Vincent J. Vohnout

Technical description of the adaptive suspension vehicle

This paper contains descriptions and specifications of the major mechanical systems of the Adaptive Suspension Vehi cle. It also contains an overview of the computer software and hardware architectures. Experimental response curves for the principal servo systems are presented.

Computer-aided design of a leg for an energy efficient walking machine

Abstract Vehicles with legs instead of wheels have been studied for a number of years. One of the reasons for interest in such vehicles is that animals use only 10% as much energy as wheeled or tracked vehicles when traveling over rough terrain. The leg geometry is the most crucial aspect of the design since it strongly influences the efficiency of the vehicle. The legs should be simple in structure, and when the motion of the body is on a horizontal straight line, only one actuator per leg should be active in order to have good energy efficiency. The design of an energy efficient walking machine leg is described in this paper. In the design procedure, the motion of the leg is considered first, and a very simple leg developed from a 4-bar linkage and designed using a computer-aided interactive program is described. Second, the forces on this leg during a typical motion cycle are discussed. The leg is driven by a primary actuator for straight line walking and two secondary actuators which vary working height and change direction. A prototype of the leg is being built in The Department of Mechanical Engineering at The Ohio State University.

Hyperplastic forming: Process potential and factors affecting formability

Aluminum has an outstanding potential for reducing the mass of automobiles. One of the key problems is that it is very difficult to form without tearing. This paper has two distinct goals. First, the authors argue in an extended introduction that high velocity forming, as can be implemented through electromagnetic forming, is a technology that should be developed. As a process used in conjunction with traditional stamping, it may offer dramatically improved formability, reduced wrinkling and active control of springback among other advantages. In the body of the paper they describe the important factors that lead to improved formability at high velocity. In particular, high sample velocity can inhibit neck growth. There is a sample size dependence where larger samples have better ductility than those of smaller dimensions. These aspects are at least partially described by the recent model of Freund and Shenoy. In addition to this, boundary conditions imposed by sample launch and die impact can have important effects on formability.

Pressure heterogeneity in small displacement electrohydraulic forming processes

Electrohydraulic (submerged arc discharge) forming of sheet metal parts has been used as a specialized high speed forming method since the 1960’s. The parts formed generally had a major dimension in the 5 to 25 cm range and required gross metal expansion in the centimeter range. In the descriptions of this process found in the literature, the pressure front emanating from the initial plasma generated by the arc is considered to be uniformly spherical in nature. At least one commercial system used this model to design hardware for pressure front focusing to optimize the forming process[1] and it has been the subject of continued research [2]. Recently, there has been commercial interest in adopting the electro-hydraulic method for the production of much smaller parts requiring very high die contact pressures but little gross sheet expansion. The forming of these small shallow parts required only a few kilojoules but proved to be problematic in other terms. The process development clearly showed indications of random patterns of large pressure heterogeneity across distances in the millimeter range. The apparent pressure heterogeneity produced unacceptable small scale variation in the part geometry. A test program was designed to verify and quantify this effect using a target (die) consisting of a flat plate having small closely spaced holes. This 50 mm diameter target proved very effective in clearly showing the extent of the heterogeneity as well as the approximate local pressures. Various discharge energies were investigated along with different chamber shapes and pressure transfer mediums. The pressure heterogeneity across the target face was a common feature to all experiments. These test results indicate that a uniform pressure front model can be seriously in error for the electrohydraulic process as implemented to date. The results of a qualitative hydro-code model of the test system including the discharge event are presented. The model results are similar enough to the experimental to imply that the coaxial electrode’s inherent off center discharge is a primary suspect among potential explanations for the observed heterogeneity in terms of asymmetric shock interaction. The absence of this phenomena in the earlier electrohydraulic forming literature is also discussed.

Power system of a multi-legged walking robot

Abstract The power system of a legged vehicle is considerably more complex than the one used by a conventional land vehicle because of the wide range of power demands and the coordination and stability issues due to the large number of degrees of freedom. This paper is concerned with the conceptual and physical characteristics of the power system of a rough terrain, six-legged, walking vehicle. Modelling techniques and detailed analytical and simulation models are developed for the vehicle power system consisting of the prime mover, energy storage system, mechanical drives, hydraulic actuation systems and the associated control systems. Dynamics of the various subsystem and their interactions have been studied for control and optimization purposes. Validation of the models is provided by several experiments performed on a prototype leg and the vehicle.

Improved Formability by Control of Strain Distribution in Sheet Stamping Using Electromagnetic Impulses

Stamping failures consist of, broadly speaking, either tearing (excessive local strain energy) or wrinkling (insufficient or inappropriate local strain energy). Good parts are produced when the strain energy or plastic work is effectively distributed during the forming process such that tears and wrinkles are eliminated. The process window framed by tearing and wrinkling limits can be rather small for some materials, notably aluminum alloys. At present, there are no established methods of directly controlling the forming energy distribution within the tool during a stamping operation. All current commercial methods attempt plastic strain control at the sheet boundary by various binder geometries and pressure profiles. While improvements by active control of draw beads and binder pressure have led to improved stamping performance, these methods still broadly rely on tool geometry to set the energy distribution. We have recently developed and demonstrated a method for more directly controlling the distribution of forming energy in a stamping operation based on an extension of electromagnetic (EM) impulse forming. We now have techniques for embedding and operating EM pulse actuator coils in stamping tools. These coils can be operated in a single high power pulse or as a series of lower energy pulses occurring several times during the forming stroke. A single high power pulse can provide the advantage of increased material forming limits of high velocity forming. However, applying a series of lower power pulses can increase forming limits without exposing the tooling and coil to large shock loads. Multiple pulses reduce the maximum strain levels by engaging more of the part material in the forming process which mimics (eliminates) the use of lubricants. Conventional production stamping rates are technically obtainable with proper integration of the EM impulse circuit with the forming press and tooling. This paper focuses on the basic design approach of our multiple pulse technique and integrated process forming results. Comparisons to other augmented stamping processes as well as conventional stamping are presented in terms of both simple metrics, such as draw depth and strain distributions.