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This thesis contains the results of Phase-1 of a project funded by Ford Motor Company. The objective is to study the feasibility of Acousto-Ultrasonics (AU) as a nondestructive technique for assuring the quality of adhesively bonded sheet-metal used for automobiles. Other nondestructive (NDT) techniques were also applied viz., ultrasonics. radiography and thermography to supplement and verify the results of the AU technique. The AU Technique demonstrated the best results in terms of its sensitivity to the variations in the properties of the interface. Regions having kissing bonds or regions lacking adhesive were easily identified by this technique. These regions contribute to the mixed mode failure. A bond quality (BQ) model is suggested to take into account the mixed mode failure. Destructive testing results show fairly consistent correlation of BQ values with the breaking strength of the adhesive joint failing in mixed mode failure. The BQ values were calculated from the SWF (stress wave factor) values generated by the AU technique. No correlation was observed between the SWF values and the breaking strengths of the bonds failing cohesively. Cohesive failures occur at higher loads than those for mixed mode failures. These are, of course, governed by the maximum possible strength of a joint. More work needs to be done to develop a better way to analyze signals for differentiating total cohesive failure, at least for academic interest. The results strongly suggest the potential of this technique for quantitative evaluation of such types of bonding. Automation of this technique can be developed for application on the assembly line of the motor-car industry. Future work to make this technique more efficient and sensitive is suggested. / Master of Science

Produktkoncept för en dubbelhaspel för plåt – För effektivisering inom stålindustrin vid hantering av plåt, är ett projekt som genomförts på Karlstads universitet i samarbete med Camatec Industriteknik AB och är ett examensarbete i högskoleingenjörsutbildningen ’Innovationsteknik och Design’. Projektet handlar om att ta fram ett produktkoncept för en dubbelhaspel. Camatec Industriteknik AB är ett konsultföretag och arbetar i en nära relation med företaget Camcoil Systems AB. Camcoil Systems AB tillverkar idag enkelhasplar, maskiner som används inom stålindustrin vid hantering av tunn plåt, bandplåt. Camcoil Systems AB har uttryckt en önskan att på sikt även tillverka dubbelhasplar. Genom detta projekt läggs en grund för Camcoil Systems AB att ta vid och vidareutveckla det framtagna konceptet. För att ta fram ett hållbart produktkoncept har fyra huvudkategorier undersökts; marknad, teknik, design samt budget. Säkerhet är en kategori som också tas hänsyn till i projektet. I projekt tillämpas designprocessen för att nå målet. En förstudie ligger till grund för hela projektet, där de fyra nämnda huvudkategorierna samt vetenskapliga teorier vad gäller perception, färglära, produktutveckling samt gestaltningslagar behandlas. Det framtagna konceptet består av enkla former uttryckt i runda former där dess utseende och funktion går hand i hand och på så sätt förstärker varandra. Konceptet besitter samtidigt en hållbar teknik och en god säkerhet som ryms inom Camcoil Systems AB’s kostnadsram. Med det framtagna konceptet skapas ett hållbart underlag och möjliggör en vidareutveckling för Camcoil Systems AB att på sikt vara en potentiell aktör på marknaden vad gäller dubbelhasplar. / Product concept for a double-reel for sheet metal – For a more effective process in steel-industry in handling sheet metal, is a project as implemented at Karlstad university in cooperation with Camatec Industriteknik AB and is an examination of the engineering education ’Innovationsteknik och Design’. The project is about to develop a product concept for a double-reel. Camatec Industriteknik AB is a consulting company and works in a close relationship with the company Camcoil Systems AB. Camcoil Systems AB manufactures single-reel’s, machines as used in the steel industry in handling thin sheet, strip steel. Camcoil Systems AB has expressed the desire to in the future be a double-reel manufacture. By this project Camcoil Systems AB wants to build a base to develop the produced concept. In order to develop a sustainable product concept there are four major categories in this project which are investigated; Market, technology, design and budget. Security is something that is also taken into consideration in the project. The design-process is applied in order to achieve the goal. A feasibility study is the basis for the entire project, where all these four main categories, scientific theories regarding to perception, colour theory, product development and design laws are treated. The produced concept is built upon a clean design in which the functions and the design are synchronized towards each other. In that way, they reinforce each other. There are also a sustainable technology and a good security. At the same time the costs are not too high. With the produced concept, there is a foundation which enables a further development for Camcoil Systems AB to be a potential entrant for the market in producing double-reels.

Die Entwicklung von verzweigten Blechstrukturen, die mit Hilfe der innovativen Verfahren Spaltprofilieren und Spaltbiegen hergestellt werden, erfordert eine Erweiterung des verwendeten Produktentwicklungsansatzes. Im Sonderforschungsbereich 666 wurde dafür der Algorithmen-basierte Produktentwicklungsprozess eingeführt. Im Unterschied zu etablierten Produktentwicklungsprozessen, werden mathematische Optimierungsalgorithmen mit Randbedingungen aus den formalisierten Anforderungen wie Bauraumrestriktionen oder Lasten verwendet, um optimierte verzweigte Blechstrukturen zu entwickeln. Da in der mathematischen Optimierung nicht alle Informationen aus der Fertigung berücksichtigt werden können, müssen die optimierten verzweigten Blechstrukturen fertigungsgerecht optimiert werden. Dazu wird in diesem Beitrag zunächst ein Fertigungsrestriktionsmodell eingeführt. Basierend auf den gewonnen Erkenntnissen aus dem Modell wird dann ein Ansatz zur teilautomatisierten fertigungsorientierten Optimierung von verzweigten Blechstrukturen eingeführt und anhand eines Beispiels validiert.

A research report submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in partial fulfilment of the requirements for the degree of Master of Science in Engineering. Date: September 2017, Johannesburg / The focus in this research investigation is to investigate the Process Parameter Optimisation in Laser Beam Forming (LBF) process using the 4.4 kW Nd: YAG laser system – Rofin DY 044 to form 200 x 50 x 3 mm3 mild steel - AISI 1008 samples. The laser power P, beam diameter B, scan velocity V, number of scans N, and cooling flow C were the five input parameters of interest in the investigation because of their influence in the final formed product. Taguchi Design of Experiment (DoE) was used for the selection and combination of input parameters for LBF process. The investigation was done experimentally and computationally. Laser Beam Forming (LBF) input parameters were categorised to three different levels, low (L), medium (M), and high (H) laser forming (LBF) parameters to evaluate parameters that yield maximum bending and better surface finish/quality. The conclusion drawn from LBF process is that samples which are LBFormed using low parameter settings had unnoticeable bending and good material surface finishing. On the other hand, samples LBFormed using medium parameters yielded visible bending and non-smooth surface finishing, while samples processed using high LBF parameters yielded maximum bending and more surface roughness than the other two process parameters. / MT2018