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Risultati finali
The results consist of methods to accomplish Life Cycle Assessment of the innovative technologies and products (and the materials used there in) in order to assess the environmental impacts of the new ultra light machine tools.
The Life Cycle Assessment studies will be carried out following internationally recognised standards as expressed by the ISO 14.040 series, which dictates the guidelines for the main phases of an LCA in the following way:
- ISO 14.040 - Life Cycle Assessment: Principles and Guidelines;
- ISO 14.041 - LCA: Life Cycle Inventory Analysis;
- ISO 14.040 - LCA: Impact Assessment;
- ISO 14.040 - LCA: Interpretation.
After defining the goal and scope of the study, the system boundaries and the functional unit, an inventory of data regarding the possible and estimated inputs (energy consumption) and outputs (emissions to air, water, waste produced) in the innovative production processes will be done.
The collected data will then be translated into specified impact categories, as recognised by SETAC:
- Global warming;
- Acidification;
- Eutrophication;
- Photochemical smog;
- Stratospheric ozone depletion.
A final interpretation of the results will then be possible.
The specifications and a description of the approach have been provided.
Relating to the impact assessment an analysis on energy saving aspect has been also carried out for the three ultra-light machine demonstrators.
New methodology based on CAD 3D and FE techniques, which allow fast and reliable mass optimisation procedures in order to reduce TTM and virtually predict the performances of new designed product.
The results consist of advanced methodologies suitable to simulate structural behaviour of innovative materials like honeycomb sandwich structure and composites in order to perform reliable and efficient FEM analysis and design optimisation.
The solutions of mass-reduction problem in the field of machine tools design involves an iterative process in which specific design variables are altered with the aim of minimising weigh criteria in the most effective manner while at the same time taking due account other important conditions like:
- Maximise global static and dynamic stiffness of the machine;
- Maximise damping effect;
- Increase first natural frequency of the structure.
An improvement of the computer based support of the machine design process can be achieved via automation of the iterative design procedures for that problem category. A suitable means of achieving this involves the combined deployment of FE (Finite Element) optimisation processes and methodologies, which enables selected product characteristic (lightness) to be improved through optimal use of innovative material (Size, Shape, topology optimisation). Therefore this method can help the designer to develop optimal structures at a very early stage in the design process. This avoids time consuming and expensive design loops.
Beyond this, the development of FE model able to simulate structural anisotropy effects and damping property related this advanced materials are of fundamental importance to perform in a reliable and efficient manner the above mentioned analysis.
Therefore the achieved results include:
- Analysis of structural and damping property of innovative materials; theoretical analysis regarding static, dynamic and thermal behaviour of innovative light material has been carried out. This analysis will allow to evaluate different effect related to anisotropy, non-linearity and damping properties (viscous, structural,..) which can influences the final results of FEA. This in turn means to determine which material parameters and in which way they have to be considered to prepare the FE model of the structure (in order to make a reliable and time efficient the analysis).
- FE mathematical model for innovative material structural simulation; on the basis of above theoretical analysis, FE model (typology of Element, geometry, boundary conditions, FE material parameters, joint aspects) that better represent the physical behaviour of the different kind of material used to design ultra-light structures have be defined. These models, using commercial FE solvers, are suitable to perform static, dynamic (modal, FRF) and thermal analysis innovative structures.
- FE optimisation methodology for mass reduction: a methodologies based on automatic FE optimisation loop to address mass-reduction problem in the field of machine tools design have been provided. This methods includes automated calculation procedures (size, shape and topology) in which specific design variables are altered with the aim of minimising weigh criteria in the most effective manner while at the same time taking due account other important conditions like: maximise global static and dynamic stiffness of the machine; increase first natural frequency of the structure.
- Testing procedures: experimental testing procedures to characterise composite material from static and dynamic point of view have been provided together with test results on specimen and representative sample of machine tool parts.
The proposed methodologies have developed and validated in different FEM-environment in order to get the maximum benefits for each partners).
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