AI-based design methodologies for hot form quench (HFQ®)

This thesis aims to develop advanced design methodologies that fully exploit the capabilities of the Hot Form Quench (HFQ®) stamping process in stamping complex geometric features in high-strength aluminium alloy structural components. While previous research has focused on material models for FE simulations, these simulations are not suitable for early-phase design due to their high computational cost and expertise requirements. This project has two main objectives: first, to develop design guidelines for the early-stage design phase; and second, to create a machine learning-based platform that can optimise 3D geometries under hot stamping constraints, for both early and late-stage design. With these methodologies, the aim is to facilitate the incorporation of HFQ capabilities into component geometry design, enabling the full realisation of its benefits. To achieve the objectives of this project, two main efforts were undertaken. Firstly, the analysis of aluminium alloys for stamping deep corners was simplified by identifying the effects of corner geometry and material characteristics on post-form thinning distribution. New equation sets were proposed to model trends and design maps were created to guide component design at early stages. Secondly, a platform was developed to optimise 3D geometries for stamping, using deep learning technologies to incorporate manufacturing capabilities. This platform combined two neural networks: a geometry generator based on Signed Distance Functions (SDFs), and an image-based manufacturability surrogate model. The platform used gradient-based techniques to update the inputs to the geometry generator based on the surrogate model's manufacturability information. The effectiveness of the platform was demonstrated on two geometry classes, Corners and Bulkheads, with five case studies conducted to optimise under post-stamped thinning constraints. Results showed that the platform allowed for free morphing of complex geometries, leading to significant improvements in component quality. The research outcomes represent a significant contribution to the field of technologically advanced manufacturing methods and offer promising avenues for future research. The developed methodologies provide practical solutions for designers to identify optimal component geometries, ensuring manufacturing feasibility and reducing design development time and costs. The potential applications of these methodologies extend to real-world industrial settings and can significantly contribute to the continued advancement of the manufacturing sector.Open Acces

A Systematic Approach to Human Powered Vehicle Design with an Emphasis on Providing Guidelines for Mentoring Students

The objective of this research is to provide guidebook that approaches the design of a human powered vehicle (HPV) from a systematic view for an ASME competition. The guidebook introduces students to design and enhances their current understanding related to design, general engineering principals, and engineering principals specific to HPVs. In terms of the design process a combination between the traditional design process and the systems engineering design process is discussed. From here the design process in broken into six main sections for the guidebook, and an evaluation section used to emphasis the usefulness of the guidebook. First an overall view of the traditional and system engineering design processes are given, along with an overview of the human powered vehicle competition (HPVC). This is followed by details of project planning and problem development. Next the conceptual stage is introduced where concept generation and evaluation methods and examples are discussed. Embodiment design is given in the following section, where solution variants are modeled in a preliminary layout. Next, methods of how to create a more defined preliminary layout are given in the detail design section were a definitive layout is established. Finally prototyping, testing, redesigns, and final design recommendations are outlined in the last section. In addition, the guidebook provided is meant to serve as a method that can be used to mentor students in the design process of an HPV. As such, the guidebook has been developed through a literature review of design theories, managerial, organizational, and engineering practices that have had beneficial impacts, and past experiences with designing HPVs. In terms of past experiences, the interactions with students involved in a creative inquiry at Clemson University have used as a subjective means to outline some of the important design considerations needed to be discussed. Additionally, Clemson\u27s HPVs have primarily consisted of tadpole tricycles and as such, a more in depth analysis is included for this particular HPV style

Proceedings of the Conference on the Design of Leak-tight Fluid Connectors

Aerospace technology and design considerations for leak-tight separable, semipermanent, and permanent fluid connectors - conferenc

Specification and design of a measuring system for spring systems in cold form tooling

Spring systems are components on which science rarely focuses. Their universality, operating dynamics and low acquisition costs are factors that delay research. The fact that science does not document and present results on this topic forces and encourages companies to develop their own methods, research and results. Measuring equipment represents a key element for the continuous improvement of a process with actual performance data of process components. An accurate performance indication of a component makes a significant difference in the final quality of the product. In this thesis, the principle of measurement for spring systems as well as the respective machine design are presented. Practical cases related to metal forming processes were analysed to define machine requirements. It was decided to aim for a machine working the dynamic regime, with testing force capacity up to 30 kN and measuring displacement until 10 mm. A positioning system for tool die motion was also analysed, without compromising the required accuracy. This dissertation reflects a solid basis for the design of the machine, since practical cases were analysed to adjust and validate the system face the real needs. A group of experts was also heard to ensure that the system complied with the requirements needed in the field. The results allow to guarantee a good process control for a type of mechanical system on which the scientific documentation is very limited.Os sistemas de molas são componentes nos quais a ciência raramente se concentra. A sua universalidade, dinâmica operacional e baixo custo de aquisição, são fatores que desmotivam a investigação em torno deste assunto. O facto de a ciência não documentar e apresentar resultados sobre esse tópico, força e incentiva as empresas a desenvolverem seus próprios métodos, pesquisas e resultados. Os equipamentos de medição representam um elemento-chave para a melhoria contínua de um processo, com dados reais de desempenho dos componentes do processo. Uma indicação precisa do desempenho de um componente faz toda a diferença na qualidade final do produto. Nesta dissertação, são apresentados o princípio de medição para sistemas de molas, bem como o respectivo projeto de máquinas. Foram analisados alguns casos práticos relacionados com processos de conformação de metais, para definir as características necessárias para o equipamento. Estabeleceu-se como requisitos uma máquina que trabalhasse em regime dinâmico, com capacidade de teste de força até 30 kN e admitindo deslocamentos da mola até 10 mm. Também foi analisado um sistema de posicionamento para o movimento das ferramentas, sem comprometer a precisão necessária. O documento reflete uma base sólida para o projeto da máquina, uma vez que foram analisados casos práticos para ajustar e validar o sistema perante as necessidades reais. Foi ainda ouvido um grupo de especialistas neste assunto, para garantir que o sistema cumpria com os requisitos necessários na prática. Os resultados permitem garantir um bom controlo de processo para um tipo de sistema mecânico sobre o qual a documentação científica é muito limitada

Aeronautical engineering: A continuing bibliography with indexes (supplement 321)

This bibliography lists 496 reports, articles, and other documents introduced into the NASA scientific and technical information system in Sep. 1995. Subject coverage includes: design, construction and testing of aircraft and aircraft engines; aircraft components, equipment, and systems; ground support systems; and theoretical and applied aspects of aerodynamics and general fluid dynamics

The Commercial Application of Missile/Space Technology, Parts 1 and 2

This report is concerned with the transfer of technology from missile and space programs to non-missile/space applications in the United States. It presents the findings of a University of Denver Research Institute study sponsored by a National Aeronautics and Space Administration (NASA) grant awarded in November 1961. Initial stimulation for the unsolicited proposal leading to this study came from a 1960 Brookings Institution report to NASA, Proposed Studies on the Implications of Peaceful Space Activities for Human Affairs

Standard Specifications for Highway and Bridge Construction, 2012

When referenced, the 2012 edition of the Iowa Department of Transportation’s (Iowa DOT) Standard Specifications for Highway and Bridge Construction shall be used for contract work awarded by the Iowa DOT. They may also be incorporated by reference in other contract work on secondary, urban, local systems, or other contract work in which the Iowa DOT has an interest. As modified by the General Supplemental Specifications, these Standard Specifications represent the minimum requirements and may be modified by Supplemental Specifications, Developmental Specifications, and Special Provisions on specific contracts. These Standard Specifications have been written so the Contractor’s responsibilities are indicated by plain language using the Imperative Mood and Active Voice form. Sentences are of the form: Construct isolation joints at all points where driveways meet other walks, curbs, or fixtures in the surface. Ensure finished members are true to detailed dimensions and free from twists, bends, open joints, or other defects resulting from faulty fabrication or defective work. Personnel preparing the JMF shall be Iowa DOT certified in bituminous mix design. The Contracting Authority’s responsibilities are (with some exceptions) indicated by the use of the modal verb “will”. Sentences are of the form: The Engineer will obtain and test density samples for each lot according to Materials I.M. 204. Payment will be the contract unit price for Fabric Reinforcement per square yard (square meter). These standard specifications contain dual units of measure: the United States Standard measure (English units) and the International System of Units (SI or “metric” units). The English units are expressed first then followed by the metric units in parentheses. The measurements expressed in the two systems are not necessarily equal. In some cases the measurements in metric units is a “hard” conversion of the English measurement; i.e. the metric unit has been approximated with a rounded, rationalized metric measurement that is easy to work with and remember. The proposal form will identify whether the work was designed and shall be constructed in English or metric units

Ninth DOD/NASA/FAA Conference on Fibrous Composites in Structural Design, volume 1

This publication contains the proceedings of the Ninth DOD/NASA/FAA conference on Fibrous Composites in structural Design. Presentations were made in the following areas of composite structural design: perspectives in composites; design methodology; design applications; design criteria; supporting technology; damage tolerance; and manufacturing

Measuring the Effectiveness of Vietnam’s National Action Plan to Increase Helmet Use among Child Motorcycle Passengers in Three Major Cities.

Motorcyclists account for 75% of the estimated 22,000 fatalities caused by road injury each year in Vietnam. Helmets, widely worn by adult motorcyclists, are a cost-effective and proven intervention. Despite legislation mandating that children 6 years and above must wear helmets, child helmet use rates in Vietnam were low. In response, AIP Foundation leveraged evidence from its previous communications campaign to advocate Vietnam’s National Traffic Safety Committee (NTSC) to issue a National Child Helmet Action Plan for all 63 provinces during 2015. As part of the action plan, AIP Foundation adapted and expanded its communications campaign design from three target cities (Hanoi, Ho Chi Minh City, and Danang) to nationwide, focusing on 12 other provinces in Vietnam. The objective of this study was to evaluate the progress of the action plan toward its aim to a transformational increase in child helmet use in the 15 target cities and provinces by the end of 2015. Helmet observations at systematically sampled schools in the target provinces before and after the first phase of the action plan. The results from the final evaluation of the previous communications campaign are serving as the baseline for three target cities and post-observations will take place in April and November 2015. AIP Foundation measured baselines at the remaining 12 target provinces in March 2015 and will conduct a post-observation in November 2015. If funding is available, an additional post-observation will take place in all 15 target cities/provinces in November 2016 to assess the sustainability of the action plan. Average helmet wearing rates increased from 38% across the three target cities in March 2014 to 69% in April 2015. Hanoi experienced the greatest increase: from 23% in 2014 to 69% in 2015. In Danang, child helmet use increased from 37% to 75%, and in Ho Chi Minh City, the rate increased from 48% to 68%. An integrated campaign with national government leadership can bring about a substantial change in child helmet use. The adaptations applied to the action plan implementation have had a greater effect than the previous communications campaign