With the ever-increasing number of polymer materials and the current number of commercially available materials, the polymer gear design process, regarding the wear lifetime predictions, is a difficult task given that there are very limited data on wear coefficients that can be deployed to evaluate the wear behavior of polymer gears. This study focuses on the classic steel/polymer engagements that result in a wear-induced failure of polymer gears and proposes a simple methodology based on the employment of optical methods that can be used to assess the necessary wear coefficient. Polymer gear testing, performed on an open-loop test rig, along with VDI 2736 guidelines for polymer gear design, serves as a starting point for the detailed analysis of the wear process putting into service a digital microscope that leads to the evaluation of the wear coefficient. The same wear coefficient, as presented within the scope of this study, can be implemented in a rather simple wear prediction model, based on Archard’s wear formulation. The developed model is established on the iterative numerical procedure that accounts for the changes in tooth flank geometry due to wear and investigates the surface wear impact on the contact pressure distribution to completely describe the behavior of polymer gears in different stages of their lifetime. Although a simple one, the developed wear prediction model is sufficient for most engineering applications, as the model prediction and experimental data agree well with each other, and can be utilized to reduce the need to perform time-consuming testing.

(1) Background: With the ever-increasing number of polymer materials and limited data on polymer gear calculations, designers are often required to perform extensive experimental testing in order to establish reliable operational data for specific gear applications. This research investigates the potential of a Polyvinyldene fluoride (PVDF) polymer material in gear applications, considering various loading conditions and different types of gear transmission configurations, including both self-mated mesh and steel/PVDF mesh. (2) Methods: PVDF gear samples were tested on a specially designed test rig that enables active torque control and temperature monitoring in order to obtain the necessary design parameters and failure modes. Each test for certain load conditions was repeated five times, and to fully investigate the potential of PVDF gear samples, comparative testing was performed for Polyoxymethylene (POM) gear. (3) Results: Tribological compatibility, tooth load capacity, and lifespan assessment, along with the types of failure, which, for some configurations, include several types of failures, such as wear and melting, were determined. Temperature monitoring data were used to estimate the coefficient of friction at the tooth contact of analyzed gear pairs, while optical methods were used to determine a wear coefficient. (4) Conclusions: The tribological compatibility of polymer gear pairs needs to be established in order to design a gear pair for a specific application. PVDF gear samples mated with steel gear showed similar lifespan properties compared to POM samples. Temperature monitoring and optical methods serve as a basis for the determination of the design parameters. PVDF is an appropriate material to use in gear applications, considering its comparable properties with POM. The particular significance of this research is reflected in the establishment of the design parameters of PVDF gear, as well as in the analysis of the potential of the PVDF material in gear applications, which gives exceptional significance to the current knowledge on polymer gears, considering that the PVDF material has not previously been analyzed in gear applications.

This paper presents the development and implementation of integrated intelligent CAD (computer aided design) system for design, analysis and prototyping of the compression and torsion springs. The article shows a structure of the developed system named Springs IICAD (integrated intelligent computer aided design). The system bounds synthesis and analysis design phases by means of the utilization of parametric 3D (three-dimensional) modeling, FEM (finite element method) analysis and prototyping. The development of the module for spring calculation and system integration was performed in the C# (C Sharp) programming language. Three-dimensional geometric modeling and structural analysis were performed in the CATIA (computer aided three-dimensional interactive application) software, while prototyping is performed with the Ultimaker 3.0 3D printer with support of Cura software. The developed Springs IICAD system interlinks computation module with the basic parametric models in such a way that spring calculation, shaping, FEM analysis and prototype preparation are performed instantly.

The development process of the knowledge-based engineering (KBE) system for the structural size optimization of external fixation device is presented in this paper. The system is based on algorithms for generative modeling, finite element model (FEM) analysis, and size optimization. All these algorithms are integrated into the CAD/CAM/CAE system CATIA. The initial CAD/FEM model of external fixation device is verified using experimental verification on the real design. Experimental testing is done for axial pressure. Axial stress and displacements are measured using tensometric analysis equipment. The proximal bone segment displacements were monitored by a displacement transducer, while the loading was controlled by a force transducer. Iterative hybrid optimization algorithm is developed by integration of global algorithm, based on the simulated annealing (SA) method and a local algorithm based on the conjugate gradient (CG) method. The cost function of size optimization is the minimization of the design volume. Constrains are given in a form of clinical interfragmentary displacement constrains, at the point of fracture and maximum allowed stresses for the material of the external fixation device. Optimization variables are chosen as design parameters of the external fixation device. The optimized model of external fixation device has smaller mass, better stress distribution, and smaller interfragmentary displacement, in correlation with the initial model.

Goal of this research was to develop and manufacture planetary gearbox prototype using rapid prototyping technology (additive manufacturing). Developed prototype was used to visually analyse the design of the planetary gearbox. Also, it was used to improve and innovate education of students on several courses at Mechanical Design study program at Faculty of Mechanical Engineering. It is shown that low cost rapid prototyping technology can be used to manufacture prototypes of complex machines and machine elements. Prototypes manufactured using this technology have same functionality like the real one. Main limitation is the fact that they cannot sustain real world loads and stresses. This paper shows opportunities which low cost rapid prototyping technology is offering in improvement and innovation of education process at engineering schools and faculties. All complex and heavy machines can be manufactured using this type of technology and on that way more precisely presented to the students.

Structural size optimization of a device for external bone fixation within a formed iterative hybrid optimization algorithm was presented in this paper. The optimization algorithm was in interaction with the algorithms for generative design and FEM analysis and completely integrated within CATIA CAD/CAM/CAE system. The initial model, representing the current design of the bone external fixation device Sarafix, was previously verified by experimental testing. The formed hybrid optimization algorithm was created as an integration of the global (SA method) and local (CG method) algorithm. The constraints of the optimization model are the clinical limitations of the interfragmentary displacements and the material strength. The optimized design has less weight, greater rigidity and less transverse interfragmentary displacements at the point of fracture compared to the current design.

Proportional–integral–derivative (PID) control is the most common control approach used to control active magnetic bearings system, especially in the case of supporting rigid rotors. In the case of flexible rotor support, the most common control is again PID control in combination with notch filters. Other control approaches, known as modern control theory, are still in development process and cannot be commonly found in real life industrial application. Right now, they are mostly used in research applications. In comparison to PID control, PI-D control implies that derivate element is in feedback loop instead in main branch of the system. In this paper, performances of flexible rotor/active magnetic bearing system were investigated in the case of PID and PI-D control, both in combination with notch filters. The performances of the system were analysed using an analysis in time domain by observing system response to step input and in frequency domain by observing a frequency response of sensitivity function.

This paper presents the development and experimental verification of a generative CAD/FEM model of an external bone fixation device. The generative CAD model is based on the development of a parameterized skeleton algorithm and sub-algorithms for parametric modeling and positioning of components within a fixator assembly using the CATIA CAD/CAM/CAE system. After a structural analysis performed in the same system, the FEM model was used to follow interfragmentary fracture displacements, axial displacements at the loading site, as well as principal and Von Mises stresses at the fixator connecting rod. The experimental analysis verified the results of the CAD/FEM model from an aspect of axial displacement at the load site using a material testing machine (deviation of 3.9 %) and the principal stresses in the middle of the fixator connecting rod using tensometric measurements (deviation of 3.5 %).The developed model allows a reduction of the scope of preclinical experimental investigations, prediction of the behavior of the fixator during the postoperative fracture treatment period and creation of preconditions for subsequent structural optimization of the external fixator.

ABSTRACT During process of product development and design, it is important to keep production cost as small as possible. One way to reduce the production cost is by degrading the quality of the product, which is “worst-case” scenario and it should not be used. Another way is to turn to the application of new knowledge and insights, which enables better utilization of resources and processes. New knowledge may include new materials and/or new technologies, but may also include new ways and methods of product development and design. The increasing complexity of products, the use of new materials, methodologies and technologies, require increasing computer support for the design process. Because of this, there is a need for a better scientific approach and a better understanding of the design process using a number of software design tools, interaction between these tools and better collaboration between designers. This paper describes the process of developing the knowledge based intelligent integrated computer aided design (IICAD) system for the calculation, dimensioning and development of a bridge crane model with two main supports. This methodology of IICAD software development can be used to develop numerous other IICAD computer systems for various fields of engineering. Main contribution of this paper is above mentioned and presented methodology. Also, goal of this paper is to prove that standard computer aided design (CAD) systems, needs to be expanded with this knowledge based intelligent integrated systems to achieve higher levels of performance.

The purpose of a car jack is lifting the car and maintaining it at a certain height during different repairs. This paper focuses on the design of car jack, which belongs to the basic equipment of cars. Cars jacks are used mainly for changing tires and small repairs of a car. The aim of this paper was to create a parametric CAD model of a car jack and carry out numerical structural analysis of the car jack using the created parametric CAD model. The development of the parametric CAD model and structural analysis was performed using the CATIA V5 system. This paper describes the modern way of creating more complex mechanisms, which support quick modification of its parameters, and thus the entire design. The whole model of the car jack was parametrized. The stresses obtained by finite element method (FEM) analysis were confirmed with the analytical calculation in characteristic parts of the design, with some exceptions. At the end of the paper, an analysis of the obtained results was performed, on the basis of which specified conclusions were made.

– There is a lot of papers concerning gears topology optimization, but all of them are limited to the topology optimization of gear body. Gear tooth is not taken into consideration so far. Gear tooth was not optimized before because optimised structure could not be produced. By advancing of additive manufacturing technology, now, gear tooth can be produced in a form of shell body with empty space inside. In this paper, mass of spur gear tooth is optimized in relation to Von-Misses stress on critical places on the gear tooth. Optimization goal is to find optimal shell thickness of shell body spur gear tooth.

The subject of this paper is conceptual design and stress analyses of the composite frame for a special mauntain bike. The existing solutions for frames of this type were analyzed, and the design was conceptualized, which was thoroughly analyzed for extreme loads occurring on the Dirt Jump Mountain Bike Frames. By using the methodology of conceptual design, we have obtained a conceptual solution of the frame, which has been evaluated as optimal one based on a set of criteria. We later confirmed this hypothesis by the stress and other analyzes we carried out to validate the frame, and found that the chosen conceptual solution really meets all the criteria.

Integrated intelligent CAD systems (IICAD) can be developed for different purposes. The objective of this article is to emphasize the advantages of the use of IICAD systems in comparison with the classic systems. The article shows a structure of one such developed system, namely the IICADv system. This system is used for automatization of activities undertaken during the realization of certain phases of the process of designing of shafts, especially the synthesis phase. The development of a module for computation of the shaft and integration of the entire system was performed in the C# programming language, while shaping of the shaft was performed in the CATIA system. The interlinking was performed thanks to previously modelled basic 3D models. In such way, utilizing the advanced IICADv system, the computation and shaping of the shaft is done almost instantly. The results of the use of the IICADv systems are generated final 3D models of the shaft, ready for use by numerous other applications.