Unlisted: Projects and Design Portfolio

 

 

Welcome to my Projects and Design Portfolio, where I showcase a collection of innovative projects that highlight my expertise in 3D modeling, simulation, and development, driven by a passion for precision and innovation.

 

• Development and Validation of Quasi-Active Active Seat Suspension with Magnetorheological Damper and Magnets at the University of Wollongong
  

 

 

Overview: This project aimed to develop a device combining magnetorheological damper and negative stiffness technologies to create a quasi-actively controllable seat suspension, enhancing vibration reduction and driving comfort.

Tools Used:

• Simulink
• Solidworks
• Ansys

Process:

1. Achieving Negative Stiffness:
   • Experimentation: Negative stiffness was achieved using radially arranged magnets.
   • Torque Output: The experiment produced a maximum torque of 3.5 Nm, which was lower than the 15 Nm predicted by Simulink modeling due to differences in magnetic strength (1.65 T modeled vs. 0.65 T actual).
2. Results:
   • Vibration Reduction: Despite the lower torque, the negative stiffness component reduced seat displacement and acceleration by around 15% without control.
   • Model Validation: Adjusting the magnetic strength in Simulink provided torque values closely matching experimental results (around 3.8 Nm).

• Graphs showing torque vs. displacement with adjusted magnetic field values.

• Seat Displacement with and without negative stiffness

Challenges and Solutions:

• Magnetic Strength Discrepancy: Addressed by recalibrating the Simulink model with actual magnetic strength values.
• Torque Output: Future improvements include using larger and stronger magnets and exploring different magnet types, such as electromagnets.

Future Work:

1. Magnet Size and Strength:
   • Experiment with thicker (100mm) magnets to achieve higher torque outputs in the 10-15 Nm range.
   • Optimize part design for better performance and compactness.
2. Magnet Types:
   • Test electromagnets with adjustable strength to achieve variable torque and more compact designs.
3. Control Systems:
   • Explore advanced control systems like H-infinity to generate necessary torque and enhance system control.

Conclusion: Integrating a negative stiffness component into an MR damper for seat suspensions shows promise. The project demonstrated a significant reduction in seat displacement and acceleration, validating the potential of this approach for vibration control. Future research should focus on optimizing magnet size, strength, and control systems to improve torque output and overall system effectiveness.

Reflection: This project enhanced my understanding of advanced suspension systems and control strategies. The hands-on experience with MR dampers and negative stiffness components provided valuable insights into vibration control and system optimization. Also, the experimentation helped me further hone my design and product development skills.

 

• Design and Analysis of a pulpwood loader using FEM at the University of Wollongong
  

 

Overview: This project aimed to analyze the mechanical properties of pulpwood fibers using finite element analysis (FEA) to optimize processing techniques and enhance material efficiency.

Tools Used:

• Matlab
• Ansys

Process:

Model Development:

• Geometry and Meshing: The pulpwood fibers were modeled and analyzed both in Matlab and Ansys.
• Material Properties: Mechanical properties such as modulus of elasticity and tensile strength were assigned based on experimental data and literature review.

FEA Simulation:

• Loading Conditions: Simulated tensile tests were conducted to analyze the behavior of pulpwood fibers under different loading conditions.
• Results Analysis: Stress distribution and deformation characteristics were analyzed to identify critical failure points and optimize material usage.

Results:

• Stress Distribution: Simulation results revealed localized stress concentrations at ends and along defects, highlighting areas prone to failure during processing.
• Deformation Analysis: The deformation of the tip of the loader was found to be 10 cm in Ansys which is different than the 19cm value obtained in Matlab.

Conclusion: FEA proved instrumental in analyzing pulpwood fiber behavior and optimizing processing techniques for improved material efficiency in paper production. The insights gained from this study lay the groundwork for future advancements in pulpwood processing technologies.

Reflection: This project deepened my proficiency in FEA applications for materials analysis and provided valuable insights into the mechanical behavior of framed structures. The experience gained will help me in future research and development efforts in optimizing sustainable materials for industrial applications.

 

•  Design and Analysis of Handlebar and Top Tree for touring motorcycle at Yatri Motorcycle
  

 

 

Overview: This project focused on designing and analyzing the handlebar and top tree for a motorcycle. The primary objective was to enhance these components’ structural integrity and manufacturing feasibility, ensuring they could withstand various forces encountered during motorcycle operations.

Tools Used:

• SolidWorks
• Ansys

Results:

• Improved Design: The final design of the top tree was robust enough to handle various forces and fatigue loading with a reduced failure rate of 20%.
• Material Selection: Aluminum was chosen for its cost-effectiveness, environmental stability, and ease of manufacturing.
• Testing Recommendations: The design needs further testing in physical environments with an acceptable variance of around 5-10%.

Reflection: This project provided invaluable experience in iterative design and structural analysis, highlighting the importance of addressing stress concentrations and ensuring vibration resistance. SolidWorks and Ansys were instrumental in refining the designs, and the project underscored the critical role of material selection in engineering. This experience has significantly enhanced my ability to develop robust and efficient mechanical components for use in real applications.

 

• Design and Fabrication of Three-Wheeled Vehicle for a Single Driver at Kathmandu University
  

Overview:

This project focuses on the design and fabrication of a single-driver three-wheeled vehicle utilizing recycled engines from old motorcycles. The primary objective was to create a cost-effective and environmentally sustainable vehicle solution using locally available materials.

Tools Used:

• SolidWorks
• ANSYS

Results:

• Design and Development: The project utilized black MS pipes for the frame, ensuring a balance between strength and weight. Power transmission relied on gasoline-powered engines salvaged from old bikes, driving a chain mechanism to two rear wheels.
• Steering and Braking System: A rack and pinion steering system provided precise control, complemented by disc brakes for efficient braking performance.
• Simulation and Calculation: Extensive simulations in SolidWorks included impact tests on the chassis, validating structural integrity under various loads. Brake and steering calculations ensured optimal performance and safety standards.

Reflection:

This project has been a transformative journey, highlighting the immense potential in repurposing existing resources to create innovative automotive solutions. By salvaging engines from old motorcycles and using locally sourced materials, we not only developed a functional three-wheeled vehicle but also promoted sustainable engineering practices. The rigorous simulations and structural analyses conducted underscored the critical importance of robust design and material resilience in ensuring vehicle safety and performance. This experience not only deepened our understanding of automotive engineering but also underscored the broader lesson for the industry: embracing resource efficiency and sustainable practices can lead to cost-effective solutions without compromising on quality or safety standards. As we move forward, these insights will continue to drive our pursuit of more advanced and environmentally responsible automotive technologies