International Journal of Mechanical, Industrial and Aerospace Sciences

A Holistic Approach for Technical Product Optimization

Year: 2016 Volume: 10 Issue: 1 26 - 31 Pages

Abstract: Holistic methods covering the development process as a whole – e.g. systems engineering – have established themselves in product design. However, technical product optimization, representing improvements in efficiency and/or minimization of loss, usually applies to single components of a system. A holistic approach is being defined based on a hierarchical point of view of systems engineering. This is subsequently presented using the example of an electromechanical flywheel energy storage system for automotive applications.

Modeling of a Vehicle Wheel System Having a Built-in Suspension Structure Consisted of Radially Deployed Colloidal Spokes between Hub and Rim

Year: 2016 Volume: 10 Issue: 1 16 - 25 Pages

Authors:
Barenten Suciu

Abstract: In this work, by replacing the traditional solid spokes with colloidal spokes, a vehicle wheel with a built-in suspension structure is proposed. Following the background and description of the wheel system, firstly, a vibration model of the wheel equipped with colloidal spokes is proposed, and based on such model the equivalent damping coefficients and spring constants are identified. Then, a modified model of a quarter-vehicle moving on a rough pavement is proposed in order to estimate the transmissibility of vibration from the road roughness to vehicle body. In the end, the optimal design of the colloidal spokes and the optimum number of colloidal spokes are decided in order to minimize the transmissibility of vibration, i.e., to maximize the ride comfort of the vehicle.

Wall Pressure Fluctuations in Naturally Developing Boundary Layer Flows on Axisymmetric Bodies

Year: 2016 Volume: 10 Issue: 1 10 - 15 Pages

Authors:
Chinsuk Hong

Abstract: This paper investigates the characteristics of wall pressure fluctuations in naturally developing boundary layer flows on axisymmetric bodies experimentally. The axisymmetric body has a modified ellipsoidal blunt nose. Flush-mounted microphones are used to measure the wall pressure fluctuations in the boundary layer flow over the body. The measurements are performed in a low noise wind tunnel. It is found that the correlation between the flow regime and the characteristics of the pressure fluctuations is distinct. The process from small fluctuation in laminar flow to large fluctuation in turbulent flow is investigated. Tollmien-Schlichting wave (T-S wave) is found to generate and develop in transition. Because of the T-S wave, the wall pressure fluctuations in the transition region are higher than those in the turbulent boundary layer.

Contribution to Experiments of a Free Surface Supercritical Flow over an Uneven Bottom

Year: 2015 Volume: 9 Issue: 12 2142 - 2146 Pages

Abstract: The aim of this study is to examine, through experimentation in the laboratory, the supercritical flow in the presence of an obstacle in a rectangular channel. The supercritical regime in the whole hydraulic channel is achieved by adding a convergent. We will observe the influence of the obstacle shape and dimension on the characteristics of the supercritical flow, mainly the free-surface elevation and the velocity profile. The velocity measurements have been conducted with the one dimension laser anemometry technique.

Dynamic Simulation of IC Engine Bearings for Fault Detection and Wear Prediction

Year: 2015 Volume: 9 Issue: 11 1993 - 2002 Pages

Abstract: Journal bearings used in IC engines are prone to premature failures and are likely to fail earlier than the rated life due to highly impulsive and unstable operating conditions and frequent starts/stops. Vibration signature extraction and wear debris analysis techniques are prevalent in industry for condition monitoring of rotary machinery. However, both techniques involve a great deal of technical expertise, time, and cost. Limited literature is available on the application of these techniques for fault detection in reciprocating machinery, due to the complex nature of impact forces that confounds the extraction of fault signals for vibration-based analysis and wear prediction. In present study, a simulation model was developed to investigate the bearing wear behaviour, resulting because of different operating conditions, to complement the vibration analysis. In current simulation, the dynamics of the engine was established first, based on which the hydrodynamic journal bearing forces were evaluated by numerical solution of the Reynold’s equation. In addition, the essential outputs of interest in this study, critical to determine wear rates are the tangential velocity and oil film thickness between the journals and bearing sleeve, which if not maintained appropriately, have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to calculate the wear rate of bearings with specific location information as all determinative parameters were obtained with reference to crank rotation. Oil film thickness obtained from the model was used as a criterion to determine if the lubrication is sufficient to prevent contact between the journal and bearing thus causing accelerated wear. A limiting value of 1 μm was used as the minimum oil film thickness needed to prevent contact. The increased wear rate with growing severity of operating conditions is analogous and comparable to the rise in amplitude of the squared envelope of the referenced vibration signals. Thus on one hand, the developed model demonstrated its capability to explain wear behaviour and on the other hand it also helps to establish a co-relation between wear based and vibration based analysis. Therefore, the model provides a cost effective and quick approach to predict the impending wear in IC engine bearings under various operating conditions.

An Integrated CFD and Experimental Analysis on Double-Skin Window

Year: 2015 Volume: 9 Issue: 7 1397 - 1403 Pages

Abstract: Result from the constant dwindle in natural resources, the alternative way to reduce the costs in our daily life would be urgent to be found in the near future. As the ancient technique based on the theory of solar chimney since roman times, the double-skin façade are simply composed of two large glass panels in purpose of daylighting and also natural ventilation in the daytime. Double-skin façade is generally installed on the exterior side of buildings as function as the window, so there is always a huge amount of passive solar energy the façade would receive to induce the airflow every sunny day. Therefore, this article imposes a domestic double-skin window for residential usage and attempts to improve the volume flow rate inside the cavity between the panels by the frame geometry design, the installation of outlet guide plate and the solar energy collection system. Note that the numerical analyses are applied to investigate the characteristics of flow field, and the boundary conditions in the simulation are totally based on the practical experiment of the original prototype. Then we redesign the prototype from the knowledge of the numerical results and fluid dynamic theory, and later the experiments of modified prototype will be conducted to verify the simulation results. The velocities at the inlet of each case are increase by 5%, 45% and 15% from the experimental data, and also the numerical simulation results reported 20% improvement in volume flow rate both for the frame geometry design and installation of outlet guide plate.

Investigation of the Operational Principle and Flow Analysis of a Newly Developed Dry Separator

Year: 2015 Volume: 9 Issue: 12 2138 - 2141 Pages

Abstract: Mineral product, waste concrete (fine aggregates), waste in the optical field, industry, and construction employ separators to separate solids and classify them according to their size. Various sorting machines are used in the industrial field such as those operating under electrical properties, centrifugal force, wind power, vibration, and magnetic force. Study on separators has been carried out to contribute to the environmental industry. In this study, we perform CFD analysis for understanding the basic mechanism of the separation of waste concrete (fine aggregate) particles from air with a machine built with a rotor with blades. In CFD, we first performed two-dimensional particle tracking for various particle sizes for the model with 1 degree, 1.5 degree, and 2 degree angle between each blade to verify the boundary conditions and the method of rotating domain method to be used in 3D. Then we developed 3D numerical model with ANSYS CFX to calculate the air flow and track the particles. We judged the capability of particle separation for given size by counting the number of particles escaping from the domain toward the exit among 10 particles issued at the inlet. We confirm that particles experience stagnant behavior near the exit of the rotating blades where the centrifugal force acting on the particles is in balance with the air drag force. It was also found that the minimum particle size that can be separated by the machine with the rotor is determined by its capability to stay at the outlet of the rotor channels.

Pre-Eliminary Design Adjustable Workstation for Piston Assembly Line Considering Anthropometric for Indonesian People

Year: 2015 Volume: 9 Issue: 8 1584 - 1588 Pages

Abstract: Manufacturing process has been considered as one of the most important activity in business process. It correlates with productivity and quality of the product so industries could fulfill customer’s demand. With the increasing demand from customer, industries must improve their manufacturing ability such as shorten lead-time and reduce wastes on their process. Lean manufacturing has been considered as one of the tools to waste elimination in manufacturing or service industry. Workforce development is one practice in lean manufacturing that can reduce waste generated from operator such as waste of unnecessary motion. Anthropometric approach is proposed to determine the recommended measurement in operator’s work area. The method will get some dimensions from Indonesia people that related to piston workstation. The result from this research can be obtained new design for the work area considering ergonomic aspect.

Ion Thruster Grid Lifetime Assessment Based on Its Structural Failure

Year: 2015 Volume: 9 Issue: 11 1989 - 1992 Pages

Abstract: This article developed an ion thruster optic system sputter erosion depth numerical 3D model by IFE-PIC (Immersed Finite Element-Particle-in-Cell) and Mont Carlo method, and calculated the downstream surface sputter erosion rate of accelerator grid; compared with LIPS-200 life test data. The results of the numerical model are in reasonable agreement with the measured data. Finally, we predicted the lifetime of the 20cm diameter ion thruster via the erosion data obtained with the model. The ultimate result demonstrated that under normal operating condition, the erosion rate of the grooves wears on the downstream surface of the accelerator grid is 34.6μm⁄1000h, which means the conservative lifetime until structural failure occurring on the accelerator grid is 11500 hours.

Performance Comparison between Conventional and Flexible Box Erecting Machines Using Dispatching Rules

Year: 2015 Volume: 9 Issue: 12 2133 - 2137 Pages

Abstract: In this paper, we introduce a flexible box erecting machine (BEM) that swiftly and automatically transforms cardboard into a three dimensional box. Recently, the parcel service and home-shopping industries have grown rapidly, and there is an increasing need for various box types to ship various products. However, workers cannot fold thousands of boxes manually in a day. As such, automatic BEMs are garnering greater attention. This study takes equipment operation into consideration as well as mechanical improvements in order to design a BEM that is able to outperform its conventional counterparts. We analyzed six dispatching rules – First In First Out (FIFO), Shortest Processing Time (SPT), Earliest Due Date (EDD), Setup Avoidance, EDD + SPT, and EDD + Setup Avoidance – to determine which one was most suitable for BEM operation. Consequently, SPT and Setup Avoidance were found to be the most critical rules, followed by EDD + Setup Avoidance, EDD + SPT, EDD, and FIFO. This hierarchy was valid for both our conventional BEM and our new flexible BEM from the viewpoint of processing time. We believe that this research can contribute to flexible BEM management, which has the potential to increase productivity and convenience.

Collocation Assessment between GEO and GSO Satellites

Year: 2015 Volume: 9 Issue: 12 2124 - 2132 Pages

Abstract: The change in orbit evolution between collocated satellites (X, Y) inside +/-0.09° E/W and +/- 0.07° N/S cluster, after one of these satellites is placed in an inclined orbit (satellite X) and the effect of this change in the collocation safety inside the cluster window has been studied and evaluated. Several collocation scenarios had been studied in order to adjust the location of both satellites inside their cluster to maximize the separation between them and safe the mission.

Condition Monitoring for Controlling the Stability of the Rotating Machinery

Year: 2015 Volume: 9 Issue: 12 2118 - 2123 Pages

Abstract: In this paper, the experimental study for the instability of a separator rotor is presented, under dynamic loading response in the harmonic analysis condition. The global measurement and analysis of vibration on the cement separator RC500 is carried, the points of measurement used are radial dots, vertical, horizontal and oblique. The measures of trends and spectral analysis for reconnaissance of the main anomalies, the main defects in the separator and manifestation, the results prove that the defects effect has a negative effect on the stability of the rotor. Experimentally the study of the rotor in transient system allowed to determine the vibratory responses due to the unbalances and various excitations.

Time-Frequency Modeling and Analysis of Faulty Rotor

Year: 2015 Volume: 9 Issue: 11 1979 - 1988 Pages

Abstract: In this paper, de Laval rotor system has been characterized by a hinge model and its transient response numerically treated for a dynamic solution. The effect of the ensuing non-linear disturbances namely rub and breathing crack is numerically simulated. Subsequently, three analysis methods: Orbit Analysis, Fast Fourier Transform (FFT), and Wavelet Transform (WT) are employed to extract features of the vibration signal of the faulty system. An analysis of the system response orbits clearly indicates the perturbations due to the rotor-to-stator contact. The sensitivities of WT to the variation in system speed have been investigated by Continuous Wavelet Transform (CWT). The analysis reveals that features of crack, rubs and unbalance in vibration response can be useful for condition monitoring. WT reveals its ability to detect nonlinear signal, and obtained results provide a useful tool method for detecting machinery faults.

The Current State of Human Gait Simulator Development

Year: 2015 Volume: 9 Issue: 9 1679 - 1683 Pages

Abstract: This report examines the current state of human gait simulator development based on the human hip joint model. This unit will create a database of human gait types, useful for setting up and calibrating Mechano devices, as well as the creation of new systems of rehabilitation, exoskeletons and walking robots. The system has many opportunities to configure the dimensions and stiffness, while maintaining relative simplicity.

Comparison between LQR and ANN Active Anti-Roll Control of a Single Unit Heavy Vehicle

Year: 2015 Volume: 9 Issue: 2 426 - 431 Pages

Abstract: In this paper, a learning algorithm using neuronal networks to improve the roll stability and prevent the rollover in a single unit heavy vehicle is proposed. First, LQR control to keep balanced normalized rollovers, between front and rear axles, below the unity, then a data collected from this controller is used as a training basis of a neuronal regulator. The ANN controller is thereafter applied for the nonlinear side force model, and gives satisfactory results than the LQR one.

Mechanical Testing of Composite Materials for Monocoque Design in Formula Student Car

Year: 2016 Volume: 10 Issue: 1 1 - 9 Pages

Abstract: Inspired by the Formula-1 competition, IMechE (Institute of Mechanical Engineers) and Formula SAE (Society of Mechanical Engineers) organize annual competitions for University and College students worldwide to compete with a single-seat racecar they have designed and built. Design of the chassis or the frame is a key component of the competition because the weight and stiffness properties are directly related with the performance of the car and the safety of the driver. In addition, a reduced weight of the chassis has direct influence on the design of other components in the car. Among others, it improves the power to weight ratio and the aerodynamic performance. As the power output of the engine or the battery installed in the car is limited to 80 kW, increasing the power to weight ratio demands reduction of the weight of the chassis, which represents the major part of the weight of the car. In order to reduce the weight of the car, ION Racing team from University of Stavanger, Norway, opted for a monocoque design. To ensure fulfilment of the competition requirements of the chassis, the monocoque design should provide sufficient torsional stiffness and absorb the impact energy in case of possible collision. The study reported in this article is based on the requirements for Formula Student competition. As part of this study, diverse mechanical tests were conducted to determine the mechanical properties and performances of the monocoque design. Upon a comprehensive theoretical study of the mechanical properties of sandwich composite materials and the requirements of monocoque design in the competition rules, diverse tests were conducted including 3-point bending test, perimeter shear test and test for absorbed energy. The test panels were homemade and prepared with equivalent size of the side impact zone of the monocoque, i.e. 275 mm x 500 mm, so that the obtained results from the tests can be representative. Different layups of the test panels with identical core material and the same number of layers of carbon fibre were tested and compared. Influence of the core material thickness was also studied. Furthermore, analytical calculations and numerical analysis were conducted to check compliance to the stated rules for Structural Equivalency with steel grade SAE/AISI 1010. The test results were also compared with calculated results with respect to bending and torsional stiffness, energy absorption, buckling, etc. The obtained results demonstrate that the material composition and strength of the composite material selected for the monocoque design has equivalent structural properties as a welded frame and thus comply with the competition requirements. The developed analytical calculation algorithms and relations will be useful for future monocoque designs with different lay-ups and compositions.

Batch-Oriented Setting Time Optimisation in an Aerodynamic Feeding System

Year: 2015 Volume: 9 Issue: 12 2112 - 2117 Pages

Abstract: The change of conditions for production companies in high-wage countries is characterized by the globalization of competition and the transition of a supplier´s to a buyer´s market. The companies need to face the challenges of reacting flexibly to these changes. Due to the significant and increasing degree of automation, assembly has become the most expensive production process. Regarding the reduction of production cost, assembly consequently offers a considerable rationalizing potential. Therefore, an aerodynamic feeding system has been developed at the Institute of Production Systems and Logistics (IFA), Leibniz Universitaet Hannover. This system has been enabled to adjust itself by using a genetic algorithm. The longer this genetic algorithm is executed the better is the feeding quality. In this paper, the relation between the system´s setting time and the feeding quality is observed and a function which enables the user to achieve the minimum of the total feeding time is presented.

Cost Valuation Method for Development Concurrent Phase Appropriate Requirement Valuation Using the Example of Load Carrier Development in the Lithium-Ion-Battery Production

Year: 2015 Volume: 9 Issue: 12 2106 - 2111 Pages

Abstract: In the past years electric mobility became part of a public discussion. The trend to fully electrified vehicles instead of vehicles fueled with fossil energy has notably gained momentum. Today nearly every big car manufacturer produces and sells fully electrified vehicles, but electrified vehicles are still not as competitive as conventional powered vehicles. As the traction battery states the largest cost driver, lowering its price is a crucial objective. In addition to improvements in product and production processes a nonnegligible, but widely underestimated cost driver of production can be found in logistics, since the production technology is not continuous yet and neither are the logistics systems. This paper presents an approach to evaluate cost factors on different designs of load carrier systems. Due to numerous interdependencies, the combination of costs factors for a particular scenario is not transparent. This is effecting actions for cost reduction negatively, but still cost reduction is one of the major goals for simultaneous engineering processes. Therefore a concurrent and phase appropriate cost valuation method is necessary to serve cost transparency. In this paper the four phases of this cost valuation method are defined and explained, which based upon a new approach integrating the logistics development process in to the integrated product and process development.

Numerical Analysis of Roughness Effect on Mini and Microchannels: Hydrodynamics and Heat Transfer

Year: 2015 Volume: 9 Issue: 11 1973 - 1978 Pages

Abstract: A three-dimensional numerical simulation of flow through mini and microchannels with designed roughness is conducted here. The effect of the roughness height (surface roughness), geometry, Reynolds number on the friction factor, and Nusselt number is investigated. The study is carried out by employing CFD software, CFX. Our work focuses on a water flow inside a circular mini-channel of 1 mm and microchannels of 500 and 100 m in diameter. The speed entry varies from 0.1 m/s to 20 m/s. The general trend can be observed that bigger sizes of roughness element lead to higher flow resistance. It is found that the friction factor increases in a nonlinear fashion with the increase in obstruction height. Particularly, the effect of roughness can no longer be ignored at relative roughness height higher than 3%. A significant increase in Poiseuille number is detected for all configurations considered. The same observation can be done for Nusselt number. The transition zone between laminar and turbulent flow depends on the channel diameter.

A Study of Standing-Wave Thermoacoustic Refrigerator

Year: 2015 Volume: 9 Issue: 12 2100 - 2105 Pages

Abstract: Thermoacoustic refrigerator is a cooling device which uses the acoustic waves to produce the cooling effect. The aim of this paper is to explore the experimental and numerical feasibility of a standing-wave thermoacoustic refrigerator. The effects of the stack length, position of stack and operating frequency on the cooling performance are carried out. The circular pore stacks are tested under the atmospheric pressure. A low-cost loudspeaker is used as an acoustic driver. The results show that the location of stack installed in resonator tube has a greater effect on the cooling performance, than the stack length and operating frequency, respectively. The temperature difference across the ends of stack can be generated up to 13.7°C, and the temperature of cold-end is dropped down by 5.3°C from the ambient temperature.