Mecc_in_progress

Mecc in progress Department of Mechanical Engineering

Mecc in progress Department of Mechanical Engineering

Preface p. 1 Since 1863... p. 4

History of the Department of Mechanical Engineering p. 6

Historical Roots p. 6

Recent History p. 7 Facts, Figures, Structure and Perspective p. 9

Research Budget p. 10

Staff p. 11

Scientific Production p. 11

Organization & Management p. 12

Prospects p. 13

Research Activities p. 17

Dynamics and Vibration p. 18

Mechatronics and Smart Structures p. 19

Rail Vehicle Dynamics p. 21

Road Vehicle Dynamics p. 23

Rotordynamics p. 25

Wind Engineering p. 27 Machine and Vehicle Design p. 29

Advanced Design of Mechanical Components p. 29

Structural Integrity and Prognostics p. 30

Ground Vehicle Design and Testing p. 32

Manufacturing and Production Systems p. 34 Manufacturing Processes p. 34

Manufacturing Systems and Quality p. 37

Materials p. 39

Advanced Materials p. 40

Applied Metallurgy p. 41

Steel Making and Metallurgical Processes p. 43

Measurements p. 44

New Measurement Techniques p. 44

Vision-based Measurements p. 45

Flow-Structure Interaction p. 46

Structural Monitoring p. 46

Measurements for space p. 46

Contents

The Reconfigurable Testing Facilities p. 83

The Outdoor Testing and Measuring Facilities p. 83

Manufacturing p. 83

MI_crolab - Micro Machining Lab p. 84

SITEC Laboratory for Laser Application p. 85

Water Jet Lab p. 85

Geometrical Metrology Lab p. 86

Manufacturing System Lab p. 87

Numerical Simulation p. 88

Composite Material Parts and Models p. 89

Tests of Mechanical Components p. 90

Diagnostics Lab p. 90

Gear and Power Transmission Lab p. 92

Complex Tests Lab p. 92

Outdoor Testing p. 93

Measuring Devices and Calibration p. 94

Measuring Lab p. 95

3D vision p. 96

VB Lab p. 97 Quality System p. 98

Consortia and Spin-offs p. 101

Consortia p. 102 Italcertifer p. 102

MUSP p. 103

Spin-Offs p. 104

TIVET p. 104

MCM p. 105

ISS – Innovative Security Solutions p. 105

SmartMechanical-Company p. 106

E-Co p. 107

Teaching Activities p. 108

Bachelor p. 110

Master of Science p. 110

Ph.D. Programme on Mechanical Engineering p. 111

Lifelong Learning p. 113

Contacts p. 113

Electro Mechanical Interaction and Renewable Energy p. 47

Acoustic Measurements p. 47

Rehabilitation Measurements p. 47

Whole Body and Hand Arm Vibration p. 47

Methods and Tools for Product Design p. 48

Virtual Prototyping p. 48

Product Design p. 50

Laboratories p. 53

Automotive and Electric/Hybrid Vehicles p. 54

L.A.S.T. p. 54

Vehicle Dynamics Laboratory p. 56

Electric Drives p. 57

CNC Machine Tools and Computer Aided Manufacturing p. 58

Non-destructive Tests p. 59

Mechatronics and Smart Structures Lab p. 61

Mechatronics Lab p. 61

Robotics Lab p. 63

VAL – Vibroacoustics Lab p. 63

Didactic Laboratories p. 64

Cable Dynamics p. 66

Wind Tunnel p. 68

Haptics and Virtual Prototyping p. 69

Virtual Prototyping Lab p. 69

Reverse Engineering Lab p. 70

Process Metallurgy and Materials Analysis p. 71

Microstructural Investigations and Failure Analysis Lab p. 72

Physco-chemical Bulk and Surface Analyses Lab p. 73

Process Metallurgy Lab p. 74

Characterisation of Materials Lab p. 76

Material Testing p. 77

Mechanical Behaviour of Materials Lab p. 77

High Temperature Properties of Materials Lab p. 79

Railway Engineering p. 81

The Test Bench for Pantograph-Catenary Contact p. 81

The Hardware-in-the-Loop Test Stand for Pantographs p. 81

The Secondary Suspension Test Rig p. 81

The Test Rig to Calibrate Instrumented Wheelssets p. 82

The Rotating Bending Fatigue Test Stend for Railway Axles p. 82

Preface

The Politecnico di Milano is a scientific-technological university that trains engineers, architects and

designers. Over 1,200 lecturers and researchers are operative at its Milano-Leonardo, Milano-Bovisa,

Como, Lecco, Cremona, Mantova and Piacenza campuses, attended by 40,000 students.

Since its inception, the Politecnico di Milano has focused on the quality and innovation of its

educational methods and research, developing an ongoing, fruitful relationship with the economic

and productive realities of the country through experimental research and the transfer of technological

know-how. Research, increasingly linked to education, is a priority commitment that allows the

Politecnico di Milano to achieve important results on an international level and to serve as a meeting

point between the university and industries.

One of the most active bodies of the Politecnico di Milano is the Department of Mechanical Engineering.

Since 1951 the Department of Mechanical Engineering has been rated one of the top scientific

institutions both at Italian and European level.

The Department of Mechanical Engineering has about a hundred members of academic staff, forty

members in technical and administrative staff, sixty PhD students, as well as 120 temporary research

staff.

With its state-of-the-art technological infrastructure and

research facilities, broad theoretical, methodological

and technological knowledge, international reputation

and successful alumni, the overall mission of the

Department of Mechanical Engineering is to deliver

world-class research and education in Mechanical

Engineering, with particular regard to their application

in industrial sectors, such as energy, transportation,

sustainable mobility and advanced manufacturing.■ Map of the Politecnico di Milano campuses

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The Department’s research activity includes the areas of: system dynamics, road vehicles, product

design, manufacturing technologies and production systems, measurements and product and

material development methods.

Basic research, applied research and innovation are thus key departmental activities. In fact, a

network consisting of over 250 companies acts as a strategic partner for the development of research.

Competitive research projects, as well as those related to product innovation and services, are

developed, accounting for approximately EUR 7 million per year, of which 70% comes from the private

industrial sector and 30% from public funding (National Ministries and European Community).

The Department believes that the excellence of its laboratories plays a key role in the quality of the

research. The facilities in its laboratories are continuously enhanced through significant investments.

Additionally, spin-off companies of the Politecnico di Milano were created for the technological transfer

of the results of research performed by the Department.

Basic research saw the involvement of the Department prevalently in Europe, with active participation

in various Community programmes in all those border subjects in which the methodologies and

technologies inherent in Mechanical Engineering can and must give their contribution to sectors such

as sustainable mobility, energy efficiency, smart materials and virtualization.

In this context the Department is involved in the provision of teaching programmes for the attainment

of B.Sc, M.Sc and PhD degrees in all sectors of Industrial and Design Engineering.

The words of Karl Fisch:

“We are currently preparing students for jobs that don’t yet exist . . . using technologies that haven’t been invented . . . in order to solve problems that we don’t even know are problems yet.”

sum up the guidelines of the Department whose mission is teaching through the use of educational

projects that combine the necessary methodological skills with suitable in-laboratory preparation.

■ Department of Mechanical Engineering, new facilities

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Over the years the most eminent professors have included the mathematician Francesco Brioschi (first Director), Luigi Cremona and Giulio Natta (Nobel Prize in Chemistry in 1963). Among our most distinguished alumni we can mention Giovan Battista Pirelli, who founder of the Pirelli company, and Giò Ponti, an internationally acclaimed architect.

In Italy, the term “Politecnico” means a state university offering study programmes in Engineering Architecture and Industrial Design. Nowadays, the Politecnico di Milano is organised into 12 Departments and a network of 6 Schools, spread out over 7 campuses in the Lombardy region, with central administration and management. The Schools are devoted to education whereas the Departments are devoted to research.The educational policy of the Politecnico di Milano consists in offering different curricula tailored to suit the needs of the region, considered one of most developed industrial areas in Europe.Overall, approximately 40,000 students are enrolled at the University, thus making the Politecnico di Milano the largest institution in Italy for Engineering, Architecture and Industrial Design.The Politecnico di Milano is now ranked as one of the most outstanding European universities

not only in Engineering, Architecture and Industrial Design but also in many other disciplines and is regarded as a leading research institution worldwide.In recent years, the Politecnico di Milano has also strived to develop numerous projects in collaboration with leading European, American and Asian Universities. Our Institution offers a three-year first-level degree (Bachelor of Science), a two-year second-level degree (Master of Science), a Ph.D. program and various one-year post-degree specialization degrees. All these initiatives are constantly adapted to suit a rapidly changing industrial and scientific scenario, to facilitate technological transfer and to help our graduates feel comfortable in their transition from University to the working world. The Politecnico di Milano works in close cooperation with numerous industrial partners, as we believe that the alliance between academia and industry is not only crucial for research, but also lends credence to our teaching activities.

Our University has always strived for quality and innovation in teaching methodologies, and has done so in close collaboration with both foreign and domestic institutions. In fact, our research activity constantly influences our teaching and it is this very link that has allowed the Politecnico di Milano to achieve top-level scientific results.

The Politecnico di Milano is Italy’s leading university for Engineering, Architecture and Design. Founded in 1863 by a group of scholars and entrepreneurs belonging to prominent Milanese families with the purpose of forging a new generation of executives in a young but rapidly growing economy, our Alma Mater continues to be the driving force behind social and economic innovation and growth.

Since 18 63...

“In recent years, the Faculty has taken steps to encompass the Institutes and course subjects of the same degree course, the aim being to constitute units capable of heralding the establishment of just as many university departments, aimed at creating separate Politecnico di Milano schools ı.”

ı Politecnico di Milano, Il centenario del Politecnico di Milano 1863-1963, Milano, ed. fc, 1964

Historical RootsHence, in 1951, the Institute of Mechanical Engineering and the Construction of Machinery was established with the merging of three sections (group of lecturers) which had, until that time, been separate entities.The first of these sections encompassed the lecturers of Meccanica Applicata alle Macchine (Applied Mechanics), whose subjects had been taught to the students of Industrial Engineering during the compulsory course of Meccanica Industriale e Disegno di Macchine (Machine Design and Industrial Mechanics) held by Prof. Giuseppe Colombo. As time went by, the name of the subject matter changed several times (in the academic year 1880/1881 the subject of thermodynamics was added) together with its position within the study course. In 1914-15 the lecture course was finally named Meccanica Applicata alle Macchine (Applied Mechanics). Prof. Giuseppe Colombo was Rector of the “Istituto tecnico superiore di Milano” (former name of Politecnico di Milano) from 1897 to 1921. In 1921 the role of Rector was assumed by prof. Cesare Saldini, who had also been full professor of Mechanical Technology since 1899 and emeritus professor since 1921.

Following the nomination of Prof. Ottorino Sesini to the chair of the Institute of Mechanical Engineering in 1935, the teaching programme was changed. The subject of thermodynamics was eliminated – becoming the subject of other courses – and particular emphasis was placed on the kinematics and dynamics of machinery.The second group of lecturers were teaching the subjects of machine design. These topics had been initially taught during the lecture course given by Prof. Colombo, but then from 1875/76 the lectures of Elementi delle Macchine (Machine Elements) became the subject of a separate course with the institution of a chair initially tenured by Prof. Giuseppe Ponzio. In 1895, the name of the course was changed to Costruzione delle Macchine (Machine Design). On the death of Prof. Ponzio in 1908 the course was taken over first by Prof. Federigo Giordano and subsequently, during

the post Second World War period, by Prof. Italo Bertolini.The third group of lecturers were dealing with another subject. In 1870, Prof. Giuseppe Colombo decided that it was worth instituting a lecture course, where first year students could learn the morphology of machine elements together with their graphical representation, before addressing the dimensioning of machine elements and their dynamics in the other courses. The chair of Mechanical Design and Drawing was then so instituted.

Recent HistoryIn 1951, as previously mentioned, the three Institutes that offered the above mentioned courses merged, giving life to one of the first Italian multi-subject Institutes under the directorship of Prof. Ottorino Sesini, who held this position until his retirement in 1961-62, when it was taken over by Prof. Italo Bertolini who held the position until 1969.The departments of Automotive Construction and Agricultural Mechanics – falling under the umbrella of the same study course – together with Technologies and Industrial Plants, became a part of the Institute and were directed by Prof. Antongiulio Dornig, nominated director of the institute, following the retirement of Prof. Bertolini. In the meantime, in 1965, most of the Institute had moved to a new building referred to as “la nave” (the ship), situated in Via Bonardi. The new location meant that there was now more space, especially for the

In order to have a better understanding of how the current Department of Mechanical Engineering and its organization into research lines came into being, it is necessary to go back fifty years, when, in the centenary celebration book, the question was already under debate:

History of the Department of Mechanical Engineering

■ An office in the Machine Design Institute

■ Machine Design Didactic laboratory

■ The first Machine Design laboratory

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laboratories, thus serving as the first example of a modern, efficient economy of scale.At the end of the three year period, the directorship was handed over to Prof. Giovanni Bianchi who was subsequently succeeded, for two mandates, by Prof. Emilio Massa until his election to President of the School of Engineering in 1980, when Prof. Bianchi was once again asked to complete the remainder of the three year mandate.Following the entry into force of law no. 382 of 1980, it was finally possible to implement the long-awaited departmental structure to which reference had been made in the centenary book published fifteen years earlier. Prof. Dornig was elected director of the Department of Mechanical Engineering and it was, in fact, under his aegis that the somewhat complex transition to administrative autonomy took place, being finally completed under the auspices of Prof. Andrea Capello, who served as its new director during the three-year academic period between 1984-1987. The transition was finally completed following the appointment of Prof. Giuseppe Bernasconi to director for the three-year academic period between 1987-1990, an appointment that he was unable to complete due to his failing health. In 1989, he was replaced by Vice-director, Prof. Giorgio Diana, who was also re-elected for the next three-year period from 1992 to 1995 and who started the process of the Department’s move to the new Bovisa campus.The task of organizing and implementing the Department’s move to the Bovisa campus fell first to Prof. Sergio Sirtori (1995 – 1998) and subsequently to his successor,

Prof. Marzio Falco (1998-2001). In fact, it was at the Bovisa campus that the IV School of Engineering (Scuola di Ingegneria Industriale) was established, thus marking the creation of those “separate Politecnico di Milano Schools” clearly envisaged seven years earlier.However, misfortune struck once again when the director of the Department, Prof. Falco, died after a long illness. In 2000/2001, Prof. Giorgio Diana was called in to complete the task started by his colleague, bringing it full cycle during the next two mandates which lasted until 2007 when he was forced to resign following the entry into force of new laws which prevented him from performing different institutional roles. During these years, the Department opened new laboratory facilities and a wind tunnel and increased its participation in European Union research projects. The research budget boosted the Department to the top-level ranking which it still holds today.Prof. Diana was succeeded by Prof. Ferruccio Resta who opened the new head office. The Department then went on to inaugurate new laboratories (Mechatronics, Micromechanics). In 2008, based on an international peer review of the Politecnico di Milano, the Department of Mechanical Engineering obtained one of the highest ratings in the overall ranking.

Facts, Figures, Structure and Perspective

■ The opening ceremony of the new building of the Department of Mechanical Engineering in the Bovisa Campus (2008)

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This development, supported in a virtuous loop by R&D projects, is the backbone of our success in competitive funding, thus making us one of the biggest Departments of Mechanical Engineering in Europe boasting both critical mass and top-level competencies in different research areas.

2005 2006 2007 2008 2009 2010 2011 2012

k€ 2817 k€ 3682 k€ 3869 k€ 4335 k€ 5299 k€ 5843 k€ 5718 k€ 4467 Private

k€ 1042 k€ 1299 k€ 749 k€ 1024 k€ 710 k€ 1166 k€ 1453 k€ 1227 EU

k€ 414 k€ 655 k€ 593 k€ 306 k€ 519 k€ 626 k€ 1338 k€ 309 Public

k€ 295 k€ 238 k€ 232 k€ 204 k€ 130 k€ 87 k€ 111 k€ 53 Teaching

k€ 4569 k€ 5875 k€ 5444 k€ 5870 k€ 6658 k€ 7722 k€ 8621 k€ 6056 Total

Research Budget

The vision behind our development and organization is that top-level research in Mechanical Engineering is based on the excellence of experimental skills, modern laboratories and specialised equipment together with an adequate number of research staff. In particular, our permanent staff (98 resources) are currently working on research and R&D projects in collaboration with 50% of our PhD students, while an additional 40% of temporary research assistants have been hired for specific projects, with an allocated lab space of approx. 35 sq.m. per person. Administrative and technical services are guaranteed by a service staff of more than 40 people.

Our presence and success on the competitive ‘research market’ is also based on scientific visibility and a solid international presence. The full-time researchers and academic staff are committed to a high level of scientific production with the publication of papers in ISI or Scopus journals (a total of 377 in the past four years) and widespread participation at international conferences (a total of 915 papers have been presented over the past four years). Furthermore,

over the past four years, 17 international and 20 national patents have been filed by members of the department. In addition to publishing, departmental staff sit on the board of 13 international journals and scientific societies. Between 2009-2010, the full-time staff received as many as 12 international awards for scientific activity.Particular emphasis is placed on the scientific output of young researchers: since 2005, special awards have been yearly given to the top researchers, i.e. those boasting the highest number of publications.

The research budget comes from different sources, the biggest contribution are the R&D projects with private companies (approx. 75%) followed by EU projects. 20

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Professors and researchers 98

Technical staff 26

Administrative staff 18

Research assistants 51

PhD students 58

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■ The staff of the Department of Mechanical Engineering

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The academic staff of the Department of Mechanical Engineering are organised into 6 research lines corresponding to the main groups of subjects offered in the curricula:

■ Dynamics and Vibrations;■ Machine and Vehicle Design;■ Manufacturing and Production Systems;

The various research lines, coordinated by a leader, deal with research activities and coordinate the teaching activities for courses falling under the umbrella of the same discipline.

The council, comprised by all the members of the academic staff, together with a delegation of PhD students and technical-administrative personnel, discusses and approves the administrative acts and deliberates upon the assignment of

resources and strategies proposed by the Scientific Committee.

The Head of the Department is responsible for administrative management and the management of services and is supported by the Department Scientific Committee. The Head of the Scientific Committee is responsible for strategic management. The Head of the Department is the legal representative of the Department, dealing not only with all administrative and

Organization & Management

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■ Materials;■ Measurements;■ Methods and Tools for Product Design.

institutional matters but also with research contracts. Furthermore, the Director is also responsible for implementing the deliberations made by members of the board, for coordinating the various administrative acts necessary for the research and educational activities of the research lines and for the supervision of departmental services. The Director is also personally responsible for putting forward the motions proposed by the Department at Academic Senate meetings.

The Department Board, consisting of members of the academic staff and personnel responsible for Departmental services, a Deputy Director and an Administrative Manager, prepares the budget, implements and develops the various deliberations made by members of the board and coordinates the strategic services of the Department (educational curricula, handouts and website).

The Scientific Committee, coordinated by a chairman, is constituted by one representative per research line as well as a director and a deputy director.

The Scientific Committee is responsible for harmonizing various research activities; it proposes the allocation of resources among the research lines, assesses planning and the research results of the various research lines and prepares an annual summary of the Department’s scientific output.

Despite the attempts made on an International level (The Future of Mechanical Engineering 2028, ASME), it still remains difficult to give a long-term forecast of the evolution of the world of research with which the Department of Mechanical Engineering should interact, even though it is possible to share several areas of common focus:

• the world of mechanical engineering is continually evolving towards hybrid scenarios thanks to the continual influx of contributions from related sectors;

• research, in the specific areas of mechanics, is increasingly associated with similar, interdisciplinary themes such as sustainable mobility, transport, energy, materials and design.

• technologies and methodologies are continually evolving and, as a consequence, so are their applications.

Examples of these changes are: the evolution of the Automotive world with hybrid traction systems; the evolution of machines towards mechatronic systems; the evolution of metallic materials to composite and smart materials and of working processes to eco-compatible and energy efficient production systems right up to continuous and systematic product innovation.Even the research market, against which the Department is continually forced to match itself, changes on a daily basis.Now that the European Community has become a key player and European industry holds an extra weapon in terms

Prospects

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of innovation, new developing realities are increasingly becoming the order of the day.Within this context, the Department of Mechanical Engineering aims at maintaining its dual role as a research structure and as teaching, by pursuing its objective of acting as a reference point in all those fields constituting mechanical engineering on a national level; of strengthening international leadership in several research sectors in which it excels, of availing itself of sustainable, efficient and technologically advanced research laboratories and, finally, of guaranteeing sustainable and flexible research in new, unexplored sectors.

To achieve its mission and the goals set, over the past five years, the Department has invested in unique, high-quality experimental laboratories which have enabled it to establish collaboration programmes with the private sector and to participate in European and national research projects, by providing the tools for basic research.

The Department has thus strengthened its fund- raising abilities with basic and applied research projects for over EUR 7 million of which 70% comes from the private sector and 30% from the EU and the public funding. In particular, several key activities include:

• participation in 24 projects of the Seventh framework programmes;

• obtainment of financing from the Ministry of Economic Development for many projects in the field of Sustainable Mobility, Energy Efficiency and Made-in-Italy;

• successful application to 12 R & D projects financed by Regione Lombardia in the last two years;

• establishment of partnerships with other organisations of the Politecnico di Milano for projects involving large Italian and European industries such as, AgustaWestland, EDF, ENI, ENEL, PIRELLI and for important infrastructure projects such as the activation of high speed railway lines;

• establishment of the first national centre on railway transportation in partnership with Rete Ferroviaria Italiana, Trenitalia, ABB, Ansaldo Breda, Bombardier and Fondazione Politecnico di Milano (Joint Research Centre);

• participation in various projects financed by the Regione Lombardia and Emilia Romagna.

Furthermore, the Department of Mechanical Engineering has upgraded activities related to technological transfer and the promotion of research, with participation in privately-owned consortiums (Italcertifer with the companies of the FS group and MUSP with the main industrial realities in the machine tool sector); additionally, five spin –offs (T.I.Ve.T, MCM, ISS, SmatMechanical-Company and E-Co) have been established.Over the past few years, the Department has invested in the growth and training of young researchers thanks to the internal financing of “Young Researcher” projects such as:

• SMILE: Shape Memory alloy Integration in Light weight thin Elements. The use of SMA for light composites with a high damping (SMILE). The aim of the project is to develop a new concept composite

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material characterised by a high damping/weight coefficient ratio. The composite consists of a polymeric matrix and a thin sheet of shape memory material, suitably micro-worked using a “mesh” geometry and drowned in the matrix.

•Hy-LAP: The mechanical behaviour of hybrid joints of thin sheets in a light alloy.

The project is based on the characterisation, the micrographic analysis and the static and fatigue mechanical behaviour of hybrid joints obtained by means of ultrasound welding and the gluing of light alloy sheets.

• PhoCUs: Study of a concentration photovoltaic system for urban environments and the creation of a reduced prototype.

The idea is to create a modular component based on Fresnel lenses (or similar lenses with a low visual impact) that allows for the

development, even in urban environments, of high-efficiency photovoltaic systems using multijoint cells of spatial derivation.

• LODYNA: Creation of a dynamometric scale with Bragg Fibres in a composite material. The aim of the project is the design of a dynamometric scale featuring high mechanical characteristics (in terms of an optimum stiffness/density ratio with respect to metallic alloys) and good measurement performance (fewer signal measurement disturbances, especially in aggressive environments and an advantageous cost/channel ratio).

• Modelling, design and control of EddyCurrentSeparationsystems(ECS)forcarscraprecycling:Recycling of End-of-Life Vehicles is becoming more and more important due to environmental aspects, legislation and due to concerns about the availability of

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Research Activitiesscarce materials. Therefore, there is need to increase the efficiency of separation processes (recovery and grade) for complex material mixtures. This project focuses on the Eddy Current Separation technique for separating non-ferrous metal from non-metal particles in recycling systems. A multi-body, multi-particle simulation model of the process is developed that is able to simulate inter-particle interactions and impacts that typically decrease the separation efficiency.

• Self sensing and Self actuating CompositeStructures: The aim of the project is to study, develop and demonstrate the technological feasibility of composite smart structures with embedded sensors and integrated actuation. Main application areas of research are those of mechanics, structures and vehicles.

• Sure3D: Reliability and uncertainty of 3D vision-based measurements. The main goal of this project is to develop a technique to quickly and reliably quantify the uncertainty in 3D vision-based measuring systems in the full working volume; the final aim is to improve the measuring performances of such devices.

• Dynamicandfatiguelifecharacterisationof hyperelasticandviscoelasticmaterials: hyperelasic and viscoelastic materials (rubber like materials) have a very complex behaviour both in terms of dynamical response and of fatigue life. This research project aims to realise a testing device able to perform dynamic and fatigue tests on such materials in uniaxial and multiaxial strain conditions in the frequency range between 0 and 50 Hz. The tests will provide valuable data in order to better understand the behaviour of such materials.

■ Examples of fatigue failure for hybrid lap joints obtained by ultrasonic spot welding and adhesive bonding

■ The “Formula Student” vehicle during a competition

■ Tests to quantify the distribution of the uncertainty of 3D vision-based systems

Last but not least, the Department also offers ongoing support to its students not only through teaching activities involving the continuous use of experimental laboratories but also through initiatives such as Formula Student and the Shell Eco Marathon.

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The research staff is organised into 6 different research lines, which refer to the 6 main disciplines taught at the Department. Governance and coordination of the different areas and the scientific strategy of the Department is managed by the Director with the support of a Scientific Committee, while the different RLs are autonomous in terms of fund-raising and research strategy/opportunities.

Dynamics and VibrationThe research line “Dynamics and Vibrations” focuses attention on the linear and non-linear dynamic behaviour of mechanical systems and machines. Problems addressed include mechanical vibrations and stability, active and semi-active control of mechanical systems, condition monitoring and diagnostics of machinery and vehicles, fluid-structure interaction problems and the dynamics of rotating and reciprocating machines.

The approach to these problems is based on the integration of advanced modelling and simulation techniques, e.g. multi-body/finite element methods, as well as experiments performed either using cutting-edge laboratory facilities, such as the low-turbulence & boundary layer wind tunnel, or directly in the field.

The research line is split into five main research groups:

• Mechatronics and Smart Structures: deals with the active and semi-active control of mechanical systems, smart and embedded systems, Micro-Electro-Mechanical Systems (MEMS) (both actuators and sensors) and energy harvesting devices, innovative robotic applications;

• Rail vehicle dynamics: deals with the study of dynamics, vibration, safety, damage, condition-based monitoring and active control in railway vehicles and in the railway infrastructure;

• Road vehicle dynamics: deals with vehicle dynamics (performance, comfort, handling, aerodynamics), vehicle passive and active controls, tyres, hybrid/electric vehicles;

• Rotordynamics: deals with the dynamics, vibration, condition monitoring and diagnostic problems of rotating machines;

• Wind Engineering: deals with fluid-induced vibration and fluid structure interaction, including the aerodynamics and aeroelasticity of long span bridges and tall buildings and the aerodynamics of sails, vehicles and wind turbines;

all of which are at the leading edge of international state-of-art in their respective fields.

Future research trends will be directed towards developing lighter, smarter, more reliable and more environmentally friendly machines / vehicles and, more specifically, towards the theme of energy production, with particular emphasis on new technologies for wind turbines and energy harvesting devices and the enhancement of performances of rotating machinery in power plants, condition monitoring and diagnostics.

Mechatronics and Smart Structures The Research Group “Mechatronics and Smart Structures” deals with subjects ranging from the dynamics of active and semi-active mechanical systems to the adopted drives and the necessary electronic control boards, from control logics to sensor and actuation technologies, from the design of sensor nodes to the realisation of fully actuated smart structures and intelligent robotics.

This multidisciplinary approach allows innovative research to be carried out from a truly mechatronic point of view and to cooperate fruitfully with other research areas. For presentation purposes, the research subjects can be divided into four main topics:

■ Innovative Drives and SensorsThe focus is on simulation, design and production of drives and sensors boasting innovative features and performance standards (such as high voltage and/or high performances and/or high efficiency), based on the use of new and smart materials, having micro and nano dimensions. In addition, innovative convertors, converter topologies and modulation strategies, distributed generation policies and related control strategies are also investigated.

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■ DyNAMICS AND VIBRATIONS;■ MACHINE AND VEHICLE DESIGN;■ MANUFACTURING AND PRODUCTION SySTEMS;

■ MATERIALS;■ MEASUREMENTS;■ METHODS AND TOOLS FOR PRODUCT DESIGN.

■ Calibration of a custom data logger for ski applications with an integrated 9 dof IMU platform and four load cells using a miniaturised Stewart platform.

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■ Smart Structures and SystemsFurther improvements in terms of performance, safety, LCC and reliability of mechanical systems may be obtained by transforming these systems into mechatronic ones. Thus, research focuses both on the development of innovative control algorithms, in presence of concentrated/distributed sensors and actuators, and on the re-design of traditional systems with integrated sensing and intelligence. For this purpose, wireless sensor nodes for monitoring as well as smart fully integrated actuators for active vibration damping of slender and low damped components/structures have been developed. Research is also carried out on energy harvesting devices of various natures (mechanical, electro-dynamic, piezoelectric, etc.) in order to provide the energy required by these sensors and actuators.

■ RoboticsSelf-assembling, self-optimising, self-learning and fault tolerant autonomous systems and cooperating robots are studied both theoretically through numerical models and experimentally through in-field tests.

This expertise, obtained in over 30 years of activity, is applied to several applications ranging from space robots (e.g. the Ladyfly project), to environmental protection projects (e.g. Cleanwings system for automated intelligent bins) and safety robots

(e.g. the DeeDee system). Also low cost robotic platforms for the interaction with human workers are being investigated and tested.

■ Sports and Biomechanics The know-how gained in simulation (multibody approach), design (structural response of composite materials) and testing (aerodynamic behaviour tested in the wind tunnel) is fully exploited when it comes to optimise sports devices and materials as well as the athlete’s posture, motion and training. Combining this know-how with the knowledge gained in the field of robotics, frontier research is being carried out in the field of human – machine interface and interaction (ergonomics), both from a hardware and software point of view: new designs and new products are being developed for exoskeletons, artificial limbs and organs for the functional rehabilitation of disabled people as well as for capability enhancement.

Rail Vehicle Dynamics The Railway Dynamics unit carries out research on the dynamic behaviour of railway vehicles and their interaction with the infrastructure. Research is targeted at the dynamics, vibration and durability problems of railway vehicles and their interaction with the infrastructure. Theoretical investigation is backed by extensive use of laboratory and field testing facilities.Research links have been established with some of the leading research groups worldwide. The research group also benefits from interaction with and funding from some of the main industrial stakeholders in Italy and Europe and took part in 18 research projects funded by the EC within the last three Framework Programmes (FP5 to FP7). The group is also involved in the activities of the Joint Research Centre (JRC) on railway transport, an industry-academia cooperation established by Fondazione Politecnico in 2008, bringing together a number of key national and international companies in the field of railway transport.

Research is currently being conducted in five main areas:

■ Mathematical modelling and the experimental investigation of rail vehicle running dynamics and train-track interactionInnovative approaches to the study of rail vehicle running dynamics and train-track-bridge interaction are introduced. Mathematical modelling research addresses the detailed description of vehicle and track flexibility effects and improved models for wheel-rail contact and for wheel and rail wear. Simulation methods were validated by comparisons with line measurements on vehicles of different classes and on a full scale roller rig, including one of the very few published full scale experiments on wheelset derailment. In this area, a researcher from the group co-authored an invited State-of-the-Art paper presented at the IAVSD 2011 Symposium.

■ Wheel flange climb tests performed on the BU300 roller rig at Lucchini

■ Instrumented rowing ergometer for improved training

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■ Pantograph-catenary interactionThe unit holds a world leading position in the modelling and simulation of pantograph-catenary interaction. Work in this area included the participation to the FP6 EUROPAC project and the FP7 Pantotrain project, involving the development of new modelling techniques and hardware-in-the-loop hybrid simulation. The research group has recently promoted an international benchmark on the simulation of pantograph-catenary interaction, which sees the participation of 13 universities and research centres across 3 continents. Research work also covers electrical and tribological issues in pantograph-catenary contact, a major research instrument being the full-scale test bench for pantograph-catenary contact which simulates contact between the pantograph and the contact wire under variable mechanical and electrical conditions, i.e. contact force, sliding speed and electrical current flow. High speed pantograph aerodynamics is also investigated, with intensive use of the PoliMi wind tunnel.

■ Mechatronics of railway vehiclesActive control applications are studied as a means to improve rail vehicle performance, safety and ride quality. Focus is set on the active suspension control to improve vehicle stability and curving behaviour, active control of airspring secondary suspensions, active steering and active pantograph control. In this field, researchers from the Railway Dynamics unit co-authored invited State-of-the-Art papers presented at the IAVSD 2007 Symposium and at the Railway 2012 Conference.

■ Condition monitoring and diagnostics of railway vehicles and tracks The research group has been involved in an extensive research project targeted at the homologation and condition based monitoring of the Italian high-speed network. Furthermore, within the context of the JRC activities, three research projects, dealing with the monitoring of traction equipment, pantograph diagnostics and the early detection of instability based on bogie vibration measurements, are currently under way.

■ Aerodynamics in railway vehiclesResearch on this topic deals with various aerodynamic effects on high-speed trains. Research entails the use of the Low-Turbulence & Boundary-Layer Wind-Tunnel and of advanced Computational Fluid Dynamics simulation techniques. Researchers from the group have also been involved in investigations on a European level to revise the Technical Specifications for Interoperability. In this field, a researcher from the Railway Dynamics research group has co-authored an invited State-of-the-Art paper presented at the IAVSD 2009 Symposium.

Road Vehicle Dynamics The Research Group on road vehicles deals with the modelling and experimental analysis of passenger cars, heavy vehicles, farm tractors and motorcycles exploring both mechanical and electronic aspects. Research links have been established with important automotive companies. The research is organised into five application topics.

■ Vehicle modelling and testing Several numerical Multi-Body models were developed using both commercial codes and general purpose software for vehicle dynamic simulation, allowing the optimization of performance, handling and ride comfort as well as the design of new actively controlled subsystems.In particular, a 14 degrees-of-freedom real-time car model (including a race driver model) was developed for Hardware-In-the-Loop simulations and Rapid Control

Prototyping. Moreover, a model of a heavy vehicle was developed to evaluate load spectra on axles, tyre wear and the effect of sloshing. Models of farm tractors were implemented considering the soil deformability.Innovative models of subsystems (braking system, hydraulic power steering system, power train, bushing, semi-active dampers) were also developed and integrated within vehicle models.All simulation models were validated through comparison with experimental data using the indoor and outdoor facilities of the Department. Among these, an instrumented vehicle (dynamometric hubs, braking pressure transducers, inertial gyroscopic platform, vehicle speed and sideslip angle optical sensor, dynamometric steering wheel and accelerometers) was set up for full scale tests, a Hardware-In-the-Loop test bench was developed to investigate performance of ABS and ESP control units and ad hoc test benches were designed and built to analyse the behaviour of vehicle subsystems. For motorcycles, an innovative measuring system was set up to assess the relative movements between driver and bike.

■ Tyre modelling and testingThanks to a long lasting cooperation with Pirelli Tyre, a 3D rigid ring tyre model was developed for both comfort and handling analyses also accounting for the contact patch dynamics. Several experimental indoor and outdoor tests were performed to validate it. In order to be able to correctly predict both passive and active vehicle performances, the tyre model was integrated

■ Hardware-in-the-Loop test rig for pantograph-catenary interaction

■ Scheme of the condition-based monitoring system installed on the ETR500 Y1 experimental train

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into different vehicle models. A further development of the model is presently underway to be able to better predict F1 tyre behaviour.A deformable tyre model was implemented to be able to predict the dynamics of agricultural vehicles taking into account the tread pattern design and the soil deformation.Two projects (Cyber Wheel and Cyber Tyre in cooperation with Pirelli Tyre) were carried out with the aim of turning the tyre into a sensor to provide active control systems with additional information. Several algorithms were developed and patented to estimate contact forces, grip margin and hydroplaning risk.

■ Aerodynamics The aerodynamics of several heavy vehicles (high sided lorry, tractor and semi-trailer combination, tanked truck) have been studied within the WEATHER EU Project (in collaboration with the Universities of Birmingham and Nottingham). The overturning risk associated with cross wind has been studied by means of numerical multibody - CFD coupled simulations as well as experimental tests performed in the wind tunnel of Politecnico di Milano where different atmospheric boundary layers and scenarios were reproduced.

■ Active control systemsActively controlled subsystems were designed and developed aimed at improving vehicle stability, performance and ride comfort: a semi-active differential (currently equipping F430) was developed in cooperation with Ferrari. A Brake Torque

Vectoring control logic was designed to enhance vehicle performance; semi-active dampers were employed to improve ride comfort, while active camber control and suspensions with active kinematics were developed to enhance vehicle handling performance. Active suspensions were also applied to prevent rollover of heavy vehicles induced by cross wind and sloshing.

■ Hybrid / electric vehiclesResearchers have been involved and are presently working on several projects and activities with hybrid/ electric vehicles: optimisation of delivery management with electric commercial vehicles in Milan, hybridisation of a city car and of a commercial 3.5 ton van (from design to prototype), modelling and energy flow analysis in high performance hybrid cars and heavy duty operating machines and the study of full electric retrofit for Alfa Mito. In this research field different international patents were issued.

Rotordynamics This Research Group focuses on general problems inherent to real rotating machinery and traces an ideal path that:

• starts with the mechanical design of the rotor and its related components;

• passes through the set-up of the machine and related start-up problems;

• continues with condition monitoring of the machine;

• eventually ends with the diagnosis and identification of possible faults, with special attention being paid to the early detection of faults.

This general approach is devoted to discovering methods and models that are, in any case, related to both real and industrial applications, with follow-up of the experimental validation of the theory. The use of specially designed test-rigs or actual case studies and data obtained from industrial partners usually means that validation is based on well-grounded data. Furthermore, it is also worth pointing out that the test-rigs employed and described hereinafter are of a fairly large scale and designed to simulate the behaviour of either real machines or real components.

■ Fully instrumented vehicle for testing innovative control logics

■ Roller Bearing failure

■ Rotor of an industrial steam turbine

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In order to cover the topics of the research line, four main research themes are operative:

• simulation of the dynamic behaviour of industrial rotating machines;

• identification and diagnosis of industrial rotating machines and their components;

• condition monitoring of industrial rotating machines;

• dynamic behaviour of rotating machine components, such as roller and oil-film bearing, blades etc.

Thanks to the support of industrial partners producing rotating machinery and their components, great expertise has been gained with various design problems and different types of motors, turbines for power generation (hydraulic, steam and gas) or special high-speed machines, such as multi-shaft geared compressors, turbo-molecular pumps or atomizers. In all these cases, simulation models and specific software tools have been successfully developed and industrially tested. Conversely, with partners involved in the use of rotating machinery, operating problems have been investigated among which effective condition monitoring is the most important in order to avoid impending failures or malfunctions (which, in some cases, could be potentially catastrophic or very dangerous) or, in the event of a failure or malfunction occurring, to quickly identify and repair it.These two requirements are a valid reason to create a service system dealing with condition monitoring, bearing diagnostics, balancing and on-site problem solving based on individual customer requirements, the aim being to define specific alarm criteria and to develop a model based method for fault identification, mainly in the frequency domain. Not only does this method have the advantage of identifying the type of fault but also its severity (such as, for example, unbalance or crack depth) as well as location along the shaft-line (e.g. which bearing suffered a failure or which sealing is too tight or badly assembled thus causing friction when the machine is subjected to critical speeds during run-ups or coast-downs).

Wind Engineering Research on “Wind Engineering” is one of the cornerstones of the Department of Mechanical Engineering. Initiated in 1970 by Prof. Giorgio Diana it focuses on cables, suspension bridges and wind-induced dynamics. A major advance was recently made thanks to unique opportunities offered by the “Low-Turbulence & Boundary-Layer Wind-Tunnel”, facility realised through the key role of the Department’s Wind Eng. Research Group. The wide spectrum of experimental applications offered by the Wind Tunnel (buildings and large structures, trains, vehicles, sails and high Reynolds Number base research) resulted also in the development of new research topics. The strength of the Research Group is the availability of a top-class experimental facility combined with the Department’s strong tradition in numerical modelling of structure and systems dynamics. The combined experimental-numerical approach allows original contributions, recognised at international level, to be provided in a multidisciplinary approach to Wind Engineering applied to the fields of Structure Dynamics, Mechanical Systems Vibrations, Vehicle System Dynamics and Sailboats design.The research is focused on developing powerful numerical models allowing for predictive analysis of wind-structure interaction problems, always supported by experimental validation. The CFD approach is also a research branch

of increasing interest, focused on the physical insight and parametric analysis of the experimental approach. Finally, the reliability of predictive numerical simulations is always validated by specific wind-tunnel procedures and full scale testing.

The Research Group is organised into six application topics:

■ Bridge Wind Engineering: the most significant example is the aerodynamic design of the Messina Suspension Bridge. Predictive simulation of bridge dynamics and stability due to turbulent wind relying on innovative numerical approaches based on and validated by experimental Wind-Tunnel

■ Test rig for static and dynamic characterization of journal bearings

■ Boundary Layer Wind Tunnel tests on Cable-Stayed bridge aeroelastic model

(Forth Replacement Crossing)

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techniques. Internationally recognised originality and effectiveness of innovative aerodynamic solutions and research approaches proposed for super long span bridges already applied in state of the art structures (Stonecutters Bridge deck section, Hong Kong).

■ Cable Wind Interaction: internationally recognised know-how resulting in worldwide extensively used numerical methods developed to define wind-induced cable vibrations. The research team has been responsible for innovative cable structures wind interaction design, including the Java-Bali and Gibraltar undersea crossing, the Yang-Tze and Orinoco overhead crossing, the London-Eye, etc..

■ Wind Engineering in High Rise Buildings: state of the art research activities and expertise in the field of high rise buildings and large flexible roofs, taking advantage of a superior Boundary Layer Wind Tunnel and a well established structure dynamics expertise.

■ Vehicle Wind Interaction: strong synergies between wind tunnel experimental techniques and numerical modelling in road and railway vehicle-dynamics with advantageous applications to the critical safety-related problem of

high-speed-trains and vehicles in cross-flow, resulting in the recent definition of “Technical Specifications for Interoperability” (TSI) of international relevance.

■ Sailboat applications: wind-tunnel tests on the sails of America’s Cup boats, taking advantage of unique experimental facilities (twisted flow) rated among the three most representative in the world (together with Auckland and Southampton).

■ Wind Turbines Aerodynamics: experimental and numerical CFD LES approaches taking advantage of fully controlled scaled model wind turbines allowing understanding of boundary layer, wakes and orography effects. An innovative active real time controlled test rig is available for simulation of the wave-structure-wind interaction on off-shore wind turbine models.

This research area is devoted to advanced design methods and structural integrity of mechanical components. These activities are the subject of important contracts and grants from European Union.This research line aims to study both basic and general topics such as multiaxial low and high cycle fatigue prediction criteria, assessment of the structural integrity of cracked elements, the behaviour of materials in extreme conditions (low temperature, impacts), damage of composite materials and adhesives, with the integration of advanced design methods for mechanical systems and components (metal replacements, automotive subsystems, railway components, helicopter components, energy...).

Advanced Design of Mechanical Components The field of advanced mechanical components and machine design involves a number of different objectives and new developments: increasing lightness and reliability, designing customised materials and reducing environmental impact.The achievement of all of these goals involves an in-depth knowledge of new design methods, optimum use of materials and of the mechanical behaviour of materials.The basic topics developed by thee Advanced design research group are related to fracture and /or damage mechanics of materials, both composite materials (short and long fibre reinforced polymer matrices)

and special metal alloys and the effect of surface treatments on the fatigue behaviour of materials. All these topics are developed both by means of extensive experimental investigations – carried out in dedicated laboratories – and in-depth theoretical and numerical studies, involving the development of numerical models.The advanced design of gears and mechanical transmissions puts its basis in these basic studies. The main focus is on increasing the system reliability, particularly in order to increase its fatigue life and to reduce the environmental impact (reduced noise emissions and higher efficiency).Noise emissions have been studied by implementing experimental techniques to measure transmission errors and noise emission levels and by developing a software to predict transmission errors.The application of fatigue prediction approaches to composite materials and adhesive joints for the construction of mechanical components is another relevant research topic. Several

■ High Speed Train aerodynamics: wind tunnel tests of cross-wind effects on a moving vehicle

■ Sailboat testing using the twisted flow experimental facility

■ CFD-Large Eddy Simulation of wind turbine - atmospheric boundary layer interaction

Machine and Vehicle Design

■ Fatigue crack propagation in an adhesive composite joint

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ratcheting, RCF). The latest developments in this area include dedicated tests and analyses for corrosion-fatigue impact on axle durability and NDT inspections (RSSB-T728 and WOLAXIM projects). Research partners in this field are: i) BAM (Germany), IWM (Germany); TWI (UK) and METU (Tr).Regarding the mechanical behaviour of materials is the life and integrity assessment of turbine and aircraft components, within the framework of important EU projects (MANHIRP, PREMECCY), an in-depth knowledge on the mechanical characterisation and modelling at high temperatures under low-cycle fatigue,

on multiaxial fatigue on the propagation of long and short cracks and on the mechanical behaviour at a high strain rate has been acquired. The material models developed were subsequently incorporated into prognostics software for the life prediction of aero-engine parts (project E-Break), helicopter rotor and fuselage parts and turbine components.

The application of advanced methods for life evaluation and prognostic (flaw and defect tolerance, ballistic and vulnerability assessment) purposes has been considered for developing helicopter components. In this field, thanks to several research projects (HECTOR and ASTYANAX projects for the European Defence Agency), the application of Health and Usage Monitoring Systems and the definition of prognostic approaches, involving both metallic (Al and Ti alloys) and composite materials (sandwich and composite structures), used for the construction of fuselages and rotor components (in cooperation with SINTEF (No) and the University of Patras (Gr)), have also been developed.

applications are related to this research field, the construction of a prototype bus for the European project LITEBUS, the construction and optimisation of automotive components (clutch pedals...) with particular emphasis on the environmental impact and materials recycling and the optimisation of trans-tibial protheses with specific importance given to comfort, reliability and cost-effectiveness.

Demanding applications (CRFP composite booms, impact resistance of CFRP, prognostics and resistance of hybrid joints) are the topic of the regional project STIMA Studies on the mechanical behaviour of steels and alloys under extreme conditions have been undertaken to improve the reliability of piping used for oil and gas transportation.

Structural Integrity and PrognosticsThe methods developed to analyse the mechanical behaviour of materials (fracture mechanics, short cracks and damage mechanics) are the basis for the development of new methods for the structural integrity assessment of structural and mechanical components.The application of a fitness for purpose assessment (flaw acceptance, welded joints, crack propagation and thermo-mechanical loads) of mechanical components under service conditions is the basis for many applications in this area; service life and development of life tests for hydraulic components, flaw assessment in gas cylinders, service life of earthmoving components, residual life of pressure vessel components with defects and thermo-mechanical stress cycles on heating components.In the field of the structural integrity assessment of railway components, some research projects are currently active (EURAXLES, SUSTRAIL), whose key topic is the estimation of the propagation lifetime and its impact on inspection intervals and design criteria for axle safety. Improving the durability of railway axles by cold-rolling has been the topic of the project MARAXIL (cooperation with IWM). Important research findings with the EU cooperations (TC24 of ESIS – European Structural Integrity Society) have been a significant scale effect in crack growth (directly tested on a dedicated full-scale test bench) and a set of SIF solutions for typical axle geometries. Other important applications have been made in the area of wheelset integrity (bogie frame, wheels) using specific analysis tools for different damage mechanisms (fatigue of welds,

■ Fatigue testing of a composite rod

■ Ballistic impact simulation in tail rotor shaft of helicopter

■ Finite element analysis of a complete railway wheel-set

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The application of inspection intervals on components has also led to the development of an activity devoted to the improvement of the performance of ultra sound controls for different applications (railway axles, helicopter rotor components, tilt-rotor wing spar, bogie frame parts and the hydraulic cylinders of earthmoving machines).

Ground Vehicle Design and TestingThis research line focuses on both theoretical and experimental issues related to the design and construction of ground vehicles. These activities refer to modelling, optimal design, construction and testing of ground vehicles, their subsystems or special laboratory devices.From a theoretical point of view, the scientific approach is focused on the Optimal Design of Complex Systems. For almost twenty years, numerical methods referring to Multi-objective Optimisation have been developed and applied effectively to a number of different case studies ranging from structural design to the active safety of road vehicles right up to mechatronics. In 2006, the book “Optimal Design of Complex Mechanical Systems with application to vehicle engineering” (published by Springer, Berlin Heidelberg) has represented a significant achievement together with many recognitions in international forums (ASME, IAVSD).

A new laboratory (Laboratory for the Safety of Transport-LaST, founded in 2001), focusing on experimental activities is currently up-and-running.Particular attention is devoted to green, safe and smart vehicles.

Hydrogen and solar prototype electric vehicles have been built. The body is made from carbon fibre. In 2009, the team’s hydrogen fuelled prototype obtained the Italian record for energy efficiency (2741 km per litre of gasoline) at the Shell Eco Marathon competition (Germany, 2009).

At the Shell Eco-Marathon Europe 2011, the solar vehicle, Apollo set the new world record of 1108 km/kWh (equivalent to 9757 km/l), breaking for the first time the barrier of 1000 km/kWh.Research has been undertaken on innovative design of brakes (either mechatronic or conventional) both for road or off-road vehicles.

The design and testing of suspension systems for road vehicles focuses both on active safety and Noise-Vibration-Harshness (NVH) performance. NVH projects have employed the RuotaVia: a completely original (own design) horizontal axis steel drum, providing a running contact surface for road or railway vehicle wheels (max speed >400 km/h). Innovative six axis load cells (own design) were designed and patented and used for NVH assessments.With regard to pneumatic tyres, rolling resistance, NVH performance and full non linear characteristics - both on and off road vehicles were measured at LaST. Other projects dealt with snow chains, headrests, axle durability and road accidents reconstruction.

The InTenso+ system, was patented and developed to obtain the inertia properties of vehicles and their subsystems and it has found many applications ranging from cars and race vehicles to space satellites.A special project focusing on the measurement of forces at wheel/ground interface was implemented. An own design smart wheel was optimised, constructed and employed. Thanks to this device, it was possible to theoretically highlight the improvement of ABS and ESP systems.

■ Experimental fatigue test on main rotor hub of helicopter

■ Apollo set the new world record of 1108 km/kWh, breaking for the first time the barrier of 1000 km/kWh.

■ InTenso system during a test.

■ Patented six axis measuring wheel

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Manufacturing and Production Systems

research group. Targeted studies on specific industrial problems are often carried out in collaboration with partner companies and considerable know how has been acquired on several manufacturing processes and applications, including conventional and unconventional material removal techniques, metal forming, joining and welding, surface treatments.

The majority of group activities is focused on several main research areas. These include (a) basic research regarding the physical phenomena governing manufacturing processes, (b) applied research devoted to the implementation of new technologies in an existing processing chain and (c) the development, characterisation, monitoring and diagnosis of machine tools.As regards basic research, the quality and performance parameters of processes are investigated by means of laboratory tests in order to relate them to process variables. This allows for the building of extensive process knowledge, from which “technological operating windows” can be readily derived for an optimal tuning of the processes at the shop floor. Examples of such achievements include the modelling of tool wear, residual stresses, defects of surface integrity, loss of accuracy due to cutting kerfs and burrs. These and other specific issues are investigated for both conventional processes for new or difficult-to-work materials (such as cellular metal, hybrid materials, advanced composites,

Transformation processes play a key role in the strategies adopted by industrial companies who wish to compete on the market with high quality, sustainable products. Material and information transforming processes use not only technologies and physical systems but also methods and tools to design and manage transformation activities during product life cycles, i.e. from the design phase right up to production, supply and eventual disposal, re-use or recycling of the products in question. Technological solutions for future transformation processes need to respond to the increasing needs of competitiveness and global sustainability.

As a consequence, it is of prime importance to study those processes, related to industrial products, involving not only the use of both traditional and innovative materials but also obtained by means of production systems capable of being adapted to different, more dynamic requirements. This research line aims at designing and developing new technological solutions for future transformation processes. Several research topics are developed within this particular framework. The mechanical and technological characteristics of transformed materials and the relationships between the material characteristics and the transformation process parameters are investigated. This knowledge facilitates the setting-up of new production processes, the selection of technological variables for the running of cost-effective programmes in changing environments and the

development of physical prototypes based on innovative transformation processes, also considering the environmental impact: use of energy, materials, and process emissions.

The methodologies and tools for the design, management and control of production processes as well as components and systems for transformation activities are conceived, designed and developed using software tools. The use of these advanced tools will not only help industrial engineers to achieve optimum design of production systems but will also improve management and control procedures.The research line is organised into two main themes, namely “Manufacturing Processes” and “Manufacturing Systems and Quality”.

Manufacturing ProcessesTo gain competitive advantages in their markets, industrial companies must develop and maintain the ability to manufacture products that not only comply with strict quality requirements but that are also cost-effective. In order to achieve this, they need to stay at the leading edge of manufacturing technologies either by improving their processes, acquiring new available processes or even developing new processes. Each of these strategies calls for in-depth knowledge regarding the way in which technologies are evolving and how process innovations impact on everyday manufacturing practice.The design, test and implementation of solutions for future manufacturing requirements is the overall goal of this

■ 5-axis machining of micro components

■ Process simulation: deep-drawing versus hydroforming case study

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high strength alloys) and unconventional processes such as laser beam processing, plasma arc and water jet machining, micro-machining. The combination of a number of different technologies in one process chain is often studied in order to exploit related strengths and develop hybrid manufacturing solutions.Applied research deals with challenging industrial cases, where the limitations of current solutions require new approaches based on unconventional processes. A short list of case histories highlights a wealth of unusual applications currently being explored in the group’s laboratory using state-of-the-art machinery: water jet and laser cutting on composite and other difficult-to-machine materials; fibre laser for cladding of high resistance products like gas turbine engine blades; ultrasonic welding for thin parts in aluminium and magnesium; hybrid processes based on adhesive bonding and ultrasonic welding for difficult-to-weld

materials such as magnesium; diode lasers for surface hardening in situations where accessibility is a problem; water jet and fibre laser to drill titanium and magnesium alloys for aerospace and medical applications; metal foaming for lightweight structures that have stiffness and vibration damping requirements; five-axis micromachining for high precision parts such as bio-absorbable stents, micro-actuators and micro-fuel cells; FEM simulation of metal forming processes.Machine tools are another area where design and experimental knowledge is acquired using the most updated methods.

An improved use of existing machines is made possible by defining their proper operating range in order to avoid chatter and other stability problems and to enhance the energetic efficiency of machine tools and production systems. Innovative machine concepts and subsystems have been developed (and often patented), including

an abrasive dosing system and an additive injection system for water jet cutting, a steel deposition method for nitrided metal partsand an optimised pre-stressed design for high tonnage press frames. As a further application of machine tool knowledge, monitoring systems for advanced statistical process control and diagnostics, based on typical signal profiles for process variables (current, force pressure, power, temperature and others depending on the specific process), are developed.

Manufacturing Systems and Quality Process innovation is not always sufficient to improve the competitiveness of a manufacturing company. In some ways the process is just one of the three elements that solve manufacturing problems. The other two are the product and the production systems: the former imposes its design specifications and the need to verify them at every stage of the process chain; the latter brings about many different constraints related to the availability of equipment, tooling and other types of resources. If all three issues are not carefully evaluated,

it is highly unlikely that a technological solution can meet the demanding requirements of quality, cost, productivity and responsiveness.

This research group studies the dynamic relationships between product, process and production systems in order to translate them into innovative design, management and control methodologies for manufacturing companies. However, this is not to say that manufacturing technologies are treated as pure abstraction!

The development of a methodology starts from an analysis of the real needs of a company or an industrial sector. Relevant knowledge is acquired through experimental plans or extensive data collection on the shop floor. The procedures implemented are based on technical standards and worldwide best practices. Results are tested at manufacturing facilities and deployed by means of software tools. Finally, the overall problem to be solved is anything but abstract: what are the causes of uncertainty of a process and how can they be controlled and (if possible) avoided?

■ Unconventional manufacturing: remote laser welding and abrasive water jet cutting

■ Layout scheme for production system configuration and balancing

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On the product side, the main research focus is on how the results of manufacturing processes can be controlled to guarantee product quality. Modern dimensional control techniques are experimented in the metrology lab, where several types of high precision geometrical measurements, ranging from large to micro scale, are taken.

This allows for an evaluation of all the ways in which the geometry of a workpiece can actually deviate from design specifications. This knowledge is not only helpful in terms of having a better understanding of processes, but also serves as the basis for the development of the custom procedures of monitoring and statistical process control.

These help decide what, how and when to control a production line or a supply chain and, ultimately, allow for the reduction of manufacturing defects and costs. As a feedback for engineers, information about geometric product variability is incorporated into innovative methods of tolerancing and process planning.Research on production systems focuses on the development of performance evaluation tools. These are based on a detailed modelling of all system resources including machines (with related tools and fixtures), inspection stations and material handling devices. The dream of each production manager is that all these items are organised to work in tandem to maximise productivity,

avoid bottlenecks and recoup all possible failures with minimum impact on system performance. Therefore, these tools are the basis for a rational approach to decisions, such as system configuration and balancing, as well as for operational planning tasks (routing, scheduling, etc.) which ensure an optimal usage of resources.

MaterialsThe Materials Research Line at the Department of Mechanical Engineering is focused on the study of metallurgical production processes, characterisation of structural materials and coatings. Excellent research products have been obtained both on fundamental research issues (e.g. nanostructured materials, chemical interaction between slag and molten metal, inclusions and liquid melts, powder metallurgy) and on applied research (e.g. failure analysis and damage of materials, coatings for specific applications).The laboratory system at the Department of Mechanical Engineering includes a series of equipments and analytical instruments dedicated to the experimental research of materials. Among these, a microstructural lab covers metallographic sample preparation, optical microscopes, microhardness, scratch and wear testers as well as a glow discharge optical spectrometer for bulk and in-depth chemical composition measurements. A scanning electron microscope lab hosts a recently acquired instrument equipped with an EDS microprobe and electron back-scattered

diffraction systems. A thermal analysis lab is equipped with muffle and tubular furnaces and a TG/DTA/DSC system. The facilities also boast several universal testing machines covering an extremely wide range of material testing conditions (static and fatigue loading at room, low and high temperatures, tension and compression creep, wear, fracture mechanics, fatigue crack growth, creep crack initiation and growth) and an X-ray diffractometer for residual stress measurement. Research on casting and plastic deformation processes is supported by facilities for the melting and casting of alloys and slags using a resistance furnace that can be operated up to a maximum temperature of 1750°C. Experimental rolling trials can be performed by means of a laboratory rolling system while studies on sheet formability can be conducted thanks to the use of suitable equipment.Projects carried out in recent years addressed the activities related to three main research topics: Advanced Materials (AMT), Applied Metallurgy (APM), Steelmaking and Metallurgical Processes (SMP).

■ CMM based geometric model reconstruction

The type of tool depends on the level at which management needs to be supported: virtual manufacturing and inspection software is usually provided at a workstation level, while analytical methods and discrete event simulation help to optimise different types of performance indicators at a system level.

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Advanced Materials The activities of the Advanced Materials research group are related to metallurgy and the processing of advanced and non-conventional metallic alloys such as nanostructured and ultrafine grained metals, aluminium, magnesium and titanium alloys for special and highly-demanding applications, non-ferrous superalloys and related coatings for high-temperature service.During the past decade, a lot of effort has been invested in the development of ultrafine grained (UFG) alloys boasting grain sizes in the range of 100-500 nm, produced using the severe plastic deformation technique. Thanks to this method, a significant refinement of the alloy microstructure has been achieved by extensive plastic straining of the material at either room or moderately high temperatures. The Advanced Materials research group is currently involved in gaining increased insight into the evolution, stability and strengthening of these UFG metals. Promising achievements, based

on the same principles but suitable for the generation of ultrafine grained structures in industrial metalworking plants, were also obtained in the development of more industrially-based processing techniques.In recent years, extensive investigations have also been carried out on short and long term microstructural stability and the mechanical behaviour, at high temperatures, of both conventional and innovative aluminium and magnesium alloys. Important scientific results were also obtained in the study of medium

and long term creep behaviour and the associated microstructural modifications of conventional and advanced aluminium alloys (e.g. 2014, 2014 modified with Ag, 2618 alloys) produced either by extrusion, forging or casting. Similar activities were also carried out on experimental high-temperature magnesium alloys containing rare earth elements, with special emphasis on castability and the resulting properties of parts produced by die-casting. In a more recent project, high-temperature formability and the mechanical and microstructural behaviour of a number of wrought magnesium alloys (e.g. AZ31, ZM21, AZ61, AZ80, WE43 alloys) were also investigated within the framework of a research activity focusing on the development of biodegradable devices for biomedical applications. In order to be plastically formed into small devices, the candidate materials for these applications should possess suitable properties. They should also be capable of sustaining significant stresses during service, while progressively dissolving into the human body (releasing biocompatible elements).Coatings and the thermo-chemical surface treatments of special-purpose alloys such as titanium alloys and nickel-based alloys for aerospace and other heavy-duty applications are also studied as a natural extension of the specific activities of the Advanced Materials research group. Investigations on the diffusivity of elements and the tribological behaviour of Titanium alloys treated by Plasma nitriding were performed in order to improve the thickness and efficiency of the hardened layer resulting in improved performance of the titanium parts

requiring servicing in critical tribological environments. Similarly, aluminising and other diffusive coatings are investigated as suitable surface modification processes for aerospace and power-generation turbine parts.

Applied Metallurgy Improving a product’s success depends on the attention paid to the materials engineering aspects of decisions that occur during product development and manufacturing. A materials engineering perspective is necessary today to make good decisions that can increase the likelihood of producing a successful product.Focusing attention on material properties is crucial for the proper selection of engineering materials in order to target desired functionality and reliability at the desired cost. Similarly, applying an investigational knowledge based process that looks at damage phenomena involved is an effective way to seek cost-effective solutions which enhance reliability at the right product cost, thus targeting the customer’s needs. Applying both of these approaches, that are mainstreams of the applied metallurgy field, leads to the translation of customer needs into basic material requirements that will serve a successful engineering design phase.

■ Microstructural analysis of a welded sample broken under creep loading

■ Development of ultra-fine grained Mg alloy by extrusion and laser cutting to produce biodegradable stents

■ Grain structure of a Titanium alloy

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Fitting engineering product requirement needs to apply multicriteria decision making processes based on knowledge of the relationship between material properties and failure behaviour in relation to specific environments and the loading conditions set. Control of material properties depends on controlling several sources of variations, while controlling variations requires a deep comprehension of the causal relationship existing between microstructure and manufacturing processes, including pre and post-treatments (massive, or bulk, and surface treatments). Regarding the frontiers of materials compliant with EC needs for pollutant emissions reduction, the research group has been coordinating a EU project that focuses on scaling-up to the industrial scale magnesium based alloys manufactured by no-melting processes (i.e. using low energy consuming, no gas used) capable of realising a nanostructured (<1 microns) microstructure that guarantees the highest specific strength currently available for engineering metals. Similarly, innovative semi-solid magnesium alloys produced by the Thixomolding process, an environmental friend and innovative injection molding manufacturing process, have been investigated in order to enhance mechanical properties, specifically toughness and fatigue resistance, for weight reduction needs in the automotive sector.Recently a new innovative field covered by

the group is a new engineering application of novel magnesium based materials developed as hydrogen storage via the solid state method.Concerning the bulk heat treatment of steel, the research group focuses on the study of optimising mechanical properties at the core of large blooms. During the quench step, different cooling rates can occur in various regions, mainly depending on bloom size. Difference in microstructure can be suffered by semifinished components.Surface treatments have been investigated in order to deal with and inhibit surface failures by contact fatigue. Pitting and micropitting mechanisms and sources have been researched. Practical guidelines and models for proper surface hardened layers design have been developed.Innovative heat treatments were studied on sintered steels originating from powder metallurgy in order to introduce cost benefits and significantly reduce the distortion of the parts.Finally, as a sort of back-process for optimal products, failure analysis and forensic engineering is one main applicative issue of the Applied Metallurgy research group. Specifically, root case failure analysis is today an important discipline to support the development of new products, to improve existing products and to assist a court in determining the facts of an accident. Failure analysis is generally asked to determine the root cause of failures in order to propose solutions or to assess responsibility by wider material perspectives to prevent future occurrence, and/or to improve the performance of the device, component or structure.

Steel Making and Metallurgical Processes This activity focuses on items related to steelmaking and metallurgical processes based on the following topics: melting and refining processes for the improvement of product quality and plant innovation; energy efficiency in metallurgical processes and their environmental impact (fumes, slag treatment etc.); solidification (continuous casting, ingot casting, foundry, welding); plastic deformation of metal alloys and related mechanical and formability properties obtained from end products. The study of melting processes is mainly related to enviromental issues associated to blast furnace process and to the use of the Electric Arc Furnace in steel melting processes. In this instance, particular emphasis was focused on the innovation of burners and supersonic oxygen injection and on the stabilisation of the foaming slag in order to increase energy savings and decrease steel bath oxidation during the melting and de-carburation process. A wide experience concerning the treatment and the recycle of slag and fumes powder has been developed in order to reduce the environmental impact through a correct intertization process. Studies performed on steel refining processes are related to the

possibility of achieving a good control of the quality and quantity of the non-metallic inclusions formed within the steels. The study of the solidification process is related to the application of ingot casting and continuous casting plants to perform steel semis production. Computational simulation and the study of the solidification microstructure were extended to in-line thin slab casting coupled with the direct rolling of the steel strips. Moreover, just recently, the interaction between induced electromagnetic fields and the solidification microstructure was investigated. Original techniques for the producion of open cell foams has been developed for high temperature melting point alloys.This last item was also dealt with during the study of plastic deformation processes. Particular emphasis was focused on identifying, the relationships between applied operative parameters (thermal range, total applied deformation, deformation rate), induced crystrallographic textures and the end mechanical properties of the materials treated. This approach was not only applied to steel and stainless steel but also to copper alloys. The description of the technological process (rolling, extrusion, wiredrawing) studied is given by means of the original application of FEM analysis approach.

■ Carbon acid corrosion of gas cylinder

■ Analysis of Solidification and plastic deformation processes: continuous casting of steel

■ Steelmaking process analysis: LD converter

■ Fatigue fracture surface of an aluminium wire

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The group involved in the Mechanical and Thermal Measurements (MTM) shares a common background not only in the development and qualification of new measurement techniques but also in the customisation and application of well-known measurement principles for innovative fields. In recent years the development of science and technology has allowed the creation of new measuring devices and contemporarily it has strongly increased the need to measure a number of quantities both for industry and research. In this scenario, knowledge and skills in the field of measurements are widely required; due to these reasons the members of this research group are implementing a multidisciplinary approach in close contact with many other research areas, bringing to their activities a wide know-how, ranging from electronic instrumentation, to data management and analysis, to static and dynamic system behaviour, always keeping in mind the metrology issues and the need for quality in experimentation and testing, both industrial and scientific.The research activities are sustained by a strong orientation towards acting in an international scenario, fostering and establishing international contacts in specific areas considered strategic to improve the group research capabilities. These researches are strengthened by a number of activities related to European research projects as well as projects funded by the Italian or European Space Agency. Contacts with a number of foreign Universities,

Research Centres and companies complete the international network.In the abovementioned scenario the MTM research focus includes design, development, metrological characterisation of measurement systems and standardisation, as well as the implementation of innovative experimental techniques. The main trends carried out by the MTM group are summarised in the following.

New Measurement Techniques The research in this area deals with testing of MEMS devices and use of MEMS for innovative monitoring applications; wirelss MEMS, fibre optic sensing, new strategies for sensor networks and data management, support to risk analysis.

Vision-based MeasurementsThe main scientific activity is in the field of 2D and 3D image-based measurements with particular reference to the following measuring principles: Digital Image Correlation (DIC), Fringe projection 3D scanning, stereoscopy and thermal imaging. The contributions to these research topics cover both the measuring techniques development and the corresponding applications in complex and hostile environments. The mentioned measuring techniques are applied in a wide variety of research themes, including: thermal imaging for diagnostic purposes, strain field measurements with DIC to analyse the mechanical behaviour of concrete beams, metallic elements, welded joints and fibre reinforced polyamide, DIC algorithm customisation for the estimation of the

dynamic loading due to jumping crowds on stadia stands (with applications for security purposes), PIV analysis through an original vision-based particle tracking technique, 3D biometrics for security through stereoscopic imaging of human faces, development and qualification of calibration techniques for fringe-based 3D scanners, vibration monitoring of structures and cables through image acquisition and processing, robot guidance and bin picking, stereoscopic vision and time-of-flight techniques to study the static and dynamic behaviour of race sailboats, train pantograph and civil structures in wind tunnel tests, industrial vision, also with complete design of measurement systems, particularly focused on 3D approaches, forensic imaging for crime fighting (in cooperation with the Forensic Anthropology Laboratory of the University of Milan LABANOF). A part of these research activities is carried out in the Vision Bricks Lab (VB Lab). A spin off company, Innovative Security Solution (ISS), constitutes the technology transfer means to bring the research outcomes from this area to the industrial world, especially for robot guidance and bin picking applications, but also for other 3D vision products.

Measurements

■ 3D Digital Image Correlation for tension tests analysis

■ Vision-based system for 6 degrees-of-freedom rider dynamic analysis

■ Fringe projection-based 3D scanning for personal

identification by means of 3D biometrics

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Flow-Structure Interaction It deals with base research on flow cylinder interaction and bridge aerodynamics; testing service on wind response of tall buildings, wind induced vibrations of power head transmission lines, aerodynamics of long-span suspension and cable stayed bridges, water induced vibrations of submarine structures and hydraulic vulnerability of river bridges.

Structural Monitoring In this ambit two main activity fields are active.

■ Building health monitoring: in this field the research deals with design and implementation of automatic systems for continuous measurement, monitoring and diagnosis relying on static and dynamic parameter measurements; development and validation of techniques for structural safety assessment; studies on different modal analysis techniques to identify structural parameters and their evolution over time for eventual damage detection; numerical simulation of damage effects and experimental results validation; infrastructure monitoring and evolution, especially for railways, high rise building response to wind and earthquakes, studies on people-structure interaction and serviceability assessment of stadia structures during public events. Examples of monitored structures include: Duomo di Milano, Meazza stadium in Milan, the Humber Bridge (UK), Punta Faro towers at Messina Straits, Torrazzo di Cremona, the Milan subway system.

■ Transportation measurements: in this field the research deals with vehicle/substructure interaction, effective track maintenance strategies, pantograph-catenary interaction analysis to guarantee reliability of the current collection, short pitch corrugation measurement and evolution, vehicle dynamics measurements and testing, NVH, noise and vibration annoyance and comfort, intelligent tyres and intelligent transportation systems.

Measurements for space In this field the research deals with instrument design, design and development of optical/near-infrared instruments for remote sensing, dynamic errors in atmospheric temperature measurements, modelling of mechanical disturbances on Fourier spectrometers, measurement data analysis/correction. An example of the activities carried-out is the “MIMA” (Mars Infrared Mapper) project. The developed spectrometer operates in the 2-25 µm spectral range with a spectral resolution of 5 cm-1. The thermal and opto-mechanical design has been fully carried out by the Mechanical and thermal measurements team, along with the assembly integration and testing. Three mechanisms, the cover/calibration system, the interferometer swing mechanism and the locking systems have been

designed and developed, using DC motors, piezoelectric and Shape Memory Alloys based actuators specifically developed for this application.

The purposely developed Interface vibration damping system and kinematic mounting have enabled using the mechanically weak KBr optics (yield stress lower than 5 MPa) despite the large design loads (1000 m/s2) and the wide temperature range (90÷120 °C).

Electro Mechanical Interaction and Renewable EnergyIn this ambit three main activity fields are active.

■ Active, semi-active, semi-passive and passive control of systems and structures deals with: development of vibration reduction strategies with different approaches, especially semi-passive and semi-active. Attenuation of vibrations is usually achieved employing smart materials (e.g. piezo-materials), FPGA systems and time-variant or time-invariant electrical networks. Different strategies have been developed taking into consideration different requirements (i.e. mono-modal, multi-modal and broad-band attenuation).

■ Harvester efficiency characterisation: deals with the evaluation of the mechanical design for piezo harvesters, to improve their capability to produce energy. ■ Renewable energy: deals with design, modelling and monitoring of devices to get energy from marine currents.

Acoustic Measurements The research in this field is mainly focused on sound source localisation (beamforming, near field acoustic holography, Helmotz Equation Least Squares techniques – HELS advanced volume intensimetry), measurement tools to develop acoustic barriers (arrays of microphones and loudspeakers), active, semi active and passive noise control.

Rehabilitation Measurements design and development of sensors and measurement techniques to help intelligent and more effective rehabilitation after serious injuries: techniques are developed to improve existing devices, design new ones (robots for patented rehabilitation methods) and define their metrological features.

Whole Body and Hand Arm VibrationIt deals with the development of measurement techniques for the assessment of the vibration exposure of people, mostly due to work related activities but also with attention to everyday life, including sports; modelling and characterisation of vibration sources for the tools and machines; design optimisation bound to the reduction of the vibration transmitted to the users.

■ The long-term monitoring of Duomo di Milano

■ Large structures vibration monitoring

■ The Fourier spectrometer “MIMA” (Mars Infrared Mapper) during the mechanical qualification tests

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This research line encompasses two research topics: Virtual Prototyping and Product Design, whereby the fundamental methods and tools underlying both disciplines and their interconnections are investigated and applied to industrial study cases. The research line comprises 12 permanent researchers who are not only actively involved in all research activities and numerous funded research projects but also in educational activities, mainly through courses at the School of Industrial and Information Engineering and at the School of Design.The group working on Virtual Prototyping addresses topics related to virtual prototyping for product design and evaluation, functional simulation, physics-based modelling and simulation, ergonomic validation based on virtual humans, new methods and tools for interacting with virtual models and reverse engineering.The group working on Product Design addresses topics related to process

modelling, engineering knowledge management, product innovation methods, systematic innovation principles and methods, topology optimisation systems and process and data interoperability. For the most part, research in both areas is supported by public funding from the Italian Ministry of University and Research, from the European Commission and from direct collaborations with Italian and international companies operating in various industrial sectors.

Virtual PrototypingThe Virtual Prototyping research group aims at promoting growing scientific interest in Virtual Reality technologies developed to support product design, simulation, testing and evaluation. Methodologies, tools and enabling technologies are developed, evaluated and applied in various industrial domains, including those pertaining to the automotive, aeronautics, household appliances and industrial design sectors.

The group has pioneered the use and development of haptic interfaces and is one of the most active European groups working in this area. More specifically, the group has coordinated two European FP6 projects on the development of novel haptic interaction tools for industrial design: the T’nD project (www.kaemart.it/touch-and-design) and the SATIN project (www.satin-project.eu). The result of the T’nD project is a haptic system for virtual shape modelling and exploration based on two end effectors: a scraping tool and a sanding tool. The SATIN project has developed a new interaction tool based on the multimodal use of haptics, sound and stereo vision to evaluate and modify digital shapes.The group has set up a Virtual/Augmented Reality environment based on the integration of optical tracking systems, see-through stereoscopic head-mounted displays and haptic devices for the development of applications for functional and ergonomic product simulation. Dynamic programmable interaction devices, which simulate control devices (knobs, dials and buttons), have been developed within the context of national

projects (the MIUR-FIRB SIMBAR project and the MIUR-PRIN2003 VERVE project) and integrated into applications for the ergonomic validation of industrial products (e.g., microwaves, washing machines) and into a seating-buck recently developed for the virtual testing of a vehicle driver seat, within the context of the MIUR-FIRB2005 PROGIMM project.

Research activities on physics-based modelling and simulation began in 1994 following participation in national and European projects addressing the topics of non-rigid product simulation (car-top roofs, cable handling, non-rigid product packaging) and garment design. The group has developed methods and systems for modelling, visualisation and simulation of deformable objects using a particle-based approach; it has also developed a software environment for physics-based modelling and garment simulation together with a physics-based simulation method oriented towards virtual prototyping in industrial sectors. The group has also contributed to the development of an integrated environment supporting the design of the 3D garments used in the MIUR-PRIN2003 Vi-Cloth project. The system is being extended and used within the context of the MIUR-FIRB Made-In-Italy project.Finally, the group has developed strong competencies in the area of Reverse Engineering, based on optical scanning techniques integrated into the product development lifecycle. Depending on the

Methods and Tools for Product Design

■ Microphone array measurements on Truck Engine and acoustic emission map (dB) in the 4000 Hz Range, showing the air intake contribuition

■ Multimodal interaction with virtual prototypes

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type of objects provided by companies, different reconstruction methodologies have been developed. The group also featured as a partner in the European CUSTOM-FIT project (www.custom-fit.org) supporting the definition of a methodology based on Reverse Engineering and physics-based techniques for the design of customised lower limb prostheses.

The laboratories used by these groups are equipped with state-of-the-art virtual reality and augmented reality technologies and tools. The Virtual Prototyping Lab is equipped with a stereo, optically tracked, power wall integrating a 6-DOF haptic device (by Haption), and 10 high performing workstations and a high-performance parallel computer (NVidia Tesla S1070), capable of developing massively parallel algorithms using the CUDA framework on GPGPU hardware, for the development of virtual prototyping applications and real-time realistic rendering.

The Haptic Lab is equipped with various haptic devices (Phantom devices, MOOG-HapticMaster systems) that allow users to physically touch 3D virtual objects. The lab also hosts the European T’nD and SATIN project prototypes. The Reverse Engineering Lab is equipped with VI-9i Minolta and NextEngine optical 3D scanners and a MicroScribe MX digitiser. Furthermore, the lab hosts an additional optical measuring system consisting of an Atos II 3D digitiser, a KR3 KUKA® robot arm, a 6DOF and a high-precision positioning control used to generate high-quality polygon meshes.

The Virtual/Augmented Reality Lab is equipped with innovative technologies for the development of VR/AR applications for use in product development. The lab houses the seating-buck and the VICON 460 optical tracking system equipped with 6 M2 cameras and several immersive and see-through head-mounted displays.

Product DesignThe research group on Product Design has been working for more than 30 years in the area of methods and tools supporting product development, including domains such as geometric modelling, parametric and feature-based modelling, CAD, PDM and Knowledge Based Engineering (KBE) systems. These domains have recently been incorporated into a larger area known as Product Lifecycle Management - PLM, where novel methodologies and tools,

supporting product development lifecycles, are developed. These range from the inventive tasks involved in the conceptual design phase to the management of sustainability issues related to product reuse, disassembly, dismantling and recycling.The group has developed methods for modelling product development processes and for analysing reengineering business processes (using IDEF, ARIS, UML techniques) motivated by the adoption of rapidly evolving “Computer Aided” tools and techniques, and has worked on the integration of various techniques and their validation within the context of industrial projects. A Roadmap for the evaluation of impacts, benefits and costs related to the adoption of new and innovative technologies for knowledge and innovation management in product development processes has been developed.

This methodology has been validated within the context of the European FP6 VIVACE project (www.vivaceproject.com) in collaboration with major European aeronautical companies, and has also been applied to various industrial case studies.Several methodologies based on KBE systems and DfX principles have been developed, explored and tested in different industrial contexts. In-depth work has been carried out on KBE topics within the context of the VIVACE project, thus offering the possibility of gaining deeper insight into the activities performed in the aeronautical field.The group also boasts specific competencies in the field of Systematic Innovation, mastering methodologies such as TRIZ and

developing tools for both inventive design and problem solving for product and process innovation. The same techniques have also been customised for strategic applications, such as technology benchmarking and forecasting, validated by means of several industrial case studies in different fields, such as, for example, household appliances, healthcare devices, the food industry, manufacturing technologies etc.

As one of the founding members of the APEIRON association (www.aperon-triz.org), whose mission is to disseminate systematic innovation practices to industries, and in particular to SMEs, the group has contributed to the construction of a worldwide network of universities aimed at the definition of a standard TRIZ curriculum (universitytriz.wikidot.com/), in keeping with the requirements of the majority of large companies where TRIZ education is actually committed to consulting services.This activity is also focused on the transition from human-based innovation techniques to Computer-Aided systems, as demonstrated by the active role played in the IFIP Working Group 5.4 (Computer-Aided Innovation); within this context, further research has also been carried out to demonstrate the possibility of integrating the whole design process, from the earliest stages of problem setting right down to automated design driven by knowledge and design rules. These activities, funded partially by the MIUR-PRIN2003 PROSIT project (www.kaemart.it/prosit), aim at studying possible solutions for integrating innovative tools: PLM, Engineering

■ Multimodal interaction with virtual prototypes

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Knowledge Management, Computer-Aided-Innovation systems and topology optimization tools within the product development cycle.A study aimed at demonstrating the possibility of applying an innovative hybridisation kit to existing vehicles fitted out with internal combustion engines in order to transform them into dual mode vehicles was recently carried out. The modified vehicles are thus equipped with the original internal combustion engine (already present in the original vehicle set-up) and with an electric propeller obtained using the innovative hybridisation kit. The group has also contributed to the European MODTRAIN project (www.modtrain.com) for the development of an innovative linkage for rail vehicles.

The group has also participated in the FP6 INTEROP-NoE research network (www.interop-vlab.eu), focusing on data interoperability, applications and processes and addressing issues related to the problem analysis of data interoperability in product development.

In order to perform all of the above mentioned research activities, the group has equipped one of its laboratories with 20 PCs and workstations, used by researchers and PhD students for the development of PLM applications. The workstations are equipped with several software suites and applications, including PLM tools, TRIZ-based software suites such as Creax and Altair for the development of topology optimisation applications.

■ “Touch and design” for high quality surface generation

Laboratories

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The vital core of research at the Department are its laboratories. In fact, the Department boasts several of the finest set-ups in Europe - developed following its transfer to the Bovisa Campus - fitted out with all the necessary, most up-to-date cutting-edge equipment in the different research areas.The Department has always aimed at guaranteeing the excellence of its laboratories, continuing to invest heavily thanks to the subsidisation of funds raised through research contracts.

The laboratories of the Department of Mechanical Engineering are grouped into 18 areas as described in the next sections.

L.A.S.T.La.S.T. was officially inaugurated in July 2001.Research activity at La.S.T. is mainly devoted to the passive and active safety of road vehicles. The following topics refer to active safety.

■ InTenso TesT rIg

The InTenso test rig can measure the location of the centre of gravity and the full inertia tensor of rigid bodies. The test rig consists of a three bar pendulum carrying the body under investigation. The spatial motion of the pendulum is recorded by means of absolute encoders. The components of the inertia tensor are identified by a numerical procedure based on a mathematical model describing the motion of the pendulum. The main characteristics of the test rig are:measuring range: from 50 up to 3500 kg, with an error of less than 1% on the principal inertia moments.

Automotive and Electric/Hybrid Vehicles■ ruoTaVIa

The RuotaVia is composed of a horizontal axis steel drum, providing a running contact surface for road vehicle wheels. A number of measurements, on either full vehicles or vehicle sub-systems, such as single suspension systems, tyres, rims, braking systems or rail wheels, can be taken. The drum is driven by an asynchronous 160 kW motor. Two speed gearbox. First natural frequency of the drum: 80 Hz.Max speed >400 km/h. Max force on the drum: 100kN.

■ MeasurIng hubs and 6 axIs load cell

These sensors can measure the 3 forces and 3 moments acting on a point of a structure. Different measuring hubs and general purpose 6-axis load cells have been manufactured and tested. Furthermore, mathematical models have also been implemented to evaluate the performances of such devices.

The measuring devices described are based on a special, statically determined, three cantilever/spoke structure. In the case of hubs being measured, this type of structure replaces the wheel centre.

A telemetry system has been designed and employed to transmit the signals deriving from the measuring hubs to a data storage unit.

■ duMMy for The objecTIVe eValuaTIon of VehIcle rIde coMforT A dummy has been designed and constructed to measure the same vertical and longitudinal accelerations that would be felt by a human subject at body-seat interfaces. The dummy has a vibrating mass moving along the spine axis. The mass is connected to the H point by means of adjustable springs and an adjustable magnetic damper.

■ InTenso test rig in operation

■ Suspension systems under test on the Ruota Via test rig

■ Prototype Apollo. At the Shell Eco-Marathon® Europe 2011, Apollo set the new world record of 1108 km/kWh, breaking for the first time the barrier of 1000 km/kWh.

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■ hydrogen VehIcles, solar VehIcles

Innovative vehicles, that have won awards at Shell Eco Marathon events (BOSCH Technical innovation award 2007, Autodesk Design award 2009) have been developed. An extremely low energy consumption (equivalent to 2741km per litre of gasoline)was achieved both with the vehicle powered by H2 as well as the one powered by solar panels.

Vehicle Dynamics LaboratoryThe aim of the vehicle dynamics laboratory is to enable students to apply the theoretical knowledge acquired in the field of vehicle dynamics to real situations. In order to achieve this purpose, a moving laboratory was set up. This consists of a vehicle instrumented with an inertial gyroscopic platform to measure not only vehicle chassis acceleration and roll but also pitch and yaw rates, an optical sensor to measure the slip

angle and speed of vehicles, dynamometric hubs to measure tire-road contact forces, a dynamometric steering wheel to measure steer angle and torque, pressure transducers to measure braking pressure on the calipers and several accelerometers to measure road induced vibrations.

The moving laboratory thus allows students to measure vehicle dynamics directly. It also enables them to perform all the tests required to both set up and validate the numerical models developed.Moreover, the possibility of by-passing the vehicle ECU (Electronic Control Unit) is now being studied in order to transfer and test on the vehicle the control strategies for vehicle dynamics of the vehicle control implemented by the students.

The vehicle dynamics laboratory is also equipped with an efficiency measurement system to measure train driving efficiency.

In the case of conventional vehicles, propelled by an Internal Combustion Engine (ICE), this efficiency is evaluated by using the information available on the vehicle’s communication network (CAN bus). This information originates from all the transducers, generally installed on board. As regards taking efficiency

■ Test bench for the assessment of the dynamic stability of two wheeled vehicles

Electric DrivesThe Laboratory of Electrical Drives is a lab specialised in the research, development and testing of electrical drives for industrial and transport applications. The research team has knowledge and expertise in the design of: electromagnetic actuators and motors, power electronics converters, embedded control systems and algorithm custom electronic boards for measurements and monitoring.

The lab is provided with three electric drive test benches with the following rated data:• 35 Nm -7 kW 7500 rpm (braking-motoring);• 2500 Nm – 6500 rpm (controlled passive braking);• 500 Nm 100 kW (braking-motoring).

All the test rigs are fully instrumented for measuring all the electric quantities (voltages, currents, power and energy) and also the mechanical ones ( speed and torque).

The test rigs are suitable for testing electric motors, power converters and complete

measurements on innovative vehicles (full electric or hybrid), the laboratory is also equipped with a set of transducers for electrical power flow measurement.Both measurements (obtained from CAN buses and electrical power trains) are coordinated in order to accurately estimate hybrid power train performance.

electrical drives fed by an industrial electric grid (up to 100 kW) or DC voltage (0-600 Vdc 20kW – 0-100Vdc 400A – 0-25Vdc 1600A).The lab can perform tests on a complete drive in order to define: rated value, dynamic and control performances, operating range and efficiency analysis.

The lab is also supplied by different power suppliers and the most recent measuring

■ Hybridisation kit for passenger cars: detail of the hybrid propulsion system mechanical connection.

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CNC Machine Tools and Computer Aided Manufacturing

instrumentation (scopes, current and voltage probes, high accuracy multimeter, LCR meter, analog and digital data loggers).

In the lab facility, all the instrumentation for custom electronic board prototyping

The Department of Mechanical Engineering operates in many fields of research. All these fields of research require constant development of the mechanical components necessary for the realisation of prototypes useful for testing.Having an internal centre for production of these components allows the times of experimental tests to be speeded up.

The realisation of prototypes is an iterative process and only the constant interaction between the researcher and workshop allows the result to be obtained in a short time.The Department of Mechanical Engineering has developed an internal dedicated workshop where there are several traditional and CNC machine tools and dedicated CAD/CAM centres.

The synergy with leading companies in the production of tools and in the field of CAD/CAM software also allows us to offer ourselves as a partners to the industry sector on topics such as the optimisation of cutting parameters and the study of complex strategies CAM.

The main available equipment of this area of laboratories is composed of:

• 4 Axis CNC Vertical Machining Centre HAAS;

• 3 Axis CNC Vertical Machining Centre FIDIA;

• 3 Axis CNC High Speed Vertical Machining FIDIA;

• CNC Turning Centre Biglia; • CNC Lathe Haas;• CNC Milling Machine HAAS;

• Presetting Conti; • Presetting Speroni;• Traditional machine tools;• Software CAD/CAM: Auton/Esprit, Catia, Solid Edge.

The laboratories in this area boost the research activities mainly in the following research fields:

• Computer Aided Manufacturing; • Tools performance;• Tools duration.

is available both for signals and power converters.The research team is also involved in the outdoor testing of electric and hybrid vehicles that can be fully instrumented using all the laboratory facilities.

Non-destructive TestsDue to the rapidly increasing importance and to the modern normative requirements of non-destructive testing (NDT) for the structural integrity assessment of structures and mechanical components, the experimental activity carried out in this laboratory deals with the application of traditional and novel NDT methods to the critical aspects regarding the production of materials and the design, maintenance and prognostics of mechanical systems.

In particular, metals, polymers, ceramics and composites are experimentally characterised by visual (VT), liquid penetrants (PT), magnetic particles (MT), ultrasonic (UT), acoustic emission (AE) and eddy currents (ET) methods and also by a series of experimental stress analysis techniques: electric resistance strain gages, 2D and 3D digital image correlation (DIC), fibre Bragg gratings, x-ray diffractometry (XRD), photoelasticity (PSA), thermography, holographic interferometry (HI) and brittle coatings. Depending on the technique to be applied, inspections

and measurements are carried out both in the lab and on-site. Where the relevant procedures require it, the personnel of the lab is qualified and certified at Level II and III in the EN473/ISO9712 frame. It has also to be added that the lab is being accredited under the ISO17025 standard.


• PT: fluorescent, color contrast and post-emulsifiable materials;

• MT: fluorescent and color contrast; two magnetic yokes (both AC and DC), a permanent magnet, a magnetoscope (max 6000 A) with different prods and a flexible cable;

• UT: a Gilardoni analogic flaw detector (MG9s) and two Gilardoni digital flaw detectors (RDG500 and RDG2500) with different straight and angled single and double crystal probes; a Harfang X32 phased array flaw detector with 32 crystals probes at 2.5, 5 and 10 MHz; a TOFD flaw detector;

■ Overlap between computed, observed and numerical isochromatic fringes for a centre cracked disc under tensile loading

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• ET: a Nortec 1000S+ flaw detector; a Casoni EEC 35+ flaw detector; different absolute and differential probes;

• DIC: 2D and 3D systems for static and dynamic measurements at highly different scales, from microscope images to large structure analysis;

• XRD: a StressTech X-Stress 3000 X-ray diffractometer;

• PSA: a transmission polariscope and a reflection polariscope;

• HI: a class 3b high-power helium neon laser system;

• CIVAnde numerical tool for the simulation of UT and ET inspections.

The laboratories in this area boost the research activities in different research areas: the first one regards the increase of knowledge and the optimisation of the NDT methods and procedure themselves.

From this point of view, the capabilities of different techniques are studied in order to define or refine the probability of detection (POD) curves considering both the traditional experimental approach and the novel model-assisted probability of detection (MAPOD) one.

A second aspect regards the interpretation of NDT responses which, most of the times, are not yet fully understood: special experiments, such as for example, the application of photoelasticity to visualise sound beams or the optimisation of many parameters in DIC, or numerical approaches, such as CIVAnde or the finite element method, are applied to produce more understanding.

A third activity is the characterisation of the scattering of defects on the NDT stimulus in order to improve sizing.

The second research area of the lab is the development of novel NDT procedures and approaches for the inspection of particular or difficult applicative cases. Examples are the development of: an ET methodology to individuate corrosion-fatigue damage in railway axles or a UT one, based on guided waves, for the structural health monitoring of aeronautical composite panels.

■ Ultrasonic phased array inspection of a railway axle sample containing defects

Mechatronics and Smart Structures LabThe Mechatronics and Smart Structures Lab (M&SSlab) focuses on mechatronics applications ranging from domotics to industrial robotics. Particular emphasis is given to the integrated design of smart systems for noise and vibration control that couple micro-sensors, energy harvesting devices, miniaturised actuators and innovative control architectures. Thus, the approach needs to be multidisciplinary: combining a thorough understanding of the system, a deep knowledge of edge-cutting sensor and actuator technologies and a comprehensive experience of state-of-the-art control algorithms allows the design of groundbreaking devices and systems.

The laboratory is equipped with all the mechanical and electronic instrumentation necessary to design and test the developed devices: shakers, an impedance tube for the testing of noise propagation and the design of noise suppression algorithms, rapid prototyping boards that allow the immediate implementation of Matlab/Simulink® and LabView® codes… Also small scale test benches reproducing different control challenges (from maglev to fluid flow) are available to immediately test developed strategies. As far as robotics is concerned, high precision redundant architectures (closed loop parallel kinematic chains as well as cooperating robots) have been analysed, designed and tested together with “soft” systems, combining active,

adaptive, self-optimising, portable plug-and-produce components with advanced sensing and actuating functionalities, in which the deformability of both joints and links is used for improving HRI (human robot interaction) at the cost of more complex control algorithms for compensating vibrations and positioning errors.

Mechatronics LabThe Mechatronics Lab is equipped with small scale test benches that represent simple mechanical systems and allow for the easy, realistic testing of the innovative control logics directly implemented in Matlab/Simulink®. These benches range from vibration control (both linear and torsional vibrations), to motion control (in addition to a linear and rotational single and double pendulum system, a magnetic levitation plant is also available) to process control (a duct equipped with multiple temperature sensors, heating elements and a blower, a system to regulate the water level in multiple coupled tanks, an industrial plant emulator that allows for the set-up of control logics to compensate for backlash and deformability and friction along the transmission line and a 4 floor lift model to test PLC logics) right up to robotics (the proprietary logic of an industrial robot is interfaced with Matlab/Simulink® in order to facilitate the study of new trajectories and interface the robot

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with vision systems, etc.). In addition to the benches, the Mechatronics Lab is also equipped with several additional sensors, such as accelerometers, displacement transducers (both lasers and LVDTs), force

sensors, a precision balance, thermocouples and multimeters, that not only allow for parameter identification of the various test benches but also complete the measurement set-up for redundant control feedback.

■ Design and testing of a MEMS gyro Robotics LabThe research group is assisted by both Italian and foreign researchers, graduates and thesis students from different disciplines including mechanics, electronics, computer sciences and work organisation. Numerous international research centres from different continents are also involved in Robotics Lab projects. Laboratory skills include expertise in software development and applications, the use of innovative robotic technologies and the development of prototypes in collaboration with the main international research centre. New concepts in intelligent robotics are tested in international projects for space robotics, environmental protection, neuromotor control and automotive assistance in safety.

Future applications currently in the pipeline include reconfiguration in robotics and intelligent systems in mechanics.

■ Mechatronics and robotics teaching lab

VAL – Vibroacoustics LabVibroacoustics Lab competencies cover the vibrations of continuous structures and related radiated sound in various applications, ranging from industrial machinery to household appliances, from railway systems to musical instruments.

On account of being based on state-of-the-art experimental techniques, vibroacoustic analysis complies with the most recent computational methods.

Competencies:• experimental modal analysis;

• indoor and outdoor radiated sound measurements;

• noise source identification and mapping;

• acoustic material testing;

• active control of noise and vibration;

• computational techniques (FEM-BEM).

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Didactic Laboratories


• ICP piezo-accelerometer sets, covering different frequency, sensitivity and measurement ranges;

• different sized impact hammers having different frequency, sensitivity and measurement ranges;

• magnetostrictive actuators and electrodynamic shakers;

• a set of ICP microphones with an integral preamplifier;

• a multi-channel data acquisition system;

• a Brüel & Kjær impedance tube kit 4206/4206-T.

The impedance tube kit permits acoustic material testing in a 50Hz-6.4 kHz frequency range including the measurement of acoustic impedance and admittance, coefficients for sound absorption, reflection and transmission loss. Additionally, feedback active noise control tests, based on a secondary source driven according to an adaptive control algorithm, can be performed.

■ Identified (Experimental Modal Analysis) and calculated (FEM) vibration mode of a grand piano soundboard

■ Finite element modelling and experimental modal analysis on a washing machine cabinet

The Department of Mechanical Engineering takes care of the connection between theory and practice in the teaching activity. With this goal in mind, the Department makes a huge effort in order to allow the students to have practical teaching experiences in the ambit of dedicated areas, properly equipped with up to date instrumentation. Due to this reason specific

laboratories devoted to experimental didactics were also developed, together with the experimental laboratories dedicated to the research. In these structures the students have the chance to apply the concepts gained during theoretical lessons in order to execute practical experiences assigned by the teaching staff.

The didactic laboratories have the following thematic areas: machines and vehicles design, metallurgy, mechanical and thermal measurements, mechatronics and virtual prototyping.Some of these laboratories, such as those concerning mechanical and thermal measurements, mechatronics and virtual prototyping, can host a huge number of students that, working in small teams, develop didactic experimental activities. Other didactic laboratories use equipment shared with the research staff for experimental studies, such as machines for tensile tests or electronic microscopes. These last laboratories can host a lower number of students at a time and therefore in these cases the experimental activities are organised with small groups of students that use the laboratory in different times.

The extremely good feedback obtained every year by the experimental activities for the didactics confirms that this type of teaching approach is good and pushes us to a continuous improvement also in this field.

The didactic laboratories of the Department of Mechanical Engineering cover more than 1500m2 and are organised as follows:

• metallurgic analysis didactic laboratory (400m2);

• mechatronics didactic laboratory (150m2);• measurements didactic laboratory (200m2);

• material testing didactic laboratory (300m2);

• manufacturing processes didactic laboratory (450m2).

The didactic laboratories of the Department of Mechanical Engineering are used by the students of Aerospace Engineering, Automation Engineering, Energy Engineering, Management and Production Engineering, Mechanical Engineering and Design&Engineering.

In total more than one thousand students use our didactic laboratories every year.

■ Didactic experiences in the Measurements didactic laboratory

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The study of cable dynamics represents a key-point in several application fields. In particular the knowledge of the cable damping properties allows the correct estimation, through numerical models, of its response to external inputs such as the wind disturbance. Moreover, because of the small damping associated with these kinds of structures and the consequent instability issues arising when they are immersed in force fields (e.g. cross wind), the use of suitable damper devices are often mandatory. In this sense experimental activities able to define the performances of these devices (e.g. Stockbridge force vs

displacement Frequency Response Function) allow their introduction in the previously defined numerical models. Finally the combined system “cable+damper” (or “cables bundle+spacers”) can be studied and the effective dynamic properties can be evaluated.

All these tests can be carried out following the international standards (e.g. IEC 61897:1998), through a certified ISO 9001 procedure (ITALCERT–Certificate N° 121gSGQ01, SINCERT SGQ N° 023A, N° SGA A20D), or the customer specifications.

The experimental activities can be summarised as:

• cable self damping (Decay Method, Power Method and Inverse Standing Wave Ratio);

• stockbridge damping performances (Force vs displacement FRF, mechanical impedance…);

• cable effectiveness test (cable + damper);

• spacers stiffness and damping properties (hysteretic cycle…).

Cable Dynamics

The laboratory equipment of this laboratory can be summarised as:

• gearing Watson electro-dynamical shaker + amplifier (V617/DSA4-8k);

• unholtz&Dickie electro-dynamical shaker + amplifier (SA15-S452);

• B&K 1050 controller;

• electro-mechanic actuator for the “50m length” cable span tensioning;

• HBM 250 kN load cell for the “50m length” cable span tensile load;

• Kistler 30 kN piezoelectrical load cells for Stockbridge dissipative force;

• B&K accelerometers for the cable and the Stockbridge vibratory state;

• strain gage for the cable stress close to the clamp;

• laser transducers for the cable nodes vibrations;

• accelerometers and load cells conditioning and amplifiers;

• NI DAQ board.

The laboratory is mainly equipped with a 50 m test span: special care has been devoted to the project of the dead ends and the tensioning sets.

■ The 50 m test span for cable dynamics testing

■ The Gearing & Watson Electrodynamic exciter and the laser displacement transducers

■ Control and acquisition systems

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Wind Tunnel Haptics and Virtual PrototypingThe Laboratories at the Department of Mechanical Engineering use the Bovisa Wind Tunnel (operative since 2001) for testing purposes. This facility has a dual purpose. On the one hand, it serves purely as a research tool and, on the other, as a modern instrument for high-technology industrial applications offering advantageous reciprocal synergies. In particular, the Department of Mechanical Engineering is responsible for wind engineering research and applications.Thanks to two different test rooms, the facility is able to offer a wide range of test set-ups and alternatives.

■ Boundary Layer Test SectionIn terms of dimensions, the Boundary Layer test section measures 14m x 4m; it has a maximum wind velocity of 16m/s and a turbulence index of <2 percent. The constant section test room, measuring 35m in length, allows for the setting up of upstream passive or active turbulence generators, used to simulate either the atmospheric boundary layer or harmonic wind. A special device, used for twisted flow generation, has been designed to carry out tests on sailboats. This test section is equipped with a turntable measuring 13m in diameter.

■ Low Turbulence Test SectionThe Low Turbulence test section measures 4m in width, 3.84m in height and 6m in length. Tests can be performed either in a closed test section or in an open jet. Maximum wind velocity is 55m/s while the turbulence level is less than 0.1 percent. The test section is equipped with a turntable (measuring 2.5m in diameter) and a traversing system designed to take wake measurements. Several model supports are equipped with a positioning system in order to vary the incidence angle.

The expertise of the staff working at the Wind Tunnel Facility covers a broad spectrum of wind engineering research and applications topics:

• road and railway vehicles;• buildings and large roof structures;• suspension and cable-stayed bridges;• sailboats;• wind energy.

■ Boundary Layer Wind Tunnel tests on High-Rise buildings (City Life Development Milano)

The haptics and virtual prototyping lab is equipped with the state of the art of Virtual and Augmented Reality technologies for:

• stereoscopic visualisation;

• haptic interaction;

• 3D sound rendering;

• motion capture;

• high-performance parallel computing.

Some of these devices are prototypes developed in the context of national and EU funded research projects.

The research activities can be classified into:

• development and use of Virtual and Mixed Prototypes for testing interactional and functional aspects of industrial products;

• development of software and hardware technologies for Virtual and Mixed Reality applications;

• deformable object simulation on massively parallel computers.

The equipment has been used in several European and national research projects, as well as in industrial projects.

Furthermore, these resources and equipment are used by the students of the Master of Science and by PhD students, to carry out studies related to the topics of their thesis or of their research.

Virtual Prototyping Lab The Virtual Prototyping Lab is equipped with 10 high-end workstations running several professional software applications for the development of virtual prototypes used for the aesthetic, ergonomic and functional analysis of products prior to manufacture.

The Lab includes a virtual room equipped with a Cyviz - VIZ3D system for 3D stereoscopic visualisation based on passive rear-projection technology, used for the visualisation of virtual prototypes in real scale. Virtual environments and products boasting photorealistic quality can be displayed in real-time. The position of the user standing in front of the screen is tracked by means of an A.R.T. optical tracking system. Furthermore, the Lab is equipped with a 6 degree of freedom haptic

■ Mixed reality seating-buck

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Process Metallurgy and Materials Analysis

device - the Haption Virtuouse system - used for the development of applications based on haptic interaction with virtual objects. Computationally demanding simulations, such as the simulation of deformable objects, collision detection, numerical integration and acoustic rendering are developed by means of massively parallel algorithms using a NVidia CUDA framework on a high performing parallel Tesla S1070 computing system. Augmented Reality technologies are used for the integration of virtual objects into the real environment: the virtual objects can be seen in the context of use and can also be manipulated. This equipment is used for the development of applications requiring the digital simulation of products and their behaviour as well as for user interaction with these products in various domains, including automotive, aerospace, industrial design, textile and garments, consumer products, domestic appliances, and many others besides. As an example, a configurable seating buck integrating various technologies was developed and used to assess the functional, aesthetic and ergonomic aspects of the driving seat of a car.

Reverse Engineering Lab The Reverse Engineering Lab is equipped with the latest generation systems for real object acquisition and with software tools for the subsequent creation of digital models. More specifically, the Lab is equipped with four 3D acquisition systems: the optical 3D VI-9i Konica Minolta digitiser, a high speed, high precision laser scanner boasting a measurement accuracy of ± 50µm; a NextEngine scanner based on MultiStripe Laser Triangulation technology, featuring an accuracy of ± 0,1mm; a GOM Atos II 3D digitiser, based on the fringe pattern projection principle, with a fixed focal, mounted on a Kuka robot; and an MLX MicroScribe by Immersion, consisting of a mechanical, contact-based, manually controlled digitising device boasting an accuracy of around 0.3 mm.

These systems are used to digitise objects with various shapes, such as, for example, automotive parts, cast/stamped/plastic-moulded products, industrial design products, physical mock-ups and others.

■ “Satin” haptic strip for surfaces evaluation

■ 3D digitising for reverse engineering

This laboratory consists of a set of analytical equipments as well as processing and mechanical testing systems aimed at investigating material behaviour during processing and service. For obvious reasons, the activities carried out and the equipment

available are strictly linked to those referred to material testing labs described in the following section.

The equipment is organised in four laboratories, as described below.

■ Scanning Electron Microscopy (SEM) investigation

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Microstructural Investigations and Failure Analysis LabResearch studies are mainly aimed at identifying the microstructural features affecting the mechanical performance of metals as well as their behaviour during metalworking processes (i.e.: casting, hot/cold plastic deformation, sintering, welding…). Root Cause Failure Analysis (RCFA) represents an important field in terms of the activities performed in the lab. These investigations on ultimate failure causes are carried out through observations, experimental analyses, design of specific tests, etc… Based on a macro and micro scale approach, all the observations and data collected are used to identify the causal-effect relationships capable of fully explaining broad failure hypotheses.Microscopic devices are also used for inclusion/defect rating according to traditional and ‘extreme value’ concepts, as a support to studies in the area of structural integrity assessment.

The laboratory is equipped with a scanning electron microscope linked to detectors for microchemical and crystallographic analyses. A set of optical metallographic microscopes, hardness and microhardness testers is also available together with the full range of preparation equipment required for macro-cutting, precision sectioning, mounting, grinding, polishing and etching of the metallographic samples.

The lab is generally used to carry out microstructural analyses of metallic alloys as well as those pertaining to the failure of structural and functional parts.

Details of main equipment for microstructural analyses:

• Zeiss EVO 50XVP Scanning Electron Microscope (200 V-30 kV);

• Oxford Instruments INCA-Energy 200 X-ray EDS microanalysis module;

• Oxford Instruments INCA-Crystal 200 Electron Backscattered Diffraction System module;

• Leitz Aristomet optical microscope (25x-500x; brightfield, darkfield modes, polarised light);

• Leica MEF4A / M inverted optical microscope (50x-1000x);

• WILD Heerbrugg / Leica MZ8 Stereomicroscopes;

• ERNST Twin hardness tester (HV / HR / HB, load 150 - 1875 N);

• Zwick Z2.5/TS1, instrumented universal hardness tester (HV / HR / HB, load 2N-200N);

• Future Tech FM-700 / Leica VMHY30 microhardness testers (KV / HK; load range: 0,01-20 N).

■ Microstructure investigation: forged duplex stainless steel

■ Fatigue fracture surface analysis

Physco-chemical Bulk and Surface Analyses LabStaff expertise and the equipment found in this lab are focused, in particular, on physico-chemical analyses of metallic alloys and surface coatings. Thermal analyses for phase transformations, thermal treatment simulations and microstructural studies can be performed by means of a differential scanning calorimeter and a dilatometer capable of inducing thermal cycles from room temperature to 1600°C. In particular, the dilatometer can be successfully employed for TTT and CCT

curve determination and for investigations on transformation kinetics. A Glow Discharge Optical Emission Spectrometer is also available for accurate bulk chemical analyses and concentration profiles of samples having a chemical composition gradient from the surface to the interior.

Surface material layers are not only very important in several engineering applications but also of broad interest in the specific field pertaining to wear and/or corrosion behaviour of parts for structural and functional applications.

■ Microhardness instrumented indenter and scratch tester equipment for analyses on properties and adhesion and surface coatings

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The optimisation of the surface treating process, the strength and toughness of the surface layers under a wide range of service conditions are of paramount importance for the overall performance of the case-core system. The lab is therefore equipped with a pin-on-disk tribometer, a scratch tester and instrumented micro-hardness testers which are used to characterise the mechanical properties of such surface layers.Examples of research activities are: the optimisation of heat treatments for innovative aluminium alloys and new steel grades, the development of hardened layers of light metal parts for automotive applications as well as thermochemical surface treatments for titanium and high-temperature superalloys for aerospace applications.

Details of main equipment:

• Netzsch dilatometer equipped with furnaces boasting temperatures of up to 1350°C;

• Setaram DSC / GTA thermal analysis system equipped with furnace and rods for temperature cycles of up to 800 and 1600°C;

• Horiba Jobin-Yvon GDP2 glow discharge optical emission spectrometer (polychromator for simultaneous detection of 19 elements and dedicated UV lines for C, N, O);

• CSM pin-on-disk tribometer instruments;

• CSM Microindenter instruments for instrumented microhardness (loads from 0,01 to 10 N) and scratch tester (conical stylus with 200 µm / 100 µm tip radius, loads in the range 0.3 - 30N);

• Future Tech FM-700 / Leica VMHY30 microhardness testers (KV / HK; load range: 1-2000 g);

• Taylor-Hobson roughness tester and profilometer.

Process Metallurgy LabSimulation and experimental investigations on metallurgical processes are carried out in this lab by a series of muffle furnaces that can be operated up to temperatures of

1200°C in ambient or inert atmospheres, to simulate thermal treatments or high-temperature service. A melting resistance furnace (crucible of about 1 litre with temperatures of up to 1700°C) can be used for the production of small amounts of experimental alloys and castings while a laboratory rolling mill is available for cold and hot rolling under conventional or asymmetrical conditions.

Other plastic deformation processes can be studied by means of proper dies and experimental devices installed in a universal testing frame. Extrusion dies for small rod and tube production are available together with a hot compression/tension testing device for hot working process optimisation. Forming properties of metallic sheets and forming limit curves can also be studied by punching tests performed on mapped specimens. Finally, process development can

■ Experimental heat treatment of steel

also be conducted by means of simulations using Finite Element Methods and the application of multi-physics platforms capable of coupling fluid-mechanics, electromagnetic analysis, thermal aspects, structural-mechanics, plastic deformation processes, mass transport, solidification and diffusion phenomena.

The research unit can also provide assistance at production plants for measurements and the characterisation of industrial production processes.


• Nabertherm melting furnace (boasting a temperature of up to 1700°C);

• Carbolite tube furnace (boasting a temperature of up to 1200°C, in ambient or inert atmospheres);

• Carbolite air-recirculation chamber furnace (boasting a temperature of up to 750°C);

• Lenton chamber furnace (boasting a temperature of up to 1300°C);

• OAM rolling mill (symmetric and asymmetric operation mode, rolls of 150 mm diameter; speed: 0-20 rpm continuously adjustable).

■ Steelmaking process simulation

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Material TestingCharacterisation of Materials LabThe full characterisation of materials often requires investigations related to mechanical and corrosion factors. At this Lecco-based laboratory, additional facilities are available for both static and dynamic mechanical testing, corrosion characterisation and non destructive testing.

Experimental activities are performed by means of hydraulic and electro-mechanical universal testing machines to determine the tensile, bending and compression behaviour of materials in a static and dynamic regime. In particular, fatigue testing can outcome single material fatigue limit or full Wöhler diagram; the calculation of the Paris curve (da/dN vs ΔK) of materials is also available.

Fracture mechanic tests can also be carried out to determine material toughness parameters such as KIC, JIC, CTOD. In order to evaluate corrosion resistance, a salty fog chamber with a 400 litre capacity, is also available in the laboratory.


• Instron, MTS, DMG testing frames for static and dynamic testing (load cells from 1 to 200kN);

• ITALSIGMA machine for rotating bending fatigue;

• ERICHSEN salty fog chamber for corrosion tests in accordance with EN ISO 9227 and ASTM B 117 certification;

• ERNST Twin hardness tester (HV / HR / HB, load 150 - 1875 N);

• Zwick Z2.5/TS1, instrumented universal hardness tester (HV / HR / HB, load 2N-200N);

• Taylor-Hobson roughness tester and profilometer;

• GIILARDONI ultrasonic tester.■ Crack path in sintered steels

■ Microstructure of sintered steels from diffusion bonding powders

Material testing is a cross-cutting activity between the two main disciplines of metallurgy and mechanical behaviour of materials. The experimental activities of the latter can be grouped in two areas: Mechanical behaviour of materials and High temperature properties of materials.

Mechanical Behaviour of Materials Lab Studies dealing with the development of new materials or new coatings are the field where microstructural analysis is coupled with a thorough material characterisation under different conditions (tensile and cyclic tests, fracture properties…).An important part of the studies are dedicated to the fracture and fatigue characterisation of materials for ‘structural integrity assessment’: the material properties are the base for an assessment according to the fracture triangle (material-service-defect) in which they are combined with the analysis of service conditions and of potential defects for determining if the component is suited for a given application. Application of these concepts ranges from aerospace structures to automotive and oil & gas fields and they are also coupled with an assessment of the ultimate load that can be sustained by a structure, where static fracture properties are combined with FE analyses of the cracked structure.A traditional field of application is also the fatigue and durability assessment of the components, where the determination of the S-N diagram under different

conditions (load spectra, corrosion) allows researchers to make accurate life predictions for components. In this field a particular role is played by the ability to run HCF tests (N > 106 cycles) with tests containing micronotches representing the extreme defects that can be present in the material.In recent years an increasing number of activities is dedicated to the characterisation of composite materials (static and fatigue fracture resistance, fatigue) in order to study the ‘metal replacement’ in some demanding applications. An advanced field of research is also the combination of these tests onto adhesive joints/specimens in order to make a structural integrity assessment of composite-composite or hybrid (metal-composite-joints).

■ Tri-axial (axial 250 kN, torsion 2200 Nm, pressurisation 100 MPa) universal testing machine

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The investigations into the mechanical behaviour of materials are the basis for developing constitutive models for static and cyclic behaviour, characterisation under static and cyclic fracture, endurance and fatigue testing.Accordingly the types that are currently done are:

• monotonic tensile tests with strain measurements;

• cyclic tests under monotonic (ASTM E606) and biaxial/ traxial tests with strain measurements under load/strain control;

• fracture characterisation for ductile brittle transition of materials with KIC and JIC measurements;

• crack propagation tests according to ASTM E647 with closure measurements;

• static and cyclic fracture characterisation of composites under Mode I and Mode II;

• fatigue characterisation (S-N diagram) under axial, bending and torsional loads and multiaxial stress patterns;

• variable amplitude endurance fatigue tests under block loadings and stress histories.

Details of main equipment for mechanical behaviour of materials

• 6 hydraulic universal testing machines (force up to 250 kN) equipped with extensometers/clip-gages and environmental chambers;

• 1 hydraulic triaxial universal testing machine (Force: 250 kN; Torque 2200 Nm; pressure 100 MPa);

• 2 electromechanical universal testing machines (force up to 150 kN);

• 1 resonant testing machine for dynamic axial load applications (force 100 kN);

• 3 resonant testing machines for dynamic bending load applications (bending moment: 160 Nm);

• 3 rotating bending fatigue testing machines for specimens (bending moment: 35Nm).

■ Mono-axial 100 kN universal testing machine

■ Three point bending fixture and clip on displacement gage for fracture toughness and fatigue crack growth tests.

High Temperature Properties of Materials LabThe high temperature mechanical behaviour of materials is a specialised branch of materials characterisation for energy and engine components that are serviced at temperatures up to 1200°C, where it is important to identify constitutive equations under monotonic and quasi-static behaviour for long exposure times (creep) together with specialised techniques for determining crack initiation under quasi-static and cyclic loading and the fracture resistance.The different kind of experiments that can be carried out are:

• monotonic and quasi-static tensile and compressive stress up to 1250°C;

• cyclic tests for low-cycle fatigue characterisation up to 1000°C;

• fracture tests for JIC up to 1000°C;

• certified creep life and creep crack growth tests up to 1000°C equipped with potential-drop based crack-size measuring system.

• fatigue in HCF regime (frequency range 10-100 Hz) up to 1000°C.

• crack propagation tests (according to ASTM E647) up to 1000°C.

Typical research fields include identification of the creep behaviour of materials such as structural steels, high-temperature alloys and light alloys, with a view to defining their safe service life and property evolution

as a function of their time spent at high temperatures. Mechanical characterisation is frequently coupled with analyses on microstructural changes induced by the high-temperature service. These experimental testing campaigns are often combined with modelling activities. Hot tension and compression tests on structural and microalloyed steels at working temperatures corresponding to the range used in hot rolling and in forging is another field of considerable interest. In this case also, mechanical characterisation is carried out jointly by means of a thorough investigation of the precipitates affecting austenite grain-boundary cohesion and on the kinetics of phase precipitation, grain recrystallization and growth.Material characterisation under LCF and HCF is meant to establish material

■ Induction heater and extensometer for high temperature tests.

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Railway Engineering properties for life assessment and especially for investigating defect tolerance of energy components considering all the phases of their service life (start-stop cycles + dwell times, mission profile of gas turbines and aeroengines). The materials characterisation is also the base for the development of ‘life extension’ concepts to energy/engine components where the degradation caused by temperature/stress exposure has to be modelled and incorporated into structural integrity assessment.

The main equipment for high temperature tests is composed of:

• a universal MTS servo-hydraulic testing machine equipped with extensometers and clip gage;

• Amsler creep testing frames equipped with 5 resistance furnaces for testing at temperatures of up to 900°C, sets of LVDT transducers and data acquisition systems. This equipment allows creep tests to be carried out according to the UNI EN ISO 204 standard, in compliance with the ISO 9001-2008 standard;

• 2 single furnace creep machines equipped with extensometers and potential drop for creep-crack growth tests;

• induction heating systems and a resistance tubular furnace (temperatures up to 1250 °C) to be mounted onto axial testing machines, the RUMUL axial resonance machine and the triaxial testing machine.

■ Electromechanic machine specifically designed for constant stress or load creep tests as well as for other tests in the RT-1000°C range where materials operate in the creep regime.

■ Lever-arm creep machine for conventional creep strain and creep rupture tests equipped with 5 loading trains.

The Railway Engineering laboratory consists of some permanent dedicated test stands, of reconfigurable facilities which can be used for testing of railway components and subsystems, and of outdoor testing and measuring facilities.

The Test Bench for Pantograph-Catenary Contact: allows full scale testing of the contact between the contact wire and the contact strip under the effect of mechanical and electrical parameters, to define experimentally the effect of mechanical parameters (contact force, sliding speed)and electrical parameters on the wear of the contacting surfaces (electrical current flow). The maximum sliding speed is 250 km/h and the system can be operated under electric current flow in AC or DC mode up to 1200 A (in DC mode).

The Hardware-in-the-Loop Test Stand for Pantographs: to study pantograph-catenary interaction by means of hybrid simulation. Hybrid simulation is based on the interaction, through the use of a suitable testing apparatus and of real-time computing, between hardware components and a virtual simulation model. In this test stand, a physical pantograph is set in interaction with a catenary model: the contact forces generated at the collectors of the pantograph are measured by load cells and processed by a real-time board according to a mathematical model of the overhead equipment to derive the vertical

■ Test rig to study pantograph-catenary contact

displacements of the contact wire at the collector strips. These displacements are fed back on the pantograph head using a suitable vertical actuation system. At the same time, a lateral actuation system moves the vertical actuators across the pantograph head according to a triangular waveform to reproduce the effect of the stagger in the contact wire.

The Secondary Suspension Test Rig: this set-up aims at reproducing the dynamic behaviour of a rail vehicle secondary suspension, with special focus on the experimental investigation of active and semi-active suspensions. The rig is composed by a high-speed bogie with pneumatic secondary suspension resting on two rails which are actuated by a

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combination of vertical and roll movement. A steel structure filled by an adjustable ballast mass is placed above the secondary suspension, to reproduce in full scale the inertial and gravitational effects associated with the carbody mass. Curve negotiation is reproduced by tilting the top of rail according to a desired cant deficiency time history. Furthermore, frequency response functions can be investigated by applying harmonic displacements to the rails.

The Test Rig to Calibrate Instrumented Wheelssets: this test rig is designed to allow the calibration of wheel-rail contact force measuring systems according to the measuring system based on the application of strain gauges on the axle and wheels

■ Full scale laboratory demonstration of a pneumatic active suspension for a high speed train.

of one or more wheelsets. The test rig is designed to host various types of railway bogies after the wheelsets are instrumented by strain gauges. Hydraulic actuators are used to apply on the bogie a combination of static and dynamic loads in vertical and lateral directions and the corresponding vertical, lateral and longitudinal contact forces are measured by a system of load cells. Based on these measurements, the instrumented wheelsets can be calibrated according to different (deterministic / non-deterministic) methods.

The Rotating Bending Fatigue Test Stend for Railway Axles: this bench is used to investigate crack propagation in railway axles as a function of the service loads and of environmental conditions.

A micro-crack is created on the surface of the axle and crack propagation is studied by repeatedly measuring the dimensions of the crack as a function of the number and amplitude of the bending fatigue cycles applied. Corrosion effect can be simulated by the controlled application of water on the surface from where the crack originates.

The Reconfigurable Testing Facilities: consist of adaptable loading frames having various dimensions and allowing the dynamic / fatigue testing of railway subsystems / components ranging from large size (whole bogie, secondary suspension) to mid-small size (primary suspension, yaw dampers etc.). Force, deformation and vibration transducers

can be fitted on the system under test, depending on the specific requirements of the test being performed.

The Outdoor Testing and Measuring Facilities consist of portable actuators (including a range of instrumented hammers), portable data acquisition and storage devices and of a large set of transducers, including a linear array of 24 microphones, different types of vibration transducers (accelerometers, linear / angular displacement tranducers, gyroscopes) and strain gauge data acquisition systems. This equipment is used to perform line tests and/or modal characterisation of railway vehicles, of the railway track and of the overhead equipment.

ManufacturingTransformation processes play a key role in the strategies adopted by industrial companies who wish to compete on the market with high quality, sustainable products. Material and information transforming processes use not only technologies and physical systems but also methods and tools to design and manage transformation activities during product life cycles. Technological solutions for future transformation processes need to respond to the increasing needs of competitiveness and global sustainability.

The Laboratory of Manufacturing is mainly dedicated to support the activities of the research line Manufacturing and Production Systems, whose mission is to integrate all the activities required to transform ideas into products. It is organised in different areas dedicated to specific research subjects, and in particular:

• MI_crolab - Micro Machining Laboratory;

• SITEC Laboratory for Laser Application;

• Water Jet Lab;

• Geometrical Metrology Lab;

• Manufacturing Systems Lab.

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MI_crolab - Micro Machining LabMI_crolab activities were initiated at the Mechanical Engineering Department in 2008, following co-founding of its launch project by the Politecnico di Milano and the Italian Ministry of Education, University and Research (MIUR).

The laboratory’s mission is to study the fundamentals of the material removal mechanism during micro-mechanical machining (micro-milling, micro-drilling, micro-turning, etc.) and to apply this type of knowledge to the industrial field based on real case studies and applied research projects.Micro-mechanical machining involves tolerances on the workpiece in the vicinity of less than 3 µm; this class of precision

is commonly called “ultra precision” and can only be obtained by means of high performance machine tools, such as the one available at the MI_crolab (Kern EVO 5 axis CNC machining centre; precision on the workpiece: ±2.0 µm; spindle speed: 50,000 rpm; controller: Heidenhain).MI_crolab offers new research opportunities in the field of high precision manufacturing processes, particularly important for well established and fast-growing industrial sectors - bio-medical, energetic, aerospace and electronic - which require the production of real 3D micro-components on a wide range of materials (metallic alloys, composites, polymers and ceramic materials) and on large volumes. MI_crolab aims to promote high precision and micro-machining in Italy, offering

specific knowledge and equipment to industries through targeted projects and a network of contacts with the most important Italian and international research centres and associations in the micro-world.

SITEC Laboratory for Laser ApplicationThe SITEC-Laser was installed in 2000 with the aim of broadening the Department’s knowledge in relation to the application of power lasers. The experimental laboratory currently possesses fibre -laser sources with power ranging form 1 to 3 kW cw, and one of 50 W pw suitable for micro-machining. In addition, diode lasers (2 to 6 kW) and Nd:YAG lasers (120 W to 1 kW) are also available.

The fibre -laser sources were acquired in 2007, thus making SITEC the first Italian University laboratory boasting expertise on fibre sources and processes, even though previous research activities had already been initiated in 2004 in collaboration with IPG Photonics (Italy). This leading position is also corroborated by the organisation of an Italian workshop on high brightness laser applications, which is fast becoming the Italian forum for high brightness laser producers and users.

SITEC competencies focus on the characterisation of laser processes in terms of process definition, parameter selection and process optimisation for different laser processes, such as laser welding, cutting and drilling of different materials both at macro and at micro scale, laser cladding and laser hardening.

■ 5-axis ultra precision machining centre

Moreover, the 1 kW source was designed using a special device aimed at directly monitoring the laser process using the optical combiner of the source itself. This is a unique solution. In fact there are no other similar applications in the field of fibre lasers thus making the prototype installed at the Politecnico the only equipment available for experimental testing.

Water Jet LabResearch activities related to Water Jet (WJ) and Abrasive Water Jet (AWJ) applications were initiated more than 15 years ago thus making the WJ Lab one of the foremost in the world. These activities can be divided into two main areas: WJ/AWJ processes and the understanding of system behaviour. The first area covers traditional and new water jet applications such as the cutting of a broad spectrum of materials, surface treatments, rapid prototyping and forming.The research area on system behaviour deals with simulation, measurement and

■ Laser cladding

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control of the most relevant quantities and signals generated by the pumping system (oil and water pressure and flow rate, electric power required by the pump, piston velocity, abrasive mass flow rate, water jet velocity and structure, etc.). The aim of this area is to evaluate the performance of system components; to monitor their working conditions (also for diagnostic purposes); to explain process physics, to identify a system model as an instrument for the study of new components and to analyse the effect of the plant (pump and handling system) on machining quality. Furthermore, specific equipment was also developed by the WJ Lab to improve machining capabilities: a patented closed loop controlled abrasive feeder, a laser Doppler water jet velocity measuring instrument and an additive mixing and injecting system were engineered, created and made available for research and industrial project applications.Additionally, the WJ Lab can count on a WJ/AWJ plant (a 5 axis Tecnocut handling system and a 380 MPa flow pump). Other unconventional technologies available at the lab include plasma cutting and ultrasonic metal welding.

Geometrical Metrology LabThe Geometrical Metrology laboratory of the Department is devoted to performing high accuracy measurements. The laboratory is located in a strictly controlled environment (80 m2) with a

■ Water Jet cutting

temperature range of 20° ± 0.5° C (0.2 °C/hour and 0.5 °C/m limits) and a relative humidity of 45% ± 5%. Additionally, it is isolated from external vibrations (low pass frequency cut-off 4 Hz, with 0.001 m/s² up to 50 Hz). This creates a perfect environment for research and industrial applications involving dimensional and geometrical measurements. At present, the laboratory owns the following measuring instruments:• Alicona Infinite Focus micro coordinate measurement system (vertical resolution of up to 10 nm);

• Zeiss Prismo 5 VAST MPS HTG coordinate measuring machine (EL,MPE = 2,0 + L/300 µm);

• Microrep DMS 680 universal length measuring system (EL,MPE = 0,5 µm);

• Zeiss Rondcom 41-A roundness and cylindricity measuring instrument;

• Mahr Perthometer PGK surface finish measuring instrument.

Together with several other traditional measuring instruments, including length, geometric and micro-geometric reference material standards. At present, the laboratory is accredited for geometric master calibration and CMM performance verification.

The Geometrical Metrology lab boasts competencies in the geometrical characterisation of manufacturing processes, complex shaped products reconstruction and verification, uncertainty evaluation and cost effective inspection planning. In particular, research in the lab is focused on studying and developing:

• scale independent geometrical metrology methods (from large to micro scale), like multi-sensor data fusion and manufacturing signature model identification;

• approaches for coordinate measuring system inspection planning, from sampling strategies to sensor configuration and path planning;

• virtual CMM software for task specific uncertainty evaluation.

Manufacturing System LabThe Manufacturing Systems Lab is equipped with servers and workstations for research and teaching. A variety of commercial software is currently available at the lab including CAD/CAM (SolidEdge, Esprit, Hypercam, Parasolid, CATIA), manufacturing system simulation (ARENA), mathematical and constraint programming (ILOG CPLEX, SOLVER, SCHEDULER) and process simulation (VERICUT). Moreover, a set of internally developed software is installed and available for research, industrial applications and

consulting. These ensure the most advanced research results achieved in the lab in the areas of manufacturing system analysis, production and process planning and machine tool simulation. The software FLOWLINE is based on analytical methods for manufacturing systems analysis. FLOWLINE is capable of estimating the production flow performance of complex manufacturing systems both rapidly and accurately. It represents a valid alternative to simulation during the system configuration / reconfiguration phase. The TPS software TPS (Total Production Scheduling) is able to generate production plans and schedules under finite capacity constraints, based on constraint programming. TPS is currently successfully implemented in real production plants covering several industrial sectors.With regard to simulation, the research carried out has generated a language for production flow optimisation (DEOS, Discrete-Event Object-oriented Simulation), applications for machine tool simulation (customised plug-ins for VERICUT) and reconfigurable simulation models for the design of diagnostic laboratories for health care applications. The list of software available in the lab is continuously upgraded depending on research requirements and results. The Lab is connected via a video-conferencing system to a European network of labs called VRL KCiP, recently transformed into the European EMIRACLE Association, and it is part of the Visionair European research infrastructure for virtual manufacturing applications.

■ CMM based product verification

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Numerical SimulationThe numerical simulation supports the research and development activities that include the verification of product behaviour and their optimisation as well as support for the definition of the experimental test rig required by the laboratory physical tests on the products. To this purpose, the laboratory is equipped with a set of computational software, both commercial and developed by internal research groups. All of this software runs on dedicated server also able to realise parallel computing.The most of the software tools as well as the hardware are structured in order to obtain a certified output, meaning that they produce results associated with a formal proof that are correct.The laboratories in this area boost the research activities mainly in four research fields, as briefly described below.Geometric modeling and numeric simulation of machine components subject

to physical phenomena of static or dynamic type and also in the presence of fluids.Virtual simulations for design, product development, optimisation, ergonomic analysis and comfort.Study of the systems and the methods of technical verification of numerical models in connection with experimental models.Techniques of geometric modelling for virtual simulation.

■ Numerical analysis of the dynamic behavior of a fan chassis

■ Geometric modelling and numerical analysis for the definition of an experimental test rig for a washing machine

■ Geometrical model for the design and optimisation of a tram boogie

Composite Material Parts and ModelsThe possibility to manufacture models in carbon fibre or composite materials is assuming more and more importance in many research fields. In particular these models can be adopted in wind tunnel (WT) tests and control logic development test rigs.

Concerning the WT tests, the lightness and stiffness are two very important features in all the aerodynamic “static” tests. On the other hand, aero-elastic models can also be created considering a suitable design of the composite structures (reproduction of the dynamic properties).

Besides WT applications, composite models represent a very attractive solution in many control test rigs. The possibility to embed sensors and actuators (e.g. FBG optical fibre and piezoelectric patches) inside the model leads to the so-called “smart structures”. In this field several studies are carried out dealing with observation and actuation issues as well as the development of innovative control strategies for vibration suppression.

For the WT tests, the experimental activities in which carbon fibre or composite materials are used can be summarised as:

• vehicle aerodynamics;

• civil application aerodynamics (high rise buildings, long span bridges,…);

• sail plan analysis (with rigid sails).

Test rigs for vibration control applications have been created for the study of:

• independent Modal Space Control (IMSC);

• disturbance Estimators;

• resonant Controllers;

• distributed sensors control.

The models are created mainly by applying the “vacuum bagging” technique. Other techniques are also available. The 120°C oven dimensions are 2x2x1.5 m.The control laboratory has also 1 D-Space and 2 National Instruments (NI) PCIE-6259 control boards and several consumable materials (FBG, piezoelectric patches…).

■ Composite material model of sails for performance evaluation by means of wind tunnel tests

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Tests of Mechanical ComponentsThe Laboratory Tests on Mechanical Components performs tests on full scale components. Components can be either simple machine elements (i.e. cogwheel or bearings), sections of complex devices (i.e. power transmission lines or modules of aircraft fuselage) or complete machines (i.e. crane lifting or household appliances).

The large size of our laboratories also allows to set up tests both on mechanical components and civil constructions (i.e. acoustic panels for railway lines or portions of bridge carpentry).

Different types of tests are performed: static strength tests, tests to characterise the dynamic behaviour of the components, fatigue tests, approval tests, etc.

The main areas of experimentation are: machine construction, railway, automotive, aviation, civil constructions and household appliances.

The design of a suitable set-up test, able to reproduce real load conditions, is performed by our researchers, who can count on hydraulic and electric actuators, controlled motors, shakers, test machines and innovative devices for the application of forces.

The availability of modular frames, together with the internal workshop, allows the design of the more realistic and congenial set-up test.


• hydraulic and electrical actuators with capacities between 2 KN and 1000 kN;

• shaker with capacity between 100 N and 20 kN;

• electric drives with capacities up to 100 kW;

• test frames dimensioned for loads up to 1000 kN that can host larger objects, up to 15 metres high.

The laboratories in this area boost the research activities mainly in the following research fields:

• energy;

• transportation;

• aerospace;

• constructions and land infrastructure.

Diagnostics LabThe Diagnostics Lab applies the experience acquired by the Rotordynamics Research Group and, in particular, that related to the dynamics of rotating machinery for power generation. It has now also been expanded to encompass general machine diagnostics including machine and traction equipment components.Outdoor testing performed by the Diagnostics Lab includes:

• technical assistance during initial start-ups of new power generation installations;

• power plant activation tests for thermal and hydro turbines. This service includes monitoring the correct functioning of safety systems;

• “on-site” diagnostics of rotating machinery, in particular with regard to power generation.

Ongoing collaboration is currently under way with Franco Tosi, Ansaldo, General Electric and Edison.The Diagnostics Lab is also involved in the diagnosis of machine and traction equipment components: roller and oil-film bearings, gearboxes and transmissions;

electrical motors and turbine blades.The Diagnostics Lab is equipped with:

• hardware and software for field testing;

• test rigs for oil-film bearing analysis, diagnostics and characterisation;

• test rigs for roller bearing diagnostics;

• test rigs for gearbox/transmission diagnostics.

A joint cooperation project with Bombardier Transportation has seen the instalment of a full-scale test rig for the diagnosis of train traction equipment in Vado Ligure (SV).

■ Full scale test-rig for the diagnostics of traction system of high speed trains. This rig is able to reproduce the dynamics of wheel/track contact and it is suitable for the diagnostics of components like gear and rolling element bearing and for the testing of other components, like joints, motors, etc.

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Gear and Power Transmission Lab The following testing facilities are available at the Gear and Power Transmission laboratory:

• a VIBRU test bench for TE (Transmission Error) and noise measurements on single gear sets and gearboxes, a 100 kW AC motor, boasting a maximum speed of 3800 rpm, and two eddy current brakes equipped with high resolution optical encoders;

• a Back-to-Back bench for pitting, micropitting and scuffing tests boasting a circulating power of up to 300 kW and a load torque applied by means of a rotating hydraulic actuator thus making it suitable for variable load amplitude (VLA) tests. Splash or oil jet (in- and out- of mesh) lubrication;

• a mechanical resonance pulsator for STF (Single Tooth Fatigue) bending tests at constant load amplitude;

• a 30 kW DC motor/brake test bench for endurance and efficiency tests on gearboxes.Thanks to the general purpose testing machines available at the Department, in addition to backlash and torsional stiffness tests, VLA STF tests can also be carried out.

Complex Tests LabThe laboratories at the Department of Mechanical Engineering are constituted by three large covered areas, capable of hosting large experimental set-ups. In particular, thanks to the size of these areas, tests on full-scale components can be carried out.Among others, experimental tests have been conducted on metallic structures, civil structures, operating machines, vehicles, aircraft, railway vehicles and their components.

■ 100 kW “VIBRU” test rig for transmission error, vibration and noise of gears

■ “back-to-back” test rig for gears with hydraulic torque application

Several types of tests are conducted at the laboratories: fatigue tests, in accordance with the regulations in force, resistance control and characterisation of static and dynamic behaviour, modal identification, vibration and noise controls and the setting-up of active-control systems for machines and complex systems.

We are also able to carry out test bench (bench-test) prototypes for the analysis of specific industrial needs. In particular, with regard to railway activities, the labs are equipped with three complex test benches: the first, in accordance with international regulations, is designed to carry out fatigue tests on railway boogies. The second is a frame, capable of not only hosting and moving a railway boogie but also a section of a full-scale wagon, in order to optimise the active-control system of pneumatic secondary suspensions. The third test bench recreates load conditions during wheel-rail contact. Thanks to this last set-up, suitably instrumented railway boogies can be gauged and then sent on-line to register and diagnose the actions exchanged between the wheel and the rail under service conditions.

Furthermore, there are also several hydraulic actuators which can be controlled in a closed or forced closed loop position. In order to simulate service actions, actuator capacity varies between 1 and 1000kN. Additionally, our digital multi-channel control systems allow for complex test management.

Outdoor TestingThe Department of Mechanical Engineering is equipped to perform a wide variety of field tests. A few examples of the options on offer are listed below:

• Railway dynamics: the Department boasts years of experience in this field and a number of ongoing partnerships with the FS group (Italian railway company), AnsaldoBreda, ATM Spa (Milanese Public Transport Company), Firema and many others.

• Vibration measurements: varying competencies range from mechanical system characterisation to vibration impact on individuals.

• Dynamic testing of civil structures: tests to check and verify project hypotheses, design and deployment of integrated measurement systems for the purpose of structural health monitoring. The department has years of expertise in this field with examples including the G. Meazza stadium, the Duomo and the new Regione Lombardia complex, the highest building in Italy.

• Noise measurements: the department offers a series of technologies targeted at noise source localisation. Among these, worthy of particular note are beamforming, acoustic holography, 3D acoustic intensity and the HELS method.

• In-field evaluation of load cycles and the load spectra of running machinery, exploiting integrated strain, acceleration and displacement measurements.

• Non-contact measurements using vision based techniques.

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Measuring Devices and CalibrationThe experimental aspects of the research plays a crucial role in the activity of the Department of Mechanical Engineering, therefore a huge effort is done to continuously enrich and renew the experimental facilities. In this perspective the Measuring Devices and Calibration Laboratory manages the whole procedure of transducer maintenance and calibration.

Politecnico di Milano is a calibration Laboratory accredited by Accredia

(calibration laboratory number 104). The calibration sector for acceleration is located at the Department of Mechanical Engineering.

The Department of Mechanical Engineering has also developed processes for calibration activities, mainly used for calibrating the laboratory instrumentation. These processes, part of the quality Management System implemented by Politecnico di Milano, involve:

• calibration of vernier calipers;

• verification and calibration of force measuring systems;

• geometric masters calibration by means of CMM

• calibration of micrometers for external measurement;

• calibration of extensometers used in uniaxial testing;

• calibration of measurement circuits in strain gage applications;

• calibration of Weighing machines;

• calibration of Electromechanical manometers;

• calibration of LVDT.

The equipment in the Measuring Devices and Calibration Laboratory is composed of about 2000 transducers and measuring devices for the measurement of a huge number of quantities, including: lengths, acceleration, temperature, pressure, mass, acoustic emission and forces.Other relevant equipment includes: data acquisition and storage devices, telemetry systems and spectral analysers.

Thanks to the abovementioned skills in metrology and to the large amount of available equipment, a number of experimental activities rely on the Measuring Devices and Calibration Laboratory for the experimental activities of different research types, ranging from systems static and dynamic analysis to structural long term monitoring, and including experimental vehicle dynamics, material testing and so on.

Measuring LabThe activity of the mechanical and thermal measurements laboratory of the Lecco Campus is devoted to the monitoring and control of systems involving mechanical and thermal quantities. Along with the common topics related to metrology and instrumentation characterisation, the laboratory develops instruments and measuring systems for nonstandard applications. A relevant part of the laboratory activities are focused on the design, development and testing of instruments and components for space applications. The laboratory is active in acoustic measurement problems and in particular in the use of acoustic intensity as a tool for noise sources characterisation. Measurement and reduction of vibrations transmitted to workers is studied, with reference to both the hand-arm system (HAV) and the whole body (WBV).

The main available equipment in this area of laboratories is composed of:• instruments for vibration measurement: laser vibrometers, 2d scanning systems and single point, with velocity and displacement measurement capability, software for modal shapes visualisation. Measuring systems for hand-arm and whole-body vibration measurement and vibrations exposure assessment in accordance with the ISO5349 and ISO2631 standards. Piezoelectric accelerometers with frequency bandwidth up to 50 kHz, multichannel conditioning and DAQ system with sampling frequencies up to 500 kHz, software for frequency analysis

■ In field measurements of natural frequencies and mode shaped of the buckets of a Pelton runner

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• geometric measurements with both conventional contact instrumentation and with contactless systems. Geometric and displacement measurements based on images data processing.

• force and pressure measurements, load cells both based on piezoelectric elements and strain gages bridges. Contact pressure mapping system based on capacitive mats.

• strain measurement based on electrical strain gages, conditioning system for

3D vision

static and dynamic measurements with bandwidths up to 30 kHz.

• acoustic measurements, sound pressure level, 3D intensimetry, noise monitoring, coherence based source separation, testing methods with calibrated sound sources and floor testing machines.

• temperature measurements multichannel conditioning and recording system for thermocouples and RTD, thermal mapping with microbolometric thermal imager, setup for thermo-vacuum testing.

• facility for full qualification of space components according to ECSS standards, both for mechanical and thermal environments, thermo-vacuum 80-400 K for thermal cycling and thermal tests, electro-dynamic shaker and closed loop controller for sine, random and shock testing, pneumatic system for landing-type shock acceleration generation.

■ Thermo-vacuum chamber with feed-through for electromagnetic shaker, allowing for the mechanical testing of components under space-like environment

The experimental activity carried out in this laboratory include: three-dimensional acquisition of physical objects through active and passive systems, study of active range devices with single laser sheet or multiple sheets of light (pattern projection), image based 3D acquisition, calibration of digital cameras, metrological characterisation of active and passive three-dimensional measurement systems, 3D measurement systems integration, polygonal modelling from dense and sparse clouds of instrumentally acquired 3D points, texture mapping, digital replicas in the fields of industry, design, cultural

heritage for the purpose of project, quality control, documentation, communication and virtual exploration.The main available equipment of this area of laboratories is composed of:

• double camera pattern projection range device GOM ATOS;

• 3D scanner based on a single sheet of laser light Minolta 9i, including its calibration system and turntable for rapid 3D acquisition of small objects;

• 3D Scanner based on quadruple sheet of laser light NextEngine, including turntable.

• heavy weight tripod suitable for laser scanners;

• calibrated test objects for instrument characterisation;

• portable grid for camera calibration;

• various software for modelling from acquired 3D data. Photogrammetry software.

Application of active three-dimensional acquisition systems for generating reality-based digital models of mock-ups and industrial products in fields such as Engineering and Design, with various size and geometrical complexity, from small objects for daily use to car components and entire boats. Application of active and passive three-dimensional acquisition systems for generating digital replicas of Cultural Heritage, from small artifacts to buildings and complex archaeological structures.

VB LabVB Lab, which stands for “Vision Bricks Lab”, is the Image Processing Laboratory of the Politecnico di Milano’s Department of Mechanical Engineering. A vision brick can be described as a hardware or software component having well-defined and well-documented inputs and outputs.

The choice of name underlines the fact that the laboratory’s goal is to build up only reusable components. The aim of this methodological approach is to allow staff members to continuously increase laboratory expertise and to dramatically reduce dead time.

The VB Lab aims at:• improving the efficiency of current research activities;

• making its expertise available to the Department of Mechanical Engineering;

• transferring technological know-how to other research centres and to the industry.

The VB Lab is mainly involved in industrial, biomedical and forensic fields. It cooperates with several other Italian and European laboratories on a number of research projects. At the same time, it has the necessary expertise and technology to deal with the needs of the industry and end users active in the fields in which it operates. The VB Lab is a valuable scientific partner for regional, national and European research grant projects.

■ 3D scanning for classification of carcasses of bovine animals

■ 3D vision system for pantograph dynamic measurement analysis

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Preface99

Quality SystemBased on the feasibility study of a Quality System carried out in 1991, the Politecnico di Milano developed a Quality System (SQP) to manage the multidisciplinary experimental activities supporting planning, research and technology development, in compliance with the requirements of European quality standards.

The aim of the Quality Management System adopted by the Politecnico di Milano is to ensure that internal processes are performed in compliance with the specifications outlined in the reference rules.

The Politecnico di Milano Quality Management System encompasses:

• multidisciplinary experimental activities pertaining to research, testing and calibration;

• calibration activities under Accredia accreditation;

• test activities under Accredia accreditation;

• educational activities and specific projects for institutional teaching methodologies;

• design and technological development activities;

• consultancy for the planning of quality systems and/or quality/environment integrated management systems.

The Department of Mechanical Engineering plans and develops its own processes for service implementation. Based on scope and time frames, each service undertakes an activity planning

program based on annual objectives, available resources and validating and monitoring activities. The results of these planning activities are then adapted to suit the needs of each single service.

The Quality System adopted by the Department of Mechanical Engineering guarantees the fairness, transparency and accuracy of all managerial activities pertaining to relationships with users involved in providing performance realised by its own area in the SQP field, including those, if necessary, subcontracted both to internal and external customers, considered as activities of experimentation, calibration, consultancy and training.

The Quality Management System implemented by the Department of Mechanical Engineering fully complies with the ISO 9001 standard for the processes regarding training activities, higher academic education and some of the experimental activities.

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The Quality Management System also involves the internal calibration of several types of measuring instruments. Among them: force measuring systems, vernier calipers, micrometers for external measurement, Weighing machines, extensometers, LVDT, measurement circuits in strain gage applications, Electromechanical manometers, Geometric masters calibration by means of CMM.

The Department of Mechanical Engineering Laboratory complies with the ISO/IEC 17025 standard and is accredited by ACCREDIA for some of the experimental activities (LAB N° 1275 D) as officially stated in the Accredia website.

Furthermore, the Department also hosts the calibration section for acceleration of Politecnico di Milano, subject to Accredia accreditation (calibration laboratory number 104). Accredia link http://www.accredia.it/

Consortia and Spin-offs

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Italcertifer

MUSP

MUSP (Macchine Utensili e Sistemi di Produzione, Machine tools and production systems) – a laboratory focused on applied research in the machine tools industry – was established in 2005 in Piacenza.The original idea of a laboratory was conceived at the IV School of Engineering at the Piacenza branch of the Politecnico di Milano. In 2004, the Lab project started to take shape after being included in PRIITT (Plan for Industrial Research, Innovation and Technology Transfer), promoted by the Emilia Romagna Region. This plan

was heavily subsidised by the Fondazione di Piacenza e Vigevano.Not only does MUSP belong to the Emilia Romagna High Technology Network but also to the regional platform for Advanced Mechanics and Materials.

Italcertifer, the Italian Institute for Railway Research and Certification, was incorporated in 2001 to implement the European Union’s fundamental regulations on freedom of movement for goods, capital and persons. The EU’s growth and expansion is closely linked to the development of a viable network of communications by rail, road and air between all member States. The abolition of national borders turned out to be essential to the vitality of infrastructure viability. The free circulation of goods and people within the EU requires a ‘no-borders’ railway network based on the total inter-operability of individual national railway systems. In order to build a truly trans-European railway system, over the past decade, the EU has enacted a number of directives concerning both high-speed and ordinary trains. Over time, all these regulations have been incorporated into Italian Government Legislative Decrees.

Basically speaking, both European and, consequently, Italian legislation foster three macro-processes:

• implementation by building firms, infrastructure managers and railway companies;

• certification by independent safety verification agencies;

• green-light start-up procedures by national authorities.

In order to enter the European railway market, all operators must submit components and sub-systems for certification. The inter-operability of the Trans-European railway system is governed by Inter-operability Technical Specifications, STI, stating applicable requirements. In addition to railway builders, managers and companies, a key role is also played by verification and certification bodies such as Italcertifer.Italcertifer intervenes from the very beginning by supplying analyses and virtual reality prototype simulations, with particular attention being paid to software and systems safety architectures certification. The Italcertifer evaluation process complies with EN 50129 regulations:

• safety case and documentation examination;

• functional aspects and safety integrity;

• conformity with applicable Cenelec regulations.

Italcertifer’s highly specialised research and testing laboratories use accredited test protocols certified by third parties or by Certifer itself. Standard measurement processes are guaranteed by a constant control of the laboratories accreditation procedures in order to perform, simultaneously, multiple tests as required by STI or specific customer needs. Italcertifer relies on university laboratories, the RFI Experimental Institute and the Trenitalia

laboratory on rolling stock technologies in accordance with National and European Railway regulations on SINAL accredited tests. A specific test laboratory is devoted to the study of braking systems and verifications while a testing site, powered by its own substation, investigates single sub-systems and electric power components. Among Certifer state-of-the-art mobile laboratories, the ETR 500 Y1 train is devoted to the experimentation and certification of high speed lines. It also conducts real-time monitoring of all critical parameters, including rolling stock stability and pantograph-catenary integration. The ETR 500 Y1 is the first train designed to collect data at speeds of up to 350 km/h in accordance with European regulations n. 22/2004 and 17025. As regards conventional railways, Certifer uses Archimede, an RFI diagnostic train operating at speeds of up to 200

km/h, covering 115 basic parameters on railway line verification. The development and verification of last-generation signal systems such as the Train Running Control System, SCMT and the European Rail Traffic Management System, ERTMS, are monitored by two specially equipped Trenitalia Ale 601 Electric Multiple Units.

Italcertifer is equipped to support customers during all stages of the homologation procedure involving components and subsystems that will be used by the Italian Railway network. Italcertifer’s strong points include unparalleled professionalism, an in-depth knowledge of railway systems and full interaction with other similar European agencies. Italcertifer is Italy’s reference point on the railway market boasting full certification capabilities on the European railway scene.

Consortia

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TIVET

MCM

ISS – Innovative Security Solutions

The MUSP Lab reports to the eponymous Consortium whose current partners are:

• Companies: Capellini, Jobs, Lafer, Mandelli, MCM, Sandvik, Samputensili, Tecnocut, Working Process.

• Universities: Politecnico di Milano, Università Cattolica.

• Associations: UCIMU, Confindustria Piacenza.

• Institutions: Fondazione di Piacenza e Vigevano, Piacenza Province, Piacenza Municipality.

Five research areas, and a small group dedicated to marketing and innovation, are nowadays operative:

Area 1: Configuration and Management of Integrated Production Systems. Area Head: Andrea Matta, Politecnico di Milano

Area 2: Precision Engineering and Acceptance Testing. Area Head: Giovanni Moroni, Politecnico di Milano

Area 3: Advanced Design, Materials and Technologies. Area Head: Michele Monno, Politecnico di Milano

Area 4: Sector Studies and Protection of Intellectual Property. Area Head: Paolo Rizzi, Università Cattolica

Area 5: Production Technologies for the Aerospace Industry. Area Head: Matteo Strano, Politecnico di Milanoi-MUSP: Innovazione MUSP. Area Head: Mario Salmon

Founded in: 2005

Sector: Mechanical Engineering

Activity: T.I.Ve.T deals with the design, development and industrial use of innovative passive, semi-active and actively controlled and regulated systems for aircraft, maritime vehicles, road vehicles, trains and vehicles for special applications.

In particular, its aim is to develop active dampers for vehicles in order to improve both performance and safety. At present, the company is involved in the development of rail vehicle systems.

Product under development: An active anti-yaw electromechanical damper

Reference market: Automotive

Contact: [email protected]

Founded in: 2006

Sector: Industrial and Power Electronics

Activity: MCM’s line of business consists in the development, design and supply of digital control and static energy conversion systems that can be used as critical components in various applications for energy saving purposes. The cornerstone of MCM technology is the Universal Digital Control System providing an advanced interface for the public electricity network for Distributed Generation systems. This interface is suitable for all sources including wind power, photovoltaic and gas-fired microgeneration plants as well as mini hydroelectric plants.

Products: Digital controllers, static energy converters, electronic power feeders, special drives for electrical machines electric engines.

Reference Market: Distributed electric generation plants, from renewable and alternative sources (wind power, photovoltaic, gas-fired micro-cogeneration and mini hybrid power plants), electronics for energy efficiency, electric traction for vehicles and laboratory instrumentation and equipment.

Contact: [email protected]

Website: www.mcmenergylab.com

Founded in: 2006

Sector: 3D robot guidance, product and process quality control

Activity: ISS has a broad expertise in various methodologies related to measurement for industry:

• 2D and 3D vision• active triangulation• time-of-flight• traditional sensorsand in the most advanced data analysis techniques.

Spin-offs

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SmartMechanical-Company

In particular, ISS develops and markets high-technology solutions for:• robot guidance for bin-picking• product and process quality control

These two application fields are tightly connected, as they share measurement and analysis methodologies. Moreover, they are the basis of effective flexible manufacturing systems, which are more and more important to be able to compete in the current global market.The most relevant ISS product is 3D CPS (3D Control and Picking Solution): this is an embedded 3D robot guidance system which integrates a laser scanner and an on-board intelligence, so being able to perform all the 3D measurement and analysis tasks needed to estimate the poses of the parts present in the bin. This product may be the key to solve machine loading problems

in flexible manufacturing systems allowing capitalisation of the robot’s versatility, currently limited by a completely rigid mechanical periphery.In relation to product and process quality control, ISS is able to project innovative solutions customised on specific application needs.In particular regarding:• geometric conformity analysis;• assembly analysis;• surface integrity analysis;• alphanumeric characters reading by means of OCR algorithms.

Products: 3D CPS, customised solutions for product and process quality control.

Reference market: Industrial automation

Contacts: [email protected]

Website: www.issweb.it

Founded in: 2012Sector: Experimental Mechanics, Automotive

Activity: SmartMechanical-Company has been created to exploit a number of patents originated within Politecnico di Milano.

E-Co

Founded in: 2012

Sector: Automotive

Activity: E-CO’s core business consists in the development, design, prototyping, production and system integration of hybrid conversion kits to obtain vehicles with low or no environmental impact in order to allow a sustainable mobility and a quick growth of the hybrid and electric market.

Products: Range Extender and Hybrid Transformation kit.

Reference Market: there are three target markets: production of kits for the hybridisation of vehicles

(“Transformers” market); “ad hoc” hybrid transformation of fleets of vehicles for standard and/or specific applications (PA, Corporate market), technology support (Design & Engineering) for hybrid systems for Manufactures/OEMs to develop own vehicles and subsystems. Perspective: production of kits for private end users.

Contact: Ing. Paolo Bernardini.

Website: www.eco-hev.com

The products developed on the basis of the patents are:

• SM-InTenso+/SM-InTensino+: test systems able to measure the location of the centre of gravity and the inertia tensor of vehicles and subsystems, the main characteristics of the test systems are very high accuracy and limited testing time;

• SM-LC: family of six axis force and torque sensors that include transducers and interface electronics able to measure accurately the three force and three torque components acting on a structural element (Fx, Fy, Fz, Mx, My, Mz);

• SM-Wheel: family of six axis force and torque measuring wheels that include transducers and wireless interface.

electronics designed for real time data acquisition on cars, heavy vehicles and motorcycles.

Products: Systems for measuring the inertia tensor of rigid bodies (SM-InTenso+, SM-InTensino+). Six Axis Force & Torque Sensors, Measuring wheels (SM-Wheel) and load cells (SM-LC).

Reference market: Road vehicles, indoor road vehicle testing, laboratory instrumentation and equipment.

Contacts: [email protected]

Website: www.SmartMechanical-Company.it

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1st and 2nd year

Bachelor of Science

3rd year (preparatory path)

3rd year (professional path)

1st year

2nd year

Master of Science

PhD

The teaching activity of the staff of the Department of Mechanical Engineering is mainly concentrated within the School of Industrial and Information Engineering, nevertheless a significant contribution is also provided for other Schools of the Politecnico di Milano.

The Mechanical Engineering programme courses are taught at three campuses: Milano Bovisa (the largest campus), Lecco and Piacenza.The Mechanical Engineering study programme has a three-level structural organization: Bachelor of Science, Master of Science and PhD.

Teaching Activities

The Bachelor of Science graduate is a university-trained professional, having the ability to develop products or manage industrial processes. The use of consolidated engineering methods and technologies that do not require the development of complex and innovative technologies is normally required of a Bachelor of Science graduate.

The Master of Science graduate is a professional capable of independently developing innovative projects related to products, processes or production systems, both in the industrial and advanced tertiary fields.A PhD graduate in Mechanical Engineering is a highly qualified professional who is able to carry out independently complex applied research projects, organise a team and perform complex activities.

■ Structure of the Mechanical Engineering study programme

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Master of Science

BachelorThe aim of the Mechanical Engineering programme is to provide a broad-based education and training in mechanical engineering sciences and their applications that will enable graduates to meet the challenges of carrying out a number of different jobs by providing them with a sound scientific, economic, technical and practical background in order to guarantee the necessary knowledge required to carry out professional activities.A Bachelor of Science graduate involved either in design or production processes must have an advanced technical preparation in applied mechanics and machine design, energy transformation, construction materials, fluid mechanics, manufacturing, total lifecycle management and the basics of industrial automation.

Professional perspectivesStudents graduating with a Bachelor of Science will have the ability to design and develop mechanical products or processes, to coordinate the installation and the commissioning of complex machinery and mechanical systems, to manage and maintain production plants and, finally,

to make technical evaluations, conduct inspections and perform technical services at industrial level. Technical skills are typically focused on the mechanical industry sector, even though such skills can be deployed in the broader industrial engineering field, or in service-oriented companies and in public administration. Bachelor of Science graduates, trained at the Politecnico di Milano, will thus have multiple opportunities to work in a number of industrial sectors. Students are asked to develop a complex project by applying all the necessary functional, construction and energy skills acquired on successful completion of the programme. Additionally, Bachelor of Science graduates are trained in disciplines related to the manufacturing industry (production plants) involving design activities, the production and development of new technologies, measurement techniques and the choice of the most appropriate materials. Each qualification of each academic level described previously, corresponds to a well defined professional capable of engaging successfully in the job market.

The Master of Science in Mechanical Engineering prepares professionals who are capable of independently developing projects related to product or process

innovation, both in the industry and service sectors.The wide range of tasks and duties required of a mechanical engineer involve a sound

preparation of core subjects provided by an in-depth scientific approach; additionally a broad overview of technical applications is provided to help gain immediate employment. In particular, the aim is to prepare and develop graduates’ ability to design, build, implement and optimise the use of products or plants and machinery, their actuation mechanisms and related services. Thanks to this approach, particular attention is focused on technical preparation in all areas of mechanical engineering and mechanics which, thanks to thorough grounding, allows for rapid adaptation to various business needs.Together with Bachelor of Science graduates, Master of Science graduates share in-depth preparation which encourages a well-balanced curriculum of practical and theoretical training and, as a consequence, the ability to confront real-world technological issues as engineering professionals. Master of Science graduates differ from Bachelor of Science graduates due to a greater ability to innovate and apply complex models to manage, service, design and improve upon existing as well as new products or processes.

The Master of Science qualification provides access to PhD courses, second level Specialisation and second level University Master Programmes.

Professional perspectivesThe Master of Science graduate in Mechanical Engineering is a professional boasting an advanced cultural and professional education, capable of independently developing innovative projects related to product or process development. The Master of Science graduate in Mechanical Engineering has a thorough grounding in functional, constructive and energy-related disciplines and is trained to select materials and related manufacturing and processing technologies. Furthermore, graduates have the ability to evaluate systems and their components in terms of layout design, management of plant machinery and related services. In addition to in-depth knowledge in the field of automation, other skills include an ability to take measurements and carry out inspections. Apart from the mechanical industry, many of our graduates enter other fields including the design, operation and maintenance of plants and machinery.

Ph.D. Programme on Mechanical Engineering

The PhD Course in Mechanical Engineering is organised within the Department of Mechanical Engineering, and included in the PhD School of Politecnico di Milano. The Programme

covers a number of different disciplines in the field of Mechanical Engineering, being devoted, in particular, to innovation. It addresses both theoretical and experimental activities referring to different

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Lifelong Learningresearch areas including Dynamics and Vibrations of Mechanical Systems and Vehicles, Machine and Vehicle design, Manufacturing and Production Systems, Methods and Tools for Product Design, Materials, Measurements and Experimental Techniques.

The Faculty’s academic staff is mainly made up of Professors from the Department of Mechanical Engineering at Politecnico di Milano.

Research activities benefit from the availability of the wide range of experimental facilities described in section 5.

The PhD Programme aims to serve industrial needs in the fields of research and development related to Mechanical Engineering; PhD graduates are prepared to embrace careers and industrial paths at the forefront of technology, responding efficiently to industrial requests for innovation and highest level research.

At the end of the Programme they will be expected to manage innovative research activities, holding top-level roles in key enterprises both in Italy and in the international outlook.

Each year an average of 30 students, many of whom are supported by scholarships from public institutions and private companies, register in the Doctoral Programme in Mechanical Engineering.

During a 3 year period PhD candidates will master a continuative research activity that will lead to a Doctoral Thesis, and take part in courses designed to develop full expertise in structuring research programs, pertinent to refining tools and methods in order to develop high-level research in the last part of the PhD period. Students are also prompted to attend stages, external courses, national and international seminars, conferences and workshops, encouraged to participate in national and international research projects, asked to develop scientific paper writing and paper presentation and to support teaching activities. International mobility of PhD candidates is also strongly recommended by means of agreements and protocols with foreign institutions and with extra financial support for students with scholarships.

CONTACTS

Headof theProgramme: Prof. Bianca M. Colosimo: [email protected]

Secretary: Rosalia Agostino: [email protected]

Location: Department of Mechanical Engineering, Politecnico di Milano www.mecc.polimi.it

Address: via Giuseppe La Masa 120156 Milan, ItalyTel. +39 02 2399 8227Fax +39 02 2399 8202

Training and ongoing, technical-professional refresher courses, targeted at company personnel, are one of the tools inherent in developing innovative skills, increasing competitiveness, fostering Research & Development and, finally, motivating not only technical staff but also professionals to remain focused on continual improvement. Dedicating oneself full-time to refresher courses and training, devoted to research and innovation, in a stimulating environment such as that offered by the Politecnico di Milano is undoubtedly not only useful but also highly productive, offering interesting returns in terms of know-how, new ideas and new stimuli. Bearing these objectives in mind and following the success achieved during past editions, the Politecnico di Milano offers a series of well-coordinated, highly targeted training courses. Strongly endorsed by

companies in the sector, for over a decade, these courses are continually updated to respond to the contemporary needs of a fast-moving world. Each year, the Department’s academic staff, all specialists in their own individual field, assisted by highly skilled outside professionals and experts, offer some ten courses which are attended by more than one hundred participants. Several of the programmes offered include tests and on-site simulations at the Department’s laboratories, considered among the most advanced and modern in Europe in mechanics-related sectors.

The aim of these courses is to respond to the need to find a more responsibly aware approach, based on a comparison between the world of academia and the more practical world of companies.

Contacts DEPArtmEntofmECHAniCAL EnginEEringmAinbUiLDing:

via G. La Masa, 120156 MilanoITALY

HeadSecretary:Ph. +39-02.2399.8500Fax +39-02.2399.8202

forfurtherinformation:e-mail: [email protected]

Website: www.mecc.polimi.it

Edited by: eManuele Zappa and paolo pennacchI

Book Design: graphIcaMenTe – MilanoPrinted by: sTaMpa 2009 – Azzate (VA)Photography by: corrado crIscIanI

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