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Nieuwe generatie van lichtgewicht mobiliteitsproducten en externe protheses
Iedere gram telt…
Geert Smits, Mifa Aluminium BV, Aalberts Industries NV
The Dutch population numbers 16.7 million inhabitants today• 4,7% (± 800,000 people) of Dutch
population need aids to enhance mobility• Cain• Crutch• Walking frame• Wheelchair
• 5,4% (± 900,000 people) of Dutch population use anatomic aids• Orthopedic shoes• Orthesis• Prosthesis
Data from CBS
Like everyone else• Stay active• Be independent• Have a social life• Have a professional career• Participate in sports
Mobility and anatomic aids• Designed according to their
individual needs• Shape• Size
…But everyone wants lighter aids
Easier to lift / push Competitive advantage Energy efficient
And stiffer. And more comfortable.
More efficient transfer of muscle power
Better absorbance of shocks
Translation of user requirements into the right material
• Light and strong - Specific Strength
Material selection by the Ashby approach
Translation of user requirements into the right material
• Light and strong - Specific Strength• 1. Magnesium Alloys• 2. Aluminium Alloys• 3. Titanium Alloys• 4. Steels
Material selection by the Ashby approach
Translation of user requirements into the right material
• Light and strong - Specific Strength• 1. Magnesium Alloys• 2. Aluminium Alloys• 3. Titanium Alloys• 4. Steels
• Light and stiff - Specific Stiffness• 1. Magnesium Alloys• 2. Aluminium Alloys• 3. Titanium Alloys• 4. Steels
Material selection by the Ashby approach
Translation of user requirements into the right material
• Light and strong - Specific Strength• 1. Magnesium Alloys• 2. Aluminium Alloys• 3. Titanium Alloys• 4. Steels
• Light and stiff - Specific Stiffness• 1. Magnesium Alloys• 2. Aluminium Alloys• 3. Titanium Alloys• 4. Steels
• Shock absorbent - Specific Damping Capacity• 1. Magnesium Alloys• 2. Steels• 3. Aluminium Alloys• 4. Titanium Alloys
Material selection by the Ashby approach
Pros and cons of Magnesium
• 40% lighter than Aluminium• 250% lighter than Titanium• 400% lighter than Steel• 30% better absorption of
vibrations than Aluminium
• Low deformability at room temperature
• Low corrosion resistance• No readily available
technology for manufacturing Magnesium parts
+ -
Total Performance Approach
Extrusion MachiningBending
Welding and assemblyFinished product Coating
Challenges: Extrusion• Optimization of die design• Optimization of billet
homogenizing treatments• Optimization of extrusion
temperature and speed• Determination of extrudate
strength
Challenges: bending• Determination of minimum
relative bending radius• Optimization of bending speed• Determination of spring-back• Optimization of bending
temperature
Bending at room temperature, speed 1 rpm
Bending at 150°C, speed 1 rpm
Challenges: Machining• Optimization of feed rate• Optimization of cutting speed• Optimization of depth of cut
Challenges: Coating• Optimization of pretreatments• Optimization of process
parameters• Optimization of lacquering step• Wear resistance of coating• Corrosion resistance of coating
Challenges: Welding and assembly• Optimization of pre-treatments• Optimization of filler feeding• Optimization of alternating current• Determination of joint strength
Phase II: Manufacturing and biomechanical testing of prototypes • Starts summer 2012• Selection of prototypes• Design of prototypes• Manufacturing of prototypes• Biomechanical testing of
prototypes
Sharon WalravenSilver medalist – Olympic Games Sydney 2000 (Ladies single)Gold medalist – Olympic Games Beijing 2008 (Ladies double)
Phase II: Manufacturing and biomechanical testing of prototypes • Novel ultra-light wheelchair for
tennis-star Sharon Walraven
Future spin-offs after completion of the project• Light-weight magnesium coated
profiles and parts for• High end sport bikes• Automobiles• Airplanes• Portable electronics
The members of the consortium would like to thank …..