Sharif Digital Repository

Purpose: An important challenge of the osteotomy procedures, particularly in the case of large and complex corrections, is the fixation of the osteotomy site. The purpose of this study is to propose a practical and cost-effect methodology for the plate adapting problem of osteotomy surgery. Design/methodology/approach: A novel patient-specific plate contouring methodology, based on rapid prototyping (RP) and multi-point forming (MPF) techniques, was developed and evaluated. In this methodology, a female mold is fabricated by RP, based on the geometry of the osteotomy site and estimation of the plate spring back. The mold is then used to configure a MPF die, which is then used for press... 

Access to a prototype during R&D can play a crucial role in early identification of the weaknesses in the design. Under circumstances that a particular commercial subsystem with the exact required specific features is unavailable, the realization of such a prototype can be delayed. In this paper, an example of rapid prototyping for a dual-channel biosignal data acquisition system based on the open-source concept is described. The selected biosignal is the finger photoplethysmogram. Except for Matlab, all other software components are open-source. The hardware design of the optical sensor utilized to record the signals is also open-source, making the system extremely affordable with the... 

Continuity of service of wind energy conversion systems as well as their reliability and performances are some of the major concerns in this power generation area. Six-legs AC/DC/AC converters are normally used in modern wind energy systems like as in the system with a doubly-fed induction generator (DFIG). A sudden failure of the converter can lead to the total or partial loss of the control of the phase currents and can cause serious system malfunction or shutdown. Therefore, to prevent the spread of the fault to the other system components and to ensure continuity of service, fault tolerant converter topologies associated to quick and effective fault detection and compensation methods... 

In this paper, an FPGA-based fault-tolerant back-to-back converter without redundancy is studied. Before fault occurrence, the fault-tolerant converter operates like a conventional back-to-back six-leg converter, and after the fault, it becomes a five-leg converter. Design, implementation, and experimental verification of an FPGA-based reconfigurable control strategy for this converter are discussed. This reconfigurable control strategy allows the continuous operation of the converter with minimum affection from a fault in one of the semiconductor switches. A very fast detection scheme is used to detect and locate the fault. Implementation of the fault detection and of the fully digital... 

The performance of cellular solids in biomedical applications relies strongly on a detailed understanding of the effects of pore topology on mechanical properties. This study aims at characterizing the failure mechanism of scaffolds based on nodal connectivity (number of struts that meet in joints) and geometry of the pores. Plastic models of scaffolds having the same relative density but different cubic and trigonal unit cells were designed and then fabricated via three dimensional (3-D) printing. Unit cells were repeated in different arrangements in 3-D space. An in-situ imaging technique was utilized to study the progressive deformation of the scaffold models. Different nodal... 

Purpose - The purpose of this paper is to present an improved methodology for design of custom-made hip prostheses, through integration of advanced image processing, computer aided design (CAD) and additive manufacturing (AM) technologies. Design/methodology/approach - The proposed methodology for design of custom-made hip prostheses is based on an independent design criterion for each of the intra-medullary and extra-medullary portions of the prosthesis. The intra-medullar part of the prosthesis is designed using a more accurate and detailed description of the 3D geometry of the femoral intra-medullary cavity, including the septum calcar ridge, so that an improved fill and fit performance... 

Rapid prototyping is a promising technique for producing tissue engineering scaffolds due to its capacity to generate predetermined forms and structures featuring distinct pore architectures. The objective of this study is to investigate the influences of different pore geometries and their orientation with respect to the compressive loading direction on mechanical responses of scaffolds. Plastic models of scaffolds with cubic and hexagonal unit cells were fabricated by three-dimensional (3-D) printing. An in situ imaging technique was utilized to study the progressive compressive deformation of the scaffold models. In both cubic and hexagonal geometries, organized buckling patterns relevant... 

Medical applications of rapid prototyping have an increasing trend, making the future of RP more and more promising. These applications may include design, development, and manufacture of medical devices and instrumentation, as well as implant design, anatomical modeling, surgical planning, surgical implants, and prosthesis fabrication. This paper provides a new methodology for customized hip prosthesis that could provide high accuracy of femoral canal reconstruction via 3D modeling of prosthesis stem, 3D modeling of prosthesis neck, and facilitating the communication between the designer and surgeon. Combining RP technologies and rapid tooling with this novel custom-made hip prosthesis,... 

This paper presents a prototype of a high-throughput 4x4 64-QAM MIMO receiver consisting of a channel matrix QR decomposition, a soft-output K-Best MIMO detector and a Convolutional Turbo Code decoder. The proposed MIMO receiver provides low processing latency and a pipelined architecture scalable to a larger number of antennas and constellation order. Therefore, it is suitable for LTE-Advanced and IEEE 802.16m broadband wireless standards. A rapid prototyping platform interfacing MATLAB with Xilinx ISE was used in the development of the 4x4 64-QAM MIMO receiver. The receiver utilizes 96% of the slice LUTs and 78% of slice registers on Virtex-5 FX130T FPGA, operating at a maximum frequency... 

A choreography specifies activities and interactions among a set of services from a global point of view. From this specification, local implementations or peers can be automatically generated. Generation of peers that precisely implement the choreography specification is not always possible: this problem is known as realizability. This paper presents an encoding of the Chor choreography calculus into the FSP process algebra. This encoding allows to: (i) validate and verify Chor specifications using the FSP toolbox (LTSA), (ii) generate peer protocols from its choreography specified in Chor, (iii) test for realizability of the Chor specification, and (iv) generate Java code from FSP for... 

A rapid wax injection tool of a gearbox shift fork was designed, simulated, and manufactured using rapid prototyping and rapid tooling technology to save time and cost of producing wax models used for the investment casting process. CAE simulation softwares, in particular, MoldFlow, are used to get wax injection moulding parameters such as filling parameters, temperature profiles, freeze time, speed, and pressure. The results of this research were compared with conventional wax model production methods. The criteria of such comparison were based upon parameters such as time, cost, and other related characteristics, which resulted in saving of 50% in time and 60% in cost. In this research,... 

All Rapid Prototyping and CNC material removal processes use information which is extracted from a CAD system. There are several ways to convert CAD data into usable manufacturing information. In this paper, five methods of translating CAD data into a usable manufacturing format are explained. These five methods are data translation from CAD files in STL, DXF, STEP-NC, and IGES formats as well as a platform-dependent area method of manufacturing information in a desirable format. For each method, algorithms and details about the CAD data translation into usable manufacturing and prototyping processes formats are presented. Finally, applications of each approach and its pros and cons are... 

This chapter defines rapid manufacturing (RM) as a technique for manufacturing solid objects by the sequential delivery of energy and/or material to specified points in space. Current practice is to control the manufacturing process by using a computer-generated mathematical model. This chapter compares the large speed and cost advantages of RM to alternative polymer or metal manufacturing techniques such as powder metallurgy manufacturing or die casting. Moreover, the RM as an application of solid freeform fabrication for direct manufacturing of goods is addressed. Unlike methods such as computer numerical control (CNC) milling, these techniques allow the fabricated parts to be of high... 

This paper presents a closed-loop laser cladding process used in nonplanar deposition of desired metallic materials. In the proposed system, the deposited layer geometry is continuously controlled via a sliding mode controller (SMC). The controller, which uses the scanning speed as the control input, is designed based on a parametric Hammerstein model. The model is a parametric dynamic model with several unknown parameters, which are identified experimentally using the recursive least squares method. The designed SMC is robust to all model parameters' uncertainties and disturbances. The results showed that the tracking accuracy improves and the chattering effect reduces if an integrator on... 

In this paper, a feedforward proportional-integral-derivative (PID) controller is developed to effectively control the clad height in laser solid freeform fabrication (LSFF). The scanning velocity is selected as the input control variable and the clad height is chosen as the output. A novel knowledge-based Hammerstein model, including a linear dynamic and a nonlinear memoryless block, is developed, and its parameters are identified offline using experimental data. The architecture of the controller consists of a PID and a feedforward module, which is the inverse of the identified model. The advantage of adding a feedforward path to the PID controller is evaluated experimentally, in which the... 

Purpose - Dimensional accuracy analysis of wax model created by room temperature vulcanization (RTV) silicone rubber molding to be used in investment casting is presented. The purpose of this paper is to discuss the effective parameters of dimensional accuracy in RTV tooling technique. Design/methodology/approach - After producing a pattern by stereolithography (SLA) and then creating the RTV silicone rubber mold by the SLA pattern, dimensional accuracy of wax models produced by RTV tool are analyzed. Design of experiments (DOE) using the Taguchi approach is used for analysis and determination of optimum condition. Findings - Experiments show that the dimensional accuracy in RTV technique is... 

In the present work, the densification and microstructural evolution during direct laser sintering of metal powders were studied. Various ferrous powders including Fe, Fe-C, Fe-Cu, Fe-C-Cu-P, 316L stainless steel, and M2 high-speed steel were used. The empirical sintering rate data was related to the energy input of the laser beam according to the first order kinetics equation to establish a simple sintering model. The equation calculates the densification of metal powders during direct laser sintering process as a function of operating parameters including laser power, scan rate, layer thickness and scan line spacing. It was found that when melting/solidification approach is the mechanism... 

Cu-alloyed sintered steels are one of the main product groups in ferrous powder metallurgy (P/M). To expand the application of P/M technology to different sectors of industry and to create new market, it is believed that rapid prototyping and short serial production of sintered parts for functional testing is important. In the present work, rapid prototyping of sintered Fe-C-Cu steel powders by direct metal laser sintering (DMLS) process was studied. Fe, Fe-0.8%C, Fe-2%Cu, Fe-4%Cu, Fe-0.8%C-2%Cu-0.35%P powders were laser sintered in widely varying conditions. The densification and microstructural features of the sintered parts were evaluated. The results revealed that rapid prototyping of... 

In the present work, the densification and microstructure of M2 high speed steel powder processed by direct laser sintering method was studied. Test specimens were produced using a 200 W continuous wave CO2 laser beam at different scan rates ranging from 50 to 175 mm s-1. The building process was performed under argon and nitrogen atmospheres in order to evaluate the role of sintering atmosphere. It was found that the sintered density strongly depends on the laser scan rate and thus on the duration time of the laser beam on the surface of the powder particles. Generally, with a decrease in the scan rate higher densification was obtained. However, formation of large cracks and delamination of... 

In the present work, the role of graphite addition on the laser sintering of iron powder was studied. Powder mixtures containing iron and 0.4, 0.8, 1.2, and 1.6 wt.% graphite were prepared by blending elemental powders. These powders were sintered layer-by-layer under nitrogen atmosphere using a continuous wave CO2 laser beam. A laser power of 70-225 W, scan rate of 50-600 mm s-1, scan line spacing of 0.1-0.3 mm, and layer thickness of 0.1 mm was used. It was found that the processing parameters play a key role on the densification of the iron-graphite powder mixtures. The addition of graphite enhances the densification of the iron powder and improves the surface quality of the laser...