Open Access
Novel sensorized additive manufacturing-based enlighted tooling concepts for aeronautical parts
(Springer Nature, 2024-07-31) Uralde Jiménez, Virginia; Veiga Suárez, Fernando; Suárez, Alfredo; López, Alberto; Goenaga, Igor; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
This paper presents lightweight tooling concepts based on additive manufacturing, with the aim of developing advanced tooling systems as well as installing sensors for real-time monitoring and control during the anchoring and manufacturing of aeronautical parts. Leveraging additive manufacturing techniques in the production of tooling yields benefits in manufacturing flexibility and material usage. These concepts transform traditional tooling systems into active, intelligent tools, improving the manufacturing process and part quality. Integrated sensors measure variables such as displacement, humidity and temperature allowing data analysis and correlation with process quality variables such as accuracy errors, tolerances achieved and surface finish. In addition to sensor integration, additive manufacturing by directed energy arc and wire deposition (DED-arc) has been selected for part manufacturing. The research includes the mechanical characterisation of the material and the microstructure of the material once manufactured by DED-arc. Design for additive manufacturing" principles guide the design process to effectively exploit the capabilities of DED-arc. These turrets, equipped with sensors, allow real-time monitoring and control of turret deformation during clamping and manufacturing of aeronautical parts. As a first step, deformation monitoring is carried out within the defined tolerance of ± 0.15, which allows a control point to be established in the turret. Future analysis of the sensor data will allow correlations with process quality variables to be established. Remarkably, the optimised version of the turret after applying DED technology weighed only 2.2 kg, significantly lighter than the original 6 kg version. Additive manufacturing and the use of lightweight structures for fixture fabrication, followed by the addition of sensors, provide valuable information and control, improving process efficiency and part quality. This research contributes to the development of intelligent and efficient tool systems for aeronautical applications.
Open Access
Development and tests of a neonatal portable foldable emergency incubator
(World Scientific, 2018-08-03) Ballesteros Egüés, Tomás; Arana Navarro, Ignacio; Pérez Ezcurdia, Amaya; Alfaro López, José Ramón; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
Open Access
Wall fabrication by direct energy deposition (DED) combining mild steel (ER70) and stainless steel (SS 316L): microstructure and mechanical properties
(MDPI, 2022) Uralde Jiménez, Virginia; Suárez, Alfredo; Aldalur, Eider; Veiga Suárez, Fernando; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza
Direct energy deposition is gaining much visibility in research as one of the most adaptable additive manufacturing technologies for industry due to its ease of application and high deposition rates. The possibility of combining these materials to obtain parts with variable mechanical properties is an important task to be studied. The combination of two types of steel, mild steel ER70-6 and stainless steel SS 316L, for the fabrication of a wall by direct energy deposition was studied for this paper. The separate fabrication of these two materials was studied for the microstructurally flawless fabrication of bimetallic walls. As a result of the application of superimposed and overlapped strategies, two walls were fabricated and the microstructure, mechanical properties and hardness of the resulting walls are analyzed. The walls obtained with both strategies present dissimilar regions; the hardness where the most present material is ER70-6 is around 380 HV, and for SS 316L, it is around 180 HV. The average values of ultimate tensile strength (UTS) are 869 and 628 MPa, yield strength (YS) are 584 and 389 MPa and elongation at break are 20% and 36%, respectively, in the cases where we have more ER70-6 in the sample than SS 316L. This indicates an important relationship between the distribution of the materials and their mechanical behavior.
Open Access
Development of an inexpensive rollover energy dissipation device to improve safety provided by ROPS
(Elsevier, 2019-02-21) Latorre Biel, Juan Ignacio; Ballesteros Egüés, Tomás; Arana Navarro, Ignacio; Alfaro López, José Ramón; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
Open Access
Application-oriented data analytics in large-scale metal sheet bending
(MDPI, 2023) Penalva Oscoz, Mariluz; Martín, Ander; Martínez, Víctor; Veiga Suárez, Fernando; Gil del Val, Alain; Ballesteros Egüés, Tomás; Favieres Ruiz, Cristina; Ingeniería; Ingeniaritza
The sheet-metal-forming process is crucial in manufacturing various products, including pipes, cans, and containers. Despite its significance, controlling this complex process is challenging and may lead to defects and inefficiencies. This study introduces a novel approach to monitor the sheet-metal-forming process, specifically focusing on the rolling of cans in the oil-and-gas sector. The methodology employed in this work involves the application of temporal-signal-processing and artificial-intelligence (AI) techniques for monitoring and optimizing the manufacturing process. Temporal-signal-processing techniques, such as Markov transition fields (MTFs), are utilized to transform time series data into images, enabling the identification of patterns and anomalies. synamic time warping (DTW) aligns time series data, accommodating variations in speed or timing across different rolling processes. K-medoids clustering identifies representative points, characterizing distinct phases of the rolling process. The results not only demonstrate the effectiveness of this framework in monitoring the rolling process but also lay the foundation for the practical application of these methodologies. This allows operators to work with a simpler characterization source, facilitating a more straightforward interpretation of the manufacturing process.
Open Access
Advancements and methodologies in directed energy deposition (DED-Arc) manufacturing: design strategies, material hybridization, process optimization and artificial intelligence
(IntechOpen, 2024-09-27) Uralde Jiménez, Virginia; Suárez, Alfredo; Veiga Suárez, Fernando; Villanueva Roldán, Pedro; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
This chapter explores the latest advancements and methodologies in directed energy deposition (DED-arc) manufacturing. The introduction sets the stage for understanding the significance of these developments in the context of modern manufacturing needs. The discussion includes design strategies for DED-arc, emphasizing topological optimization, functional design, and generative design, alongside the application of artificial intelligence (AI) in enhancing design processes. Innovative approaches to material hybridization are detailed, focusing on both multilayer and in situ techniques for combining different materials to optimize component performance. The paper also covers slicing and pathing, examining slicing strategies, the use of lattice structures, and the implementation of 2D and 3D patterns to improve manufacturing efficiency and product quality. The conclusion summarizes key findings, discusses their implications for the additive manufacturing industry, and suggests potential future research directions in DED-arc technology, highlighting the emerging trends and innovations that are shaping the field.
Open Access
Analysis of the machining process of short carbon fiber-reinforced polyamide additive manufactured parts
(Elsevier, 2024) Suárez, Alfredo; Veiga Suárez, Fernando; Penalva Oscoz, Mariluz; Ramiro, Pedro; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza
In recent years, additive manufacturing technologies have revolutionized the production of parts, particularly in the aeronautical sector. This new manufacturing paradigm has created significant challenges and opportunities for researchers in materials and manufacturing processes. One important aspect is the development of optimal strategies for finishing-oriented machining of parts produced through additive manufacturing. This article focuses on the analysis of reinforced polyamide materials and the integration of large-scale additive manufacturing using Big Area Additive Manufacturing (BAAM) technology, along with robotic systems for subtractive machining. The aim is to explore the potential of integrating additive and subtractive processes to produce high-quality, large-scale components. The study examines the production and subsequent machining of reinforced polyamide parts using BAAM technology, showcasing the advantages and promising results observed. By combining additive manufacturing with subtractive machining, this research contributes to the ongoing advancements in the field of manufacturing, particularly in relation to reinforced polyamide materials. The findings presented in this article shed light on the potential of integrating additive and subtractive processes in the manufacturing industry, paving the way for more efficient and high-quality production methods.
Open Access
Design, manufacturing, validation of a multi-orientation tilt test bench for testing vehicles rollover and tests of ATV-Quad for agricultural applications
(MDPI, 2021) Bacaicoa Díaz, Julen; Ballesteros Egüés, Tomás; Arana Navarro, Ignacio; Aginaga García, Jokin; Latorre Biel, Juan Ignacio; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
A rollover test bench has been designed, manufactured, and validated for analyzing the all-terrain vehicle (ATV)-Quad overturn of diverse vehicles in different configurations, such as installing a rollover protection system (ROPS), considering drivers of different physical constitutions, the appropriate use of safety belts, or having a full or empty fuel tank. The main purpose of this research is to determine the tilt angle of the vehicle that triggers the ATV-Quad overturn. The scope of the design and development of the newly conceived bench include the mechanical structure, the electronics and the control. It can simulate static and dynamic rollover in different directions. As a main conclusion, it can be stated that the performance of the test bench was successful, since it allowed for the development of several ATV models, equipped with different dummies, in a variety of configurations. In particular, it was possible to assess the effectivity of the AD-ROPS system (automatically deployed ROPS), regarding the protection of the driver of the vehicle. Moreover, multiple tests, performed with diverse ATV-Quads in the developed bench and in different configurations, have been reported and their results discussed.
Open Access
Benefits of aeronautical preform manufacturing through arc-directed energy deposition manufacturing
(MDPI, 2023) Suárez, Alfredo; Ramiro, Pedro; Veiga Suárez, Fernando; Ballesteros Egüés, Tomás; Villanueva Roldán, Pedro; Ingeniería; Ingeniaritza
The paper introduces an innovative aerospace component production approach employing Wire Arc Additive Manufacturing (WAAM) technology to fabricate near-finished preforms from Ti6Al4V titanium. Tensile tests on WAAM Ti6Al4V workpieces demonstrated reliable mechanical properties, albeit with identified anisotropic behavior in horizontal samples, underscoring the need for optimization. This alternative manufacturing strategy addresses the challenges associated with machining forged preforms, marked by a high Buy To Fly (BTF) ratio (>10), leading to material wastage, prolonged machining durations, elevated tool expenses, and heightened waste and energy consumption. Additionally, logistical and storage costs are increased due to extended delivery timelines, exacerbated by supply issues related to the current unstable situation. The utilization of WAAM significantly mitigates initial BTF, preform costs, waste production, machining durations, and associated expenditures, while notably reducing lead times from months to mere hours. The novelty in this study lies in the application of Wire Arc Additive Manufacturing (WAAM) technology for the fabrication of titanium aircraft components. This approach includes a unique height compensation strategy and the implementation of various deposition strategies, such as single-seam, overlapping, and oscillating.
Open Access
Symmetry and its application in metal additive manufacturing (MAM)
(MDPI, 2022) Uralde Jiménez, Virginia; Veiga Suárez, Fernando; Aldalur, Eider; Suárez, Alfredo; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza
Additive manufacturing (AM) is proving to be a promising new and economical technique for the manufacture of metal parts. This technique basically consists of depositing material in a more or less precise way until a solid is built. This stage of material deposition allows the acquisition of a part with a quasi-final geometry (considered a Near Net Shape process) with a very high raw material utilization rate. There is a wide variety of different manufacturing techniques for the production of components in metallic materials. Although significant research work has been carried out in recent years, resulting in the wide dissemination of results and presentation of reviews on the subject, this paper seeks to cover the applications of symmetry, and its techniques and principles, to the additive manufacturing of metals.