This document summarizes Rohit Bhagat's mechanical engineering portfolio, including 8 projects from 2012-present. The projects involve designing a cocoa bean grinding and winnowing station, a vertical reciprocating conveyor, a cable-driven 3D printer, optimizing riblet structures on UAV wings for drag reduction, minimizing dampers in earthquake-prone buildings using genetic algorithms, automating production of a lifting trolley, modeling an airplane and power drill using FEA, and using an Arduino microcontroller to calibrate a thermistor and control a stepper motor. Solidworks and ANSYS were used for modeling and simulations. The projects demonstrate Rohit's skills in design, analysis, automation, and programming for
Plasma arc cutting parameters using taguchi methodchiragkolambe
In this paper, we have tested on a plasma arc
cutting machine but by using the Taguchi method. This
machine is accurate, high finishing. This process is very
cheap than another process like laser cutting. In the market,
this process has a high demand. In this paper, we will go to
study the Cutting Speed and Arc Gap and another import
factor in this process are using the Taguchi method by using
Minitab 17. We went Analysis Taguchi Analysis: surface
roughness, kerf versus speed, ... ideas, air gap. By using this
method ANOVO we will find General Linear Model: surface
roughness versus speed, ... ides, air gap In this research we
will use Mild Steel E350
SIMULATION OF THE DRILLING PROCESS IN GFRP COMPOSITES USING SYSTEM DYNAMICS A...IAEME Publication
This paper intends to present the System Dynamics (SD) as a novel method to
simulate the thrust force developed during drilling of GFRP composites. Good quality
holes are extremely fundamental so as to accomplish equally good joints amid
creation of components prepared from composite for better execution. Since the
nature of a drilled hole is subject to material properties and machining conditions, it
is important to think about the impacts of these factors on the nature of hole obtained.
In the present work, the machining parameters thickness of the material, drill point
angle, drill size, drill speed and feed rate are selected to evaluate their effect on the
quality of the hole. Past works uncover the fact that the damage caused to the drilled
hole is primarily due to the thrust force. Consequently it is fundamental to limit the
thrust force so as to accomplish better quality of the drilled hole. The SD simulation
model was implemented through a causal loop diagram. A mathematical equation
used in the simulation was developed utilizing the Design of Experiments (DOE)
technique. VENSIM programming was utilized to create and run the SD model. The
SD simulation results were compared with Artificial Neural Networks (ANN) results,
Response Surface Methodoly (RSM) results and the experimental results. A decent
agreement was seen between SD, ANN and RSM results
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
“Mobile mast for The Radar carrier Vehicle”, the working object is taking the images and giving the information to costal security services. This FE Assembly has the different subassemblies.Those names are Aerial Antenna Assembly, Aerial rotary Assembly, and Azimuth drive Assembly, Chassis & Sub frame, 4-Bar mechanism and Palette without riggers. The total Wight of this model is 30.590 tones. This FE Model can be configuration into two FE Models. These are
Deployed 0 Degrees and Deployed 90 Degrees.For the static analysis in the deployed condition, the assembly rests on outriggers.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
Cyclic Life Establishment of First Stage Compressor Blade - Aircraft Jet EngineIJERA Editor
In this project an attempt is made to identify the cyclic life, modal efficacies for assessing the life that is declared
by the Original Engine Manufacturer. Using the Goodman diagram and knowing the mean stress of the blade for
all rpm conditions.
Comparison of stress between winkler bach theory and ansys finite element met...eSAT Journals
Abstract Crane Hooks are highly liable components and are always subjected to failure due to the amount of stresses concentration which can eventually lead to its failure. To study the stress pattern of crane hook in its loaded condition, a solid model of crane hook is prepared with the help of CATIA (Computer Aided Three Dimensional Interactive Application) software. Pattern of stress distribution in 3D model of crane hook is obtained using ANSYS software. The stress distribution pattern is verified for its correctness on model of crane hook using Winkler-Bach theory for curved beams. The complete study is an initiative to establish an ANSYS based Finite Element procedure, by validating the results, for the measurement of stress with Winkler-Bach theory for curved beams. Keywords: Crane Hook, CATIA, ANSYS, Curved Beam, Stress, Winkler-Bach Theory
Design, Analysis and weight optimization of Crane Hook: A Reviewijsrd.com
Crane hook are highly liable component and are always subjected to failure due to accumulation of large amount of stress which can eventually lead to its failure .In this present work, to study the different design parameter & stress pattern of crane hook in its loaded condition for different cross section, the design and drafting of crane hook will be prepared by using ANSYS 14.5. By finite element analysis, the stress which is to be formed in various cross section are compared with design calculation .The stress concentration factors are used in strength and durability evaluation of structure and machine element. In this work and also we observe the parameter that affects the weight reduction.
Structural analysis of steering yoke of an automobile for withstanding torsio...eSAT Journals
Abstract
The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and
steady movement of the vehicle. It consists of two yokes, one on each shaft, connected by a cross-shaped intermediate member i.e.
spider. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some
common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults, material processing
faults as well as the user originated faults. In this paper finite element analysis of the component is carried out to find the stress and
displacement of the final product. For modeling of the component, CATIA V5 R17 software is used. Preprocessing work like meshing
and analysis work is carried out in HYPERWORKS software. Using FEA analysis, we can identify the nature and characteristics of
stresses acting on the yoke and also evaluate the influence of the loads/ mass/ geometry/ boundary conditions over the yoke.
Keywords: Steering Yoke, Structural analysis, FEA, CATIA V5, Hyper works
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This paper addresses the use of algorithmic design paired with additive manufacturing and their
potential impact on architectural design and fabrication of a full-sized building, as demonstrated with the AMIE
project. AMIE (Additive Manufacturing and Integrated Energy) was collaboration to 3d print a building and
vehicle. Both the car and building were designed to generate, store and share energy in an effort to reduce or
eliminate reliability on the power grid. This paper is intended to outline our methodology in successfully
designing for these innovative strategies, with a focus on the use of computational design tools as a catalyst for
design optimization, integrated project delivery, rapid prototyping and fabrication of building elements using
additive manufacturing.
Unmanned Aircraft System (UAS) 3D Product Comparisons to Airborne LiDARMerrick & Company
Technical comparison of 3D UAS imaging products to airborne LiDAR data products. Presented by Matt Bethel, Director of Technology for Geospatial Solutions at Merrick & Company (www.merrick.com) on February 18, 2014 in Denver, Colorado. International LiDAR Mapping Forum (ILMF) - http://www.lidarmap.org/international
The peer-reviewed International Journal of Engineering Inventions (IJEI) is started with a mission to encourage contribution to research in Science and Technology. Encourage and motivate researchers in challenging areas of Sciences and Technology.
Plasma arc cutting parameters using taguchi methodchiragkolambe
In this paper, we have tested on a plasma arc
cutting machine but by using the Taguchi method. This
machine is accurate, high finishing. This process is very
cheap than another process like laser cutting. In the market,
this process has a high demand. In this paper, we will go to
study the Cutting Speed and Arc Gap and another import
factor in this process are using the Taguchi method by using
Minitab 17. We went Analysis Taguchi Analysis: surface
roughness, kerf versus speed, ... ideas, air gap. By using this
method ANOVO we will find General Linear Model: surface
roughness versus speed, ... ides, air gap In this research we
will use Mild Steel E350
SIMULATION OF THE DRILLING PROCESS IN GFRP COMPOSITES USING SYSTEM DYNAMICS A...IAEME Publication
This paper intends to present the System Dynamics (SD) as a novel method to
simulate the thrust force developed during drilling of GFRP composites. Good quality
holes are extremely fundamental so as to accomplish equally good joints amid
creation of components prepared from composite for better execution. Since the
nature of a drilled hole is subject to material properties and machining conditions, it
is important to think about the impacts of these factors on the nature of hole obtained.
In the present work, the machining parameters thickness of the material, drill point
angle, drill size, drill speed and feed rate are selected to evaluate their effect on the
quality of the hole. Past works uncover the fact that the damage caused to the drilled
hole is primarily due to the thrust force. Consequently it is fundamental to limit the
thrust force so as to accomplish better quality of the drilled hole. The SD simulation
model was implemented through a causal loop diagram. A mathematical equation
used in the simulation was developed utilizing the Design of Experiments (DOE)
technique. VENSIM programming was utilized to create and run the SD model. The
SD simulation results were compared with Artificial Neural Networks (ANN) results,
Response Surface Methodoly (RSM) results and the experimental results. A decent
agreement was seen between SD, ANN and RSM results
International Journal of Engineering Research and Applications (IJERA) aims to cover the latest outstanding developments in the field of all Engineering Technologies & science.
International Journal of Engineering Research and Applications (IJERA) is a team of researchers not publication services or private publications running the journals for monetary benefits, we are association of scientists and academia who focus only on supporting authors who want to publish their work. The articles published in our journal can be accessed online, all the articles will be archived for real time access.
Our journal system primarily aims to bring out the research talent and the works done by sciaentists, academia, engineers, practitioners, scholars, post graduate students of engineering and science. This journal aims to cover the scientific research in a broader sense and not publishing a niche area of research facilitating researchers from various verticals to publish their papers. It is also aimed to provide a platform for the researchers to publish in a shorter of time, enabling them to continue further All articles published are freely available to scientific researchers in the Government agencies,educators and the general public. We are taking serious efforts to promote our journal across the globe in various ways, we are sure that our journal will act as a scientific platform for all researchers to publish their works online.
“Mobile mast for The Radar carrier Vehicle”, the working object is taking the images and giving the information to costal security services. This FE Assembly has the different subassemblies.Those names are Aerial Antenna Assembly, Aerial rotary Assembly, and Azimuth drive Assembly, Chassis & Sub frame, 4-Bar mechanism and Palette without riggers. The total Wight of this model is 30.590 tones. This FE Model can be configuration into two FE Models. These are
Deployed 0 Degrees and Deployed 90 Degrees.For the static analysis in the deployed condition, the assembly rests on outriggers.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
Cyclic Life Establishment of First Stage Compressor Blade - Aircraft Jet EngineIJERA Editor
In this project an attempt is made to identify the cyclic life, modal efficacies for assessing the life that is declared
by the Original Engine Manufacturer. Using the Goodman diagram and knowing the mean stress of the blade for
all rpm conditions.
Comparison of stress between winkler bach theory and ansys finite element met...eSAT Journals
Abstract Crane Hooks are highly liable components and are always subjected to failure due to the amount of stresses concentration which can eventually lead to its failure. To study the stress pattern of crane hook in its loaded condition, a solid model of crane hook is prepared with the help of CATIA (Computer Aided Three Dimensional Interactive Application) software. Pattern of stress distribution in 3D model of crane hook is obtained using ANSYS software. The stress distribution pattern is verified for its correctness on model of crane hook using Winkler-Bach theory for curved beams. The complete study is an initiative to establish an ANSYS based Finite Element procedure, by validating the results, for the measurement of stress with Winkler-Bach theory for curved beams. Keywords: Crane Hook, CATIA, ANSYS, Curved Beam, Stress, Winkler-Bach Theory
Design, Analysis and weight optimization of Crane Hook: A Reviewijsrd.com
Crane hook are highly liable component and are always subjected to failure due to accumulation of large amount of stress which can eventually lead to its failure .In this present work, to study the different design parameter & stress pattern of crane hook in its loaded condition for different cross section, the design and drafting of crane hook will be prepared by using ANSYS 14.5. By finite element analysis, the stress which is to be formed in various cross section are compared with design calculation .The stress concentration factors are used in strength and durability evaluation of structure and machine element. In this work and also we observe the parameter that affects the weight reduction.
Structural analysis of steering yoke of an automobile for withstanding torsio...eSAT Journals
Abstract
The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and
steady movement of the vehicle. It consists of two yokes, one on each shaft, connected by a cross-shaped intermediate member i.e.
spider. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some
common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults, material processing
faults as well as the user originated faults. In this paper finite element analysis of the component is carried out to find the stress and
displacement of the final product. For modeling of the component, CATIA V5 R17 software is used. Preprocessing work like meshing
and analysis work is carried out in HYPERWORKS software. Using FEA analysis, we can identify the nature and characteristics of
stresses acting on the yoke and also evaluate the influence of the loads/ mass/ geometry/ boundary conditions over the yoke.
Keywords: Steering Yoke, Structural analysis, FEA, CATIA V5, Hyper works
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
This paper addresses the use of algorithmic design paired with additive manufacturing and their
potential impact on architectural design and fabrication of a full-sized building, as demonstrated with the AMIE
project. AMIE (Additive Manufacturing and Integrated Energy) was collaboration to 3d print a building and
vehicle. Both the car and building were designed to generate, store and share energy in an effort to reduce or
eliminate reliability on the power grid. This paper is intended to outline our methodology in successfully
designing for these innovative strategies, with a focus on the use of computational design tools as a catalyst for
design optimization, integrated project delivery, rapid prototyping and fabrication of building elements using
additive manufacturing.
Unmanned Aircraft System (UAS) 3D Product Comparisons to Airborne LiDARMerrick & Company
Technical comparison of 3D UAS imaging products to airborne LiDAR data products. Presented by Matt Bethel, Director of Technology for Geospatial Solutions at Merrick & Company (www.merrick.com) on February 18, 2014 in Denver, Colorado. International LiDAR Mapping Forum (ILMF) - http://www.lidarmap.org/international
The peer-reviewed International Journal of Engineering Inventions (IJEI) is started with a mission to encourage contribution to research in Science and Technology. Encourage and motivate researchers in challenging areas of Sciences and Technology.
Modeling and Analysis of Support Pin for Brake Spider Fixture by Fem Using An...IOSR Journals
Abstract: A fixture is designed and built to hold, support and locate every component to ensure that each is
drilled or machined with accuracy and manufactured individually. A fixture can be designed for a particular
job. A brake spider includes a spider body with a central opening and a slot for receiving a camshaft and
bracket assembly. The brake spider is attached to axle housing via the central opening. The form to be used
depends on the shape and requirement of the work piece to be machined. In the existing fixture, used for
modeling brake spider component, only five components were machined per hour. In the present work, detailed
study of brake spider component is carried out and design is modified to increase the productivity. The new
fixture design is carried out by using CATIA V5 modeling software and it is critically evaluated for the failure of
support pin component, by finite element method (FEM) using ANSYS software. This modified design is adapted
in the fabrication of fixture and is tested for its productivity. It is found that there is a considerable enhancement
in the productivity to seven components per hour with required accuracy.
Key Words: Fixture; support pin; ansys; brake spider; CATIA V5; FEM
Suitability of Composite Material for Flywheel Analysis IJMER
The paper deals with analysis of flywheel in which comparison of flywheel existing material
and test material are done. There must be proper design and analysis of flywheel in order to meet the
necessity to smooth out enormous oscillations in velocity that occur during a cycle of i.c.engine in a
flywheel. So here some finite element analysis tools are used for design and analysis purpose. Then results
are compared with existing material.
Computational Estimation of Flow through the C-D Supersonic Nozzle and Impuls...IJMTST Journal
In this paper, CFD analysis of flow within, Convergent – Divergent rectangular super sonic nozzle and super sonic impulse turbine with partial admission have been performed. The analysis has been performed according to shape of a super sonic nozzle and length of axial clearance and the objective is to investigate the effect of nozzle-rotor interaction on turbine’s performance. It is found that nozzle-rotor interaction losses are largely dependent on axial clearance, which affects the flow within nozzle and the extent of flow expansion. Therefore selecting appropriate length of axial clearance can decrease nozzle-rotor interaction losses. The work is carried in two stages:1) Modeling and analysis of flow for rectangular convergent divergent super sonic nozzle. 2) Prediction of optimal axial gap between the nozzle and rotor blades by allowing the above nozzle flow. In the present work, using a finite volume commercial code, ANSYS FLUENT 14.5, carries out flow through the convergent divergent nozzle study. The nozzle geometry is modeled and grid is generated using ANSYS14.5 Software. Computational results are in good agreement with the experimental ones.
Computational steering Interactive Design-through-Analysis for Simulation Sci...SURFevents
Computational steering has evolved with advances in computing and visualization technologies. This session will showcase interactive design-through-analysis techniques that seamlessly integrate computer-aided design and simulation-based analysis tools. The approach replaces traditional simulation-based analysis with IgANets, which embeds physics-informed machine learning into the Isogeometric Analysis paradigm. IgANets train parametrized deep networks to predict solution coefficients of B-Spline/NURBS representations, enabling instantaneous evaluation and interactive feedback loops. A first-of-its-kind demonstrator coupling IgANets with a novel user frontend, developed at SURF, will be presented to initiate a new trend in computational steering towards interactive design-through-analysis.
International Journal of Engineering Research and Development IJERD Editor
• Electrical, Electronics and Computer Engineering,
• Information Engineering and Technology,
• Mechanical, Industrial and Manufacturing Engineering,
• Automation and Mechatronics Engineering,
• Material and Chemical Engineering,
• Civil and Architecture Engineering,
• Biotechnology and Bio Engineering,
• Environmental Engineering,
• Petroleum and Mining Engineering,
• Marine and Agriculture engineering,
• Aerospace Engineering.
Sinds de komst van de computer zijn de ontwerpmogelijkheden sterk toegenomen. De vertaling van het ontwerp gebeurt echter nog vaak via plannen, die dan op de werf met traditionele bouwmethoden worden uitgevoerd. Al de informatie die digitaal beschikbaar is gaat als het ware verloren bij deze stap. Digitale fabricatie brengt hier verandering in, door een directe verbinding te maken tussen het ontwerp en de productie. Het reëel object is als het ware een exacte kopie van het virtueel model.
SPIF staat voor Single Point Incremental Forming. Door met behulp van een industriële robot het metaal geleidelijk aan in te duwen volgens een bepaalde gereedschapsbaan (toolpath), is er een grote verscheidenheid van geometrie mogelijk. Aangezien er geen mal nodig is voor dit proces, is het ideaal voor prototyping. Ook in architectuur is deze ontwerpvrijheid uiteraard een grote meerwaarde.
Via één of meerdere test cases zou ik de mogelijkheden van deze techniek in een architecturale context willen onderzoeken. Mogelijke toepassingen zijn bijvoorbeeld een zelfdragende gevel of een dakconstructie die door zijn geometrie geen dragende onderstructuur meer nodig heeft. Gebaseerd op een bestaand project van een carport, heb ik als voorbeeld een structuur gemodelleerd en onderworpen aan een bepaalde belasting. In het tweede geval is op dezelfde geometrie een grid van ribben toegevoegd, en duidelijk is dat de doorbuiging aanzienlijk verbetert.
Aangezien het een integraal proces van ontwerp tot productie is, lijkt het me interessant om dit binnen één software af te handelen. Zo heb ik getracht om het toolpath, nodig om de robot aan te sturen, ook binnen Grasshopper te genereren. Als output geeft dit een reeks met coördinaten en richtingsvectoren.
Na het structureel optimaliseren van het ontwerp en de vertaalstap naar de robot-instructies, kan de productie beginnen. Als laatste aandachtspunt zullen de afzonderlijke elementen moeten geassembleerd worden, zodat zij werkelijk functioneren als één geheel.
Gert-Willem Van Gompel
Master in de ingenieurswetenschappen: architectuur
1. Mechanical Engineering Portfolio
Rohit Bhagat,
Master of Science in Mechanical Engineering,
University at Buffalo, State University of New York
Phone: 858-249-8569
Email: rohitbhagat6@yahoo.com
LinkedIn: www.linkedin.com/in/rohitbhagat611
2. 1. Design and Fabrication of Automated Grinding and Fan Winnowing Station (Freelancer) April 2015-
Present
Aim: To design and fabricate a cocoa bean grinder and winnowing station with a capacity to hold 50 kg beans.
Implementation: Design and selection of the components like hopper, crusher, structural members, motors,
controller, vibrating table, sieves, vacuum unit, etc. Created a 3D model and performed FEA on critical parts.
3D model of the vibrating system
3D model of the grinder and winnowing station assembly
Conclusions:
The design satisfies the customer requirements.
FEA shows the design is safe.
The project is still in progress and would be manufactured soon.
Vibrating
table
Sieve
Chute
Vibrating
Motor
Spring &
Standoff
assembly
Hopper
Crusher
Vacuum
Unit
3. 2. Design and Fabrication of Vertical Reciprocating Conveyor (VRC) (Fall 2012-Spring 2013, DECON Pvt
Ltd, India)
Aim: To design and fabricate a semi-automatic material handling lift with a capacity of 1000 kg.
Implementation: Developed an optimum design procedure for a semi-automatic material handling lift with a payload of 2
ton. Created a 3D model of the VRC and performed FEA on the critical parts. Incorporated safety features including safety
cam, chain tensioner, electro-mechanical door locks & top/bottom safety switches.
3D Model of VRC and its carriage
Drive assembly and Safety cam
4. Stress and Deformation analysis on the carriage using ANSYS workbench
Stress and Deformation analysis on the drive assembly using ANSYS workbench
Stress and Deformation analysis on the structure using ANSYS workbench
5. Layout showing the safety and control features incorporated in the system
Conclusions:
• Safe and reliable design.
• Satisfies the problem statement.
• Safety of structure was also verified by Simulation tools.
• High positioning accuracy obtained.
• Less noise during operation.
6. 3. Cable Driven 3D Printer: a Novel Additive Manufacturing Machine (Spring 2014, University at Buffalo)
Aim: To develop a novel 3D printer concept which doesn’t exist in the commercial market.
Implementation: Cables were implemented for extruder motion in order to provide large work space, faster posiitioning,
eliminate moving platform and for simple and reconfigurable design. The concept was inspired from cable driven robots
and the sky cam. Modeling and control of a cable driven 3D printer were studied in detail. The printer was designed for 3
degree of freedom, with motion of the extruder in X, Y, Z directions. Kinematic and static analyses were performed on the
cables and the extruder mounting plate to determine the position of the printing head and the force exerted on it to
maintain static equilibrium.
Cable Driven 3D printer
Extruder
Spool & its shaft
Outer frame
Spool mounting rod
Bottom Frame
Top Frame
Protective Glass
Heating Bed
Extruder
Stepper Motor
Extruder Frame
Heating Coil
Nozzle
Spur Gears
Mounting plate
Cable attachment screws
Filament carrying tube
Cooling Fan
7. Exploded view of Extruder & the whole assembly
FEA on 3D printer frame, printing platform and platform mounting plate
Conclusion:
Inexpensive, simple and lightweight 3D printer.
Flexibility to print large as well as small objects, even of irregular shapes.
The setup is easily reconfigurable and any addition of cables, motors or pulleys can be done effortlessly
Would provide faster build rate.
Extruder motion would be very precise considering the Kinematics and static analysis.
8. 4. Shark Skin Structure on a UAV to Reduce Drag: 3D Printing Approach (Spring 2014, University at
Buffalo)
Aim: Investigating the optimization of shark-mimicking riblet structure geometry for Unmanned Aerial Vehicle (UAV)
wings to be fabricated using additive manufacturing. Studying the drag reduction after the incorporation of scales.
Implementation: The effect of shark-mimicking riblet structure geometry for drag reduction in UAV design were
modeled and simulated. This modeling phase was then linked to an optimization process to derive optimum riblet
structure geometry parameters. In addition, preliminary results of 3D printed shark riblet structure geometry were also
outlined.
For optimum riblet geometry, a part of the wing was considered.
3D Model of (a) Blade (b) Scalloped (c) Saw tooth geometries
3D Model of UAV wing with blade riblets
Modeling and FEA of UAV wing, with & without scales
Conclusion:
• Incorporation of blade riblets on the UAV wing reduces drag by approximately 7%.
• A 7% reduction in drag can have a considerable impact on fuel consumption of the aircraft and help lower costs.
• In future, this result could further be validated by a wind tunnel test.
• Fused Deposition Modeling gives relatively poor precision and hence other printing methods can be looked into.
• Blade riblets can also be incorporated on fuselage and the tail of the aircraft to further improve efficiency.
• Parts can be optimized for the FDM process such that only build material is required without any support
structure, thus giving considerable cost savings.
9. 5. Optimizing Number & Placement of Dampers in Earthquake Prone Buildings (Fall 2014, University at
Buffalo)
Aim: To optimize the number and locations of tuned mass dampers that are installed in high-rise buildings.
Implementation: A model presenting the connection between drifts and the number of tuned mass dampers for an n-
storey building was developed. Then genetic algorithm method was used to optimize the total number of dampers in the
building and some tests were applied to optimize the location of dampers. A comparison was set up between a 10-storey
building optimized using the proposed method, and same building with all floors damped.
tttttt
iiiii
uxkxcxm
gxmqkqc
s
The above equation was used to find out the minimum number of dampers using Genetic Algorithm toolbox from
MATLAB. Bounds were set on the damper and building parameters to find the minimum number of dampers. A state
space model was created and trials were performed to try out different orientations of dampers. The optimum combination
found out was 2 dampers on each of the 10th
, 9th
& 8th
floors, 1 damper on 7th
& 5th
floors and none on the remaining floors.
This was then compared with a full damped building consisting of 1 damper on each floor to check the responses.
Response of the 8th
floor with full damped building
Response of the 8th
floor with the proposed approach
Conclusions:
A 10 storey building model under seismic excitation was used for comparison. Genetic algorithm provided an
effective way to minimize the number of dampers. It also allowed us to set the bounds on the parameters. The
minimum number of dampers obtained was 8.
A state space model was used to plot the response of each floor.
The comparison between the 2 methods showed us that the relative drifts for all the floors are within the limits
even after reducing the number of dampers. This would result into significant cost saving.
Choosing the best damper and its installation location is very crucial for structural safety, this general approach
can surely form the basis of calculations for the same.
0 2 4 6 8 10 12 14 16 18 20
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0.25
displacement(m)
time (sec)
With damper
Without damper
0 2 4 6 8 10 12 14 16 18 20
-0.25
-0.2
-0.15
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0.25
displacement(m)
time (sec)
Without dampers
With dampers
10. 6. Automated Manufacturing Process of a Lifting Trolley (Fall2014, University at Buffalo)
Aim: To develop a manufacturing plan and implement automation for production of an industrial lifting trolley.
Specifications:
It can lift up to 1000 pounds of load.
Platform dimension:48 x 38 inches
The maximum height of the scissor is 46 inches.
The motion of platform is achieved with a single cylinder.
Minimal finish requirement.
Implementation: The topics covered in this project were final design, parts to be manufactured/sourced, process plan,
factory layout, machine quantity and production timings, optimization of process, automation and its implementation,
prototyping.
3D Model of the lifting trolley
Fabricated prototype of the lifting trolley
Conclusions:
Implemented automated process for production of lifting trolley.
Successfully incorporated cellular manufacturing in process plan.
The optimization model can be used to reduce total production time.
Automation processes can be easily modified as per the requirement.
Platform
Mounting
Plate
Cylinder
Base Frame
Scissor Arm
Handle
Wheel
11. 7. Modeling and FEA of a Plane and a Power Drill (Spring 2014, University at Buffalo)
Aim: To create 3D models of airplane and power drill and to perform FEA on the same.
Implementation: 3D models for airplane and power drill were created using SolidWorks. Isometric and exploded
views were also obtained. Bill of materials was generated.
Stress and Deformation analysis on the airplane
Isometric and Exploded View and BOM of airplane
12. Stress and Deformation analysis on the power drill
Isometric and Exploded View and BOM of power drill
Conclusion: 3D modeling and FEA analysis was effectively carried out using SolidWorks
13. 8. Implementing Arduino microcontroller to calibrate a thermistor and control a stepper motor (Spring 2014,
University at Buffalo)
Aim:
a) To calibrate the thermistor to provide an approximate temperature reading.
b) To create 2 modes in arduino sketch, one that will light up the LED when the thermistor is touched and giving the
temeprature reading continuously. Second mode would allow to send the steps for the stepper motor.
c) To make the LED blink which is connected to port no.13 when the motor is moving.
Implementation: Online arduino tutorials were followed to make the proper connections and to write a code to fullfil the
aim of the assignment.
Thermistor calibration
This assignment was performed to calibrate the thermistor with the help of Arduino Microcontroller. A code was written
in the Arduino sketch, such that, the Led light up when the thermistor was touched also giving the temperature reading
continuously.
Output:
Code written in the Arduino sketch and its output
14. Connections
Control of stepper motor
The assignment was to control the stepper motor with the help of Arduino microcontroller.A code was written to send
steps manually and the LED should light up when the motor is in motion.
Connections
Conclusion: The thermistor and the stepper motor were effectively controlled with the use of Arduino.
15. 9. Design of a Conveyor System for a Coal Handling Plant (Spring 2013, University of Pune)
Aim: To design a trough belt conveyor system with a load carrying capacity of 70 TPH.
Implementation: Selected a suitable standard belt for the given load and speed. Designed the Head pulley, tail pulley
and snub pulley. Calculated the number and size of idlers required and selected the standard sizes for carrying and return
idlers. Selected the drive system based on the load capacity and pulley dimensions. Calculated the different resistive
forces acting on the conveyor and also designed the takeup pulley and counter weights to maintain tension in the belt.
Designed the frame to support the structure.
Conveyor assembly drawing
16. Conveyor Part Drawings
FMEA on the system
Conclusions:
Designed a standard trough belt conveyor system for a coal handling plant.
Performed Failure Mode Effects Analysis (FMEA) on the system.
10. Modeling, Simulating & Controlling a Servo Motor using LabView (Fall 2013, University at Buffalo)
Aim: To simulate the mathematical model of servo motor and compare it with an actual motor. To control the motor.
Implementation: Simulated mathematical model of servo motor from derived transfer function and studied the results for
different frequencies, keeping the amplitude constant. Compared the input voltage/signal, simulated model position and
actual motor position. Found proportional and derivative gains to meet design specifications and verified these results in
Simulink; simulated this PD controller and implemented the controller to evaluate its performance.
Main VI to control the simulated motor
17. Conclusions:
Succesfully simulated the mathematical model of motor and compared it with the actual motor position and the
reference signal.
Found the PD gains according to the design specifications and implemented this controller. Using the PD
controller, these three signals overlap as the derivative action produces faster response and so simulated and
actual motor positions match with the reference signal.
11. Miscellaneous
3D Model of a rim and a tire
Planetery Gear Drive