Design and Manufacturing of a Prototypical Assembly of an Inline-four Engine Using Rapid Prototyping Technology

Bakalářská práce se zabývá tématem prototypování a tvorbou 3D modelu jako součásti procesu produktového vývoje. Prototypový model motoru je konstruován s využitím parametrické aplikace CATIA v5 a vyroben s použitím aditivní výrobní technologie– metoda Fused Deposition Modeling. Teoretická část práce se věnuje problematice produktového vývoje, aditivní výroby a řadou konstrukčních a funkčních charakteristik motoru. Praktická část práce pak popisuje proces návrhu a výroby prototypového modelu motoru. Práce je ukončena technicko-ekonomickým zhodnocením navržené sestavy.The bachelor’s thesis focuses on the topic of prototyping and 3D model–making as a part of the product development process. The model is designed with the use of CATIA v5 parametric application and it is manufactured with the use of Additive Manufacturing technology–Fused Deposition Modeling. The theoretical part of the thesis addresses the topic of Product Development, Additive Manufacturing technology as well a number of engine design and functional characteristics. The experimental part of the work then describes the process of designing and manufacturing of the engine model. The work is concluded with a techno-economic evaluation of the designed assembly.

The energy efficient engine project

The Energy Efficient Engine Project is directed at providing, by 1984, the advanced technologies which could be used for a generation of fuel conservative turbofan engines. The project is conducted through contracts with the General Electric Company and Pratt and Whitney Aircraft. The scope of the entire project and the current status of these efforts are summarized. A description of the preliminary designs of the fully developed engines is included and the potential benefits of these advanced engines, as well as highlights of some of the component technology efforts conducted to date, are discussed

Advanced Gas Turbine (AGT) powertrain system

A 74.5 kW(100 hp) advanced automotive gas turbine engine is described. A design iteration to improve the weight and production cost associated with the original concept is discussed. Major rig tests included 15 hours of compressor testing to 80% design speed and the results are presented. Approximately 150 hours of cold flow testing showed duct loss to be less than the design goal. Combustor test results are presented for initial checkout tests. Turbine design and rig fabrication is discussed. From a materials study of six methods to fabricate rotors, two have been selected for further effort. A discussion of all six methods is given

The 30 GHz solid state amplifier for low cost low data rate ground terminals

This report details the development of a 20-W solid state amplifier operating near 30 GHz. The IMPATT amplifier not only met or exceeded all the program objectives, but also possesses the ability to operate in the pulse mode, which was not called for in the original contract requirements. The ability to operate in the pulse mode is essential for TDMA (Time Domain Multiple Access) operation. An output power of 20 W was achieved with a 1-dB instantaneous bandwidth of 260 MHz. The amplifier has also been tested in pulse mode with 50% duty for pulse lengths ranging from 200 ns to 2 micro s with 10 ns rise and fall times and no degradation in output power. This pulse mode operation was made possible by the development of a stable 12-diode power combiner/amplifier and a single-diode pulsed driver whose RF output power was switched on and off by having its bias current modulated via a fast-switching current pulse modulator. Essential to the overall amplifier development was the successful development of state-of-the-art silicon double-drift IMPATT diodes capable of reproducible 2.5 W CW output power with 12% dc-to-RF conversion efficiency. Output powers of as high as 2.75 W has been observed. Both the device and circuit design are amenable to low cost production

Minimization of Waste Generation in Steel Sectors

The operation in the integrated steel plant can be classified into three different groups. The first group involves iron making process comprising sintering and agglomeration, coke making and blast furnace operations. Steelmaking which includes all operations from primary steelmaking through secondary steelmaking to ingot/continuous casting constitutes the second group. Rolling and finishing processes including pickling, coating, shearing and other finishing operations constitute the third group . At all these stages enormous amounts of wastes are generated. These wastes have a wide ranging impact on the environment. Thus, minimization of waste through integrated waste management has gained special significance in the present scenario. This paper suerunarizes the scope to reduce waste generation of all kinds in the steel sector. It has been concluded that through the introduction of latest processing technologies, waste can be drastically reduced and whatever generated can be recycled in the process stream or converted into value added products

Design for manufacturability

Design for Manufacturability represents a new awareness of the importance of design as the first manufacturing step. It recognizes that a company cannot meet all its objectives with isolated design and manufacturing operations. The Design for Manufacturability approach embodies certain underlying imperatives that help maintain communication between all components of the Manufacturing and Design system and permit flexibility to adopt and to modify design during each stage of the product realization. Design for Manufacturability cannot be bought or sold and it should be implemented by management. Complete support of management to the implementation is very important to the success of the Design for Manufacturability. In this thesis Design for Manufacturability and its inputs a proposed product concept, a proposed process concept and a set of design goals are explained, associated methodologies are discussed, and their effect on the design of a product and a plan implementation of design for manufacturability is developed

Automated process planning for metal hybrid additive and subtractive manufacturing

The manufacturing industry is currently evolving from mass production to mass customization and ultimately towards mass personalization. Direct Digital Manufacturing (DDM) is deemed as a key to the future of manufacturing, and Hybrid Additive and Subtractive Manufacturing (Hybrid AM/SM) can be a path to realize it. While Hybrid AM/SM equipment are being developed, automated process planning for them is far from being integrated. Enabling automated process planning for Hybrid AM/SM will bring the integrationof AM and SM to an unprecedented level. This research problem spans multiple aspects of Computer Aided Design (CAD), Computer Aided Process Planning (CAPP) and Computer Aided Manufacturing (CAM). This presentation introduces several proposed methods for AM/SM automated process planning, including an out-of-envelope method, Design-for-Hybrid systems and future integration modes for Hybrid AM/SM. The results of this work will enable integration of the extraordinary geometric capabilities of Additive Manufacturing with the precision of subtractive methods

Production Scheduling in Integrated Steel Manufacturing

Steel manufacturing is both energy and capital intensive, and it includes multiple production stages, such as iron-making, steelmaking, and rolling. This dissertation investigates the order schedule coordination problem in a multi-stage manufacturing context. A mixed-integer linear programming model is proposed to generate operational (up to the minute) schedules for the steelmaking and rolling stages simultaneously. The proposed multi-stage scheduling model in integrated steel manufacturing can provide a broader view of the cost impact on the individual stages. It also extends the current order scheduling literature in steel manufacturing from a single-stage focus to the coordinated multi-stage focus. Experiments are introduced to study the impact of problem size (number of order batches), order due time and demand pattern on solution performance. Preliminary results from small data instances are reported. A novel heuristic algorithm, Wind Driven Algorithm (WDO), is explained in detail, and numerical parameter study is presented. Another well-known and effective heuristic approach based on Particle Swarm Optimization (PSO) is used as a benchmark for performance comparison. Both algorithms are implemented to solve the scheduling model. Results show that WDO outperforms PSO for the proposed model on solving large sample data instances. Novel contributions and future research areas are highlighted in the conclusion