Synopsis:
We require analytical or numerical relationships for prediction of strength and fatigue properties of the thermoplastic pultruded structural elements obtained by experimental and simulation study.
A Masters student will work towards design of testing specimens, development of mechanical test plans and static/fatigue testing. The design of the specimens will be evaluated using Finite Element Analysis (FEA). The obtained analytical or numerical relationships will be applied to damage initiation and failure simulation of the specimens by FEA under static and fatigue loading.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1-2
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Ivan Sergeichev, senior research scientist
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
Thermoplastic structural elements have a broad application in aerospace and infrastructural industries. Nowadays there are many well-developed technologies of thermoplastic welding, but at the same time, there is gap in applied researches of process simulation and static and fatigue strength of the joints.
Synopsis:
We require finite element models for process simulation of welding joints of thermoplastic structural elements and prediction of strength and fatigue properties of the joints obtained by experimental and simulation study.
A Masters student will work towards the process simulation of welding joints of thermoplastic structural elements, design of testing specimens, development of mechanical test plans and static/fatigue testing. The design of the coupons and sub-component specimens will be evaluated using Finite Element Analysis (FEA). The obtained simulation and testing results will be applied for the development of the two-stage predictable FEA models of the joints that include the state of the joints after the process simulation, as the first stage, and damage initiation and failure analysis under static and fatigue loading as the second stage.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1-2
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Project Co-advisor:
Ivan Sergeichev, senior research scientist
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
The Ongoing Project
Background:
Today, polymer composite components of complex shapes are widely used in aerospace, construction and other industries. Examples of such components include structural elements of composite bridge structures (beams, bridge decking, girders), elements of power line supporting structures of GFRP, elements of aircraft structures, etc. Being rather expensive compared to structures made of traditional structural materials such as wood, concrete and metals, polymer composite structures can nevertheless successfully compete with their traditional counterparts in many applications, especially where the weight or corrosion resistance of a structure is a decisive factor. However, they also have to remain cost effective. One way of achieving this goal is the use of large integral structures with low production costs. This approach is feasible and is utilized in various industries, however it requires a good control of process-induced deformations as they may result in deviations of finished item dimensions, exceeding specified limits, and, consequently, in problems with fitting of components of complex structures during assembly. The task of producing items with a specified shape is usually solved experimentally (by trial-and-error method) through variation of process parameters. Such iterative procedure can be quite expensive, labor-intensive, and ineffective, especially in case of large components fabrication, thus making the task of developing mathematical models to predict process-induced residual stresses and deformations in composite structures an urgent problem.
One of the most efficient methods to produce structural profiles of polymer composite materials is a pultrusion process. Pultrusion, in principle, is a process, where a continuous reinforcement (fiber roving and tapes) is pulled through an impregnation bath containing thermoset resin and then fed into a heated forming die determining the geometry of pultruded profile cross section, where resin cure takes place.
Сonsequently, the development of mathematical methods of predicting process-induced deformations in pultrusion is important for mass implementation of composite materials in construction.
Synopsis:
The objective of the project is to develop a virtual process chain for the pultrusion process, which takes into account all the physical phenomena, leading to the emergence of strains and stresses, such as the dependence of matrix thermomechanical characteristics on temperature and degree of polymerization, the anisotropy of properties of composite material, the rate of chemical reaction of thermoset matrix polymerization, and thermal and mechanical contact with a die. The developed simulation methods will describe a temperature field distribution, a degree of curing and a stress-strain state in pultrusion profile during production. The developed model will be verified by experiments.
Potential Impact: Aerospace and infrastructural industries; implementation of advanced composites
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Co-supervisor:
Dr. Alexander Safonov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
Fused Deposition Modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. It is one of the techniques used for 3D printing. FDM works on an “additive” principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. Today, this technology has been actively used for the manufacturing of loaded structures. However, it is connected with the problem of justifying the strength of the FDM structures. This task is complicated by the fact that using this technology for the structures with complex shape obtained by topological optimization methods. Therefore, the production of test samples for these structures is extremely challenging. Also the FDM material is formed gradually by the method of layering. Therefore, the development of effective methods for prediction of properties of materials and constructions must be made based on methods of mathematical simulation of technological process parameters, and prediction of the mechanical properties.
Synopsis:
The purpose of this study is to develop methods for numerical prediction and experimental validation of properties of structures produced by Fused Deposition Modeling (FDM). The mathematical models of material behavior will be implemented within the ABAQUS environment, accounting for the dependence of resin thermomechanical characteristics on temperature and degree of crystallinity, the rate of chemical reaction, and thermal and mechanical contact with a mold. The developed simulation methods will describe a temperature field distribution, a degree of crystallinity, a residual stress-strain state, prediction of mechanical properties of material in FDM structures. The simulation results will be validated on 3D printers of the CDM2 center . The developed methods will be important from the scientific and practical points of view, since they allow to virtual justify the strength of structures produced by this technology.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Co-supervisor:
Dr. Alexander Safonov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
One of the important tasks for the successful implementation of composite materials in civil infrastructure is the study of the mechanical properties of materials after fabrication and repeatability. It is necessary to reduce the time and number of tests during implementation of new types of resin and reinforcing materials. Effectively this can be achieved by developing methods to predict properties of composite based on the methods of modelling the formation of the material during the manufacturing process. One of the most efficient methods to produce structural profiles of polymer composite materials is a pultrusion process. Pultrusion, in principle, is a process, where a continuous reinforcement (fiber roving and tapes) is pulled through an impregnation bath containing thermoset resin and then fed into a heated forming die determining the geometry of pultruded profile cross section, where resin cure takes place. Сonsequently, the development of mathematical methods of prediction and parametric study of properties of composite materials produced by pultrusion process is important for mass implementation of composite materials in construction.
Synopsis:
The purpose of this study is to develop methods for numerical prediction of properties of composite materials produced by pultrusion process. The mathematical models of material behavior will be implemented within the ABAQUS environment, accounting for the dependence of resin thermomechanical characteristics on temperature and degree of polymerization, the rate of chemical reaction of thermoset matrix polymerization, and thermal and mechanical contact with a die. Modeling methods developed describe a temperature field distribution, a degree of curing and a stress-strain state during pultrusion process. For parametric study the special simulation scheme will be developed using pSeven software suite. pSeven is a platform for automation of engineering simulation and analysis tasks, multidisciplinary optimization and data mining. The simulation results will be validated on experimental pultrusion machine of the center CDM2. The developed methods will be important from scientific and practical point of view since they allow to virtual justify of the strength of composite materials in construction.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Co-supervisor:
Dr. Alexander Safonov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
Thermoplastic composites are getting popularity in modern industry. This type of composites have a special phase transition into soft state due to high temperatures. This effect is used for forming of complex geometry details with high strength properties. This technique is generally used in automotive industry and taking its first steps in aerospace area. Problems of implementation of thermoplastic composites in safe and light structures are in the lack of reliable models of mechanical behavior of neat thermoplastic material, especially at high temperatures and different degree of crystallinity. High temperatures and variations of crystallinity in composites have essential value during cool down process after and during forming. Their influence realizes reduction of strength properties, which can consequently cause matrix failure or defect nucleation.
Synopsis:
We require special mathematical models for explanation of thermoplastic material behavior with strong dependence on degree of crystallinity and high temperatures. New material models will be implemented into FEM Abaqus software to model cells of periodicity to estimate failure of composite material at different combination of temperature and crystallinity parameters.
A Masters student will work on periodic cells of composite material at micro level. Failure analysis is going to be realized in parametric way to obtain failure envelope for temperature and crystallinity of the material. All analysis will be performed numerically in Abaqus FEM software.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1-2
Project Advisor:
Dr. Andrey Ushakov
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
Test project to use the industrial robot to play air hockey game. The KUKA robot will use machine vision system for detecting the position of the puck on the table. Then robot will move accordingly to protect its goal.
Synopsis:
In this project a Master student will work with an industrial robot KUKA. The system of computer vision will be created in the integrated development environment MS Visual Studio using C#(C/C++) language. Programming inside the robot will be implemented using a standard programming language of the robot. Communication between the robot, sensors and computer (with vision system program) will be implemented by a PROFINET LINE.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion will obtain the following knowledge and expertise:
Number of Students: 1-2
Starting Date: Fall 2016
Background:
Such systems are used in pharmaceutical manufacturing. The system is installed on conveyer and sorts pills by size and color. The robot picks up the pills and places them in the blister.
Synopsis:
In this project a Master student will work with an industrial robot FANUC-M1. The system of computer vision will be created in the integrated development environment MS Visual Studio using C#(C/C++) language. Programming inside the robot will be implemented using a standard programming language of the robot. Communication between the robot and computer (with vision system program) will be implemented by a TCP/IP connection.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion will obtain the following knowledge and expertise:
Number of Students: 1-2
Starting Date: Fall 2016
Background:
Manual sorting of waste is ineffective. Robot using vision system will take plastic bottles and aluminum cans from the waste.
Synopsis:
In this project student will need to design and construct a simple 2(3) axis robot (including all the mechanics and electronics components). Robot CPU will be written in C/C++. Eventually, the robot will be placed on the conveyor and tested.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion will obtain the following knowledge and expertise:
Number of Students: 1-2
Starting Date: Fall 2016
Background:
Currently fracture fixation follows technology that’s decades old. The three main categories include external fixation, plates and screw fixation, and intramedullary nailing. For the majority of pre-articular fractures, plates and screws are the method of choice. However, this can become cumbersome with comminuted and unstable fracture patterns. Furthermore, decreased bone density of certain patient’s makes application of screws a difficult task. This Masters project will attempt to solve the fracture complexity and bone density problems while maintaining or improving overall fracture healing.
Synopsis:
A Masters student will work towards design and manufacturing of the new fixation design for fractured and shattered bones. The concept is application of dual layered plates. The first layer includes a small disc with metal pegs protruding from it. The second layer is a full plate with pegs on the undersurface that “locks” into the first layer and all of its components.
The project requires an advanced material selection followed by design of mechanical components. Materials and mechanical testing and Finite Element Analysis (FEA) will be used to evaluate the performance of the new design using available equipment and software at Skoltech. This project will need collaboration between Skoltech and a Health research center in Russia to examine possibility of using this new design on real cases.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1-2
Starting Date: Fall 2016
Background:
The electrochemical corrosion measurements at elevated temperatures (≥ 300 ºC) is a challenging job due to the losing stability in hydrothermal environments, and the very low concentrations of ionic species to measure corrosion rate. Generally, in metals such as steel and aluminum, the actual corrosion propagation will drastically reduces after formation of protective oxide layer. The corrosion rate can be as low as few microns per year. Corrosion measurement at high temperature using traditional techniques such as mass loss measurement will require a substantial experimental time. To this end, an electrochemical technique which is capable of in-situ measurement of the instantaneous corrosion rate at high temperature condition is required.
Synopsis:
We require a new experimental electrochemical system for measuring corrosion rates in elevated temperature electrolyte solutions. The newly designed electrochemical system will be a lab scale system, but it should be capable of in-situ corrosion measurements. The ideal system must be flexible to perform testing at different temperatures and pressures.
A Masters student will work towards design and development of a lab scale high temperature corrosion testing apparatus. The testing device will be analyzed, and its performance and accuracy will be evaluated using available Finite Element Analysis (FEA) to simulate corrosion formation at elevated temperatures.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
1- Materials science.
2- Comprehensive knowledge of different corrosion mechanisms in materials.
3- Computer Aided Design (CAD).
4- Design and manufacturing of low pressure chemical systems.
5- Finite Element Analysis (FEA) in the area of thermal science and corrosion.
6- Preparation of technical reports and scientific articles.
Number of Students: 1-2
Starting Date: Fall 2016
Background:
Product Lifecycle Management (PLM) is both a set of sophisticated tools and methodologies aiming to support the complete lifecycle of products and systems from their inception to their end of life. Centered on the product development cycle and particularly detail design, it integrates software tools that support digital product modeling, analysis and manufacturing of complete mechatronics products being developed by very large teams of engineers and staff. Set-based design is a product development methodology that aims to improve the product development cycle by studying multiple options in depth before making a final decision that can integrate a combination of those options.
Synopsis:
The current project aims to develop further set-based design methodologies, data structures and PLM technologies for concurrent design and engineering starting at the concept development stage and encompassing all phases of the product lifecycle.
One or two Master’s students will work to develop a better understanding of set-based design and will test its potential implementation in best in-class PLM systems such as Siemens NX and Team-center. They will also look at the possibility to develop a new type of PLM system better suited to support the complete lifecycle in an Industry 4.0 environment.
Learning Outcome:
Graduate students after accomplishment of this research project and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1-2
Project Advisor:
Dr. Ighor Uzhinsky
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
The impact of suspension drops on substrates is relevant to many technologies, for example, to printed electronics, additive manufacturing, spraying of liquid friction modifiers, and plasma coating technology. These technologies can benefit from a better understanding the influence of solid particles on impact phenomena.
Synopsis:
A Master student will experimentally study the influence of nano- and micro-particles on the drop impact phenomena in a wide range of conditions associated with above-mentioned technologies. The student will carry out the experiments on a set-up developed in Skoltech. The experimental videos will be processed by image-processing tools. Obtained data will be analyzed and new insights into behavior of drop suspensions will be obtained.
Learning Outcome:
Graduate students after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1
Project Advisor: Prof. Iskander Akhatov
Co-advisor: Dr. Viktor Grishaev
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
Practically all bio- and synthetic polymers known today consist of single-stranded, covalent backbones. The indispensable functions of many (for both life, in general, and in the daily life of every human being) result from their chemical structure and how these macromolecules arrange into higher-order structures. For some applications, polymers both as ultrathin film and in bulk are used in a networked form and cease to be considered as single stranded. Because the segments between the netpoints have a length distribution, they cannot be regarded as ordered 2D or 3D structures either. The creation of useable, “infinitely” extended, covalently constructed and structurally defined, periodic 2D polymers has been a dream of chemists for decades and numerous attempts towards this goal have been reported. Though enormous progress has been made, even today only few synthetic polymers are known that meets all the above criteria. The mastering of the very high level of structure control inherently associated with a realization of such a goal can be considered a major driving force for our work in this area. Also, given the structural novelty of periodic 2D polymers, the exploration of their property space is another major motivation.
Synopsis:
We need to synthesize a series of monomers bearing photoreactive substituents to examine their ability of to serve as building blocks for 2D polymers after being spread at the air/water interface.
A Masters student will work towards design and synthesis of monomers for 2D polymerization on a Langmuir trough at the air/water interface.
Learning Outcome:
Graduate student after accomplishment of this research study and successful completion of the Master’s degree will obtain the following knowledge and expertise:
Number of Students: 1
Project Advisor:
Dr. Oleg Lukin
Center for Design, Manufacturing, and Materials (CDMM)
Skoltech
Starting Date: Fall 2016
Background:
The cylinders block of automobile engine undergoes intensive loads during the exploitation. Mainly, this includes significant friction load due to the movement of pistons within cylinder block. First cylinder blocks were made from cast iron due to the good combination of mechanical and functional properties. Due to the need to facilitate the construction of automobile during the last few decades, aluminum alloys were widely implemented. From this point of view, it is interesting to develop wear resistance coatings for aluminum alloys to be used in the automotive industry.
Synopsis:
As was mentioned above, aluminum alloys are characterized by low wear resistance. High entropy alloys, which were developed during the last few decades, show a good combination of mechanical properties (hardness, tensile strength), functional properties (wear resistance) and so on. From this point of view, these alloys, could be promising candidates for manufacturing coatings on aluminum alloys for increasing their wear resistance. As for the methods of coating deposition on the aluminum alloys for automotive industry, different approaches can be used including thermal spraying, magnetron sputtering, laser cladding and so on.
Number of Students: 1-2