Examensarbeten för masterexamen // Master Theses (IMS)

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Effects of Heat Treatment on Residual Stresses in Additive Manufacturing
Kristensen, Rasmus; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Hryha , Eduard; Karslsson , Henrik; Alkaisee, Rasha
Metal additive manufacturing (AM) is constantly developing and expanding into new segments. The automotive industry has so far not implemented AM to any larger extent. One reason is the relatively high cost of AM-components, but mainly due to the materials that are available is not used to a larger extent within the automotive sector e.g. titanium and stainless steel. Powder Bed Fusion–Laser Beam (PBF– LB), the most developed metal AM-method had, until recently, a limited range of materials available. However, recently several low-alloyed carbon-containing steels, that are commonly used in vehicles and machined components have been developed. One issue with increased carbon content is that the material has shown to be difficult to manufacture with PBF–LB. Moreover, heat treatment and its influence on residual stresses, microstructure and hardness are not yet known. This thesis focuses on the residual stresses and how they are affected by the heat treatment on samples printed in a low alloy medium carbon steel, 42CrMo4 (AISI 4140). The heat treatments applied in this thesis were not intended to be optimised for 42CrMo4, but rather investigate a more industrial approach using relatively standard heat treatment cycles. After analysing the different heat treated samples it was found that in a regular quench and temper cycle, the parts achieved similar hardness as conventionally manufactured 42CrMo4 using the same heat treatment. Samples exposed to a direct temper cycle, hence just tempered as-printed, showed promising results in terms of residual stresses. This knowledge may serve as a basis to further research and development of heat treatment cycles to better utilise 42CrMo4 steels in the automotive sector
Design and development of robust removable attachment system to fasten handheld objects
Bhardwaj, Aarush; Jhaveri, Pranjal; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Malmqvist, Johan; Malmqvist, Johan
Improvement of Final Demand Data Flow at Polestar, Refining Final Demand Management in the Geometry Assurance Process
Eken, Gizem; Hamza, Medina; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Wärmefjord, Kristina; Stenlund, Andreas
Geometric variations in components, despite modern manufacturing precision, can detract significantly from a vehicle’s functionality and perceived quality. Geometry assurance is crucial for managing these variations by ensuring robustness and high product quality through assigning favorable tolerances. Moreover, efficient data management plays a significant role in geometry assurance, facilitating the necessary exchange of information across various stages of the product realization loop. This thesis focuses on optimizing the data flow and management of final demand data within the geometry assurance process at Polestar, a Swedish automotive company specializing in the production of electric vehicles. This master’s thesis aimed at mapping the current geometry assurance process at Polestar, and by identifying and mitigating inefficiencies, propose improvements for enhancing data quality and process performance. The scope of the study is limited to the geometry assurance process, focusing specifically on the transformation and management of final demand data throughout the distinct phases of the process. Through a literature study, interviews, a pilot study and the mapping of process activities, the current process was studied in detail. The findings reveal significant inefficiencies in the current data flow and process approach. Data flow challenges were predominantly associated with compromised data integrity, as a result of the manual steps involved in data transformation and the propagation of errors due to lack of integration between software tools. Further, the mapping of the current process outlined an approach that often lacks clarity and a solid ground. The proposed enhancements include the implementation of an API that enables automated data transfer, formatting and storing, eliminating errors associated with manual data exchange across departments and stages. It facilitates communication across three different software programs utilized in different phases of the geometry assurance process, ensuring that the demand data is linked. Through this, data flow efficiency is significantly enhanced and data quality is improved. Further, suggestions intended to optimize the overall performance of the process include implementing standardized work routines and optimizing time management practices. The suggested improvements not only address immediate inefficiencies but also lay a foundation for continuous improvement in data management practices within the company.
Integrating Discrete Event Simulation with Real Controllers, An Early Phase Approach to Virtual Commissioning in Automotive Manufacturing
Joshi, Abhinav; Rexton Moris, Frederick; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Johansson , Björn; Nyqvist, Per; Albo, Anton; Andersson , Dennis
Virtual commissioning is a continuously growing and developing area in the field of production, it helps companies stay competitive in the ever-growing sector of manufacturing. VC is a way to test logic control using computerized models even before they are commissioned onto the production line. This thesis aims at creating a comprehensive technical setup to test PLC Logic through Discrete Event Simulation (DES). A virtual model created with DES software is used to visualize and monitor the functioning of the PLC Logic. This thesis makes use of literature study and interviews with stakeholders to gather knowledge on the virtual commissioning framework, based on which the technical setup was built. An experimental phase was carried out to get a better understanding of all the tools and how to integrate them. The development phase involves using the knowledge gathered through literature study and the experimental phase to build a virtual model and connect it to a virtual PLC. Post-development, the interconnected setup was tested to check the reliability of the integration. As a result, a completely tested and validated setup was established to test PLC logic programs with virtual models. Conversely, the reusability and repeatability of the virtual model too are greatly increased due to the extended functions such as automated object generation and real-time visualization of the PLC logic.
Data-Driven Solutions for Green Production Integrating Resource Efficiency Assessment in Manufacturing Systems
Gonzales, Juan; Nguyen, Thommy; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Despeisse, Melanie; Qi, Fang
In response to sustainable development efforts by the United Nations 2020 Agenda, industries are aiming towards more sustainable production. The European Commission has created the classification system called EU taxonomy, establishing the definition of sustainability and sustainable activities. Consequently, European manufacturers are seeking opportunities to reduce their environmental impact, creating the need to understand how their resources are utilized. Resource efficiency methods enable the assessment of resource usage but require high data quality and availability, making the implementation difficult. One of the main challenges for resource efficiency assessment is data completeness and reliability, especially at a process level, in tandem with a lack of standardized data collection methods resulting in the implementation of RE assessment being difficult. Despite the issues, there are still opportunities and benefits of using already available data in manufacturing systems with proper indicator selection having data characteristics in mind. This project aims to leverage available factory data, select indicators based on available data, and integrate resource efficiency in manufacturing systems to identify opportunities for greener production with a resource efficiency method in line with the EU taxonomy. This project showcases a case study implementing resource efficiency assessment in an automotive plant with an assessment design that includes multiple methods to be aligned with stakeholder priorities and indicates inefficiencies of resource usage. A selection method was devised as the project’s core, designed to be general and adaptable for other cases. However, assessment methods are inherently different and data quality is a critical factor in implementing them, not only stakeholder preferences of the company. The study utilized existing data to assess resource efficiency and proposed automated data handling for future assessments to streamline the process and reduce the execution time.
Robust concept development utilising artificial intelligence and machine learning
Karlsson, Kevin; Alfgården, Hugo; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Isaksson, Ola; Knuts, Sören; Pradas Gomez, Alejandro
The 80-20 rule suggests that design decisions significantly impact downstream effects, such as product cost, with many of these decisions made during concept generation. This early commitment limits the ability to make changes later in development. Early-stage design requires a variety and quantity of concepts, but designers often fixate on existing designs, limiting innovation. In the aerospace industry, the complexity of concept development and evaluation is particularly challenging. Therefore, this study seeks to explore how AI/ML methods can aid designers in the concept development process. This thesis was initiated as a results of a 2023 internship at GKN Aerospace, which involved generating a concept for the sectioning and manufacturing of an existing part. Recognizing the intricacies of these phases, the authors explored the potential of AI/ML methods to enhance robustness in concept generation and evaluation. The aim is to evaluate how GKN Aerospace can effectively integrate AI and ML into their product development workflows. This involves understanding current methodologies and identifying gaps to address before implementation. The focus is on leveraging AI and ML to streamline complex decision-making processes, ultimately providing actionable insights for robust, efficient concept design aligned with the Zero Defect paradigm in aerospace. Additionally, the thesis identifies gaps in the organization that needs to be address before a possible integration, such as data quality and data secrecy. The result, building on extensive interview studies and literature studies is that there is potential in incorporating AI/ML in concept development processes. Although, AI methods such as LLMs, still have limitations, including confidently producing incorrect results, a phenomenon known as hallucinations. The conclusion is that Generative AI, design tools with integrated AI/ML methods, and LLMs still offers opportunities to simplify concept generation. LLMs can assist with ideation, creative reasoning, and cognitive task offloading. Fine-tuned LLMs, trained on internal documentation, provide instant feedback on less complex tasks, helping designers explore a broader design space, mitigate bias, and enhance knowledge, facilitating the development of robust design solutions
Smart Factory: Automated Calibration Operations
Karlsson, William; Thulin , Eskil; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Johansson, Björn; Bergenheim, Gunilla; Nilsson Humlehagen, Marcus; Salunkhe, Omkar
Calibration of test systems is a crucial part of radar production to ensure highquality products. The calibration process comprises many repetitive steps performed manually by operators. The process is time-consuming, which impedes the valueadding product testing in the test systems. This thesis investigates the potential for automating manual calibration processes. Furthermore, it aims to analyse the impact this would have on the availability of the test systems and the calibration quality. This was done through a process split into three distinct steps. First, a literature study focusing on collaborative robot technologies. A current state analysis was then performed to examine the current calibration process. Lastly, empirical testing was conducted by programming a collaborative robot to perform manual calibration tasks, mainly focusing on connecting and disconnecting connectors. The findings indicate that the majority of the tasks in the calibration can be performed by a collaborative robot equipped with a laser sensor and custom grippers for manipulating the cables. Some types of connectors are more challenging to handle using automation, suggesting that the process might still require an operator for certain steps, if not redesigned. The anticipated change in availability for a fully automated solution is minimal, as manual calibration will not be conducted frequently enough. An automated solution can improve calibration quality by performing tasks with better precision than operators. Nevertheless, the use of a cobot will result in greater equipment wear. The automation within this type of production environment has proven challenging, but the potential benefits of successful implementation should not be overlooked.
The re-design of an electrical three-wheeler vehicle
Shetty, Ateeth; Doiphode, Vivek; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Lindkvist, Lars; Svensson, Ola
This report presents a master’s thesis project from January 2024 to September 2024. The thesis focuses on developing a new exterior body design for an electric 3-wheeler. OMotion AB is an innovative startup focused on sustainable mobility solutions through electric vehicles (EVs). The company aims to develop a more efficient version of its EVs to capture the growing market demand for environmentally friendly transportation. The primary objective of this project is to create an efficient and aesthetically appealing exterior body design that aligns with the company’s vision and production capabilities. The exterior body design of an electric vehicle plays an important role in reducing drag, improving range, and ensuring user appeal. This project considered several factors such as aerodynamics, manufacturability, structural integrity, and visual appeal. Additionally, the company is a startup with limited capital, so the design process was constrained to minimize changes to the core components, ensuring compatibility within existing manufacturing setups and cost efficiency. The product development process for the new exterior body concept began with market, legal requirements and customer research, both internally and externally. Ideas were generated based on the research findings, followed by iterative concept development using advanced 3D modeling tools such as NX and Alias. The concepts were then refined and evaluated. Aerodynamic simulations were conducted using STAR-CCM+ to assess design efficiency, and high-quality visualizations were produced using VRED to evaluate the aesthetic appeal of the final concepts. Throughout the detailed design phase, legal requirements and manufacturing guidelines were followed to ensure feasibility and alignment with the company’s production capabilities. Despite the challenges of working within specific constraints, the final exterior body concepts developed through this thesis serve as a valuable foundation for future development. Although this project provides a comprehensive design solution for the exterior body of the new electric vehicle, further research and development are required to fully optimize the design for large-scale production. However, the outcomes of this thesis will serve as a critical reference for OMotion’s Research & Development team as they work to bring this innovative vehicle to market
Design a High-Voltage Battery Enclosure System using a new manufacturing method
Nilsson, Charlie; Osorio, Daniel; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Persson, Christer; Persson, Christer
Volvo Cars, a major company in Sweden and Europe, is partnering with Impression Technologies to develop a key part of the battery tray using a new method called Hot Form Quenching. This new method could be used for many parts of the vehicle, helping to reduce weight, improve performance, and move the company closer to its sustainability goals. This master thesis aims to explore the process of transforming a component called footgarage originally developed for High Pressure Die Casting into a sheet metal component and covering several assessment points like function performance, sustainability, part price, investment cost, manufacturing process impacts, time to market, and material base. A comparison between these two concepts will tell if this new process has a future at Volvo Cars.
Using Robots to Collect Data for Machine Vision Tasks
El-Nahass, Karim; Urbanos, Gonzalo; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Johansson, Björn; Wang, Hao
The current final assembly process of automotive wire harnesses into vehicles predominantly relies on manual labor and skill. This reliance leads to safety and ergonomic issues when lifting heavy wire harnesses and applying high-pressure manipulations to components for 8 hours a day. This thesis combines collaborative robotics and artificial intelligence to collect connector data for machine vision tasks in the automotive industry, addressing the problem of insufficient data. The research investigates an approach using a robotic setup for automated data collection. The framework includes data acquisition utilizing a UR5 robot and an Intel RealSense D435 camera; robot-camera communication using a Raspberry Pi 4b as a bridge; and an automatic labeling tool. The collected dataset comprises 8 different connectors commonly used in automotive wire harnesses. The resultant datasets (first the manually annotated dataset and second the automatic annotated dataset) are evaluated using YOLOv8, a deep-learning based object detection model. The evaluation results present a higher accuracy (mAP50 = 93.5%) for the manually annotated dataset compared to the automatic labeling approach (mAP50 = 74.4%) which suggests that there is still room for improvement on the automatic labeling tool used. This accuracy difference is concluded to be due to the inability to control lighting conditions in the workspace in the lab.
A Digital Steering Experience of the Engine in a Boat
Defaire, Lovisa; Stavhagen, Lisa; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Lindkvist, Lars; Davidson, Staffan
This Master thesis presents the development of a digital steering experience for Volvo Penta products in a boat, aiming to enhance the user and customer journey when purchasing or considering a boat equipped with Volvo Penta products. The problem addressed in this thesis is the uncertainty and anxiety boating can cause if users are not fully comfortable with the boat, its equipment functionalities, and its environment. Utilizing Design Thinking methodologies, the focus was on creating an efficient experience with an intuitive interface that meets the needs of both novice and experienced boaters. The methods used to ensure user-friendliness included a questionnaire, qualitative interviews, user observations, feedback sessions, and usability tests to gather insights and validate design decisions. The findings formed the foundation for a customer needs list, leading to the creation of three personas representing these needs. This served as a basis for the development of the digital tool, with prototypes being created and iteratively evaluated through various product development screening methodologies, including Pugh and Kesselring matrices. Additional methodologies employed to examine the market potential were a PESTEL analysis, Segmentation, Target and Position analysis, a Competitor analysis and a Business Model Canvas. The results concluded in the development of a simulator for home use developed in Unity, capable of configuring a boat, practice scenarios, and testing of Volvo Penta products and accessories. The result demonstrated increased interest in the products displayed in the simulator after its use, along with an engaging learning experience of the products. Alongside the simulator development, the market analysis identified multiple areas of market potential for the near future and for future collaborations. In conclusion, the digital steering experience offers a compelling enhancement to the traditional boating and product exploration experience when buying a boat, providing users with an engaging customer journey. Future recommendations include further refining the simulator based on user feedback and exploring additional features to increase functionality.
Training Operators in VR, A scalable solution for efficient VR training creation
Melzani, Geoffrey; Quach, Tony; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Johansson, Björn; Li, Dan; Mugur, Puranjay; Söderlund, Henrik
Industry 4.0 is revolutionizing the automotive industry at an increasing speed. Many companies are exploring different ways to make different operations, within the industrialization processes, more efficient. In that context, Virtual Reality (VR) technologies are being implemented by many players in the industry, with the aim to gain in speed-to-market. Currently, companies within different industries are exploring how to integrate VR for operator training. Therefore, this thesis, conducted at Volvo Cars Corporation (VCC), in Torslanda, Sweden, aims to identify how to reduce the effort for VR operator training scenes creation with scripting, with the goal to achieve auto generation as well as large-scale implementation of VR training. The methodology implemented in this study is based on product development practices, with in this case, the product being VR operator training. First, the best adapted software to use was chosen: IPS, along with an HTC Vive hardware, to create and develop VR operator training and to envision its large-scale implementation. Furthermore, qualitative interviews and a literature review were conducted to acquire more knowledge, together with several tests and discussions with experts, to confirm and evaluate the findings. The topics covered were the identification of the relevant data to populate a VR operator training scene, the scripting for the auto generation of the scene itself and the learning facilitation, by considering the auto generation of pedagogical elements. The results were that using IPS, implementing the created scripts for auto generating a VR training scene was possible, populated with all the elements required, including the assembly, the plant layout with fixtures and storage furniture, as well as pedagogical elements such as text instructions, visual cues, and motion sequences of an assembly manufacturing. Challenges on the way of the large-scale implementation of this new type of training were identified and how to try and fix them was envisioned, to draw a blueprint for the implementation of VR operator training at VCC.
Shear-induced orientation and yielding of Cellulose nanocrystal suspensions: A Rheo-PLI study
Vinodya, Vihangi; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Kádár, Roland; Akas Mishra, Ases; Bek, Marko
This thesis presents an investigation of the shear-induced orientation and yielding behavior of CNC water suspensions by employing a Rheo-PLI technique. Cellulose is a structural protein found in plants and algae and plants produce them through synthesis.CNC has demonstrated potential in numerous applications due to its properties such as high mechanical strength, higher crystallinity, high aspect ratio, and optical properties. They are usually using in automotive industries,pharmaceutical industry, reinforcements in fillers and much more.The orientation and its microstructure highly impact to optical and mechanical properties. This study includes the preparation of CNC suspensions and analyze their rheological properties from rheological tests combined with polarized light imaging. In this study we combined the rheological tests with the polarized light imaging technique inorder to examine the yielding and shear-induced orientation of CNC structures in their suspension. We have performed hysteresis loop tests to investigate the thixotropic behavior, oscillatory tests to analyze the viscoelastic behavior, creep tests to examine the stability of CNC suspensions, and Yield stress to determine yielding behavior
Dynamic Digital Twin Through VR, Enabled by Emulate3D
Erdal, Lejla; Gubartalla, Ammar; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Johansson , Björn; Cao, Huizhong; Lopes, Paulo Victor
As Industry 4.0 technology is still evolving, research and implementation gaps due to issues such as costs, security, and lack of domain expertise for enabling Digital Twins and supportive technology need to be bridged. This thesis proposes a practical framework for enabling the connection between an Internet of Things platform and Digital Twin-compliant software for constructing a Digital Twin based on the ISO23247 standard. The simulation software provides cognitive support for the user, immersing them in the Digital Twin through Virtual Reality. Connectivity with the Internet of Things platform facilitates real-time bi-directional communication, collaboration, monitoring, and assistance. An adopted research methodology with a foundation in empirical studies was used to support and validate the presented use case based on an assembly line for a lab-scale drone factory. The results showcase a Digital Twin with Virtual Reality functions of a real-world use case implemented based on ISO 23347, in addition to potential business values related to the benefits of Digital Twins enabled by virtual reality technology.
Crisis communication for elderly
Larsson, Gabriella; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Osvalder, Anna-Lisa; Osvalder, Anna-Lisa
Machinability of bainitic steels
Papadopoulos, Pavlos; Chalmers tekniska högskola / Institutionen för industri- och materialvetenskap; Chalmers University of Technology / Department of Industrial and Materials Science; Malakizadi, Amir; Malakizadi , Amir
Recently, Volvo Trucks has been exploring various methods to reduce the CO2 footprint of large automotive vehicles. This involves not only limiting the emissions produced during vehicle operation but also minimizing the ecological impact of their manufacturing processes. One promising approach is the adoption of new materials that enable more efficient and lightweight designs. Bainitic steels are a class of materials that could meet these requirements. They offer superior mechanical properties compared to traditionally used steels with a pearlitic-ferritic microstructure, allowing for the design and production of smaller and lighter components without compromising strength. However, their enhanced mechanical properties can present challenges during machining operations. Thus, the aim of this thesis is to explore the machinability of bainitic steels and compare it with that of the currently adopted pearlitic-ferritic steels. Both materials were characterized in detail, focusing on microstructure evaluation, examination of non-metallic inclusions, and hardness testing. Additionally, a series of face turning operations were performed on each material to obtain data regarding cutting insert wear development, the impact of tool wear on machining forces, the interaction between the workpiece material and the cutting tool, the protective layers formed on the tool surfaces, and the effects of different cutting conditions on machining forces and chip formation. Overall, it was found that tool wear is more aggressive when machining bainitic steels, and machining forces are also higher. The layer formed on the cutting inserts exhibits relatively small differences between the two materials. Furthermore, chip breakability is slightly better during the machining of bainitic steel.
Analysis and Development of User Interface for Home Care Airflow Generators
(2002) Bligård, Lars-Ola; Wass, Sofia; Chalmers tekniska högskola / Institutionen för produkt- och produktionsutveckling; Chalmers University of Technology / Department of Product and Production Development
Crack Propagation under Combined Thermal Cycling and Mechanical loading
(2004) Lansinger, Johan; Chalmers tekniska högskola / Institutionen för material- och tillverkningsteknik; Chalmers University of Technology / Department of Materials and Manufacturing Technology
Konceptutveckling av förvaringsmöbler och handfat för badrum
(2005) Mannefred, Malin; Chalmers tekniska högskola / Institutionen för produkt- och produktionsutveckling; Chalmers University of Technology / Department of Product and Production Development
Visuell känslighetsanalys. En metod för utvärdering av delningskoncept på bilkarosser
(2005) Forslund, Karin; Chalmers tekniska högskola / Institutionen för produkt- och produktionsutveckling; Chalmers University of Technology / Department of Product and Production Development

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