1. Under the guidance of:
DR. I.A. Palani
Dr. C.p. Paul
Presented by:
Sandesh Dhurve
Nishchay Sharma
I.i.t. Indore R.r.c.a.t. indore
1

2. contents
Research Objective
• Project Title
• Overview
Introduction to Shape Memory Alloy
• Nitinol
Rapid Manufacturing using Lasers
• Experimental setup
• Obtained results
Spring & Parallel Manipulator
• CAD model
• Analysis using ANSYS
References
2

3. Rapid
Manufacturing of
Nitinol using
Lasers
• Deposition of Ni-Ti
powder on Ti plate
using High power
Laser deposition
• Manufacturing of a
leaf spring
Parallel
Manipulator with
SMA springs
• CAD modeling of the
parallel manipulator
• Modeling of helical
and leaf springs
Analysis using
ANSYS
• Analyzing the
behavior of SMA
springs with respect
to temperature
• Study of the actuation
mechanism of SMA
springs in 3-DOF
parallel manipulator
Research Objective
3

4. Shape Memory Alloy
 It remembers its shape
 Deformed shape + Heat = Original shape
 The high temperature causes the atoms to
arrange themselves into the most compact
and regular pattern possible
 Example: Copper-Aluminum-Nickel,
Copper-Zinc-Aluminum,
Iron- Manganese-Silicon and
Nickel-Titanium alloys
4

5. APPLICATIONS
 SMA have applications in industries like-
Medical: Mending bones, Stent in artries, Eyeglass frames, Tooth clips
Safety: Anti-scalding devices and fire sprinklers
Military: Nitinol couplers in F-14 fighter planes
Robotics: As an actuator
5

6. NITINOL (Ni-Ti)
 Was discovered in Naval Ordnance
Laboratory (NOL), Maryland, USA
 Ni- 50% , Ti- 50%
0
10
20
30
40
50
60
70
80
290 310 330 350 370 390 410
Young'sModulus(GPa)
Temperature (K)
Young's Modulus v/s Temp
Temperature
(K)
Young's Modulus
(GPa)
294.25 27.17
299.85 24.82
305.35 22.41
310.95 20.06
316.45 25.72
322.05 31.37
327.55 36.96
333.15 42.61
338.75 48.27
344.25 54.88
349.85 61.43
355.35 64.19
360.95 63.16
366.45 62.06
372.05 63.92
377.55 65.78
383.15 67.64
388.75 69.5
394.25 71.36
399.85 70.81
405.35 70.33
410.95 69.78
416.45 69.29
FACT: Even 0.l wt% variation of composition
causes 10 K error of transformation temperature.
HIGHLY SENSETIVE TO COMPOSITION!!
6

7. SME in NiTinol
By change in phase from
Martensite to Austenite
Monoclinic FCC
(Martensite) to BCC
(Austenite)
7

8. ADVANTAGES
 Compactness, allowing for reduction in overall actuator size.
 Very high power/weight ratio comparatively
 Accessible voltages can accomplish thermo elastic transformation
 Higher strain recovery
 Higher strength
 Noiseless and silent operation
 High corrosion resistance
8

9. LIMITATIONS
 Heat Dissipation, need Mechanism for cooling
 Less Stiffness / high Flexibility
 Relatively expensive to manufacture and machine
compared to other materials such as steel and
aluminum.
 Most SMA's have poor fatigue properties ( a steel
component may survive for more than one hundred
time more cycles than an SMA element. )
9

10. Rapid manufacturing using lasers
(LRM)
FABRICATION OF PARTS
CAD Model Powder Material
EXTENSION OF LASER CLADDING PROCESS
Deposition of a metal on
another
Metallurgical bonds are
formed
STEP TOWARDS FEATURE BASED DESIGN &
MANUFACTURING
10

11. Experimental setup
Schematic diagram:
Ni + Ti powder
Ni
Ni Ti
Powder
Feeder
CNC
• High power Laser
• 5 axes manipulator
with CNC control
• Argon atmosphere
(965 mbar)
• No moisture!!
Closed
loop
process
control
Guide Laser
• Marking the
trajectory
• ƛ=605nm
• Red color laser
Nozzle
• Laser nozzle
dia.= 3.29mm
• Powder feed
nozzle
dia.=1.96mm
Deposition
• Melting of
powder by
power laser
(IR) ƛ=1080nm
• Power of laser=
700W
Deposition mechanism
of Ni-Ti powder on Ti
plate 11

12. POWER LASER SPECIFICATIONS
 ƛ=1080nm (IR laser); feed= 4gm/min
 Ytterbium laser system YLS-2000
 A coolant is used for cooling the nozzle.
 Temperature of nozzle is kept around 21-22 C
 Maximum power of the laser= 2000W
 Power during process= 700W
LRM based CNC Machine
Power of the laser is adjusted to get
proper penetration, melting and
deposition. Less power causes poor
melting and high power causes
sputtering!! 12

13. Modeling & Simulation
 Helical spring
Diameter of spring…………………..D = 1.5mm
Wire diameter………………………..d = 0.5 mm
Number of turns……………………..n = 40
Length of fully compressed spring….L= 20 mm
 Leaf spring
Rectangular cross section…………..w = 5mm
h = 5mm
Arc radius…………………………..r = 37.5 mm
 Parallel manipulator with helical spring
 Parallel manipulator with leaf spring
13

14. Spring simulation.avi
14

15. Temp (C) Deflection (mm) Force (N) Deflection (mm) Force (N) Temp (C) Deflection (mm)
25 0.0054 0.1 10.4130 0.1 25 10.9300
35 0.0235 0.2 20.8260 0.1 35 13.1570
45 0.0416 0.3 31.2380 0.1 45 10.2030
55 0.0597 0.4 41.6510 0.1 55 7.4750
65 0.0774 0.5 52.0640 0.1 65 5.9168
75 0.0958 0.6 62.4770 0.1 75 4.7720
85 0.1139 0.7 72.8890 0.1 85 4.4750
95 0.1320 0.8 83.3020 0.1 95 4.5630
105 0.1501 0.9 93.7150 0.1 105 4.3518
115 0.1681 1 104.1300 0.1 115 4.1642
125 0.1862 0.1 125 4.0842
Force suppressed,
Variable temperature
Temperature suppressed ,
Variable force
Force and Temperature both
acting
Result for helical spring
0.0000
2.0000
4.0000
6.0000
8.0000
10.0000
12.0000
14.0000
5 15 25 35 45 55 65 75 85 95 105 115 125 135
Deflection(mm)
Temperature (C)
Force and Temperature both acting
15

16. 16

17. Temp (C) Deflection (mm) Force (N) Deflection (mm) Force (N) Temp (C) Deflection (mm)
25 0.0093 10 6.0999 10 25 6.4027
35 0.0403 11 6.7099 10 35 7.7051
45 0.0713 12 7.3199 10 45 5.9729
55 0.1024 13 7.9299 10 55 4.3740
65 0.1335 14 8.5398 10 65 3.4603
75 0.1645 15 9.1498 10 75 2.7898
85 0.1955 16 9.7598 10 85 2.6161
95 0.2265 17 10.3700 10 95 2.6681
105 0.2576 18 10.9800 10 105 2.5454
115 0.2886 19 11.5900 10 115 2.4373
125 0.3197 20 12.2000 10 125 2.3925
Force suppressed,
Variable temperature
Temperature suppressed ,
Variable force
Force and Temperature both
acting
Result for Leaf spring
0.0000
1.0000
2.0000
3.0000
4.0000
5.0000
6.0000
7.0000
8.0000
9.0000
5 15 25 35 45 55 65 75 85 95 105 115 125 135
Deflection(mm)
Temperature (C)
Force and Temperatrue both acting
17

18. parallel
manupulatorsimulation.avi
18

19. Force (N) Temp ( C ) Total Spring 1 Spring 2 Spring 3
0.05 Environmental 20.2930 10.522 10.7260 16.3430
0.05 35 22.2210 11.093 12.2990 17.8990
0.05 45 20.1280 10.465 10.6050 16.2100
0.05 55 17.7010 9.6972 8.9032 14.2510
0.05 65 15.9280 9.0501 7.8294 12.8190
0.05 75 14.3210 8.3799 6.9504 11.5160
0.05 85 13.8350 8.1568 6.6986 11.1240
0.05 95 13.9650 8.2092 6.7682 11.2290
0.05 105 13.6010 8.0367 6.5820 10.9350
0.05 115 13.2620 7.874 6.4107 10.6610
0.05 125 13.1030 7.7921 6.3321 10.5330
Result for Parallel manipulator with
helical spring
Deflection (mm)
0.0
5.0
10.0
15.0
20.0
25.0
5 15 25 35 45 55 65 75 85 95 105 115 125 135
Deflection(mm)
Temperature (C)
Total
Spring 1
Spring 2
Spring 3
19

20. 20

21. Force (N) Temperature ( C ) Total Leaf 1 Leaf 2 Leaf 3
1000 25 1.8658 1.8658 1.1747 1.1969
1000 35 1.9659 1.9659 1.2291 1.2529
1000 45 1.8510 1.8510 1.1612 1.1831
1000 55 1.6976 1.6976 1.0702 1.0903
1000 65 1.5812 1.5812 0.9993 1.0185
1000 75 1.4751 1.4751 0.9334 0.9520
1000 85 1.4547 1.4547 0.9178 0.9362
1000 95 1.4811 1.4811 0.9304 0.9487
1000 105 1.4709 1.4709 0.9209 0.9390
1000 115 1.4632 1.4632 0.9127 0.9306
1000 125 1.4691 1.4691 0.9128 0.9306
Deflection (mm)
Result for parallel manipulator with Leaf Springs
0.0000
0.5000
1.0000
1.5000
2.0000
2.5000
5 15 25 35 45 55 65 75 85 95 105 115 125 135
Deflection(mm)
Temperature (C)
Total
Leaf 1
Leaf 2
Leaf 3
21

22. REFERENCES
22
 http://www.stanford.edu/~richlin1/sma/sma.html
 www.wikipedia.org
 Peter R. Barrett, Daniel Fridline. “User Implemented Nitinol
Material Model in ANSYS”.
 Kaan Divringi & Can Ozcan. “Advanced Shape memory alloy
material models for ANSYS”. Ozen Engineering Inc.
 Eiji makino, Takashi Mitsuya, Takayuki Shibata. “ Fabrication
of TiNi shape memory actuator for micropump”. Proc. SPIE
3891, Electronics and Structures for MEMS, 328 (September
29, 1999); doi:10.1117/12.364458
 Shape Memory Alloy, BTP Report by Saurabh Maghade and
Sahil Agarwal.

23. THANK
YOU!!
ANY
QUESTIONS??
23