is a high agreement between the simulation results in the distal tibia and the literature regarding. CONCLUSIONS: In this study, strain-adaptive bone remodelling processes are simulated using the FE method. The results contribute to a better understanding of the biomechanical behaviour of the ankle joint and hence are useful for the optimisation of the implant geometry in the future.

Investigation on the Microstructure of ECAP-Processed Iron-Aluminium Alloys.

The present work deals with adjusting a fine-grained microstructure in iron-rich iron-aluminium alloys using the ECAP-process (Equal Channel Angular Pressing). Due to the limited formability of Fe-Al alloys with increased aluminium content, high forming temperatures and low forming speeds are required. Therefore, tool temperatures above 1100 °C are permanently needed to prevent cooling of the work pieces, which makes the design of the ECAP-process challenging. For the investigation, the Fe-Al work pieces were heated to the respective hot forming temperature in a chamber furnace and then formed in the ECAP tool at a constant punch speed of 5 mm/s. Besides the chemical composition (Fe9Al, Fe28Al and Fe38Al (at.%-Al)), the influences of a subsequent heat treatment and the holding time on the microstructure development were investigated. For this purpose, the average grain size of the microstructure was measured using the AGI (Average Grain Intercept) method and correlated with the aforementioned parameters. The results show that no significant grain refinement could be achieved with the parameters used, which is largely due to the high forming temperature significantly promoting grain growth. The holding times in the examined area do not have any influence on the grain refinement.

Finite Element and Finite Volume Modelling of Friction Drilling HSLA Steel under Experimental Comparison.

Friction drilling is a widely used process to produce bushings in sheet materials, which are processed further by thread forming to create a connection port. Previous studies focused on the process parameters and did not pay detailed attention to the material flow of the bushing. In order to describe the material behaviour during a friction drilling process realistically, a detailed material characterisation was carried out. Temperature, strain rate, and rolling direction dependent tensile tests were performed. The results were used to parametrise the Johnson-Cook hardening and failure model. With the material data, numerical models of the friction drilling were created using the finite element method in 3D as well as 2D, and the finite volume method in 3D. Furthermore, friction drilling tests were carried out and analysed. The experimental results were compared with the numerical findings to evaluate which modelling method could describe the friction drilling process best. Highest imaging quality to reality was shown by the finite volume method in comparison to the experiments regarding the material flow and the geometry of the bushing.

Challenges in the Forging of Steel-Aluminum Bearing Bushings.

The current study introduces a method for manufacturing steel-aluminum bearing bushings by compound forging. To study the process, cylindrical bimetal workpieces consisting of steel AISI 4820 (1.7147, 20MnCr5) in the internal diameter and aluminum 6082 (3.2315, AlSi1MgMn) in the external diameter were used. The forming of compounds consisting of dissimilar materials is challenging due to their different thermophysical and mechanical properties. The specific heating concept discussed in this article was developed in order to achieve sufficient formability for both materials simultaneously. By means of tailored heating, the bimetal workpieces were successfully formed to a bearing bushing geometry using two different strategies with different heating durations. A metallurgical bond without any forging defects, e.g., gaps and cracks, was observed in areas of high deformation. The steel-aluminum interface was subsequently examined by optical microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). It was found that the examined forming process, which utilized steel-aluminum workpieces having no metallurgical bond prior to forming, led to the formation of insular intermetallic phases along the joining zone with a maximum thickness of approximately 5-7 µm. The results of the EDS analysis indicated a prevailing FexAly phase in the resulting intermetallic layer.

Characterization and Modeling of Nano Wear for Molybdenum-Based Lubrication Layer Systems.

As a result of global economic and environmental change, the demand for innovative, environmentally-friendly technologies is increasing. Employing solid lubricants in rolling contacts can reduce the use of environmentally harmful greases and oils. The aim of the current research was the development of a solid lubricant system with regenerative properties. The layer system consisted of a molybdenum (Mo) reservoir and a top layer of molybdenum trioxide (MoO3). After surface wear, Mo is supposed to react with atmospheric oxygen and form a new oxide. The determination of the wear volume of thin layers cannot be measured microscopically, which is why the wear behavior is initially determined on the nano level. In this work, single Mo and MoO3 coatings prepared by physical vapor deposition (PVD) are characterized by nano testing. The main objective was to determine the wear volume of the single coatings using a newly developed method considering the initial topology. For this purpose, nano-wear tests with different wear paths and normal forces were carried out and measured by in situ scanning probe microscopy (SPM). Based on the characteristic values determined, the coefficient of wear was determined for wear modeling according to Sarkar. The validation of the wear model developed was carried out by further wear tests on the respective mono layers.

Mechanical and Thermal Influences on Microstructural and Mechanical Properties during Process-Integrated Thermomechanically Controlled Forging of Tempering Steel AISI 4140.

Thermomechanical treatment (TMT) describes the effect of thermal and mechanical conditions on the microstructure of materials during processing and offers possible integration in the forging process. TMT materials exhibit a fine-grained microstructure, leading to excellent mechanical properties. In this study, a two-step TMT upsetting process with intermediate cooling is used to demonstrate possibilities for a process-integrated treatment and corresponding properties. A water-air-based cooling system was designed to adjust different phase configurations by varying the target temperature and cooling rate. Four different thermal processing routes and four combinations of applied plastic strains are investigated in standardized mechanical tests and metallographic analyses. The applied TMT results in a finely structured bainitic microstructure of the investigated tempering steel AISI 4140 (42CrMo4) with different characteristics depending on the forming conditions. It can be shown that the demands of the standard (DIN EN ISO 683) in a quenched and tempered state can be fulfilled by means of appropriate forming conditions. The yield strength can be enhanced up to 1174 MPa while elongation at break is about 12.6% and absorbed impact energy reaches 58.5 J without additional heat treatment when the material is formed after rapid cooling.

Multi-Layer Wear and Tool Life Calculation for Forging Applications Considering Dynamical Hardness Modeling and Nitrided Layer Degradation.

As one of the oldest shaping manufacturing processes, forging and especially hot forging is characterized by extreme loads on the tool. The thermal load in particular is able to cause constant changes in the hardness of the surface layer, which in turn has a decisive influence on the numerical estimation of wear. Thus, also during numerical wear, modeling hardness changes need to be taken into account. Within the scope of this paper, a new implementation of a numerical wear model is presented, which, in addition to dynamic hardness models for the base material, can also take into account the properties of a nitride wear protection layer as a function of the wear depth. After a functional representation, the new model is applied to the wear calculation of a multi-stage industrial hot forging process. The applicability of the new implementation is validated by the evaluation of the occurring hardness, wear depths and the locally associated removal of the wear protection layer. Consecutively, a tool life calculation module based on the calculated wear depth is implemented and demonstrated. In general, a good agreement of the results is achieved, making the model suitable for detailed 2D as well as large 3D Finite Element calculations.

Numerical investigations on the strain-adaptive bone remodelling in the periprosthetic femur: influence of the boundary conditions.

BACKGROUND: There are several numerical investigations on bone remodelling after total hip arthroplasty (THA) on the basis of the finite element analysis (FEA). For such computations certain boundary conditions have to be defined. The authors chose a maximum of three static load situations, usually taken from the gait cycle because this is the most frequent dynamic activity of a patient after THA. MATERIALS AND METHODS: The numerical study presented here investigates whether it is useful to consider only one static load situation of the gait cycle in the FE calculation of the bone remodelling. For this purpose, 5 different loading cases were examined in order to determine their influence on the change in the physiological load distribution within the femur and on the resulting strain-adaptive bone remodelling. First, four different static loading cases at 25%, 45%, 65% and 85% of the gait cycle, respectively, and then the whole gait cycle in a loading regime were examined in order to regard all the different loadings of the cycle in the simulation. RESULTS: The computed evolution of the apparent bone density (ABD) and the calculated mass losses in the periprosthetic femur show that the simulation results are highly dependent on the chosen boundary conditions. CONCLUSION: These numerical investigations prove that a static load situation is insufficient for representing the whole gait cycle. This causes severe deviations in the FE calculation of the bone remodelling. However, accompanying clinical examinations are necessary to calibrate the bone adaptation law and thus to validate the FE calculations.

Multi-body simulation of a canine hind limb: model development, experimental validation and calculation of ground reaction forces.

BACKGROUND: Among other causes the long-term result of hip prostheses in dogs is determined by aseptic loosening. A prevention of prosthesis complications can be achieved by an optimization of the tribological system which finally results in improved implant duration. In this context a computerized model for the calculation of hip joint loadings during different motions would be of benefit. In a first step in the development of such an inverse dynamic multi-body simulation (MBS-) model we here present the setup of a canine hind limb model applicable for the calculation of ground reaction forces. METHODS: The anatomical geometries of the MBS-model have been established using computer tomography- (CT-) and magnetic resonance imaging- (MRI-) data. The CT-data were collected from the pelvis, femora, tibiae and pads of a mixed-breed adult dog. Geometric information about 22 muscles of the pelvic extremity of 4 mixed-breed adult dogs was determined using MRI. Kinematic and kinetic data obtained by motion analysis of a clinically healthy dog during a gait cycle (1 m/s) on an instrumented treadmill were used to drive the model in the multi-body simulation. RESULTS AND DISCUSSION: As a result the vertical ground reaction forces (z-direction) calculated by the MBS-system show a maximum deviation of 1.75%BW for the left and 4.65%BW for the right hind limb from the treadmill measurements. The calculated peak ground reaction forces in z- and y-direction were found to be comparable to the treadmill measurements, whereas the curve characteristics of the forces in y-direction were not in complete alignment. CONCLUSION: In conclusion, it could be demonstrated that the developed MBS-model is suitable for simulating ground reaction forces of dogs during walking. In forthcoming investigations the model will be developed further for the calculation of forces and moments acting on the hip joint during different movements, which can be of help in context with the in silico development and testing of hip prostheses.

'Pre-launch' finite element analysis of a short-stem total hip arthroplasty system consisting of two implant types.

BACKGROUND: We applied a previously established and validated numerical model to a novel short-stemmed implant for a 'pre-launch' investigation. METHODS: The implant system consists of two different implant geometries for valgus/varus-positioned proximal femurs with differences in volume distribution, head/neck angle, and calcar alignment. The aim of the design was to achieve a better adaption to the anatomic conditions, resulting in a favourable load transfer. The implant type G showed the best fit to our model, but both stem geometries were implanted; the implant type B was used to compute an 'imperfection scenario'. FINDINGS: Apparent bone density decreased by 4.3% in the entire femur with the implant type G, and by 12.3% with the implant type B. Bone mass loss was pronounced in the proximal calcar region. Apparent bone density increased at the lateral cortical ring and in the minor trochanter. The apparent bone density in the imperfection scenario was very similar to that of a straight stem, indicating a distal load transfer. INTERPRETATION: No adverse effects of the A2 short-stemmed implant system on bone remodeling could be detected. The overall bone density reduction was acceptable, and wedge fixation was not observed, indicating that there was no distal load transfer. The simulation of an incongruous implant indicates the sensitivity of our model in response to modifications of implant positioning. Correct implant selection and positioning is crucial when using the A2 system.

Investigation of the Prediction Accuracy of a Finite Element Analysis Model for the Coating Thickness in Cross-Wedge Rolled Coaxial Hybrid Parts.

The Collaborative Research Centre 1153 (CRC 1153) "Process chain for the production of hybrid high-performance components through tailored forming" aims to develop new process chains for the production of hybrid bulk components using joined semi-finished workpieces. The subproject B1 investigates the formability of hybrid parts using cross-wedge rolling. This study investigates the reduction of the coating thickness of coaxially arranged semi-finished hybrid parts through cross-wedge rolling. The investigated parts are made of two steels (1.0460 and 1.4718) via laser cladding with hot-wire. The rolling process is designed by finite element (FE)-simulations and later experimentally investigated. Research priorities include investigations of the difference in the coating thickness of the laser cladded 1.4718 before and after cross-wedge rolling depending on the wedge angle ß , cross-section reduction Δ A , and the forming speed ν . Also, the simulations and the experimental trials are compared to verify the possibility of predicting the thickness via finite element analysis (FEA). The main finding was the ability to describe the forming behavior of coaxially arranged hybrid parts at a cross-section reduction of 20% using FEA. For a cross-section reduction of 70% the results showed a larger deviation between simulation and experimental trials. The deviations were between 0.8% and 26.2%.

Bone cyst formation after ankle arthroplasty may be caused by stress shielding. A numerical simulation of the strain adaptive bone remodelling.

BACKGROUND: The history of total ankle arthroplasty (TAA) has different evolution steps to improve the outcome. The third generation implants show an overall 8-year survival rate up to 93%. The main reported reason for early failure of TAA is aseptic loosening, cyst formation is also frequently reported. The aim of the present study is to use the finite element (FE) method to analyze the adaptive bone remodeling processes, including cyst formation after TAA. METHODS: Bone characteristics applied to the model corresponded to information obtained from computed tomography. Finite element models for the tibia and the talus were developed and implant components were virtually implanted. RESULTS: The calculated total bone loss is 2% in the tibia and 17% in the talus. Cysts and areas of increased bone density were detectable dependent on prosthesis design in the tibia and talus. CONCLUSION: Our FE simulation provides a theoretical explanation for cyst formation and increasing bone density depending on implant design. However, cysts are not mono-causal, histo-chemical reactions should also be considered. Further clinical studies are necessary to evaluate the relevance of cyst formation and therapeutic strategies.

Comparative investigation of bone mineral density using CT and DEXA in a canine femoral model.

Bone density measurements using computed tomography (CT) instead of dual-energy X-ray absorptiometry (DEXA) are currently of great interest in human and veterinary medical research as it would be beneficial to use CT scans obtained for other indications also for determining bone density. For Hounsfield units (HU) measured with CT in specific regions of interests (ROIs) in one or several slice/s a correlation with bone mineral density (BMD) measured by DEXA in humans and dogs of between 0.44 and 0.77 is reported in the literature. In the present study, instead certain volumes of interest (VOIs) obtained by CT scan and the corresponding HU to the respective VOIs were compared with the bone mineral density of the corresponding areas measured by DEXA. The aim of the study was to investigate whether this procedure gives more accurate information about bone density of the bones as three-dimensional objects of the respective patient. Correlation between measured HU in the respective VOI and BMD measured with DEXA in the corresponding ROI showed a very good correlation of 0.93. Linear regression with R2 = 0.85 (p = 0.0262) was calculated. Except for VOI5, similar distribution of values and significant differences (p < 0.0001-0.0087) between ROIs/VOIs were detected. Determining HU for assessing bone mineral density in a certain volume provides more accurate results than those previously reported from two-dimensional (2D) CT measurements. © 2017 Orthopaedic Research Society. Published by Wiley Periodicals, Inc. J Orthop Res 35:2667-2672, 2017.

[FE-analysis of surface stresses for the tribological system in total hip prostheses]. / FE-Simulation zur Lokalisierung hoch beanspruchter Bereiche in der Hüftpfanne von Endoprothesen.

The implantation of a total hip prosthesis is an operation which is performed frequently due to advanced hip joint damage both in humans and in veterinary medicine in dogs. The long-term result of a hip prosthesis is mainly determined by aseptic loosening of the prosthesis; among other causes, abrasion particles of the tribological pairing are responsible for the loosening. For the analysis of the surface stresses with different tribological pairings, a finite element model was generated which was based on the CAD data of a commercial total hip prosthesis. After transmission of a physiological force in the components of the three tribological pairings ceramic/polyethylene, ceramic/ceramic and metal/polyethylene, stresses were calculated. Stresses in the ceramic/ceramic tribological pairings were conspicuously higher than in the other material pairings. In the future adapted prostheses have to be developed that ensure optimal friction and absorption characteristics of the components.

Mechanical properties of femoral trabecular bone in dogs.

BACKGROUND: Studying mechanical properties of canine trabecular bone is important for a better understanding of fracture mechanics or bone disorders and is also needed for numerical simulation of canine femora. No detailed data about elastic moduli and degrees of anisotropy of canine femoral trabecular bone has been published so far, hence the purpose of this study was to measure the elastic modulus of trabecular bone in canine femoral heads by ultrasound testing and to assess whether assuming isotropy of the cancellous bone in femoral heads in dogs is a valid simplification. METHODS: From 8 euthanized dogs, both femora were obtained and cubic specimens were cut from the centre of the femoral head which were oriented along the main pressure and tension trajectories. The specimens were tested using a 100 MHz ultrasound transducer in all three orthogonal directions. The directional elastic moduli of trabecular bone tissue and degrees of anisotropy were calculated. RESULTS: The elastic modulus along principal bone trajectories was found to be 11.2 GPa +/- 0.4, 10.5 +/- 2.1 GPa and 10.5 +/- 1.8 GPa, respectively. The mean density of the specimens was 1.40 +/- 0.09 g/cm3. The degrees of anisotropy revealed a significant inverse relationship with specimen densities. No significant differences were found between the elastic moduli in x, y and z directions, suggesting an effective isotropy of trabecular bone tissue in canine femoral heads. DISCUSSION: This study presents detailed data about elastic moduli of trabecular bone tissue obtained from canine femoral heads. Limitations of the study are the relatively small number of animals investigated and the measurement of whole specimen densities instead of trabecular bone densities which might lead to an underestimation of Young's moduli. Publications on elastic moduli of trabecular bone tissue present results that are similar to our data. CONCLUSION: This study provides data about directional elastic moduli and degrees of anisotropy of canine femoral head trabecular bone and might be useful for biomechanical modeling of proximal canine femora.

Finite element modelling of the canine and feline outer ear canal: benefits for local drug delivery?

Current therapeutic regimes of outer ear infections in dogs and cats aim at the application of efficient local therapeutics after cleaning of the acoustic meatus. One so far insufficiently answered question is if the local application of these substances results in an individually suitable drug concentration in the external ear canal. Thus, the purpose of the present study was to develop a finite element model to calculate the values of the different areas of the external acoustic meatus in dogs and cats in order to provide a tool for the benefit of an appropriate local drug dosage determination. A 3D finite element model (FEM), based on computer tomographic (CT) data sets of four dogs and two cats, was generated to determine areas and volumes of the outer ear canal. Furthermore, various ear therapeutics and cleansers were tested concerning their optimal distribution on 5 cm2 dog and cat skin. The data shows major variations of the area values of the external auditory canal in case of the different dogs but not in the examined cats. These results suggest that manufacturer's recommendations of the pharmaceuticals might be insufficient in terms of achieving an optimal drug concentration in the outer ear canal especially in larger dogs. In conclusion, the developed finite element model has shown to be suitable to calculate areas of the outer ear canal in cats and dogs and could be of help in context with the definition of optimal drug concentrations for a local drug delivery.

[Numerical investigations of the strain adaptive bone remodelling in the periprosthetic canine femur]. / Numerische Untersuchungen zum beanspruchungsadaptiven Knochenumbau im periprothetischen caninen Femur.

After surgical treatment of severe hip diseases with artificial joint prostheses aseptic loosening of the implants can occur. Unphysiologic load distribution in the periprosthetic femur and stress shielding by the prosthesis can result in bone remodelling processes. In particular a cutback of the bone mass is followed by an aseptic loosening of the prosthesis. In this context the understanding of bone remodelling processes in the prothetically treated femur is of outstanding interest for the optimisation of canine hip joint prostheses in the future. Therefore the main aim of this sudy was the numerical investigation on the change in the load distribution in the canine periprosthetic femur and the resulting bone remodelling after implantation of the cemented stem Bioméchanique. The investigations within this study were carried out using the Finite Element Analysis (FEA). The calculated bone density of the periprosthetic femur and the evolution of the mass loss show relevant stress shielding areas in different analysis regions. Therefore possible regions of aseptic loosening are indicated particularly in the proximo-medial femur. The here demonstrated numerical results are in agreement with clinical findings. For this reason the FEA-based method is a valuable tool for the prediction of bone remodelling processes.