Design of Experiments (Doe) on Suspension Test Equipment of One Part Of A Vehicle Wheel Using The Taguchi Method

Suspension is the most important thing that must be taken into account because it greatly affects driving comfort on the road. The working mechanism of the suspension consisting of spiral springs and shock absorbers is loaded vertically from the weight of the body, driver, and passengers. The uneven shape of the road surface in the form of potholes or bumps will greatly affect the comfort of the driver. This study aims to determine the effect of suspension work and the optimal value of vibration that occurs on one of the wheels of the vehicle against vertical dynamic loads. The method used in this study uses the Taguchi method which is used to determine the optimum dynamic load conditions against vibration in the suspension system.   The characteristics used in this method are "Smaller is better". Several variables such as bump height, tire pressure on the wheels, as well as vehicle body weight and passenger weight are necessary factors to calculate optimal dynamic load conditions against vibration in the suspension. Based on the results of the optimum value conditions obtained, namely the height of the mound of 5 cm, tire pressure of 32 Psi, load of 84 kg, and dynamic load of 71 kg. From the results of the contribution rate to the ANOVA obtained, factor A (bump height) and factor D (dynamic load) are significant factors while factor B (tire pressure) and factor C (load load) are insignificant factors. Under optimal conditions, there was a decrease in suspension vibration value by 49.65%

Statistical analysis of silicone oil flow through drilled plates used in RC cars

the present work studies how to determine the best combined dimensions of control variables to achieve an optimal mass flowrate in order the better damping performance on radio-controlled vehicles. According to this, we are going to design a DOE based on Taguchi´s (10) to measure the influence of fluid viscosity (μ), perimeter holes diameter (PHD), centre hole diameter (CHD) and hole length (HL) of different drilled plates used as a critical part of a RC vehicle damper. This DOE design will be L16 with three control variables already described and a fixed value (μ, WAGNERSIL S200). On the other hand, drilled plates will be 3d printed and self-designed by CAD, using ARTILLERY SIDEWINDER X1 “fdm” printing system

Proceeding Of Mechanical Engineering Research Day 2016 (MERD’16)

This Open Access e-Proceeding contains a compilation of 105 selected papers from the Mechanical Engineering Research Day 2016 (MERD’16) event, which is held in Kampus Teknologi, Universiti Teknikal Malaysia Melaka (UTeM) - Melaka, Malaysia, on 31 March 2016. The theme chosen for this event is ‘IDEA. INSPIRE. INNOVATE’. It was gratifying to all of us when the response for MERD’16 is overwhelming as the technical committees received more than 200 submissions from various areas of mechanical engineering. After a peer-review process, the editors have accepted 105 papers for the e-proceeding that cover 7 main themes. This open access e-Proceeding can be viewed or downloaded at www3.utem.edu.my/care/proceedings. We hope that these proceeding will serve as a valuable reference for researchers. With the large number of submissions from the researchers in other faculties, the event has achieved its main objective which is to bring together educators, researchers and practitioners to share their findings and perhaps sustaining the research culture in the university. The topics of MERD’16 are based on a combination of fundamental researches, advanced research methodologies and application technologies. As the editor-in-chief, we would like to express our gratitude to the editorial board and fellow review members for their tireless effort in compiling and reviewing the selected papers for this proceeding. We would also like to extend our great appreciation to the members of the Publication Committee and Secretariat for their excellent cooperation in preparing the proceeding of MERD’16

Study of a novel material solution for vibration isolation

Vibration isolation is an important requirement for many engineering systems. In particular, in the context of vibration isolation for light-weight automotive vehicles that exhibit wide variation in sprung mass, several limitations are associated with passive isolation systems. Such passive systems cannot obtain wide variations in the suspension parameters which required for reliable performance. While these technical drawbacks can be overcome by implementing active systems, these are associated with an increase in complexity, cost and potentially negative impact on reliability. In this context, composite fluid materials, which combine different components in a way that enhances an isolator’s performance, could represent a possible alternative approach with promising potential. However, the application of composite fluid materials for vibration isolations is still an underdeveloped area. The composite fluid material that is the subject of this research is referred to as Foam Filled Fluid (FFFluid). It is composed of three components, namely compressible (foam) particles, a viscous carrier fluid and a packaging material. This composite material has recently been investigated for applications in impact energy management but is not understood in anti-vibration application. Thus, the objective of this research was to understand the mechanisms, to characterise design parameters and to predict the responses of such composite material when used for vibration isolation systems. A theoretical understanding of the working principle for a FFFluid-based isolator was first achieved. Then, experimental work was conducted to assess the performance of such a device. The characterisation of the composite material was carried out via a systematic study; this study was then validated by an experimental -ivprogramme based on a Design of Experiments approach. Finally, empirical prediction models of the system were extracted by analysing the obtained data statistically. The conducted research shows that a FFFluid-based isolator possesses several advantages over commonly used existing solutions. Its main benefit is the potential capability of adjusting stiffness and damping coefficients by changing one component or more of this composite material. It was shown that increasing the volume of the composite material led to increased stiffness and damping coefficients. Besides, increasing the ratio of fluid in the mixture caused to increase the stiffness coefficient. The most important parameters that have an influence on the response of FFFluid were: the size of foam, the ratio of foam to fluid, volume of the material and fluid viscosity. Therefore, empirical models were established based on these parameters, the accuracy of these models were 85% Through the study of this novel material, the application of the FFFluid concept as a vibration isolator solution was studied. In practice, the design parameters of such a system could be adjusted through a control mechanism, to provide an adaptive solution. This could represent a suitable means to bridge the gap between passive and active suspension system in the context of vibration isolation for light-weight vehicles

Study of a novel material solution for vibration isolation

Vibration isolation is an important requirement for many engineering systems. In particular, in the context of vibration isolation for light-weight automotive vehicles that exhibit wide variation in sprung mass, several limitations are associated with passive isolation systems. Such passive systems cannot obtain wide variations in the suspension parameters which required for reliable performance. While these technical drawbacks can be overcome by implementing active systems, these are associated with an increase in complexity, cost and potentially negative impact on reliability. In this context, composite fluid materials, which combine different components in a way that enhances an isolator’s performance, could represent a possible alternative approach with promising potential. However, the application of composite fluid materials for vibration isolations is still an underdeveloped area. The composite fluid material that is the subject of this research is referred to as Foam Filled Fluid (FFFluid). It is composed of three components, namely compressible (foam) particles, a viscous carrier fluid and a packaging material. This composite material has recently been investigated for applications in impact energy management but is not understood in anti-vibration application. Thus, the objective of this research was to understand the mechanisms, to characterise design parameters and to predict the responses of such composite material when used for vibration isolation systems. A theoretical understanding of the working principle for a FFFluid-based isolator was first achieved. Then, experimental work was conducted to assess the performance of such a device. The characterisation of the composite material was carried out via a systematic study; this study was then validated by an experimental -ivprogramme based on a Design of Experiments approach. Finally, empirical prediction models of the system were extracted by analysing the obtained data statistically. The conducted research shows that a FFFluid-based isolator possesses several advantages over commonly used existing solutions. Its main benefit is the potential capability of adjusting stiffness and damping coefficients by changing one component or more of this composite material. It was shown that increasing the volume of the composite material led to increased stiffness and damping coefficients. Besides, increasing the ratio of fluid in the mixture caused to increase the stiffness coefficient. The most important parameters that have an influence on the response of FFFluid were: the size of foam, the ratio of foam to fluid, volume of the material and fluid viscosity. Therefore, empirical models were established based on these parameters, the accuracy of these models were 85% Through the study of this novel material, the application of the FFFluid concept as a vibration isolator solution was studied. In practice, the design parameters of such a system could be adjusted through a control mechanism, to provide an adaptive solution. This could represent a suitable means to bridge the gap between passive and active suspension system in the context of vibration isolation for light-weight vehicles

Simultaneous cutting of two separate sheets using plasma and parameters optimisation

This thesis investigates on the ability of using plasma technique for cutting simultaneously two parallel thin layers at different gap distances. Previous research emphasised that plasma cutting can be optimised to improve the quality and reduce phenomena. The investigation performed previously was made primarily in two-dimensional cutting plan. However, there is a lack of publication and research regarding optimisation of a three-dimensional structure cutting. This current work would help engineers to understand the practicability of thermal cutting such as plasma to process zones in the vehicle chassis similar to box sections or double layered areas. This research is aimed at wheelchair accessible vehicle converters that performs modifications in the chassis floor. This work is part of the engineering doctorate program. The research questions raised of this study lie primarily on assessing the possibility of simultaneous cutting of a double sheet (separated with an air distance) using plasma, expressly examining the possibility to reuse the energy heat exiting the first sheet’s kerf to perform a cut on the second layer. In addition, optimising the double sheets cutting, analysing the effect of the heat on thin material and reduce the resulting phenomena to their lower level (mainly surface deformation and heat affected zones). Lastly, assess the relationship strength between the parameters and the quality. Experiments were performed in four progressive phases. The first step was made to test the suitability of the plasma to process single thin sheets of 0.6 mm thick. This step was required to analyse the impact of the heat on the surface deformation and then optimise the cutting to improve the quality. The second phase of the tests were performed to verify the plasma ability to process a 3D-Structure such as double layered zones. The third phase of test was made to assess the cutting parameters suitable to process two layers simultaneously at a fixed gap 20 mm. These parameters were used as a reference for the following stage. The fourth phase was performed to optimise the double sheets structure cutting process (separated with an air distance) and minimise the impact of the heat generated during the plasma cutting on the top sheet. The Hypothesis of re-using the heat was tested and proven true, it is possible to re-employ the heat energy exiting the kerf to perform another cut. The tests showed that there was a considerable heat impact on the surface. However, this can be controlled and reduced. Cutting two sheets simultaneously may result to an offset between the top and bottom edge of the cut. Optimisation using the DOE based Taguchi approach resulted to an improvement in quality and the regression analysis showed a good fit of the models constructed, none of the values measured were outside the interval of prediction. Final tests were performed on a vehicle chassis and the results showed that a good automation can reduce the cutting process by approximatively 40min compared to manual cutting.This thesis investigates on the ability of using plasma technique for cutting simultaneously two parallel thin layers at different gap distances. Previous research emphasised that plasma cutting can be optimised to improve the quality and reduce phenomena. The investigation performed previously was made primarily in two-dimensional cutting plan. However, there is a lack of publication and research regarding optimisation of a three-dimensional structure cutting. This current work would help engineers to understand the practicability of thermal cutting such as plasma to process zones in the vehicle chassis similar to box sections or double layered areas. This research is aimed at wheelchair accessible vehicle converters that performs modifications in the chassis floor. This work is part of the engineering doctorate program. The research questions raised of this study lie primarily on assessing the possibility of simultaneous cutting of a double sheet (separated with an air distance) using plasma, expressly examining the possibility to reuse the energy heat exiting the first sheet’s kerf to perform a cut on the second layer. In addition, optimising the double sheets cutting, analysing the effect of the heat on thin material and reduce the resulting phenomena to their lower level (mainly surface deformation and heat affected zones). Lastly, assess the relationship strength between the parameters and the quality. Experiments were performed in four progressive phases. The first step was made to test the suitability of the plasma to process single thin sheets of 0.6 mm thick. This step was required to analyse the impact of the heat on the surface deformation and then optimise the cutting to improve the quality. The second phase of the tests were performed to verify the plasma ability to process a 3D-Structure such as double layered zones. The third phase of test was made to assess the cutting parameters suitable to process two layers simultaneously at a fixed gap 20 mm. These parameters were used as a reference for the following stage. The fourth phase was performed to optimise the double sheets structure cutting process (separated with an air distance) and minimise the impact of the heat generated during the plasma cutting on the top sheet. The Hypothesis of re-using the heat was tested and proven true, it is possible to re-employ the heat energy exiting the kerf to perform another cut. The tests showed that there was a considerable heat impact on the surface. However, this can be controlled and reduced. Cutting two sheets simultaneously may result to an offset between the top and bottom edge of the cut. Optimisation using the DOE based Taguchi approach resulted to an improvement in quality and the regression analysis showed a good fit of the models constructed, none of the values measured were outside the interval of prediction. Final tests were performed on a vehicle chassis and the results showed that a good automation can reduce the cutting process by approximatively 40min compared to manual cutting

Systems design methodology for personalised design customisation of sports wheelchairs

The state of the art in current wheelchair sports equipment design, demonstrates a steady progression in the process of wheelchair design improvement and adaptation to purpose in order to suit different sporting disciplines and game roles. However, the process of tuning the design of the wheelchair to suit the particular needs of elite athletes in terms of performance and ergonomic requirements, currently requires a research and evidence-based design methodology. This investigation aims to: i) characterise the sports wheelchair activity, including performance variables and design parameters in relation to the three main classification groups of wheelchair rugby athletes (high, mid and low pointers); ii) investigate the rugby wheelchair performance indicators both under game and laboratory conditions and establish critical relationships between wheelchair design parameters and the performance requirements for elite wheelchair rugby athletes; iii) identify the relevant design space for design customisation of rugby wheelchairs for individual wheelchair rugby athletes and the contribution of each design parameter to athlete’s mobility performance; iv) formulate a systems design methodology for design customisation of rugby wheelchairs that can be used to determine a high performance wheelchair design that best matches the requirements of the individual athlete. In order to effectively refine the user interphase design of the wheelchair, it is essential to narrow down the key dimensions within the design space, that are likely to have an effect on the performance of an individual athlete. The methods developed and used throughout this thesis are grounded on a number of case studies built on analysis of the test data obtained from elite wheelchair rugby athletes who volunteer for this research project. Initially, the Qualitative Function Deployment (QFD) method is used to systematically analyse data collected through international online surveys, focus groups and questionnaires from elite level wheelchair rugby players. Subsequently, experimental studies conducted on court and in the laboratory yield significant relationships between wheelchair design parameters and task-specific performance functions. Four key design factors (wheel diameter, camber angle, seat height and camber bar depth) are then iterated at incremental dimensional levels to the athlete’s current chair configuration; and tests are performed and analysed through an new extension to the Taguchi method. Subsequent analyses of acceleration, velocity, and time in the push phase of the propulsion cycle, as well as recovery time for each of the participating athletes performing a linear sprint task are correlated to the positive/negative contribution of each of the four design factors to the outlined performance variables as well as their combined effect in a specific wheelchair configuration model. Performance rankings and magnitude-based inferences on the true value of the effect statistic are then used to define a high performance design space for athlete’s wheelchair selection. This process has led to the formulation of a systems design methodology for design customisation of sports wheelchairs, which can be used across the various sporting disciplines to customize wheelchairs that best meet the athlete's needs in terms of performance and ergonomic requirements

A Design of Experiments Approach to Visor Drag Reduction on Heavy Vehicles Using Wind Tunnel Testing

Drag reduction on a scale wind tunnel model of a tractor and partial trailer was used as a case study to investigate the use of Designed Experiments. Specifically, the drag reduction benefits of replacing a tractor sunvisor with an airfoil shaped sunvisor were investigated. The airfoil-shaped sunvisor was theorized to generate thrust in the direction of travel thus reducing the net drag force. The drag force was measured using a load cell integrated into the tractor-trailer model. The experimental factors were the angle of attack, the horizontal position relative to the surface of the tractor body, the yaw angle and the wind tunnel velocity. The airfoil sunvisor orientation was optimized using an experimental design known as a Nested Face Centered Design. The optimal sunvisor airfoil was then compared to a generic sunvisor using a simple two-sample t-test. The experimental method proved to be an efficient, robust and defensible method for device optimization and comparison. The overall test results proved that the airfoil sunvisor hail no drag reduction benefit when compared to the generic sunvisor

The Effect of Backing Material on Carbon Fibre Severing for High-Volume Production of Composites

The replacement of steel with lightweight carbon fibre reinforced polymer (CFRP) represents one of the alternatives seriously considered by carmakers in preparation for the emission regulations of the future. While CFRPs have been used for a few decades across several industries, the recent price fall of carbon fibres have also made CFRPs attractive for high-volume automotive applications. Some challenges to address before the full-scale deployment of composites in the automotive industry are related to the efficient severing of carbon fibres. To address this, the present study investigated the effects of backing on the performance of carbon fibre severing through the development of a linear and a rotary cutter. The results obtained suggest that in addition to the foreseeable effect of backing hardness, the presence of backing wear marks and grooves also play a significant effect on the severing process