The primary concern of this work is real-time fluid simulation on modern programmable graphics hardware. It starts by introducing fundamental fluid simulation principles with focus on Smoothed particle hydrodynamics technique. The following discussion then provides a brief introduction to OpenCL as well as contemporary GPU hardware and outlines their programming specifics in comparison with CPUs. Finally, the last two chapters of this work, detail the problem analysis and its implementation.

Microsieves are permeable membranes with excellent properties for filtration applications. In this thesis the inkjet-technology is applied (1) to manufacture micro-porous microsieves, and (2) to reinforce the mechanical stability of float-cast, nano-porous microsieves: (1) The current process for inkjet-printed microsieves includes a manual step which is substituted by inkjet printing in order to increase the level of automation. The obtained microsieves are characterized regarding the pore size distribution. Effects which occur during the manufacture and broaden the pore size distribution are identified. Based on the results, the process is improved to obtain fully inkjet-printed microsieves with a narrowed pore size distribution. (2) The mechanical stability of fragile, float-cast microsieves is improved by the application of inkjet-printed reinforcement patterns on top of the microsieves. A machine is built to combine both technologies of float-casting and inkjet printing. The printing process is improved to manufacture reinforcement patterns of well-defined geometry. / Mikrosiebe sind permeable Membranen mit herausragenden Eigenschaften für die Anwendung in der Filtration. In der vorliegenden Dissertation wird die Inkjet-Drucktechnologie angewandt, um (1) mikroporöse Mikrosiebe herzustellen und (2) nanoporöse Mikrosiebe mechanisch zu stabilisieren: (1) Die Herstellung von Mikrosieben mittels Inkjet-Druck beinhaltet momentan einen manuellen Schritt, der durch einen Inkjet-Druckschritt ersetzt wird, um den Automatisierungsgrad des Verfahrens zu erhöhen. Die Mikrosiebe werden bezüglich der Porengrößenverteilung untersucht. Auftretende Effekte, die die Porengrößenverteilung verbreitern, werden identifiziert. Aus den Resultaten dieser Analyse wird der Prozess optimiert, um Mikrosiebe mit einer engen Porengrößenverteilung herzustellen. (2) Die mechanische Stabilität von fragilen Mikrosieben, die mittels Float-Casting hergestellt werden, wird durch das Aufbringen einer Stützstruktur mittels Inkjet-Druck verstärkt. Ein Maschinensetup wird aufgebaut um beide Technologien des Float-Castings und des Inkjet-Drucks zu kombinieren. Weiterhin wird der Prozess dahingehend optimiert, Stützstrukturen mit wohl-definierten Parametern zu erzielen.

Hardening distortions are unwanted changes in shape and dimension that arise during hardening of steel components. Uncontrolled distortions induce random errors to the manufacturing process, and have a strong negative impact on manufacturing costs. The distortions are not only caused by the hardening process, several factors from previous manufacturing steps including the component geometry itself contribute to varying extent. The aim of the current work is to investigate the main influencing factors on hardening distortions for serial produced gears. The investigations were done on two different types of gears for heavy-duty transmissions, crown wheels for the rear axle central gear and main shaft gears for the gearbox. The steel was produced using either continuous casting or ingot casting. For rectangular continuously cast steel, the effect of disabling magnetic stirring of the steel melt during casting was investigated, finding a strong reduction of gear runout for crown wheels. Segregations in crown wheels produced from the top and bottom of ingots were shown to go in opposite directions, producing opposite back-face tilts. For crown wheels quenched one at a time, influences of stacking level on the hardening tray were found, indicating an impact from small variations in the carburizing process, despite identical quenching conditions. For main shaft gears, horizontal loading gave considerably less roundness and runout errors but increased flatness errors compared to vertical loading. This thesis shows the complexity of the distortion phenomenon and how several factors interact and contribute to the final result. It is shown that factors with significant impact on hardening distortions for one component may be less important for another component. With this in mind, each type of component to be hardened should be produced by a manufacturing chain where each process step is carefully chosen with respect to minimizing distortions. / <p>QC 20170516</p>

The press-section of a paper machine holds several different types of press rolls. One of the many press roll variants is the Valmet produced press roll, ViscoNip. This press roll utilizes an extended nip in order to increase the amount of water removed. The extended press nip in ViscoNip is special since it is controllable by a pressurized polyurethane press shoe. The press shoe runs through the body of the press roll. Due to the limits of the current production process, new manufacturing methods and construction solutions are needed. In cooperation with another thesis, the current design and manufacturing process was reviewed and a plan intended to improve the current solution was formulated. The plan was to, by working together in a project, perform a product development process intended to create concepts able to utilize new methods of manufacturing. By using established methods of concept generation, such as Brainwriting 6-3-5, 11 concepts were created. Some of these concepts involved a redesign of the press shoe, leading to a need for construction and performance analysis. The other thesis focusing on the structural and mechanical performance evaluation of the new concepts. The work of this thesis focusing on researching new possible and available manufacturing solutions. The new concepts were analyzed with new and possible manufacturing methods to fulfill all the requirements. With all data, a document was created and market research was made to get feedback from more knowledgeable in the subject. Moreover, sequence analysis between the concepts with the current and those new manufacturing methods was made to further explain which manufacturing method that could solve the main problem. All in all, one different redesigned concept was deemed as having potential for further development. The current solution was also deemed as having potential for future development but only when new manufacturing methods or techniques were considered.

No description available.

Published Article / In this paper the time and cost parameters of tooling manufacturing by metal casting in rapid prototyping sand moulds are assessed and comparison is made with alternative tool making processes such as computer numerical control machining and investment casting (Paris Process). To that end two case studies obtained from local companies were carried out. The tool manufacturing was conducted according to a five steps process chain referred to as Rapid Casting for Tooling (RCT). These steps include CAD modelling, casting simulation, rapid prototyping, metal casting and finishing operations. In particular the Rapid Prototyping (RP) step for producing the sand moulds was achieved with the aid of an EOSINT S 550 Laser Sintering machine and a Spectrum 510 Three Dimensional Printer. The results indicate that RP is the rate determining step and cost driver of the proposed tooling manufacturing technique. In addition it was found that this tool making process is faster but more expensive than machining and investment casting.

Published Article / The quality of spin casting products and mould life are critically dependent on thermal conditions they undergo. In order to improve the performance of production and to optimise the spin-casting process, characteristics of the thermal process was firstly identified by means of the measurement and simulation. Furthermore the investigation of the developed control methods, including the thermal property substitute method and mixture method of the metal powder, was kept on the effect of air-cooling induced automatically from the spinning of the mould on the thermal process. <br>The air cooling system was developed to optimise the thermal process during casting, utilising a theoretical analysis of the air-flow characteristics in a cooling tube submerged in a silicon mould and the characteristics of convection heat transfer associated with the mould and cast part. A numerical simulation of the casting process was also adopted in the analysis. The effect of the developed system on the thermal process was determined experimentally and it was found that a system of aircooling, automatically induced from the spinning of the mould, is feasible in optimisation of the thermal process. <br>The developed control methods can be applied to the practice of spin casting individually or collectively according to the specific situations and requirements.

Published Article / Global issues such as energy and climate changes have impacted on both the automotive and aerospace industries, forcing them to adopt measures to produce products that consume fewer combustibles and emit less carbon dioxide. Making vehicles lighter is one of the logical ways of reducing fuel consumption. The need for light components, able to fulfil technical and quality specifications, led to market growth for tooling that is able to mass produce parts using manufacturing processes such as high pressure die casting. Competitive pressures to reduce the lead time required for tooling-up has also increased dramatically. For this reason research into various methods, techniques and approaches to tool manufacture is being undertaken globally. This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die for the production of aluminium components. Criteria for determining suitability were developed against which the technique was evaluated that included time, cost and life-expectancy. Results of accelerated testing procedures to evaluate the die material produced by the rapid prototyping technique and surface coatings and treatments of die materials for their resistance to washout, erosion, heat checking and corrosion in a high pressure die casting environment, are presented. The outcomes of this research will be used for further development and application of specific techniques, design principles and criteria for this approach.

Published Article / The design, manufacture and use of diaphragm valves in the minerals industry is becoming increasingly important since this sector is restricted from using excessive amounts of water for their operations. This forces a change in the flow properties of these devices from turbulent to laminar in nature and thus necessitates the characterization of these flows for future designs. Furthermore, diaphragm valves have a short service life due to a variety of reasons that includes the abrasive nature of the flow environment. This paper describes the activities of the Adaptronics Advanced Manufacturing Technology Laboratory (AMTL) at the Cape Peninsula University of Technology in the research and development of diaphragm valves using rapid prototyping technologies. As a first step, an experimental diaphragm valve was reverse engineered and retrofitted with ultrasonic transducers used in Ultrasonic Velocity Profiling (UVP) measurements. The use of this device enables measurements of velocity profiles to gain insight into the flow structure within the valve and the increased pressure losses generated within the valve. It also showed that components fabricated using the Z-Corporation machine could withstand the working environment of diaphragm valves. Research is now conducted on ultrasonic transducer placement in the device to further enhance the velocity profiling through the device. As a second step we produced a thin-walled stainless steel diaphragm valve using rapid prototyping technology and investment casting processes. A study of the durability of this device will be conducted and certain geometric and manufacturing aspects of this valve will be discussed.

Epoxide hydrolase I from Solanum tuberosum (StEH1) and isolated variants thereof has been studied for mapping structure-function relationships with the ultimate goal of being able to in silico predict modifications needed for a certain activity or selectivity. To solve this, directed evoultion using CASTing and an ISM approach was applied to improve selectivity towards either of the enantiomeric product diols from (2,3-epoxypropyl)benzene (1). A set of variants showing a range of activites and selectivities was isolated and characterized to show that both enantio- and regioselectivity was changed thus the enrichment in product purity was not solely due to kinetic resolution but also enantioconvergence. Chosen library residues do also influence selectivity and activity for other structurally similar epoxides styrene oxide (2), trans-2-methyl styrene oxide (3) and trans-stilbene oxide (5), despite these not being selected for.    The isolated hits were used to study varying selectivity and activity with different epoxides. The complex kinetic behaviour observed was combined with X-ray crystallization and QM/MM studies, powerful tools in trying to explain structure-function relationships. Crystal structures were solved for all isolated variants adding accuracy to the EVB calculations and the theoretical models did successfully reproduce experimental data for activities and selectivities in most cases for 2 and 5.  Major findings from calculations were that regioselectivity is not always determined in the alkylation step and for smaller and more flexible epoxides additional binding modes are possible, complicating predictions and the reaction scheme further. Involved residues for the catalytic mechanism were confirmed and a highly conserved histidine was found to have major influence on activity thus suggesting an expansion of the catalytic triad to also include H104. Docking of 1 into the active site of the solved crystal structures was performed in an attempt to rationalize regioselectivity from binding. This was indeed successful and an additional binding mode was identified, involving F33 and F189, both residues targeted for engineering. For biocatalytic purpose the enzyme were was successfully immobilized on alumina oxide membranes to function in a two-step biocatalytic reaction with immobilized alcoholdehydrogenase A from Rhodococcus ruber, producing 2-hydroxyacetophenone from racemic 2.