Orientador: Fernando de Azevedo Silva / Banca: Gustavo Aristides Santana Martinez / Banca: João Alberto de Oliveira / Resumo: Estudo de falha por fratura em eixo da laminadora de aros Leifeld, fabricado em aço de baixa liga e alta resistência, ABNT 4340, forjado, temperado e revenido, com dureza de 39 HRc, abordando aspectos de modelagem pelo método de elementos finitos, utilizando o programa Ansys e critérios de fadiga utilizando o diagrama de Goodman modificado como ferramenta de definição do limite de tensão alternada para fadiga e propostas de mudanças geométricas no eixo a fim de minimizar as tensões sobre a aba da árvore bem como eliminar a possibilidade de fratura por fadiga da mesma. O estudo procura mostrar de forma clara a montagem de um modelo sólido através de um software comercial e a interação com a realidade vivida na manutenção de fábrica, sendo que o estudo surgiu devido a falhas freqüentes e prematuras de árvores em máquinas de repuxamento de aros, de procedência alemã, usada para a fabricação de aros para pneu com câmara utilizados em caminhões e ônibus, máquina esta de propriedade da empresa Maxion Sistemas Automotivos S/A. / Abstract: This is a fracture failure analysis of a Leifeld flow forming machine spindle, manufactured in a low alloy and high resistance, ABNT 4340 steel, forged, quenched and tempered with hardness of 39 HRc, approaching modeling aspects in finite elements method using the program Ansys and also approaching fatigue criteria using the diagram of Goodman modified as a tool for definition criterion of fatigue alternate stress limit and proposed of geometric changes in the spindle in order to minimize the tensions on the brim of it as well as to eliminate the fracture possibility for fatigue of the same. The study tries to show the assembly of a solid model in a clear way through a commercial software and the interaction with the reality lived in the factory maintenance, the study was proposed due the frequent and premature spindles failures in the flow forming machine, made in Germany, used for the production of rim for tire with tube used in trucks and buses, this machine is property of Maxion Sistemas Automotivos S/A company. / Mestre

Made available in DSpace on 2014-06-11T19:28:35Z (GMT). No. of bitstreams: 0 Previous issue date: 2004-12Bitstream added on 2014-06-13T19:07:18Z : No. of bitstreams: 1 monteiro_fl_me_guara.pdf: 2693716 bytes, checksum: 79334c2a393c7aaa40e71c0ef9ab7905 (MD5) / Universidade Estadual Paulista (UNESP) / Estudo de falha por fratura em eixo da laminadora de aros Leifeld, fabricado em aço de baixa liga e alta resistência, ABNT 4340, forjado, temperado e revenido, com dureza de 39 HRc, abordando aspectos de modelagem pelo método de elementos finitos, utilizando o programa Ansys e critérios de fadiga utilizando o diagrama de Goodman modificado como ferramenta de definição do limite de tensão alternada para fadiga e propostas de mudanças geométricas no eixo a fim de minimizar as tensões sobre a aba da árvore bem como eliminar a possibilidade de fratura por fadiga da mesma. O estudo procura mostrar de forma clara a montagem de um modelo sólido através de um software comercial e a interação com a realidade vivida na manutenção de fábrica, sendo que o estudo surgiu devido a falhas freqüentes e prematuras de árvores em máquinas de repuxamento de aros, de procedência alemã, usada para a fabricação de aros para pneu com câmara utilizados em caminhões e ônibus, máquina esta de propriedade da empresa Maxion Sistemas Automotivos S/A. / This is a fracture failure analysis of a Leifeld flow forming machine spindle, manufactured in a low alloy and high resistance, ABNT 4340 steel, forged, quenched and tempered with hardness of 39 HRc, approaching modeling aspects in finite elements method using the program Ansys and also approaching fatigue criteria using the diagram of Goodman modified as a tool for definition criterion of fatigue alternate stress limit and proposed of geometric changes in the spindle in order to minimize the tensions on the brim of it as well as to eliminate the fracture possibility for fatigue of the same. The study tries to show the assembly of a solid model in a clear way through a commercial software and the interaction with the reality lived in the factory maintenance, the study was proposed due the frequent and premature spindles failures in the flow forming machine, made in Germany, used for the production of rim for tire with tube used in trucks and buses, this machine is property of Maxion Sistemas Automotivos S/A company.

Orientador: Gilberto Pechoto de Melo / Banca: Luiz de Paula do Nascimento / Banca: Silmara Cassola / Resumo: O presente trabalho apresenta a metodologia dos observadores de estado para a detecção e localização de falhas em sistemas contendo elementos finitos de placas de Kirchoff. Tal metodologia consiste na montagem de um banco de observadores de estado, o qual é capaz de detectar falhas presentes no sistema, além de localizar o componente danificado e a porcentagem de falha. As matrizes de ganho dos observadores de estado foram determinadas por dois métodos distintos: o método Regulador Quadrático Linear e das Desigualdades Matriciais Lineares. Nesse trabalho, foi utilizada uma placa plana fina montada sobre um sistema de suspensão similar ao de uma plataforma veicular, representando um veiculo simplificadamente. A modelagem da plataforma utilizada foi realizada mediante a utilização do método dos elementos finitos, considerando-se diferentes números de elemento no modelo. O tipo do elemento finito utilizado foi o elemento de placa de Kirchoff. Adicionalmente foi analisada a influência de elementos de controle junto à suspensão da plataforma no movimento da mesma. O modelo considerado, juntamente com os programas computacionais desenvolvidos, foram utilizados para a simulação do movimento da plataforma. Na literatura, normalmente são apresentadas simulações para o movimento de apenas ¼ do veículo, neste trabalho, no entanto, os programas desenvolvidos podem simular o movimento do veiculo inteiro. Foram realizadas simulações computacionais para o movimento da plataforma com a finalidade de se detectar e localizar falhas introduzidas nos elementos da suspensão e também foram realizados testes experimentais, com os mesmos fins. Mediante tais testes (teóricos e experimentais) verificou-se a eficácia da metodologia desenvolvida e a sua principal limitação: o número de elementos finitos considerado no modelo relacionado com o número de medidas efetuadas e a observabilidade do sistema. / Abstract: This work presents the state observers methodology for the detection and location of faults in systems containing finite elements of plate of Kirchoff. This methodology consists in the assembly of a bank of state observers, which is capable of detecting faults in the system, and also to locate the damaged component and the percentage of failure. The gain matrices of the state observers were determined by two different methods, these are the method Linear Quadratic Regulator and the Linear Matrix Inequalities. In this work was considered a thin plate mounted on a suspension system that is similar to a vehicle platform, representing a vehicle in a simplified way. The modeling of the platform used was performed by using the finite element method, considering different numbers of element in the model. The finite element used was the Kirchoff's plate element. It was also studied the influence of elements of control, together with the suspension of the platform, into its movement. The model considered, together with the developed computational programs, were used to simulate the movement of the platform. In the literature, usually are presented simulations for the movement of only ¼ of the vehicle, in this work, the developed programs can simulate the movement of the entire vehicle. It was realized computational simulations for the movement of the platform in order to detect and locate faults introduced in the elements of the suspension and experimental tests were also conducted with the same purpose. Through such tests (theoretical and experimental) it was verified the effectiveness of the developed methodology and its major limitation: the number of finite elements considered in the model related with the number of outputs and the observability of the system. / Mestre

La present tesi investiga l'ús de la modelització amb elements finits per a l'estudi de la biomecànica lumbar per a l'avaluació clínica. Els estudis bibliogràfics del capítol 1 mostren relacions funcionals clares entre les forces externes i les estructures i formes del teixit lumbar. Els estudis clínics demostraren que independentment del seu origen, el dolor lumbar pot veure's empitjorat per sobrecàrregues dels teixits. Les mesures experimentals són insuficients per descriure la distribució de càrrega entre els diferents teixits lumbars, és així que s'han utilitzat models d'elements finits. No obstant, la fiabilitat dels models a l'hora de predir les càrregues locals en els teixits no ha estat demostrada, essent aquest un dels objectes d'estudi.En el Capítol 2 s'elaborà un model bisegment de la columna lumbar. El model inicial es completà incloent el còrtex vertebral, una definició complerta de les juntes sinovials, les plaques terminals de cartílag i una descripció millorada de l'estructura de l'anell. Es van simular càrregues simplificades per als estudis in vitro per calcular les distribucions de tensions, deformacions i energia. El model bisegment és vàlid per interpretar les distribucions de càrrega funcionals a L3-L5 en el cas d'estructures conegudes de teixit, però el conjunt de la geometria L3-L5 necessitava ser millorat.Així al Capítol 3 es creà un model geomètric bisegment precís de L3-L5. El nou model incloïa les corregides: dimensions i formes, alçades de disc, localitzacions del nucli, formes posteriors de l'os, i distribució dels lligaments. Després de comparar a nivell biomecànic l'antiga geometria amb la nova, els resultats mostraren que els rols relatius dels teixits modelats depenen de la geometria. En general, les distribucions de càrrega predites eren més fisiològiques en el nou model. En canvi, ambdós models, reprodueixen rangs experimentals de moviment, així doncs la seva validació hauria de tenir en compte les transferències de càrrega locals.El Capítol 4 es centra en la variabilitat dels angles creuats del col·lagen de l'anell. Es crearen quatre models bisegment amb organitzacions d'anell fibrós basats en la bibliografia comparant-se sota diverses càrregues. A més es proposà un paràmetre d'estabilització de l'anell per analogia a un tub de parets gruixudes. La biomecànica del model depenia en gran mesura de l'organització de l'anell fibrós, però el paràmetre d'estabilització era soviet contradictori amb les tensions i forces predites. Així, s'assumí que la geometria de la columna i l'organització de l'anell fibrós estaven lligades. Les xarxes d'anell de col·lagen adaptades es poden determinar numèricament, però els models d'anell haurien d'estar bastats en relacions mecanobiològiques.Al Capítol 5 es presenta un model de disc artificial acoblat amb el model de L3-L5. Models bisegment amb i sense implant van ser comparats amb càrregues controlades per força o desplaçament, incloent o no l'aproximació del pes del cos. La rigidesa de la pròtesi alterava generalment les distribucions de càrrega i les rotacions controlades per desplaçament conduint a grans efectes adjacents. Incloent el pes del cos les condicions de contorn semblaven més fisòlogiques que sense. Malgrat la rigidesa del nou disc, aquest sembla més prometedor que altres dispositius comercials.En aquesta tesi s'han creat sis models nous elements finits de la columna lumbar osteoligamentosa. Les simulacions han mostrat que l'ús fiable dels models requereix d'una descripció precisa de les càrregues locals i respostes mecàniques de teixits. Les prediccions locals van estar limitades qualitativament degudes al desconeixement de les estructures de teixit tou, equacions constitutives i condicions de contorn. En canvi, els models poden ser emprats com a laboratoris in silico per superar aquestes limitacions. Basat en la informació numèrica i experimental, s'ha proposat un procediment jeràrquic per al desenvolupament qualitativament fiable de models elements finits de la columna lumbar. / This PhD thesis investigated the use of finite element modelling to study lumbar spine biomechanics for clinical assessment. Bibliographic studies reported in the first Chapter showed clear functional relations between external forces and lumbar spine tissue structures and shapes. Clinical research revealed that independently of its origin, low back pain may be worsened by altered tissue mechanical environments. Experimental measurements alone cannot truly describe the load distributions between the different lumbar spine tissues. Thus, finite element models have been used in the past. But model reliability in predicting local tissue loadings is still not manifest and has been explored in this thesis as described in the following chapters.In Chapter 2, a L3-L5 lumbar spine bi-segment model was built. An initial model was completed to include the vertebral cortex, a full definition of the facet joints, the cartilage endplates, and an improved description of the annulus fibre-reinforced structure. Simplified load-cases used for in vitro studies were simulated to calculate stress and strain energy distributions. Predictions within the L3-L5 lumbar spine bi-segment model could be interpreted in terms of functional load distributions related to known tissue structures, but the overall L3-L5 bisegment model geometry needed further update.Thus, in Chapter 3, a geometrically accurate L3-L5 lumbar spine bi-segment model was created. The new model included corrected L3 and L5 body shapes and dimensions, corrected disc heights and nucleus placements, corrected posterior bone shapes, dimensions, and orientations, and corrected ligament distributions. The new and old geometries were biomechanically compared. Results showed that the relative roles of modelled tissues greatly depend on the geometry. Predicted load distributions were generally more physiological in the new model. However, new and old models could both reproduce experimental ranges of motion, meaning that their validation should take into account local load transfers.Chapter 4 focuses on the variability of the annulus collagen criss-cross angles. Four bi-segment models with literature-based annulus fibre organizations were created and compared under diverse loads. Moreover, an annulus stabilization parameter was proposed by analogy to a thick walled pipe. Model biomechanics greatly depended on the annulus fibre organization, but annulus stabilization parameter was often contradictory with the predicted stresses and strains. Spine geometry and annulus fibrous organization were hypothesized to be linked together. Adapted annulus collagen networks may be numerically determined, but annulus modelling should be based on mechano-biological relationships.In Chapter 5, a case-study of a novel artificial disc design coupled with the L3-L5 lumbar spine model is presented. Bi-segment models with and without implant were compared under load- or displacement-controlled rotations, with or without body-weight like load. Prosthesis stiffness generally altered the load distributions and displacement-controlled rotations led to strong adjacent level effects. Including body weight-like loads seemed to give more realistic results. Although the novel disc substitute is too stiff, it is more promising than other existing commercial devices.In this thesis, six new osteoligamentous lumbar spine bi-segment finite element models were created. Simulations showed that reliable use of lumbar spine finite element models requires precise descriptions of local tissue loading and response. Local predictions were qualitatively mainly limited by a lack of knowledge about soft tissue structural organisations, constitutive equations, and boundary conditions. However, models can be used as in silico laboratories to overcome such limitations. A hierarchical procedure for the development of qualitatively reliable lumbar spine finite element models was proposed based on available numerical and experimental inputs.

Made available in DSpace on 2014-06-11T19:27:14Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-02-05Bitstream added on 2014-06-13T20:55:57Z : No. of bitstreams: 1 alegre_dm_me_ilha.pdf: 954109 bytes, checksum: 3e5701b2e8747b004da37b4ca12ca513 (MD5) / Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP) / O presente trabalho apresenta a metodologia dos observadores de estado para a detecção e localização de falhas em sistemas contendo elementos finitos de placas de Kirchoff. Tal metodologia consiste na montagem de um banco de observadores de estado, o qual é capaz de detectar falhas presentes no sistema, além de localizar o componente danificado e a porcentagem de falha. As matrizes de ganho dos observadores de estado foram determinadas por dois métodos distintos: o método Regulador Quadrático Linear e das Desigualdades Matriciais Lineares. Nesse trabalho, foi utilizada uma placa plana fina montada sobre um sistema de suspensão similar ao de uma plataforma veicular, representando um veiculo simplificadamente. A modelagem da plataforma utilizada foi realizada mediante a utilização do método dos elementos finitos, considerando-se diferentes números de elemento no modelo. O tipo do elemento finito utilizado foi o elemento de placa de Kirchoff. Adicionalmente foi analisada a influência de elementos de controle junto à suspensão da plataforma no movimento da mesma. O modelo considerado, juntamente com os programas computacionais desenvolvidos, foram utilizados para a simulação do movimento da plataforma. Na literatura, normalmente são apresentadas simulações para o movimento de apenas ¼ do veículo, neste trabalho, no entanto, os programas desenvolvidos podem simular o movimento do veiculo inteiro. Foram realizadas simulações computacionais para o movimento da plataforma com a finalidade de se detectar e localizar falhas introduzidas nos elementos da suspensão e também foram realizados testes experimentais, com os mesmos fins. Mediante tais testes (teóricos e experimentais) verificou-se a eficácia da metodologia desenvolvida e a sua principal limitação: o número de elementos finitos considerado no modelo relacionado com o número de medidas efetuadas e a observabilidade do sistema. / This work presents the state observers methodology for the detection and location of faults in systems containing finite elements of plate of Kirchoff. This methodology consists in the assembly of a bank of state observers, which is capable of detecting faults in the system, and also to locate the damaged component and the percentage of failure. The gain matrices of the state observers were determined by two different methods, these are the method Linear Quadratic Regulator and the Linear Matrix Inequalities. In this work was considered a thin plate mounted on a suspension system that is similar to a vehicle platform, representing a vehicle in a simplified way. The modeling of the platform used was performed by using the finite element method, considering different numbers of element in the model. The finite element used was the Kirchoff’s plate element. It was also studied the influence of elements of control, together with the suspension of the platform, into its movement. The model considered, together with the developed computational programs, were used to simulate the movement of the platform. In the literature, usually are presented simulations for the movement of only ¼ of the vehicle, in this work, the developed programs can simulate the movement of the entire vehicle. It was realized computational simulations for the movement of the platform in order to detect and locate faults introduced in the elements of the suspension and experimental tests were also conducted with the same purpose. Through such tests (theoretical and experimental) it was verified the effectiveness of the developed methodology and its major limitation: the number of finite elements considered in the model related with the number of outputs and the observability of the system.