Modern enhancements in teaching design theories to mechanical engineering students

This paper describes the application of computer aided design (CAD) in teaching advanced design methodologies to fourth-year undergraduate students majoring in mechanical engineering. This involves modern enhancements in teaching strategies for subjects such as design-for-X (DFx) and failure mode effect analysis (FMEA) concepts, which are traditionally categorised as advanced design methodologies. The main subsets of DFx including design-for-assembly (DFA), design-for-disassembly (DFD), design-for-manufacturing (DFM), design-for-environment (DFE) and design-for-recyclability (DFR) were covered by studying various engineering and consumer products. The unit was designed as a combination of practical hands-on workshop-based classes along with a software-based evaluation of different products. In addition to CAD, finite element modelling techniques were utilised to enhance the students’ understanding of design faults and failures. The inquiry into teaching practice and design of this fourth-year unit was carried out during past two years and it revealed some interesting outcomes from our teaching practice in terms of students’ learning experiences. Finally, the paper discusses some critical factors in the context of teaching advanced design methodologies to the undergraduates in mechanical engineering and even manufacturing engineering.

A comparative assessment of austempered ductile iron as a substitute in weight reduction applications

Manufacturing engineering has had to undergo drastic changes in the approach to material selection in order to meet new design challenges. In the automotive industry, researchers in their effort to reduce emissions and satisfy environmental regulations, have shifted their focus to new emerging materials such as high-strength aluminium alloys, metal matrix composites, plastics, polymers and of late, Austempered Ductile Iron (ADI). ADI is a good choice for design where the criterion is high performance at reduced weight and cost. The unique, ausferrite microstructure gives the material desirable material properties and an edge over other materials. A comparative study of ADI in terms of materials properties and machining characteristics with other materials is desirable to highlight the potential of the material. This paper focuses on a comparative assessment of material and machining characteristics of ADI for different applications. The properties under consideration are machinability, weight and cost savings and versatility. ADI has a higher strength-to-weight ratio than aluminium making it a ready alternative for material selection. In terms of machinability, there are some problems associated with machining of ADI due to its work hardening nature. This paper attempts to identify the possible potential applications of ADI, by critically reviewing specific applications such as machinability, overall economics and service.

A hybrid cuckoo search and variable neighborhood descent for single and multiobjective scheduling problems

Cuckoo search (CS) is a relatively new meta-heuristic that has proven its strength in solving continuous optimization problems. This papers applies cuckoo search to the class of sequencing problems by hybridizing it with a variable neighborhood descent local search for enhancing the quality of the obtained solutions. The Lévy flight operator proposed in the original CS is modified to address the discrete nature of scheduling problems. Two well-known problems are used to demonstrate the effectiveness of the proposed hybrid CS approach. The first is the NP-hard single objective problem of minimizing the weighted total tardiness time (Formula presented.) and the second is the multiobjective problem of minimizing the flowtime ¯ and the maximum tardiness Tmaxfor single machine (Formula presented.). For the first problem, computational results show that the hybrid CS is able to find the optimal solutions for all benchmark test instances with 40, 50, and 100 jobs and for most instances with 150, 200, 250, and 300 jobs. For the second problem, the hybrid CS generated solutions on and very close to the exact Pareto fronts of test instances with 10, 20, 30, and 40 jobs. In general, the results reveal that the hybrid CS is an adequate and robust method for tackling single and multiobjective scheduling problems.

Developments in machining of stacked materials made of CFRP and titanium/aluminum alloys

The aim of this article is to investigate the drilling of carbon fiber-reinforced plastic (CFRP) composite/metal stack-ups to have a details picture of the developments in this complex area. The forces and torque, chip shape, surface finish and geometry, and tool material and tool wear for drilling composite/metal stack-ups have been analyzed in details in addition to drilling mechanism of CFRP. The relation between input and output parameters was discussed and the trend of input parameters for damage free and tight tolerance holes has been investigated based on the literature. The main findings are (i) heat, built-up edge and chips generated from drilling of metallic layers damages CFRP surface, (ii) order of material layers affects the drilling outcomes significantly, (iii) coatings and step-shape on the cutting tool improves the tool performance, (iv) tool materials should be selected based on the material of metallic layer, (v) chipping, adhesion, abrasion and attrition are main tool wear mechanisms during machining of CFRP/metal stacks and (vi) application of coolant improves the machinability.

Virtual and physical prototyping for compression sportswear

For high end compression sportswear it has increasingly become a crowded and highly competitive market with almost all sportswear companies having some form of offering. This work done in conjunction with a multinational sportswear group explores the use of virtual (FEA) and physical prototyping for a new garment design to ensure a competitive product in the market place. It was found that using a variety of processes, validation and feedback was given at several stages of the development program and highlighted areas of concern well before a final product was developed.

Incorporating human perception with the motion washout filter using fuzzy logic control

Abstract—Nowadays, classical washout filters are extensively used in commercial motion simulators. Even though there are several advantages for classical washout filters, such as short processing time, simplicity and ease of adjustment, they have several shortcomings. The main disadvantage is the fixed scheme and parameters of the classical washout filter cause inflexibility of the structure and thus the resulting simulator fails to suit all circumstances. Moreover, it is a conservative approach and the platform cannot be fully exploited. The aim of this research is to present a fuzzy logic approach and take the human perception error into account in the classical motion cueing algorithm, in order to improve both the physical limits of restitution and realistic human sensations. The fuzzy compensator signal is applied to adjust the filtered signals on the longitudinal and rotational channels online, as well as the tilt coordination to minimize the vestibular sensation error below the human perception threshold. The results indicate that the proposed fuzzy logic controllers significantly minimize the drawbacks of having fixed parameters and conservativeness in the classical washout filter. In addition, the performance of motion cueing algorithm and human perception for most occasions is improved.

Machining of titanium alloy (Ti-6Al-4V)-theory to application

This article correlates laboratory-based understanding in machining of titanium alloys with the industry based outputs and finds possible solutions to improve machining efficiency of titanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects of chip formation mechanism and practical issues faced by industries during titanium machining. This study also analyzed and linked the methods that effectively improve the machinability of titanium alloys. It is found that the deformation mechanism during machining of titanium alloys is complex and causes basic challenges, such as sawtooth chips, high temperature, high stress on cutting tool, high tool wear and undercut parts. These challenges are correlated and affected by each other. Sawtooth chips cause variation in cutting forces which results in high cyclic stress on cutting tools. On the other hand, low thermal conductivity of titanium alloy causes high temperature. These cause a favorable environment for high tool wear. Thus, improvements in machining titanium alloy depend mainly on overcoming the complexities associated with the inherent properties of this alloy. Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhanced machining, hybrid machining and, use of high conductive cutting tool and tool holders improve the machinability of titanium alloy.

A transformation technique to estimate the process capability index for non-normal processes

Estimating the process capability index (PCI) for non-normal processes has been discussed by many researches. There are two basic approaches to estimating the PCI for non-normal processes. The first commonly used approach is to transform the non-normal data into normal data using transformation techniques and then use a conventional normal method to estimate the PCI for transformed data. This is a straightforward approach and is easy to deploy. The alternate approach is to use non-normal percentiles to calculate the PCI. The latter approach is not easy to implement and a deviation in estimating the distribution of the process may affect the efficacy of the estimated PCI. The aim of this paper is to estimate the PCI for non-normal processes using a transformation technique called root transformation. The efficacy of the proposed technique is assessed by conducting a simulation study using gamma, Weibull, and beta distributions. The root transformation technique is used to estimate the PCI for each set of simulated data. These results are then compared with the PCI obtained using exact percentiles and the Box-Cox method. Finally, a case study based on real-world data is presented.

A transformation-based multivariate chart to monitor process dispersion

Multivariate monitoring techniques such as multivariate control charts are used to control the processes that contain more than one correlated characteristic. Although the majority of previous researches are focused on controlling only the mean vector of multivariate processes, little work has been performed to monitor the covariance matrix. In this research, a new method is presented to detect possible shifts in the covariance matrix of multivariate processes. The basis of the proposed method is to eliminate the correlation structure between the quality characteristics by transformation technique and then use an S chart for each variable. The performance of the proposed method is then compared to the ones from other existing methods and a real case is presented.

A note on multivariate non-normal process capability analysis using "mvtnorm" library in R

In this note we examine using Genzbretz and Miwa algorithms to improve estimation of proposition of non-conformance in multivariate normal distributions. This estimation is required in the procedure outlined in Abbasi and Niaki (Int J Adv Manuf Technol 50(5-8):823-830, 2010) to determine process capability index of multivariate non-normal processes.

Manufacturing techniques and surface engineering of polymer based nanoparticles for targeted drug delivery to cancer

The evolution of polymer based nanoparticles as a drug delivery carrier via pharmaceutical nano/microencapsulation has greatly promoted the development of nano- and micro-medicine in the past few decades. Poly(lactide-co-glycolide) (PLGA) and chitosan, which are biodegradable and biocompatible polymers, have been approved by both the Food & Drug Administration (FDA) and European Medicine Agency (EMA), making them ideal biomaterials that can be advanced from laboratory development to clinical oral and parental administrations. PLGA and chitosan encapsulated nanoparticles (NPs) have successfully been developed as new oral drug delivery systems with demonstrated high efficacy. This review aims to provide a comprehensive overview of the fabrication of PLGA and chitosan particulate systems using nano/microencapsulation methods, the current progress and the future outlooks of the nanoparticulate drug delivery systems. Especially, we focus on the formulations and nano/micro-encapsulation techniques using top-down techniques. It also addresses how the different phases including the organic and aqueous ones in the emulsion system interact with each other and subsequently influence the properties of the drug delivery system. Besides, surface modification strategies which can effectively engineer intrinsic physicochemical properties are summarised. Finally, future perspectives and potential directions of PLGA and chitosan nano/microencapsulated drug systems are outlined.