UNIVERSITY OF CAPE TOWN DEPARTMENT OF MECHANICAL ENGINEERING

MEC4061F INDIVIDUAL LABORATORY/RESEARCH PROJECTS – 2012 This document contains a list of the projects available to students registered for MEC4061Z. All projects are available for selection by any student registered for MEC4061Z, provided that they have the pre/co-requisites listed (if any). PROJECT ALLOCATION Students choosing projects from the list - Use the attached sheet at the end to indicate a selection of projects of your choice. Wherever possible, the candidate will be allocated their first choice, but where there is a great demand for specific projects, this will not be possible and a later choice will be substituted. 1. MICRO UAV AIRSHIP

INTERNAL SUPERVISOR AND PROPOSED BY: C von Klemperer

The concept of small cheap reusable UAV’s, which can be deployed in an urban or rural area to provide an “eye in the sky”, is not a new one. One of the main problems with current designs is the short loiter time. Fixed wing and helicopter type designs generally are limited by fuel capacity or battery storage. Gasoline engines allow for longer flight times than electric designs, but at the expense of noise. It is proposed that a third category of micro-UAVs could provide an advantage. By using an airship design, the propulsion is only required to move the UAV rather than provide the lift / keep it in the air. This would allow for longer flight times, stable camera platforms and potentially cheaper designs. The project proposed is an initial feasibility study. The student should research current micro-UAV and airship designs with the aim of designing a simple deployable airship. It is not expected that the project will produce a flying design; rather the focus should be on demonstrating the concepts. This could include the gasbag, and / or simple flight controls. 2. DEGASSING CHAMBER

INTERNAL SUPERVISOR AND PROPOSED BY: C von Klemperer

Reinforced Polymeric Composites are generally manufactured using liquid resins which is allowed to set and for the matrix. These liquid resins are usually two part mixtures and the mixing process can introduce bubbles, which end up becoming voids in the final specimen. If the mixed resins are “degassed” under vacuum prior to use, the resulting composite is much stronger with far less residual stresses. A further advantage is that any volatiles trapped in the resin constituents are allowed to boil off in a safe manner. It is possible to buy expensive degassing chambers (R3500 – R6000), however this project is to build a portable degassing chamber for less than R1500, using the existing vacuum supply in the composites lab or elsewhere. Requirements include a suitable manifold so that the chamber can be re-pressurised without affecting other vacuum activities and a transparent window or door so that the degassing process can be monitored. 3. MULTI-LAYERED SANDWICH PANEL BLAST RESPONSE

INTERNAL SUPERVISORS: C von Klemperer & G Langdon PROJECT PROPOSED BY: C von Klemperer

The marine, land transport and naval industries use composite sandwich structures with polymeric foams. A sandwich structure basically comprises (in its simplest configuration) of two relatively stiff outer skins separated by a lightweight (and often deformable) core. Recent work on passive blast mitigation has shown that sandwich structures with deformable cores may offer improved blast protection in certain circumstances.

In previous projects, students designed and manufactured flat as well as singly curved polymeric sandwich structures. It is proposed that rather than using 20mm thick foam cores with 2.5mm glass fibre / epoxy facesheets that an equivalent mass panel could be manufactured with thin foam sheets and glass fibre epoxy sheets in a multi-layered structure. In this year‘s project, the student will need to determine suitable lay-ups and then manufacture both traditional sandwich panels as well as multi-layered panels. Some quasi-static tests must be performed and then air blast tests performed at BISRU to compare the blast response of the 2 approaches. 4. COMPOSITE BICYCLE BOX

INTERNAL SUPERVISOR AND PROJECT PROPOSED BY: C von Klemperer

Transporting a bicycle in an aeroplane is a risky affair with bicycles often getting lost and or damaged. There are some commercial solutions consisting of bike bags or boxes, although bicycle hard cases are the best solution on paper, they are often heavy, large and designed only for Road Bicycles. UCT ran a project in 2010 to build and test a composite bike box. The final product turned out to be too heavy and strong, so an opportunity exists to develop and improve on a number of aspects. • Differing types and sizes of bicycles (focussing on Mountain Bikes) • The degree of disassembly of the bicycle. • Nesting of the bicycle in the box. • Minimizing the overall size (geometry and weight) of the box. • Strength requirements and hence material (Reinforcement, no of layers, etc.) • Construction methods for moulds and the final part. • Testing of final product. Considerations of the various airlines and their requirements as well as current commercial solutions should be included. The expected output would be a prototype of the box. 5. CREEP OF KNOTS IN ROPE

INTERNAL SUPERVISORS AND PROPOSED BY: C von Klemperer & E Ismail It is widely accepted that tying a knot in a rope will reduce the strength of the rope by a percentage. There is significant disagreement as to the level of that strength reduction and also the effect of different knots and rope construction on the strength reduction. One important aspect of this is the creep of knots under constant load. A previous project studied the failure strength of various knots. This was done using the Zwick Universal Testing Machine, but the securing of the rope for testing did present some problems. This follow on project proposes to look at a second issue around knot strength. This is the creep of the various knots under constant load. This will require the design of a constant load creep tester which using weights and levers is able to apply a constant load to a knot. These creep loads would need to be determined, but should be high enough to cause measureable creep in a reasonable time period. The measurement of the creep should be simple and not require a digital or electronic solution, but some accurate method of measuring the load on the rope will definitely be required. 6. SA SOLAR CHALLENGE – SOLAR POWERED RACE CAR CHASSIS

INTERNAL SUPERVISOR: C von Klemperer PROJECT PROPOSED BY: C von Klemperer & A Kahn

Events like the World Solar Challenge and the South African Solar Challenge are designed to showcase developments and ideals in high efficiency vehicle designs and alternative energy solutions. The construction of these solar powered race cars is an expensive exercise. The design needs to be optimised before the construction of the final car begins, as the prototype is the final car.

UCT is considering an entry for this year’s race. It is proposed to develop a low cost chassis for UCT’s entry based on a Motorbike and sidecar type construction. The design should ideally be based on a second hand / scrapped motorbike to further save costs. The student would be expected to design, source and cost the proposed chassis design. It is not necessarily expected that the chassis will be built as part of the project; rather this is a paper design. Testing would involve careful analysis of the proposed design. The output should be a completed design (Full set of 2-D drawings with all parts listed, sourced and costed.) 7. DUBE TRADEPORT ULD DESIGN COMPETITION

INTERNAL SUPERVISOR: C von Klemperer PROJECT PROPOSED BY: A Gould – Dube Tradeport

Dube Tradeport in Durban at King Shaka International Airport are running a competition to design a new lighter Unit Load device for air cargo. The student on this project would be expected to research current designs and suggest improvements in material, construction and design. Dube ULD Design. “We’re getting the international design industry involved, through our association with the world-renowned DESIGN INDABA, to green our future supply chains. We aim to possibly introduce a new generation ULD that is lighter and therefore reduces the carbon emissions of the aircraft transporting it. We are running a global competition that invites designers to design the next generation Unit Load Device (ULD) for the air cargo industry and win $20 000. The air cargo industry is a billion-dollar business that utilises close to 1 million Unit Load Devices (ULDs) across the globe daily, carrying approximately 80 million tons of cargo, ranging from computer hardware to vital medical supplies. If goods are flown in, they more than likely arrived in a ULD. We have challenged the international design community to design a lighter ULD in order to reduce our impact on the planet.” See: http://www.dubetradeport.co.za/Green#Dube_ULD 8. DEVELOPMENT OF MULTI- PURPOSE PAN TILT PLATFORM

INTERNAL SUPERVISOR AND PROPOSED BY: S Marais The Robotics and Agents Research Lab has developed a sensor payload that attaches to the arm of a rescue robot. It will be useful to be able to test this sensor payload without having to operate the whole robot arm. This project is to design and build a pan tilt platform that can support a payload of 5kg. It is to have 360º rotation on the pan axis and 180º movement on the tilt. The project also includes the design and development of the supporting electronics and software to control the system. Note: All programming must be done in Labview. Pre/Co-requisite courses: Only for Elec-Mech students 9. DEVELOPMENT OF CONTROL SOFTWARE FOR A RESCUE ROBOT ARM

INTERNAL SUPERVISOR AND PROPOSED BY: S Marais Note that 2 students can be assigned to this project. The Robotics and Agents Research Lab has been developing rescue robots for the last 8 years. The 5th generation is currently being designed and manufactured by a group of MSc students. Attached to the base is a robotic arm and sensor payload. The robot arm and the sensor payload are directly controlled by the operator. If each of the individual joints had to be controlled separately and in turn this would be very taxing on the operator. With this in mind a system that assists the operator with the task is needed.

This project is to design and implement the control software for the arm using Labview. A model for the arm will have to be developed that will accurately represent the actual arm. This will then be used to work out if the load that is being lifted will result in the robot tipping over. The system developed must protect the robot from harm by the user. Pre/Co-requisite courses: Only for Elec-Mech students 10. DEVELOPMENT OF NEW REPLICA OF THE MARS ROVER ROBOT FOR THE SCIENCE CENTRE

INTERNAL SUPERVISOR AND PROPOSED BY: S Marais PROJECT PRE-ALLOCATED TO: C Slingsby (SLNCHA003)

The Robotics and Agents Research Lab was approached by the Science Centre to build a new Mars Rover robot that they can use in their space exhibition. This project is to design and build a replica Mars Rover that will be able to operate from a simple user interface, noting the target user will be children. The design must be robust as there will be repeated use/abuse. The goal for the layout is to make the appearance and functionality of the robot mimic that of the Mars Rovers but at a much reduced budget. The size of the robot is to be about the size of a shoe box. Pre/Co-requisite courses: Only for Elec-Mech students 11. DEVELOPMENT OF A NEW SENSOR PAYLOAD FOR RESCUE ROBOTS

INTERNAL SUPERVISOR ANDPROPOSED BY: S Marais The Robotics and Agents Research Lab has been developing rescue robots for the last 8 years. The 5th generation is currently being designed and manufactured by a group of MSc students. Attached to the base is a robotic arm and sensor payload. New sensors are to be added to the sensor payload to increase its capabilities. The new sensors are: a new smaller thermal camera, X-Box Kinect and a Fitpc2 to run the Kinect. All the existing sensors along with the new ones have to be incorporated into a neat functional protective housing that can be mounted on a rescue robot’s arm. Note that space, the overall dimensions of the housing, and weight will be the main constraints for this project. A Labview GUI will also have to be developed to test the sensors in the new sensor payload. Start-up and test procedures will have to developed for each sensor in the sensor payload. All coding to be done in Labview. Pre/Co-requisite courses: Only for Elec-Mech students 12. DEVELOPMENT OF A GRIPPER/MULTI-TOOL THAT CAN BE ATTACHED TO AN UNDERWATER ROBOT

INTERNAL SUPERVISOR AND PROPOSED BY: S Marais PROJECT PRE-ALLOCATED TO: J Oldnall (OLDJON001)

The Robotics and Agents Research Lab has been developing an underwater robot for the last 4 years. The 3rd generation is currently being designed and manufactured by two MSc students. This project is to design a gripper/multi-tool that can operate at a depth of 400m. The gripper must be designed to be integrated into the ROV, taking special note of:

1) Power availability. 2) Data communication standards. 3) The styling of the existing modules. 4) The maximum mass of the new module is limited to 5kg

All coding must be done in Labview as this module has to integrate into an existing project Pre/Co-requisite courses: Only for Elec-Mech students

Coating on the tools

13. DEVELOPMENT OF A DIGITAL SCOPE CHASSIS AND SIGHTING SYSTEM INTERNAL SUPERVISOR AND PROJECT PROPOSED BY: S Marais PROJECT PRE-ALLOCATED TO: T Mathew (MTHTHO019)

With the improvement and miniaturisation of camera technology, along with the development of the digital monocular, it is now becoming a reality to build a small, compact digital telescope with variable high zoom capabilities. One of the complications with the concept is the alignment of the camera with the chassis of the scope. A method for adjusting the positioning the camera’s pitch and role will have to be developed. The adjustment range is typically ±5° in both axes, with the fine adjustment of 10mm resolution at 200m. The project would involve:

1) Design the camera mount with the pitch and role adjustment system to meet the above specification. 2) Mount the camera-mount to a chassis for the scope. 3) Mount the monocular. 4) Design the supporting electronics to run the camera 5) Write the microprocessor code to control the camera.

Pre/Co-requisite courses: Only for Elec-Mech students 14. DEVELOPMENT AND TESTING OF A MARKING SYSTEM FOR MINES

INTERNAL SUPERVISOR AND PROPOSED BY: S Marais PROJECT PRE-ALLOCATED TO: K Hanekan (HNKKL001)

In the mining process the marking of where to drill is predominately done manually. This project is to investigate using a paintball marker to perform the marking task. This is in line with the long term goal of automating the mining process. This project will entail:

1) Testing the accuracy of current paintball markers. This will include looking at the effect of different paints and barrels on the accuracy. A rig will have to be built to measure ball speed.

2) Testing what effect range has on accuracy. Again looking at the effect of different paints and barrels. 3) Build a system to that can spin the paintball to some speed before firing it. This is to test if imparting spin to

the paintball will improve accuracy. Pre/Co-requisite courses: Only for Elec-Mech students 15. MACHINING CHARACTERIZATION OF NANO-AMORPHOUS COATED MICRO-ENGRAVING TOOLS USED FOR

MACHINING PRINTING HEADS / MICRO-BIOMETRICAL COMPONENTS INTERNAL SUPERVISOR AND PROJECT PROPOSED BY: R Kuppuswamy

Micro-engraving tools are widely used for finishing the etched surfaces, engraving artworks so as to produce the necessary printing heads. However the tool life of micro engraving tools measured in terms of flank wear was found to be extremely poor and also such tools experiences pre-mature tool failure viz: edge chipping off, cutting edge damages and the stress build up. Furthermore such tools are also

widely used for producing micro features on biometrical components that exhibits high hardness. The proposed project would lead to a development of new engraving tool geometry featured with nano-amorphous coating and aimed to create a engraving/micro-machining process knowhow that optimizes the performance behaviour of the micro tool-work interface. An attempt would be made to devise the micro-engraving (machining) tool with a hard outer layer that comprises of Si3N4 (25%) and AlTiN (75%) with particle size as small as 2 to 5 nm. Such configuration is expected to impart abrasive action on the cutting edge and hence micro engraving or machining of biometrical components would

Engraving Tools

become a reality. The project requires tool development, coating recipe formation and extensive machining characterization of the developed tools. Experiments would be conducted using RFM 600 Roeders High speed machining centre at Advanced Manufacturing Lab, UCT and at Industry UVP Pte Ltd, Epping. Necessary support such as fixtures, tooling would be provided by the industry. References:

F. Klocke ( I ) , T. Krieg “Coated Tools for Metal Cutting - Features and Applications”, Annals of the ClRP Vol. 48/2/1999

Luca Settineri, Maria Giulia Faga, “Laboratory tests for performance evaluation of nano-composite coatings for cutting tools”, Journal of Wear, 260 (2006) 326–332

16. REFURBISHMENT OF A 5 AXIS TOOL & CUTTER GRINDER TO A FORCE CONTROLLED MICRO-GRINDER

INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy PROJECT PRE-ALLOCATED TO: V Shaba (SHBVER001)

Increasing use of Poly Crystalline Diamond (PCD) for cutting tools and wear parts is vividly seen in automobile, aerospace, marine and precision engineering applications. The PCD inserts undergo serious of manufacturing processes such as: grinding to form the required shape and polishing to give a fine finish. These operations are not straight forward as PCD is extremely resistant to grinding and polishing. Single crystal diamond tools can be easily ground by choosing a direction of easy abrasion, but grinding PCD imposes serious difficulties as the grains are randomly oriented. Prior studies on PCD grinding using a vitrified bond diamond wheel produces surface defects such as: micro-grooving, edge chipping, cracks, and gouge marks. Therefore a new Micro-grinding technology that applies controlled amount of grinding force would be developed in this project and the results will be applied to PCD inserts grinding. A local company would be supplying their 5-axis tool & cutter grinder and the same have to be refurbished with new features. The project would be executed at Advanced Manufacturing Laboratory in close association with a local industry. References: K. Ramesh, S C Veldhuis, A Yui, WG Lewis, (2005) “Redefining the Diamond Cutting Edge: A Technique that Complements Nano-metric Surface Generation”, Journal of Materials and Manufacturing Process, 20, pp.895-903

17. DESIGN AND DEVELOPMENT OF A TEACHING KIT “DESIGN FOR MANUFACTURING & ASSEMBLY (DFMA)”

IN CONJUNCTION WITH LIFE CYCLE COSTING INTERNAL SUPERVISORS: R Kuppuswamy & C Findeis PROJECT PROPOSED BY: R Kuppuswamy

Design for Manufacturing & Assembly is a methodology for evaluating part designs and the overall design of an assembly. It is a quantifiable way to identify unnecessary parts or design features in an assembly as well as to reduce the costs. Often final year design students perform poorly on this section due to lack of information. The proposed teaching kit would enable the students to understand the cost contribution of each part by which part or feature reduction strategies can be ascertained. Furthermore the outcome of a DFMA-based design is a more elegant product with fewer parts that is functionally efficient and easy to assemble.

Machining using a PCD

tool Typical

PCD

Tools

Shown in the figure alongside is a typical DFMA input/output that facilitate the strong foundation for a better design of a system/sub-system. Components would be grouped into flat, axisymmetric and irregular and the proposed project would establish a generic process planning for estimating the manufacturing costs. Due to time limitations this project would be aimed to create a module of DFMA that emphasizes material removal process only. The student is expected to create software in Visual basic or Excel with a strong emphasis to the SA environment. References: Tsai-C. Kuoa, , Samuel H. Huangb, Hong-C. Zhangc

(2001) “Design for manufacture and design for ‘X’: concepts, applications, and perspectives”, 41(3),pp. 241-260 L. Alting,(1991) “Life cycle design”, Concurrent Engineering,1(6), pp. 19–27. Boothroyd et al., (1994) “Product design for manufacture and assembly”, Marcel Dekker, New York (1994). 18. HIGH SPEED DRILLING OF HOLES ON CFRP & CFRP-TI STACK THROUGH DRILL GEOMETRY

INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy Use of CFRP & CFRP –metal tacks are increasingly common at the aerospace industries as CFRP and Titanium offer distinct advantages such as high “strength to weight” ratio. However the material benefits often cannot be realized as there exist no efficient manufacturing processes and hence companies such as Boeing, Pratt & Whitney operate with poor manufacturing process efficiency and as a result a huge back lag of order is apparently seen. In view of the current situation aerospace industries are constantly looking for innovation in their manufacturing processes. One such area of difficult manufacturing is drilling of fibre reinforced plastic composites and metal (FRP-Metal) stacked materials and hence researches across the globe are taking place to make manufacturing and assembly more cost effective. The proposed project is aimed to perform a detailed study so as investigate drilling of titanium (Ti) plate stacked on a carbon fibre reinforced plastic panel. The effects on tool wear and hole quality in drilling using micro-grain tungsten carbide (WC) tools as well as PCD/PCBN drills would be attempted. An experimental plan would be drafted to include scientific statistical studies such as Taguchi analysis, Response surface methodology as well as intelligent manufacturing system. Upon establishing the predominant factors that need to be controlled for achieving a better hole quality a detailed study would be performed to establish the drilling process characteristics such as drill wear, drilling mechanism, chip morphology, burr formation, surface texture of holes produced, hole quality errors such as hole size, form errors and surface damage. Innovative features such as: drill geometry, process conditions, a mechanism that accelerates chip breakage and an intelligent manufacturing system would be imparted to facilitate an efficient drilling process for CFRP & CFRP-Ti stacks. Instruments such as Scanning Electron Microscope (SEM), Tool Makers Microscope would be used for tool wear analysis. Hole size and profile, surface roughness, and Ti burrs would be studied using a coordinate measuring system, profilometer, and an optical microscope with a digital measuring device. Furthermore the wear mechanism study would include XRD tests as well as metallographic analysis by which a clear line between adhesion wear, abrasion wear would be established. On the whole this project would establish the drilling sciences for CFRP & CFRP-Ti stack material and has significant industrial value.

19. CHARACTERIZATION OF HIGH PRODUCTIVITY MACHINING OF TITANIUM USING PCD BULL NOSE END MILLS

INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy PROJECT PRE-ALLOCATED TO: G Choenyana (CHNGET001)

High Productivity Machining (HPM) is becoming increasingly critical to cost effectiveness of Ti components. With cutting speeds now exceeding 200 m /min, there is increased damage on surface integrity and in service performance such as fatigue life. The project will enhance sustainability of Ti Machining by controlling functional attributes of machined surfaces, especially microstructure while simultaneously enhancing removal rates and reducing tool wear. It should be noted that application of Titanium alloys are increasingly seen at aerospace, marine, bio-medical and precision engineering due to its high strength to weight ratio and high temperature properties. A recent survey indicates that F-35 and F22 program together consumes 10.5 million pounds of Titanium /year. Such trend have spiralled the consumption of Titanium at aerospace industries. However machining rates for titanium alloys are slow and consumes high cycle time. High strength, high hardness and poor thermal conductivity of titanium contribute to the poor machining productivity and lower tool life. The high temperatures generated at the tool-work interface causes adhesion of work-material on the cutting edges and hence shorter tool life was seen. This project aims to understand the machining behaviour of Ti while using bull nose end mills. Appropriate L9 orthogonal array and response surface methodology would be established to unveil the high performance machining science of Ti using PCD tools. Past research predominantly focus on machining speed of 40 to 100 m/min and feed/tooth = 40

to 100 m. The proposed research would apply a machining speed of 200 to 250m/min and feed/tooth = 40 to 100

m. It should be noted that application of Titanium on aero-engine alloys is commonly seen and hence the development of know-how would be useful to the aero-engine component manufacturers. Furthermore the project has a support from a Diamond Research laboratory in Springs, SA. 20. CHARACTERIZATION OF HIGH PRODUCTIVITY MACHINING OF INCONEL ALLOY 718 USING PCBN BULL NOSE

END MILLS INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy PROJECT PRE-ALLOCATED TO: M Jacobs (JCBMOG007)

Superalloys and ceramics are widely used in manufacturing aerospace parts especially on engine and landing gear components. Manufacturing aerospace components especially on Inconel alloy 718 to the required size, shape and accuracy is an ardent task as the materials offer high resistance. The proposed project “Characterization of High Productivity Machining of Inconel Alloy 718 using PCBN Bull Nose End Mills” is aimed to explore new methods that can be effectively used for addressing some of the manufacturing challenges and constraints particularly for the aerospace sector. The main scope of the project are; i) Design and Development of specialized surface finishing tools for machining of new aerospace components and surface profiling of the aircraft engine parts. ii) Perform experimental studies to determine the PCD/CBN tool geometry, optimum

machining parameter and effective tool design for a serious of surface finishing tools. For each set of tool geometry and aerospace material, 3 levels of performance characterisation studies will be carried out. They are; A) Determine the ideal tool geometry; B) Establish the optimum machining parameter C) Establish the durability for each configuration Shown in the figure alongside is the schematic of the experimental plan. The project will employ several scientific analysis and techniques for investigating the PCBN tool performance while deploying the high speed machining process. Upon establishing the required HSM system resources, DOE analysis would be deployed to establish the most

critical parameters that influence the surface integrity and material removal rate. A 2 level 4 factor experimental plan would be devised and using Taguchi analysis methods the most critical parameter that influences required features would be derived. Upon identification of the most suitable parameter, extensive experimental study would

be conducted to establish the process behaviour using SEM study of surface texture, process parameters such as: cutting forces, ft/fn ratio, machining energy, chip morphology and flank wear characteristics. To acquire the required information equipment such as: Scanning Electron Microscope, dynamometer, data acquisition system, inverted microscope and software like; Labview, Matlab would be extensively used. Also design software: PRO-E/ SOLIDWORKS, HSM works would be used to configure the required CAD/CAM interface programs.

21. CHARACTERIZATION OF CUTTING FORCE SIGNATURES THROUGH WAVELET ANALYSIS INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy

Correlating the cutting force signatures to the machining science is an ardent task as the signals is a collection of both time series and frequency spectrums. However successful segregation would lead to a foundation stone for digitizing the machining process. In general Time domain analysis of cutting force signatures explains the changing phenomenon of the machining science over time. However relating the cutting force signatures to any respective machining parameter or feature is difficult owing to the complexity in the process as many variables are present at the tool-work interface. The ideal signal varies periodically with a frequency equal to the product of spindle speed and number of cutting edges. However during the interaction of cutting edges on the work piece either flank wear or adhesion of work-piece material on the cutting edge occurs resulting in a periodic random signal. On the other hand the frequency analysis such as FFT analysis shows the frequencies for the captured signals but it doesn’t show how the frequency varies in time. So both frequency and time domain analysis of signals are important to establish the interface behaviour of cutting edges on the titanium. This can be achieved through Wavelet analysis as it enables to analyse the pattern of time-frequency spectrum of the process signals. This analysis overcomes the variation of signal intensity due to noise, shifts or other similar issues. The analysis uses the long intervals to find precise and low frequency information and shorter intervals to find the information on high frequency signals. The key point of wavelet analysis is to extract information from the original signal by decomposing it into a series of approximations and details as discussed over different frequency bands Upon establishing the suitable wavelets every effort should be taken to correlate the machining science and hence process optimization as well as prediction of process performance has become a reality. This project would aim to build necessary feature extraction models for defined inputs and aimed to construct reference wavelets. The results would be used to build an appropriate feature extraction engine for building a Intelligent Manufacturing System. RFM 600 machine (see above figure) would be used to produce necessary cutting force signatures and a schematic of feature extraction engine is given alongside. 22. SMART SURFACE MANUFACTURING THROUGH CONTROL OF RESIDUAL STRESS

INTERNAL SUPERVISOR AND PROPOSED BY: R Kuppuswamy

Machining challenges of Ti6Al4V is significant depending upon its phase existence. In general Titanium alloy Ti-6Al-4V exists with a combination of α phase and β phase at standard temperature. The α phase of Ti-6Al-4V has a hexagonal closely packed (HCP) crystalline lattice structure whereas the β phase has a body centred cubic (BCC) crystalline lattice structure. To enhance the machining efficiency of Ti6Al4V it is critical to bring it to α phase especially at the tool-work interface as the structure offer less resistance to machining. For achieving the same coolant jet and high rake angle tools are previously tried so that the tool-work interface temperature can be maintained less than 980°C. However there exists no mathematical model so that the machine shop engineer can apply necessary machining parameter adjustments so as to maximize the machining efficiency. This project would aim to build appropriate residual stress

models by which surface integrity of the machined surface of Ti6Al4V can be modelled. The developed model would be validated with appropriate experiments using a RFM 600 machine and a XRD analyser.

23. EDUCATIONAL TOOLS FOR DYNAMICS I (MEC2023)

INTERNAL SUPERVISOR AND PROPOSED BY: B Kloot One of the findings that emerged from an investigation into MEC2023 in 2009 was the importance of the development of visualisation skills in students. In other words, students need to be able to visualise in their mind’s eye the movement of the variety of apparatus that is discussed and dealt with in the course. In order to aid this development and with the aim of providing educational tools to assist lecturers in Dynamics I, and keeping in mind the curriculum revision process that is underway, the aim of this project needs to provide at least five different apparatus that will demonstrate the key principles of Dynamics I. The apparatus should be a mix of moving three-dimensional models and computer animations that innovatively demonstrate key concepts and/or examples dealt with in the MEC2023 course and should engage the full extent of the syllabus. The convener of Dynamics I, Mr T Cloete, will be considered the ‘client’ in this project and the proposed apparatus be approved by him. Pre/Co-requisite courses: Dynamics I 24. DESIGN OF A PARABOLIC SOLAR COOKER SUITABLE FOR LOW VOLUME PRODUCTION BY AN INFORMAL

CRAFTSMAN INTERNAL SUPERVISOR AND PROPOSED BY: B Kloot

A parabolic solar cooker harnesses the energy of the sun to cook food and, if designed properly and under suitable weather conditions, a 0.5m2 cooker can bring a litre of water to boiling in under 20 minutes. Using solar energy helps to reduce the amount of fuel used in cooking is an important consideration for reducing electricity consumption for the nation as well as reducing firewood and paraffin use among the poor. However, constructing a solar cooker often requires metal (which is expensive) and energy in the manufacturing process which also pushes up the cost. The challenge of this project is to design a solar cooker that is cheap, sturdy and efficient and can also be easily made using wire, aluminium cans and other waste and/or recyclable materials. The design must be simple enough so that one informal craftsman can produce between 3 and 5 stoves per day. The student must draw up a business plan to this end, demonstrate that the stove can be made at the required rate, and produce an easy-to-follow manual for aspiring craftsmen. The viability of such an enterprise should also be explored. 25. DESIGN OF A DEVICE TO TRANSPORT AND PURIFY WATER

INTERNAL SUPERVISOR : B Kloot PROJECT PROPOSED BY: D Walker PROJECT PRE-ALLOCATED TO: D Walker (WLKDAL003)

The focus of this project is to improve access to clean water in areas where the infrastructure does not exist. Products such as the Hippo Roller (1) exist for the transportation of large volumes of water from the source to households, but this design does not allow for the purification of the water which still needs to be boiled or filtered. A concept called the Aquaduct Bike (2) aims to solve this problem by using the motion of pedalling a bicycle to filter water. However, the design is not suitable for the rugged conditions under which it is intended to operate. The aim of this project is to design a product with the capability to transport large volumes of water while filtering it at the same time. Due to its intended use in areas such as rural Africa the design would need to be as durable as possible and costs would need to be minimised. References:

1. Hippo Roller; www.hipporoller.org 2. Aquaduct Bike; theaquaduct.blogspot.com

26. DESIGN OF A WATER HEATING SYSTEM FOR RURAL VILLAGES INTERNAL SUPERVISOR : B Kloot PROJECT PROPOSED BY: G Campbell PROJECT PRE-ALLOCATED TO: G Campbell (CMPGEO001)

This project aims to solve the problem faced by many rural communities of heating large volumes of water for sanitation. Currently in many communities the system used is that of a large pot on a fire that is both inefficient and dangerous. Although solar geysers seem to be a solution these are in many cases too expensive for communities to attain. The idea is to adapt the principles of the Kelly kettle 1 (the use of a chimney-like chamber within a water jacket) to a system that would be appropriate for rural communities. This system seems like a good solution as the large surface area to water volume ratio helps increase efficiencies as well as the containment of the fire increases safety. There are many factors that come into play and that would have to be considered throughout the execution of the project, such as: the specific needs of the community i.e. will the water need to be filtered? What volumes of water are needed to be heated? How is the water transported? The economic status of the communities also has to be considered as most rural communities have low buying power that will thus influence decisions on materials and production processes of the system. The fuel used to power the system will also have to be closely considered, as an abundant fuel that is environmentally friendly is preferable. During the design of the system as many efficiencies as viable should be introduced so as to minimise energy loss. This project will integrate both research aspects in terms of rural needs as well as design aspects in designing the system. Reference [1] http://www.kellykettle.com/ 27. THERMAL INSULATION

INTERNAL SUPERVISOR AND PROPOSED BY: K Bennett Assess the insulating properties of commonly-available materials, suitable for use for insulating low-cost housing. Pre/Co-requisite courses: MEC4048 – Advanced Heat Transfer 28. ASSESSMENT OF THE DYNAMICALLY INDUCED AERODYNAMIC ROLLING MOMENT ON A WING IN

FORMATION FLIGHT INTERNAL SUPERVISOR AND PROPOSED BY: C Redelinghuys

Considerable fuel consumption savings could be effected by aircraft flying in formation. These savings could be offset to some degree, however, by control surface deflections required to trim the aircraft. This project focuses on measuring the induced aerodynamic rolling moments on one aircraft wing placed behind another in the event of the leading aircraft performing a dynamic manoeuvre. The work is to be performed in the closed circuit wind tunnel by modifying a test rig used by a previous student who investigated induced rolling moments under static conditions. The modifications will entail designing and constructing a suitable mechanism and electric drive system capable of changing the leading wing angle of attack as a step, ramp, or oscillating input. The trailing aircraft induced rolling moment is to be measured and analysed for a variety of leading wing motions. 29. IMPROVEMENT OF THE OPEN LOOP WIND TUNNEL

INTERNAL SUPERVISOR AND PROPOSED BY: C Redelinghuys A low speed, open circuit wind tunnel was previously constructed during a final year project. In this project the student is expected to improve the flow uniformity in the tunnel test section by modifying the construction of the large inlet section to remove unwanted geometric discontinuities. The bell-mouth inlet is to be modified accordingly. Flow uniformity is to be measured inside the test section before and after tunnel modification, and for cases where flow disturbing objects are present in front of the tunnel. The development of the boundary layer in the tunnel is to be calculated and measurement of the boundary layer velocity profile is to be attempted.

30. EXPERIMENTAL AND THEORETICAL DETERMINATION OF THE MOMENTS OF INERTIA OF A PARAFOIL PAYLOAD INTERNAL SUPERVISOR AND PROPOSED BY: C Redelinghuys

An autonomously guided parafoil system is currently under development at UCT. The instrumented payload has a mass of about 30 kg. In this project the moments of inertia of the payload are to be determined using both experimental and theoretical techniques. A literature survey on inertia measurement is to be conducted, followed by selection of a concept, detail design and construction of a low cost solution. The device is to be used for measurement of the payload inertias. The moments of inertia are also to be estimated using approximations and a CAD package. Theoretically predicted values and experimental measurements are to be compared. 31. APPLY DESIGN OF EXPERIMENTS TO DETERMINE THE MINIMUM SINK RATE OF A GYROCOPTER IN THE

VERTICAL WIND TUNNEL INTERNAL SUPERVISOR : C Redelinghuys PROJECT PROPOSED BY: M Schmid PROJECT PRE-ALLOCATED TO: M Schmid (SCHMIC068)

A gyrocopter is a device that spins (autogyrates) as it falls through the atmosphere, sinking with a low terminal velocity. In this project the optimum design of a gyrocopter that will minimize the sinking velocity is to be determined experimentally in the vertical wind tunnel. The experiment is to be planned and executed using Design of Experiments. The candidate is to self-study notes on Design of Experiments that will be provided. A rig for supporting the gyrocopter in the tunnel and a sensitive one component strain gauge balance for measuring the vertical force on the gyrocopter are to be designed. Rudimentary aerodynamic theory is to be applied to predict the performance of the gyrocopter. Predictions and measurements are to be compared. 32. PREDICTION AND MEASUREMENT OF THE SPEED OF A RADIO CONTROLLED FIXED WING MODEL AIRCRAFT

INTERNAL SUPERVISOR AND PROPOSED BY: C Redelinghuys In this project the candidate has to predict and measure the cruising speed of a radio controlled model aircraft. Introductory aerodynamic theory applied to propellers and aircraft is to be self-studied. A one component strain gauge balance and supporting rig capable of measuring the propeller thrust in the laboratory are to be designed and built. The thrust measurements are to be compared to theoretical predictions obtained by modelling the propeller aerodynamics. The aircraft speed is to be predicted by means of calculations. The aircraft cruising speed is also to be measured by performing flight tests. Finally, the theoretical and experimental results are to be compared. The candidate has to have access to a radio controlled model aircraft and a pilot capable of assisting with the experiments. 33. DETERMINATION OF AILERON AND TRIM TAB HINGE MOMENTS, AND THEIR TRIM CHARACTERISTICS

INTERNAL SUPERVISOR: C Redelinghuys PROJECT PROPOSED BY: T Langton PROJECT PRE-ALLOCATED TO: T Langton (LNGTIM004)

Wing ailerons are typically provided with trim tabs to reduce the activation hinge moments required. A previous theoretical study conducted by a masters student predicted that there are situations when, depending on the tab setting and the wing angle of attack, it will be impossible to find a stable aileron and tab trim setting. This result is to be investigated experimentally in the wind tunnel. The candidate is to design a model wing that is provided with an aileron and trim tab to be tested in the wind tunnel. Two one component strain gauge balances, capable of measuring the aileron and tab hinge moments, are also to be designed and constructed. The wing is to be supported such that the angle of attack and the aileron trim angles are adjustable. The trim characteristics of the configuration are subsequently to be investigated in the wind tunnel. A rudimentary aerodynamic model is to be applied for predicting the hinge moments. Predictions and measurements are to be compared.

34. DETERMINATION OF AILERON AND TRIM TAB HINGE DYNAMIC STABILITY INTERNAL SUPERVISOR : C Redelinghuys PROJECT PROPOSED BY: K Soal PROJECT PRE-ALLOCATED TO: K Soal (SLXKEI001)

Wing ailerons are typically provided with trim tabs to reduce the activation hinge moments required. A previous theoretical study conducted by a masters student predicted that there are situations when, depending on the dynamic pressure, the geometry and inertias, the configuration may become dynamically unstable. This result is to be investigated experimentally in the wind tunnel. The candidate is to design a model wing that is provided with an aileron and trim tab. The moments of inertia of the control surfaces are to be adjustable. The angle of attack and control surface angles are to be dynamically measured. The stability characteristics of the configuration are subsequently to be investigated in the wind tunnel. A rudimentary dynamic and aerodynamic model is to be applied for predicting stability. Predictions and measurements are to be compared. Pre/Co-requisite courses: Vibrations 35. SOLAR DESALINATION

INTERNAL SUPERVISOR : K Bennett PROJECT PROPOSED BY: A Cox PROJECT PRE-ALLOCATED TO: A Cox (CXXADR002)

A study of the viability of a small scale solar desalination plant for domestic use as well as the environmental impacts of this process. There are 3 fundamental components to this study:

● Identification of the most cost and energy efficient method for desalination using the sun’s energy. Discuss evaporation cycle and reverse osmosis.

● Creation of an effectively purified end product being drinking water ● Efficiency and scalability evaluation. Can it be reproduced for domestic use at an affordable price?

References:

Rahim N.H.A., 2001, A solar desalination plant for domestic water needs in arid areas of South Algeria, Department of Mechanical Engineering, University of Bahrain

Rahim N.H.A., 2001, Utilisation of new technique to improve the efficiency of horizontal solar desalination still, Department of Mechanical Engineering, University of Bahrain

Narayan, G. Prakash et al. “The potential of solar-driven humidification-dehumidification desalination for small-scale decentralized water production.” Renewable and Sustainable Energy Reviews 14.4 (2010): 1187-1201.

Lattemann, S. & Höpner, T., 2007, Environmental impact and impact assessment of seawater desalination, Institute for Chemistry and Biology of the Marine Environment (ICBM), University of Oldenburg

World Health Organization, 2011, Guidelines for drinking-water quality, fourth edition 36. PITCH CONTROLLED, DIFFUSER TYPE HORIZONTAL AXIS WIND TURBINE

INTERNAL SUPERVISOR : K Bennett PROJECT PROPOSED BY: J Mitchell PROJECT PRE-ALLOCATED TO: J Mitchell (MTCJOS002)

This project will involve the design, building and testing of a scaled down horizontal axis wind turbine. The design of the turbine will incorporate a pitch control mechanism, which will require the use of a microprocessor, a servo motor and external sensors. A detachable diffuser unit will also be designed in an effort to improve the efficiency of the HAWT. The testing phase of this project will incorporate using various sensors to collect experimental data correlating various power outputs to blade pitch positions. Tests will be performed using the wind tunnels in the Duncan McMillan building. Pre/Co-requisite courses: Elec-mech only.

37. COMPUTATIONAL BIOMECHANICS OF SINGLE CELLS AND THEIR MECHANICAL ENVIRONMENT INTERNAL SUPERVISORS AND PROJECT PROPOSED BY: L Dubuis & T Franz PROJECT PRE-ALLOCATED TO: L Nake (NKXLES001)

Scaffold-based tissue regeneration has emerged as a therapeutic goal for a multitude of diseases. The rationale behind the integration of functional living cells and tissues into scaffolds was the realisation that mechanical strength of the scaffolds alone are not sufficient to emulate function and durability of the replaced tissue. The regeneration of tissue is based on the function and differentiation of cells. For a long time, research on cell differentiation and tissue regeneration focused mainly at the biochemical stimulus of cells from their environment. The importance and role of the mechanical environment on cells, their function, differentiation and signalling, has only recently recognised. As such, the interactions between biology and mechanics at cell level, i.e. mechano-sensitivity and mechano-transduction, are focus of emerging fields with knowledge being still scarce. As a consequence, scaffold-based tissue regeneration evolved without a clear deduction of principles required for a rational design approach. The aim of this project is the computational study of the mechanics of single cells exposed to defined mechanical environments. The outcome of the project are expected to contribute to knowledge of the mechano-biology of cells and its role in regenerative medicine. Finite element (FE) models of single cells have to be established either by reconstructing the 3D cellular geometry from microscopy data provided or using data from literature. Mechanical properties of the cells will be obtained from literature. The models need to also represent simple mechanical environments of the cells and be able to simulate defined mechanical loadings created in in vitro (i.e. laboratory) tests. Investigations using the established FE models should focus on the transfer of mechanical loadings from environment, e.g. stretch of a membrane carrying cells, onto the cells and the resulting stresses and strains in the cells. The project can include comparison of the response of different cells in the same mechanical environment, or of the same cell in different mechanical environments and loadings, e.g. stretch, compression, shear. Pre/Co-requisite Courses: MEC4065F 38. IMPACT BEND TESTS OF BRITTLE MATERIALS

INTERNAL SUPERVISOR AND PROPOSED BY: R Govender Vehicles that may be subjected to projectile impact often have panels made of high strength, brittle materials (e.g. Armour glass, ceramic armour panels). Most impact loading scenarios involve flexural (bending) loading. Hence the development of a reliable impact bend test apparatus for brittle materials would provide useful material characterisation data for designers. This project involves conceiving, designing and implementing an impact or high strain rate bend test apparatus for brittle materials and conducting experiments at low and high strain rates on bending of suitable brittle materials. Pre/Co-requisite courses: MAM2082F 39. MIXED MODE DELAMINATION TESTING OF FIBRE REINFORCED POLYMERS

INTERNAL SUPERVISOR AND PROPOSED BY: R Govender Delamination is a common failure mode of Fibre Reinforced Polymers (FRP) and other laminated structures. Delamination failures may be classified in terms of the fracture mechanics concepts of Mode I (Opening), Mode II (In-plane sliding) and Mode III (Out of plane sliding or scissor) cracks. Most delamination failures in real world loading are a mixture of Mode I and Mode II cracks. A variety of specimen and loading geometries exist for evaluating mixed Mode I-II delamination. This project will investigate different mixed Mode I-II delamination tests, evaluating crack growth stability, mode mixity and ease of implementation. The experimental program will be applied to finding the fracture energy failure envelope for Mode I-II delamination of a suitable FRP (Glass fibre reinforced polypropylene).

40. MODELLING WAVE PROPAGATION PHENOMENA IN HOPKINSON PRESSURE BARS INTERNAL SUPERVISORS AND PROPOSED BY: R Govender & E Ismail

The Hopkinson Pressure Bar (HPB) is an experimental tool for measuring impact forces and velocities, based on wave propagation theory applied to strain gauge measurements. Traditionally, HPB have been based on elastic one-dimensional wave theory, as the bars used have usually been metal and of small diameter. Corrections for two dimensional wave effects, which affect larger diameter bars, have been successfully implemented. More recently, polymeric bars which exhibit visco-elastic wave behaviour have been studied. An experimentally derived correction map has been applied to HPB results using polymeric bars, permitting the calculation of impact forces and velocities. Impact experiments are often coupled with computational simulations. The accuracy of these simulations depends strongly on the material models and parameters. Determining visco-elastic material model parameters is a non-trivial exercise. This project will entail:

Investigating and selecting a suitable visco-elastic material model

Determining the model parameters, probably by optimising a one-dimensional explicit FE model

Implementing the material model in a 2D or 3D FE model

Comparing the wave propagation behaviour of the model to different experimental configurations Pre/Co-requisite courses: MEC4047F and MEC4065F 41. INTERRUPTED IMPACT BEND TESTS

INTERNAL SUPERVISOR AND PROPOSED BY: R Govender Impact loading of fibre reinforced polymers (FRP) and other laminated materials often leads to delamination, which can significantly weaken a FRP structure without displaying obvious visible damage. A rig has been developed to conduct impact bend tests and has been used to investigate delamination at high rates in FRP. This rig improved the range of impact bend tests by an order of magnitude. However, the specimens were generally loaded beyond catastrophic failure, which limited post-mortem examination of the specimens. This project will involve modification of the existing rig to conduct interrupted impact bend tests, which will permit more detailed post-mortem investigation of delamination failures. The modifications will include consolidation of multiple components of the existing rig onto a single mounting platform, to facilitate set-up of experiments. Pre/Co-requisite courses: MAM2082F 42. DEVELOPMENT OF A FRAMEWORK FOR THE DOCUMENTATION AND IMPLEMENTATION OF A QUALITY

MANAGEMENT SYSTEM FOR THE DEPARTMENT OF MECHANICAL ENGINEERING BASED ON THE ISO 9001:2008 QUALITY MANAGEMENT SYSTEM INTERNATIONAL STANDARD INTERNAL SUPERVISOR AND PROPOSED BY: K Balchin

Although the ISO 9001 :2008 standard is generic, which means that it is applicable to manufacturing and service organizations, it requires specific interpretation if it is to be applied at a university. This project involves developing such an interpretation of the interdependent processes such as teaching, learning and researching, and resources, particularly with reference to quality. This interpretation is to be used to develop a practical framework for the documentation and implementation of a quality management system for the Department of Mechanical Engineering in compliance with the ISO 9001 standard. Pre/Co-requisite courses: MEC4054Z 43. FRACTURE CHARACTERISATION USING ADVANCED IMAGING

INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen The characterisation of fracture surfaces using conventional light microscopy is problematic due to the topographic nature of the fracture surfaces, particularly when they are ductile. However, the application of a digital microscope with a motorised focusing stand permits a series of in-focus images to be obtained as a function of depth (z). Reconstruction of these images enables a 3-D image to be created. The proposed project will investigate the use of the digital microscope to accurately characterise and quantify the ductile-to-brittle fracture transition in steels.

Image characterisation (and possible quantification) will be correlated with actual load-displacement curves obtained from impact tests performed on the instrumented drop-weight tester.

44. CHLORINE AUTO-DOSER DESIGN FOR SWIMMING POOLS

INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen Several methods exist for the effective chlorine dosing in swimming pools and range from manual dosing through to auto-chlorinators that convert NaCl by an electrolysis process. The problem with the latter process is the high cost of maintaining the chlorinator since the electrodes are consumables. Manual dosing remains the most cost effective, but it is time consuming. In this project a concept is proposed whereby a low-cost auto-doser can be designed that is based on the Venturi effect such that chlorine granules can be introduced during the normal filtration cycle.

45. DAMAGE ASSESSMENT IN CREEP AGED STEELS

INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen Several components/structures in power generating plant are subjected to very long periods (>100 000 hours) at high temperature and high stress. The result is that the metal suffers creep damage by way of void formation and eventual void coalescence and fracture. The condition of the metal is periodically assessed by measuring the volume fraction of voids in the steel, but the standard approach is very simple and considers 2-D imaging only. The proposed project aims to acquire 3-D reconstructed images of the metal to assess the real distribution and size of the voids in the metal volume as opposed to a 2-D surface only. In this way the relationship between the voids and the initiation of fracture may be able to be better understood.

46. ELECTRICITY GENERATION IN THE GYM

INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen Rowing machines (or Ergos as they are commonly called) are popular machines not only for specific rowing training but also for general fitness training. They are sophisticated machines that measure energy output (total work), average strokes per minute, etc. They essentially rely on resistance measurement which in the most common machines is provided by wind resistance (in some cases special machines use water resistance). The key issue here is that the resistance action should closely simulate real rowing. An opportunity arises to control resistance by “magnetic-field damping” and at the same time provide a means to generate electricity that may be stored in batteries for other uses in the gym (e.g. power for lights). The proposed project will investigate these opportunities and develop designs and trial tests using an improvised Ergo arrangement (to be designed and constructed).

47. ADAPTATION OF METAL PRESS TO SUIT REQUIREMENTS FOR ERICHSEN CUPPING TEST INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen

A custom built 20 tonne metal press currently exists in the Centre for Materials Engineering which has been adapted for several metal forming operations over the years. A need has now arisen to adapt this machine to be able to perform Erichsen cupping tests which measure the “deep draw-ability” of metallic materials. Our particular interest is to be able to measure the behaviour of aluminium sheet which is used to manufacture beverage cans. The current project requires a re-design and build of the metal press, including the relevant instrumentation, so that the Erichsen test can be reliably performed. The exercise will be validated by performing cupping tests on sheet metal provided by Hulamin (Pietermaritzburg).

48. FATIGUE CRACK PROPAGATION IN SURFACE TREATED TI-6AL-4V ALLOY INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen

A study has been recently completed in the Centre for Materials Engineering that demonstrates significant deterioration in fatigue resistance of Ti-6Al-4V alloys after surface treatment. However, it is uncertain if the deterioration arises as a result of crack initiation or crack propagation effects (or indeed to what extent it is a combination of both aspects). The reason for this situation arising is that the surface treatment process involves heat treatment that not only modifies the surface, but also the bulk microstructure as a consequence of grain growth. The present project will monitor crack growth rate in surface treated samples and correlate crack growth with microstructure as a function of depth below the surface. 49. DESIGN AND BUILD SMALL PUNCH CREEP TESTING MACHINE

INTERNAL SUPERVISOR AND PROPOSED BY: R Knutsen Determination of the remanent life of steel components that have been subjected to high temperature / high stress environments is important in maintaining the operation of thermal power stations. A novel method has been developed to extract small samples from boiler tubes and turbine blades/disks without removing the components from service. However, these samples are too small for standard creep testing and hence a small punch method has recently been introduced in Europe. The purpose of the proposed project is to design and build (based on the current creep testing code of practice) a simple small punch test rig to enable valid creep tests to be performed on the sample geometries that are presently extracted from local power stations. The elements of design will require mechanical and electrical aspects and should be low cost but accurate and reliable. 50. DESIGN OF A RIG TO MEASURE THE SEALING CAPABILITIES OF O-RINGS EXPOSED TO JET FUEL

INTERNAL SUPERVISORS: A Yates and C Woolard PROJECT PROPOSED BY: C Woolard

The composition of synthetic jet fuels differs that of crude-derived jet fuels. Because of the absence of aromatic compounds rubber O-rings do not expand (swell) when exposed to fuel and may shrink over time leading to leaks. To test the effect of fuels on swelling, a rig was constructed in 2008 at the Sasol Advanced Fuels Laboratory. This rig was used by S Visram (MSc, UCT, 2009) to assess the impact of fuel additives on O-ring swell. Recently, however, R Burnham (MSc, UCT, 2012) has pointed out deficiencies in the design. It is proposed that the existing rig, described in Burnham (2012), be redesigned to correct not only the deficiencies that have been identified but also to allow it to be used not only to measure the extent of expansion but also the force exerted by the seals and the decay of this force with time. This will allow the potential for leaks to be properly assessed. The existing rig consists of 6 modules, each containing an O-ring. The rig monitors the change in O-ring thickness while being exposed to various fuels. O-rings are compressed completely by applying pressure to anvils place on the O-rings. The pressure is then released allowing the O-rings to expand. By using non-contact differential variable reluctance transducers the positions of the anvils when full pressure is applied and when the pressure has been released can be determined. This allows the extent of swell of the seal caused by a fuel to be estimated. Although extent of swell is often used as a proxy for sealing ability (Graham et al. Energy and Fuels, 2006, 20, 759) it does not measure sealing ability directly. It is thus proposed to redesign the existing rig to:

Correct the deficiencies noted by Burnham so that swell can be more accurately measured, and

Allow the sealing force exerted by the seals to be measured and importantly to measure this force with time so that the potential for leaks can be assessed by extrapolating the sealing force to zero using a suitable model.

It is envisaged that the final design will be constructed using components from the existing rig and will contain elements of the existing design and that of other instruments used in O-ring studies such as the Elastocon (http://www.elastocon.com) or that of Warren et al. (http://www.jameswalker.biz/system/pdf_docs/fichiers/ 129/original_Low_Temp_sealing_capability.pdf) as examples. Pre/Co-requisite courses: None, although Labview experience is recommended.

51. REDESIGN, MODIFY AND TEST A BAR END GRINDER INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete

A split Hopkinson bar (SHB) is a material testing apparatus that is used to obtain material strength properties at high strain rates (30% strain in 100 μs). In a typical SHB setup, stress wave are used to compress a small specimen between two long metal bars. A critical requirement is that the bar end are flat, perpendicular to the bar axis and have a uniform surface finish with a specified roughness. Commercial surface grinders are ill suited to this task because they cannot accommodate the bars, which are typically long and narrow. Furthermore, when testing hard materials, the end faces may have to be ground repeatedly. Hence, a grinding device is required that is lightweight, compact, easy to operate and accepts a variety of bar sizes. In particular, the device must be self dressing, i.e. the grinding action must ensure that grinding tool wears evenly and remains flat and perpendicular to the bar axis. A prototype bar end grinder that provides the correct grinding motion has previously been developed at UCT. However, some aspects of the design, such as the electric motor drive, did not meet all the specifications. Redesign, modify, test and evaluate a bar end grinder for the end faces of metal bars.

52. DYNAMIC PROPERTIES OF POLYMERS AT ELEVATED TEMPERATURES

INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete Due to their relatively low melting points, the properties of polymers are very sensitive to temperature changes. Hence, if polymers are to be used in structural applications, the effect of temperature on their properties must be understood. Design, build and commission a device to maintain small polymer specimens at a constant temperature between room temperature and 100°C and conduct a series of quasi-static and dynamic tests to investigate effect of elevated temperatures on the properties of a selection of polymers. The device must be portable, compact, easy to operate and must be compatible with both quasi-static and split Hopkinson bar setups with a variety of bar sizes. (A split Hopkinson bar (SHB) is a material testing apparatus that is used to obtain material strength properties at high strain rates (30% strain in 100 μs) using stress wave analysis.) 53. DESIGN, BUILD AND TEST A LOW RANGE INTERMEDIATE STRAIN RATE COMPRESSION TEST RIG

INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete In order to improve the designing protective structures, such as crumple zones of cars or V-hulls of armoured personnel carriers, it is important to have detailed knowledge of the loads that would cause injury to the human occupants. One option is to conduct numerical simulations of the human body under various loading conditions. However, this, in turn, requires detailed materials models for bone, and other biological materials, at impact strain rates. The standard material testing apparatus that is used to obtain material strength properties at high strain rates (i.e. 103 s-1) is the Split Hopkinson Bar (SHB). Over the last few years the Blast Impact and Survivability Research Unit (BISRU) has developed various SHB configuration and tested a large variety of materials, including bovine bone. Bone is an unusual material in that it is visco-elastic-brittle, i.e. its strength properties are highly time and rate dependent and it fractures at small strains. Of particular interest is the behaviour of bone at strain rates between 1 s-1 & 100 s-1. However, neither the SHB nor conventional tensile test machines are suited to this strain rate range. In response to this, a new testing method, referred to as the wedge-bar technique, has been developed. This technique has proved to be very successful at strain rates in the order of 10 s-1. However, further development and modification of the technique is required to achieve strain rates in the order of 1 s-1. Design, build and test a modified wedge-bar apparatus for low range intermediate strain rate tests. 54. REDESIGN, BUILD, TEST A SINGLE SHOT SHOCK TUBE

INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete In order to improve the designing protective structures, such as crumple zones of cars or V-hulls of armoured personnel carriers, it is important to have detailed knowledge of the way structures respond to impulsive loading events. Blast Impact and Survivability Research Unit (BISRU) has been involved in this type of research for many years. In particular, the Blast Room at BISRU has been used to conduct explosive loading experiments on a variety of structures and materials. However, the Blast Room is not suited to recreating the relatively low pressure and long duration shock waves produced by large stand off blast loading events. To address this, a prototype shock tube was

developed at BISRU, to study the blast/shock loading of plates without using explosives. As the name suggests, a shock tube is an experimental device that can produce well defined shock waves in a gas filled tube. The shock tube design proved to be successful, but had an undesirable feature in that shocks tended to reverberate up and down the tube, leading to multiple reloading of the target structure. Redesign, build and test the BISRU shock tube to be a single shot device to test small (<50 mm) circular metal plates. The term ‘single shot’ implies that the device must only produce one significant loading event and shocks must not reverberate up and down the tube. 55. DESIGN, BUILD AND TEST A ROCK ANALOGUE FOR PERCUSSIVE DRILL TESTING

INTERNAL SUPERVISOR : T Cloete PROJECT PROPOSED BY: P Fraser - Innovation Manager, Hydro Power Equipment (HPE) PROJECT PRE-ALLOCATED TO: V Shekhar (SHKVIN001)

Percussive drilling techniques are widely used in underground rock mining operations. Percussive drills can be pneumatic, hydraulic or hydro powered and consists, essentially, of a drill rod, drill bit and hammer, sometimes referred to as the ‘piston’. The drill bit is at the end of the drill rod that is in contact with the rock, while the other end is struck by the hammer, causing a stress wave to propagate along the drill rod and interact with the rock. Ideally, a large portion of the stress wave energy is absorbed by the rock, causing it to fracture. However, some of the stress wave energy typically reflects at the drill bit interface and propagated back along the drill rod towards the main body of the drilling machine. If the reflected energy is too large it can damage the drilling machine and severely shorten the operating life. Hence, a drill should not be run without being in contact with a rock. Consequently, when endurance testing a new drill design, a large number of costly rock samples are required. An alternative rock samples is to use an energy absorbing device. Ideally, the energy absorber should have the same characteristics of the rock, and is hence referred to as a rock analogue. Design, build and test a prototype rock analogue energy absorbing device. 56. DESIGN, BUILD AND TEST A MINIATURE SPLIT HOPKINSON BAR APPARATUS

INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete A Split Hopkinson Bar (SHB) is a material testing apparatus that is used to obtain material strength properties at high strain rates, of the order 103 s-1. Over the last few years the Blast Impact and Survivability Research Unit (BISRU) has developed various compression SHB configuration, including a Large SHB (20 mm diameter, 6.6 m total length) and Small SHB (12 mm diameter, 2 m total length) for testing in the strain rate ranges of 102 s-1 to 103 s-1 and 103 s-1 to 104 s-1 respectively. These two SHB setups test specimens that are typically 5 mm in both length and diameter. Smaller specimens are required for higher strain rate tests, i.e. 104 s-1 to 105 s-1, but even the small SHB setup is too large for this application, i.e. the SHB configuration must be miniaturized (possibly, 5 mm diameter, 700 mm total length. This configuration poses some interesting technical challenges, since it will be compact and will require small sensors and specimens. Design, build and test a miniature SHB installation. 57. DYNAMIC COMPRESSION AND RECOVERY OF BOVINE BONE

INTERNAL SUPERVISOR AND PROPOSED BY: T Cloete PROJECT PRE-ALLOCATED TO: T Donaldson (DNLTYL001)

In order to improve the designing protective structures, such as crumple zones of cars or V-hulls of armoured personnel carriers, it is important to have detailed knowledge of the loads that would cause injury to the human occupants. One option is to conduct numerical simulations of the human body under various loading conditions. However, this, in turn, requires detailed materials models for bone, and other biological materials, at impact strain rates. The standard material testing apparatus that is used to obtain material strength properties at high strain rates (i.e. 103 s-1) is the Split Hopkinson Bar (SHB). A SHB makes use of a striker impact to generate a stress wave that propagates in two long bars with a test small specimen sandwiched between them. By capturing and analysing the stress wave propagation, the dynamic specimen properties are inferred. Over the last few years the Blast Impact and Survivability Research Unit (BISRU) has developed various SHB configuration and tested a large variety of materials, including bovine bone. Bone is an unusual material in that it is visco-elastic-brittle, i.e. its strength properties are time and rate dependent and it fractures at small strains. Hence, bone poses some interesting technical challenges and special striker shapes and momentum trapping techniques have been devised and applied with some success.

However, the design still has some flaws and further development is required. Redesign, build and test a SHB installation for the dynamic compression testing and recovery of bovine bone. 58. DEVELOPMENT OF DATA ACQUISITION SYSTEM FOR A DROP TESTER

INTERNAL SUPERVISORS : G Nurick, R Govender & T Booysen PROJECT PROPOSED BY: G Nurick & K Balchin

A drop tester was designed and manufactured in the department about 15 -20 years ago. This device worked exceptionally well until vandals destroyed the data acquisition system. This may be an advantage to the system In that in the intervening years, both electronic systems and computational methods have changed significantly. This project will challenge a student to develop a data acquisition device (i.e. a load cell) and also develop a code to interpret the data. Pre/Co-requisite courses: Elec-Mech student 59. DEVELOPMENT OF LABORATORY EQUIPMENT FOR TEACHING/LEARNING EFFECTIVENESS IN SOLID

MECHANICS INTERNAL SUPERVISOR AND PROPOSED BY: G Nurick

One of the major deficiencies in the Mechanical Engineering programme is the inability to demonstrate and validate fundamental theoretical principles taught in the classroom. One such principle is the experimental validation of bending and deflection of structural elements. The purpose of this project is to set up a device as a laboratory for Solids II, to enable the students to verify theoretical analyses. In addition to the experimental rig, the student will be required to develop an interactive numerical model simulating the experiment. Pre/Co-requisite courses: Solids II. FEM will be an advantage. 60. PLATE IMPACT EXPERIMENTS AND MODELLING

INTERNAL SUPERVISORS : G Nurick & V Balden PROJECT PROPOSED BY: G Nurick

Note: This project can accommodate 2 students. Over the years the response of plates to impact and blast loading has been well researched. The researchers at BISRU are possibly amongst the world leaders in this field, particularly for blast loading effects. While the details of impact loading have been well researched, this type of research at BISRU is not as developed as the blast loading system. In 2011, a student project developed a swing type impactor. The purpose of this project is to use this impactor to investigate the response of circular and quadrangular plates to localised impacts and to compare the results with computational data. The project student will be required to familiarise him/her self with the impactor system and make modifications as required. The project student will be required to design and develop a clamping system for the plates and use this to perform impact experiments. Thereafter analyse the data and present the work in a recognised format. To achieve these goals the project student will need to familiarise him/her self with the analytical and computational relevant theory. Pre/Co-requisite courses: Solids II and FEM 61. GLASS IMPACT

INTERNAL SUPERVISOR AND PROPOSED BY: G Nurick In 2011 two projects were performed which allowed members of BISRU to begin an investigation into the response of glass to impact damage. During 2011, experiments were performed in two ways – a new pendulum device was developed for impact testing of glass, and a method for testing the bending resistance of glass. In 2012, the student will be required to extend one or both of these methods to further investigate the response of glass to impact loads. (For example, what values can be applied to the advertisements seen on national TV?) Pre/Co-requisite courses: Solids II.

62. ESTABLISHING THE LIMITS OF DEFECT SIZE DETECTION USING PULSE HEATING SHEAROGRAPHY NDT INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis

This project involves the establishment of minimum size and depth of defects that are provided in three different types of sandwich composites, using pulse heat excitation and the Shearography technique. The manufactured defects are of different size and are located at different depth from the inspecting surface. Attempts should be made to verify the results using the Mechanical Impedance Testing or the Ultrasonic Testing equipment, both available in the Department. 63. PULSE HEATING THERMOGRAPHIC NDT - COMPARISON OF RESULTS OBTAINED WITH TWO INFRARED

CAMERAS INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis

This project involves the feasibility study of two infrared cameras in identifying certain manufactured defects in composite specimens which will be made available to the student by the supervisor. The manufactured defects are of different size and are located at different depth from the inspecting surface. One of the objectives of this project is to determine the effect of these parameters in detecting the defects. The effect of the different types of composite materials in the test pieces may also be contextual to the results.

64. ULTRASONIC CHARACTERISATION OF DEFECTS IN COMPOSITES DETECTED WITH DIGITAL SHEAROGRAPHY

INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis The objective of this project is to determine the applicability of ultrasonic probing in determining the size as well as the depth from the inspecting surface of defects that have been identified using the laser based optical technique known as Digital Shearography. The defects are present in specimens of composite material nature such as the Sandwich type (skin core skin) and the laminate type and will be made available by the supervisor. 65. PORTABLE SHEAROGRAPHY MODULE WITH VACUUM ATTACHMENT GRIPS

INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis A prototype of a portable shearography system which incorporates thermal excitation and the ability to attach itself on to the test piece with vacuum pads has been designed and constructed. It is required to establish the performance of this module by performing near industry type tests to detect defects. To this end appropriate size test pieces with manufactured defects will be employed. 66. ESTABLISHING THE LIMITS OF DEFECT SIZE DETECTION USING PULSE HEATING THERMOGRAPHIC NDT

INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis This project involves the establishment of minimum size and depth of defects that are provided in three different types of sandwich composites, using pulse heat excitation and an infrared camera. The manufactured defects are of different size and are located at different depth from the inspecting surface. Attempts should be made to verify the results using the Mechanical Impedance Testing or the Ultrasonic Testing equipment, both available in the Department.

67. PREDICTING WITH THEORY AND VERIFYING WITH ESPI MEASUREMENTS THE YOUNG MODULUS OF COMPOSITE BEAMS INTERNAL SUPERVISOR AND PROPOSED BY: J Gryzagoridis

The objective of this project is to investigate the validity of theoretically predicting the Young’s Modulus of Composite materials. To this end using the parallel axis theorem predict the equivalent flexural rigidity, Shear rigidity and the deflection under load of a cantilever beam. Use an actual composite cantilever beam (constructed with the identical materials used in the prediction phase, with an end load) to model the solution and establish

experimentally the Beam’s Flexural Rigidity, Young’s Modulus etc. through the deflection curve obtained with the ESPI apparatus. Compare the predicted with the experimentally obtained results. 68. DEVELOPMENT OF AN ALTERNATIVE GREEN AEROSPACE MACHINING CUTTING FLUID USING SUNFLOWER

OIL INTERNAL SUPERVISORS: R Nkumbwa & R Kuppuswamy PROJECT PROPOSED BY: R Nkumbwa

Metal cutting lubricants and coolants are used every year and the cost associated to the use of metal working fluids globally is estimated at 7 billion Euros per year. In quest to minimize metal working fluid costs, some manufacturing firms have opted to adopt the use of minimum quantity of lubrication (MQL) for high speed machining of nickel alloy Inconel 718 so as to improve its machinability. MQL generally refers to a form of lubrication system which is 5 times less than flooding system. Research to determine the optimal quantity of lubrication with corresponding cutting conditions is proposed by Dinesh et al. (2010). MQL is preferred in higher federate and cutting speed and is usually supplied through a pressure nozzle at frequencies of pulses usually high speed air with drops of vegetable based oil. Trent and Wright (2000) outlines that, for lubrication and cooling of difficult to cut materials, such as nickel and titanium alloys, the lubricant jet should have good access to the tool faces. In the machining of Inconel, the heat generated is too high in the cutting zone; hence, the use of coolants and lubricants is of great importance if reasonable tool life is to be achieved as well as good surface finish for the work-piece. The heat generated at the tool-work interface may be split into four classifications, namely, that which goes into the tool, chip, cutting fluid and the work-piece. Bayer (2006) outlines that; metal deformation during cutting generates about 75% of the heat, while 25% is due to friction. This research intends to explore development of a new cutting fluid for difficult to cut materials like Inconel using graphite particles and green sunflower plant oil as an alternative metal cutting fluid. The researcher will carry out experimental machining investigations under dry cutting environment and Minimum Quantity Lubrication (MQL) with Sunflower Vegetable Oil. The performance evaluation criteria will be based on the cutting conditions and output parameter namely, machining cutting forces. 69. VISCOSITY METER

INTERNAL SUPERVISOR : G VICATOS PROJECT PROPOSED BY: J Michalow PROJECT PRE-ALLOCATED TO: J Michalow (MCHJUL004)

Analysis of viscous mucus can give information on the conditions prevailing at the oesophagus and stomach. However, to measure the viscosity of small quantities of this viscous fluid requires a special viscosity instrument which is not available for this type of research. 70. ABSORPTION REFRIGERATION SYSTEM USING ORGANIC COMPOUNDS

INTERNAL SUPERVISOR AND PROPOSED BY: G VIicatos Note: This project is suitable for 2 students Absorption refrigerators are usually constructed to operate using ammonia and water. They are also filled with hydrogen to equate the pressure difference within the system and render them independent of the requirement of a mechanical pump. The task is to design and construct an absorption system operating with R134a and an organic compound as the absorbent (TEG.DME). The reason for using different fluids is that this system does not require distillation and the refrigerant is a pure substance and not a mixture. Also it can be used in environments with food perishables without the danger of ammonia contamination in case of a refrigerant leak. Pre/Co-requisite courses: MEC4062Z

71. HEAT PIPE PERFORMANCE INTERNAL SUPERVISOR AND PROPOSED BY: G Vicatos

Solar heat pipes have a high heat transfer capability by utilising the solar energy to boil a fluid within a tube. The vapours are transferred at relatively high speed to a heat sink where after condensation return to the solar collecting region of the heat pipe, thus repeating the cycle. The actual heat pipe is a copper tube containing a volatile fluid. This copper tube is partly enclosed within a glass tube which is exposed to solar radiation. The part of the copper tube out of the glass is attached to the heat sink. A number of Heat Pipes have arrived from China, without any performance specifications. The task of this project is to design and test a heat pipe according to known literature. Test the performance of the imported Heat Pipe against the performance of your designed one and draw conclusions. 72. INVESTIGATION OF THE PERFORMANCE OF THE ICE BALL

INTERNAL SUPERVISOR AND PROPOSED BY: G Vicatos The idea of using an open flame or concentrated solar heat to make ice or to cool an insulated box is not new, but little information is available on how to actually accomplish this feat. Prior to the availability of cheap electricity, many of these small ammonia based "Icy Ball" refrigeration units could be found in homes. Over the last 30 years several experimental units have been constructed for the purpose of laboratory testing. These units were custom made by the experimenters and could not be easily replicated. The available unit from the 2011 project is to be redesigned to accommodate pressure gages and temperature indicators in various compartments, as well as ways of suctioning air out of the unit. At present the system operates by placing the boiler on hot coal, but an electric external heater must be designed to provide the heat required to drive the unit. Pre/Co-requisite courses: MEC4062Z 73. ICE-COLD INFUSION OF COFFEE BEANS

INTERNAL SUPERVISOR AND PROPOSED BY: G Vicatos Coffee beverage has become a highly skilled process in preserving the full flavour of the coffee beans. It has been claimed that for the taste, not only the beans must be processed in a certain way, but also the “brewing” process must have a control environment to capture the “aromatics” of the beans. It has also been claimed that iced coffee is not a hot brew that has gone cold or has been put into a fridge to get cold, but it has been produced by cold water infusion of coffee grains for a long period of time. During this process the volatile oils have been preserved, together with all other ingredients that give the flavour to the coffee beverage. The parameters that may affect the taste in the cold infusion are the size of the coffee grain, the duration of the process, the temperature of the water, the amount of coffee with respect to the water. Design the infusion device and set an experimental procedure to investigate the parameters affecting the taste of the beverage. Investigate ways of keeping the water cold during the diffusion process.

74. PASSIVE DYNAMIC WALKING DEMONSTRATION MODEL INTERNAL SUPERVISOR : G Vicatos PROJECT PROPOSED BY: N Singh PROJECT PRE-ALLOCATED TO: N Singh (SNGNER005)

Passive Dynamic Walking is a form of movement that makes use of the momentum and gravitational energy possessed by rigid bodies in motion. This walking gives great insight into the mechanics of the human body. It is proposed that there be an investigation into the design and modelling of a Passive Dynamic Walker mechanism, outlining its similarities to human gait and its limits.

75. PASSIVE SOLAR HEATER SYSTEM INTERNAL SUPERVISOR : G Vicatos PROJECT PROPOSED BY: B Toussaint PROJECT PRE-ALLOCATED TO: B Toussaint (TSSBIR001)

In solar heating systems, usually the heat input comes at a lower level than the water drum. This system is the well known solar panel/water drum that is installed at roof tops. However, if the heat from the solar collector is to be transported to heat exchangers below the collector’s level, then a pump is used to circulate the hot fluid. This project entails investigating the thermo-syphon system to deliver the heat generated from a solar collector to a storage tank or a heat exchanger, well below the solar panel. Investigate the type of fluid for optimum circulation and heat absorption from the solar panels. Also investigate the varying mass rate of fluid circulation with a varying solar power for applications of household heating during winter. 76. IMPROVING TRACKING ABILITY OF AN OPTICALLY ENHANCED SOLAR HEAT PIPE

INTERNAL SUPERVISOR : Dr G Vicatos PROJECT PROPOSED BY: A Campbell PROJECT PRE-ALLOCATED TO: A Campbell (CMPAND005)

Heat pipes are capable in transferring heat from the source to the application fast and at a considerable distance. In order to produce a high temperature vapour, the sunrays could be concentrated on the tube by a series of lens-systems. The project entails in using lenses instead of parabolic mirrors to concentrate the solar energy on the fluid-carrying tube and to demonstrate the design by building a prototype. By making use of a Fresnel lens, one can concentrate the sun’s energy enough to successfully heat water over 100 degrees Celsius. However, during the duration of a year, the sun’s trajectory changes having fairly drastic effects on the effectiveness of the Fresnel lens, as the focal point thus also moves. Therefore it is required to develop an effective and simple method of minimising this effect. Furthermore, it is important that this is done in a simple mechanical way, as the solar heater is intended to be of low maintenance and cost, to allow implementation within rural and poorer communities. An additional aspect to the scope of the project would be that of using the heater in a setup that would allow the sanitation of water for drinking purposes. 77. ORTHOPAEDIC TEST STAND

INTERNAL SUPERVISOR AND PROPOSED BY: F-J Kahlen Elements of an orthopaedic test stand wear built for two 2011 final year projects. One project focused on replicating the relative motion of the upper and lower half of two orthopaedic implants, while the other project concentrated on a debris collection system for generated debris. Building on the debris collection project, you will rebuild and optimize the filtration and circulation system. The filtration system is intended to hold back debris generated during the relative motion of the upper and lower half of the aforementioned orthopaedic implants. The previous design leaves room for improvement for the sedimentation of generated large-scale debris. 78. WATER RECIRCULATION SYSTEM FOR WATER TANK

INTERNAL SUPERVISOR AND PROPOSED BY: F-J Kahlen A water tank was constructed for a 2011 final year project. The water tank is to be fitted with a recirculation system. You will have to lay out the water recirculation system, calculate pressure losses in the recirculation system, select the pump and pipes, and build the actual recirculation system. Water inlet and outlet must be designed so that

minimum turbulence is generated at the water tank inlet. Demonstrate proof that the water recirculation system works as designed. 79. MODIFICATION AND CONSTRUCTION OF AN AIRPLANE WING FOR WIND TUNNEL TESTING

INTERNAL SUPERVISOR AND PROPOSED BY: F-J Kahlen Nearly all commercial airliners today are equipped with extendable, slotted flaps at the end of each wing (when looking in the direction of air flow). The most prominent example of such a configuration are the Fowler flaps of a Boeing 747, with two rows of flaps which can be extended from the main wing. The advantage of this configuration is two-fold: It effectively enlarges the surface of the wing, allowing the plane to travel at lower speeds during take-off and approach, and it is a mechanism to transport energy from the air underneath the wing to the top surfaces of the extended wings, thereby enhancing boundary layer attachment. You will design, build and test a scaled model of the wing for wind tunnel testing which will allow simulation of flow patterns as they are experienced by commercial airliners. The wing must be designed for a row of slats to be extended. The control elements to extend the flaps must be designed and integrated into the main wing. The entire configuration must be mounted in a frame that allows pitching and movement of the entire wing configuration in the vertical direction. A previous wing model must be modified for this project and lift and drag of the wing be measured in the wind tunnel. The wing model including mounting mechanism must weigh less than 10 kg. 80. CONTINUOUS BUSINESS IMPROVEMENT 1

INTERNAL SUPERVISOR : F-J Kahlen PROJECT PROPOSED BY: D Singaram PROJECT PRE-ALLOCATED TO: D Singaram (SNGDAS001)

You will investigate the root cause for system failure in a service environment. After the root cause is identified, an action plan will be derived to optimise service delivery. Appropriate metrics must be derived to substantiate improvements before and after modifications are made. The proposed changes will then be implemented to improve processes. The project requires extended off-campus assignments Pre/Co-requisite courses: MEC4095 81. CONTINUOUS BUSINESS IMPROVEMENT 2

INTERNAL SUPERVISOR : F-J Kahlen PROJECT PROPOSED BY: D Daya PROJECT PRE-ALLOCATED TO: D Daya (DYXDEE003)

You will investigate the root cause for system failure in a service environment. After the root cause is identified, an action plan will be derived to optimise service delivery. Appropriate metrics must be derived to substantiate improvements before and after modifications are made. The proposed changes will then be implemented to improve processes. The project requires extended off-campus assignments Pre/Co-requisite courses: MEC4095 82. CONTINUOUS BUSINESS IMPROVEMENT 3

INTERNAL SUPERVISOR : F-J Kahlen PROJECT PROPOSED BY: S Mzobe PROJECT PRE-ALLOCATED TO: S Mzobe (MZBSNO001)

You will investigate the root cause for system failure in a service environment. After the root cause is identified, an action plan will be derived to optimise service delivery. Appropriate metrics must be derived to substantiate improvements before and after modifications are made. The proposed changes will then be implemented to improve processes. The project requires extended off-campus assignments. Pre/Co-requisite courses: MEC4095

83. CASSETTE FEEDER DESIGN INTERNAL SUPERVISOR AND PROPOSED BY: F-J Kahlen

Note: This project may be allocated to 2 students. a) This project is about designing, building and testing components for a new generation fertilizer conveyor and spreader prototype. This is an industrial project with follow-up opportunities for pg studies. Existing conveyor belt drive systems to transport fertilizer along the length of the machine to the distribution system exhibit difficulties in conveying materials such as unscreened lime/gypsum, organic compost etc. Potential solutions can include chain or cassette system. b) The present distribution system consists of two rotating discs with mounted scoops, drive is via a simple belt drive. To increase spreading width from the present 10 - 12 meters spreading width to 18 - 24 meters (new international norms), the disc rotation must be synchronized and be fitted with larger discs. The introduction of a robust gearbox is necessary. 84. DESIGN AND MANUFACTURE OF A BULK COIN SORTER

INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail The South African Reserve Bank is interested in rolling out a large network of coin collection facilities across the country. The purpose of the service to encourage members of the public to not store their small change in a “jam jar of change” at home, as this reduces the amount of coin in circulation. This reduction in coin cost the Reserve Bank Millions in new coin production. The bank desires a machine to be designed and prototyped that will take in a collection of random coins and return the equivalent amount of money in the highest denominations possible. The project does NOT include verification of the authenticity of the money at this stage. Pre/Co-requisite courses: MEC4053Z 85. DESIGN AND MANUFACTURE OF AN AUTOMATED PIPETTE TIP PACKER

INTERNAL SUPERVISOR AND PROJECT PROPOSED BY: E Ismail In the collection of biological media for DNA testing, small plastic pipette-tips are used to prevent contamination of the more expensive pipettes. These tips are supplied loose and must be packed into trays, which are then autoclaved to remove any existing contamination before experimental work can begin. This project focuses on the design of a machine to sort the pipette tips and pack them into the trays, which may be of different configurations. Pre/Co-requisite courses: MEC4053Z 86. DEVELOPMENT OF A SIMPLE SWARM BEHAVIOUR SIMULATOR AND DEVELOPMENT OF A

REINFORCEMENT LEARNING AI SYSTEM FOR SWARM MEMBERS INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail

The behaviour of groups capable of communicating is affected by a complex balance between actions that directly benefit the individual, and those that benefit the group at large. The effect of how an individual communicates with (and interprets communication from) its peers can be simulated using a robotic “swarm” of individuals. This project requires the student to develop a computer simulation to model swarm behaviour. The focus will be on both modelling of swarms, and swarm learning. A student will first create a simple swarm behaviour simulator where swarm members are given pre-set individual behaviour on a situation-by-situation basis. The simulator will then be used to model swarm behaviour. Once a successful simulator has been created the student will focus on implementing a simple reinforcement-learning algorithm which interacts with the simulator. This will be used to create simple AI behaviour in each individual swarm member.

87. DESIGN AND MANUFACTURE OF AN UNDERWATER VISIBILITY TESTING APPARATUS, FOR LONG TERM DEPLOYMENT AT SCUBA DIVING SITES INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail

SCUBA diving at underwater sites in the Cape Peninsula area is highly condition dependent, with wave swell, wind, and water clarity affecting the success of a recreational dive. Wind information, and swell predictions are readily available from internet sources, and these are used to predict diving conditions with limited success. This project aims to develop a testing apparatus, which will allow for direct, off-site reporting of underwater visibility. It is envisaged that should a viable prototype be develop an internet based service reporting dive conditions at popular dive sites could be launched. The device will be self-powered, and will communicate with a base station via GSM. It is envisaged that optical sensing methods will be used for the water clarity reading. The device should be robust enough to withstand Cape weather conditions and a marine environment, but this robustness is not essential in the prototype phase. Because the device will be installed in publicly accessible waters the device must be inconspicuous, and as low cost as possible, to mitigate theft risk. Pre/Co-requisite courses: MEC4053F 88. DESIGN, MANUFACTURE AND TESTING OF A STRAIN-WAVE ACTIVATED QUICK RELEASE MECHANISM

INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail High-speed torsion tests are regularly used in the study of shear bands (a form of very localised plasticity). Traditional quick release systems use fracture pins in their operation. A new quick-release device is envisaged which will forgo the need for fracture pins. This project is aimed at developing the concept, as well as characterising the characteristics of a resulting design. 89. DESIGN, MANUFACTURE, AND CHARACTERISATION OF A FRACTURE PIN QUICK RELEASE MECHANISM

INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail High-speed torsion tests are regularly used in the study of shear bands (a form of very localised plasticity). Traditional quick release systems use fracture pins in their operation. This project involves designing a fast release mechanism for a torsional Hopkinson Bar. A student would be required to design and build a fracture pin quick release clamp. The design will be based on those reported on in the literature, but with modifications to meet internal requirements. This system is used to resist a constantly applied torque and to then remove that resistance very rapidly. Once the system has been designed and built basic characterisation tests must be performed. This will verify the torque the clamp can hold as well as the release rate. Some additional design will be required for the characterisation apparatus. 90. DESIGN AND MANUFACTURE OF VIBRATIONS DEMONSTRATION AND PRACTICAL RIG

INTERNAL SUPERVISOR AND PROPOSED BY: E Ismail Mechanical Vibrations is a course where students stand to gain a lot of insight through interaction with demonstration equipment. This project is intended to develop a low cost demonstration setup which could be used to demonstrate fundamental ideas in vibrations to students. It is envisaged that the apparatus developed will be transportable so that it can be set up in front of a lecture theatre or in a practical venue. Concepts to be demonstrated should include (but is not limited to) free and forced single degree of freedom vibration, viscous damping, coulomb damping, multi-degree of freedom vibration, beating, energy transfer, vibration isolation, and vibration monitoring. Pre/Co-requisite courses: MEC4047F

91. DEVELOPMENT OF A GEARBOX LEARNING TOOL FOR MEC3031S (DYNAMICS II) INTERNAL SUPERVISORS : G Langdon & R Govender PROJECT PROPOSED BY: G Langdon

Epicyclic gearboxes are first encountered in the Dynamics II course. Currently, there is an old gearbox used for a practical which receives positive feedback as a learning opportunity. Unfortunately, student numbers have increased to the point where it is impossible to ensure that every student gets “hands on” experience during the practical. This project has three components to it:

(1) involves the reverse engineering and manufacturing of a duplicate gearbox in plastic, preferably with a transparent casing to allow students to visualise the gear movements

(2) involves the analysis of the gearbox, as required by the student (could be kinematic, dynamic and/or stress analysis).

(3) The development of an “online” pre-practical or practical exercise i.e. a “virtual” gearbox. These could be identical to the current one, but doesn’t have to be. It will require the development of animations for visualisation of the kinematics.

Pre/Co-requisite courses: Proficiency in Solidworks 92. THE RESPONSE OF SHALLOW V-SHAPED PLATE STRUCTURES TO LOCALISED BLAST LOADING

INTERNAL SUPERVISORS AND PROPOSED BY: G Langdon & S Chung Kim Yuen Blast resistant structures, such as landmine protected vehicles, are often designed in a V shape with a view to deflect most of the blast energy outwards from an explosion. For instance, the Casspir landmine vehicles, first built in 1979/80 by the CSIR, South Africa, have been certified to protect its occupants against a 14kg TNT blast under its armoured monocoque “V” shape hull. While the “V” shape hull has been fairly successful in deflecting blast it results in a higher centre of gravity compare to a “shallower” structure, hence making any vehicle using the “V” shape design less manoeuvrable in rough terrain, potentially making the vehicle more unstable and more likely to overturn. A landmine vehicle with lower centre of gravity is more desirable for increase mobility. In this project, design shallow “V” hulls that would enhance mobility of current “V” shape hulls while maintaining protection levels against blast load. The student has to plan and conduct experiments to investigate the response of the shallow “V” plates to blast load on a laboratory scale, based on a literature survey of current hull technology in landmine protected vehicles. 93. ENHANCING STUDENT RISK AWARENESS

INTERNAL SUPERVISORS: G Langdon, K Balchin PROJECT PROPOSED BY: G Langdon

Students enter into the Department of Mechanical Engineering from diverse backgrounds. There is a suggestion that UCT students may not be as risk aware as they should be, given the potential hazards they will face as engineers (both during vacation work and once they graduate). This project seeks to assess the awareness of risk as students go through the departmental curriculum from 1st to 4th year. Two years ago the department surveyed students via a questionnaire to assess awareness of risk among undergraduates. The study showed that there were some flaws in the questionnaire and a complete re-design was recommended [1]. This project involves the design and implementation of a new assessment tool. A survey of the engineering curriculum to determine how risk awareness is developed in the students during their studies will also be a part of the project. Some data will be available from the 2009 project as a starting point for the student [2]. An ideal outcome would be for the student to be able to link current awareness to the curriculum in some way, and make recommendations for curriculum changes that would enhance risk awareness of UCT Mech. Eng. students. One way to do this could be to utilise existing practical/laboratories performed by Mech. Eng. students. The student should investigate how this could be implemented and if it has potential benefits.

1. G.S. Langdon, K.J. Balchin, PG Mufamadi, Evaluating risk awareness in undergraduate students studying mechanical engineering, European J. of Eng. Education, 35(5): 553-562, 2010.

2. Mufamadi, PG. Risk awareness among mechanical engineering undergraduates, final year project report, 2009.

Pre/Co-requisite courses: MEC4054Z would provide a useful background, but is not essential.

94. INVESTIGATING THE DYNAMIC PROPERTIES OF SANDWICH PANELS WITH SOFT FOAM CORES INTERNAL SUPERVISOR : G Langdon & C von Klemperer PROJECT PROPOSED BY: G Langdon

Sandwich panels are known to be lightweight and stuff, which makes them a good choice for structures in the transport industry. Some blast loading tests have been performed on sandwich panels with stiff PCV foam cores. This project will build on previous work by examining the behaviour of softer foam cores, which are more flexible. This project will investigate the mechanical properties of sandwich structures at quasi-static rates and blast loading of experiments. Variables affecting performance include the geometry, loading rate and direction, bonding, and the material properties of the constituents. The student will define the scope of work such that the influence of some of these factors on blast performance and mechanical properties will be determined during an experimental programme. 95. CHARACTERISING BLAST WAVE PROPAGATION IN TUBES

INTERNAL SUPERVISORS: G Langdon & S Chung Kim Yuen PROJECT PROPOSED BY: R Govender, S Chung Kim Yuen & G Langdon

The Blast Impact and survivability research unit (BISRU) has been performing research into the response of blast loaded structures for many years. Recently, BISRU has been developing techniques to measure the pressure distributions generated by detonating plastic explosive. The spatial and temporal distribution of the pressure loading is complex and very challenging to measure. This project will take two approaches – (1) it will use a recently commissioned tubular pendulum to examine the radial distribution of a blast load impinging upon a surface and (2) use pressure transducers to measure the pressure loading at particular points within the tube. The student must design, plan and conduct a series of experiments to demonstrate the characteristics of explosion loading and use analytical approaches to determine/describe the nature of blast loading. Pre/Co-requisite courses: Elec-Mech student 96. SIMULATING THE BLAST RESPONSE OF CYLINDRICAL SHELLS TO LATERAL BLAST LOADS

INTERNAL SUPERVISOR AND PROPOSED BY: S Chung Kim Yuen Pipes are widely used, in air, underground or underwater, as a mean of transporting goods from one place to another. However, these pipelines are constantly under threat. One possible threat is potential damage due to explosions. In an attempt to develop better protection of these pipelines, an experimental project was successfully conducted investigating the blast response of circular shells to lateral blast loads. Using data from the past experiments, model the response of cylindrical shells to lateral blast loads. Pre/Co-requisite courses: MEC4065F (FEM) 97. UNDERSTANDING THE EFFECT OF MOISTURE CONTENT ON BURIED CHARGES

INTERNAL SUPERVISOR AND PROPOSED BY: S Chung Kim Yuen Landmines are a major threat worldwide. The effect of buried explosives on a structure is a complicated and complex mechanism. While it is extremely expensive and complicated to conduct full-scale tests, for fundamental research and computational modelling, small scale testing has numerous advantages over full-scale tests. The test process can be better controlled in regards to accurate measurement of explosive size, accurate positioning of the explosive, easier to shape the explosive in different configurations (spherical, disc shaped of various diameter to height ratios), stand–off distance from soil level to target; and calibrated and controlled measurement of the impulse. Design, plan and conduct experiments to investigate the effect of moisture content of the overburden on buried charges with a view to developing an empirical relationship between impulse and mass of explosive for different depth of burial and stand-off distance.

98. THE RESPONSE OF SANDWICH PANELS WITH TUBULAR CORES TO BLAST LOAD INTERNAL SUPERVISOR AND PROPOSED BY: S Chung Kim Yuen

Blast loads from explosion (either accidental or intentional) can be mitigated by using thick armour systems that are often heavy and significantly impact structural load. Sandwich structures with lightweight cores are being widely considered for blast mitigation applications, including armour systems, because of their capability to carry transverse loads with minimal weight penalty and absorb plastic energy. The choice of the sandwich core has significant influence of the performance of the structure. Typical core can be made from tubular structures that are widely used as structural members for its high energy absorption capabilities. Design sandwich panels with tubular core structures as blast mitigators. The student must plan and perform a series of experiments to investigate the blast resistance of the sandwich structures. Blast tests using monolithic steel plates of equal mass must also be conducted to determine possible performance improvements using the more complex sandwich structure. In addition to the blast tests, material characterisation and load bearing characteristics of the core must be performed. 99. THE EFFECTS OF USING FOAM AS FILLER ON THE ENERGY ABSORPTION CHARACTERISTICS OF TUBULAR

STRUCTURES INTERNAL SUPERVISOR AND PROPOSED BY: S Chung Kim Yuen

Thin-walled structures are widely use in crashworthiness applications because of the ability to convert large amount of kinetic energy (from impact) into large plastic deformation in a predictable and controllable way. Despite its efficiency, there are numerous ways of improving the energy absorption. One of the ways is to stiffen the tubular structures by filling with cellular structures. Design and conduct experiments to investigate the effects of using foam as filler on the energy absorption characteristics of tubular structures. 100. INVESTIGATING THE DYNAMIC PROPERTIES OF TEXTILE CONCRETE

INTERNAL SUPERVISOR AND PROPOSED BY: G Langdon Textile concrete is a locally made, South African product that is suitable for many applications in buildings such as roof tiles, paving, archways etc. In an effort to make the product environmentally friendly and more economic, it is proposed to use SASOL fly-ash by-products in the concrete mixes. This project will investigate the dynamic properties of textile concrete. The project will envisage all steps of the characterisation process (literature survey, test type selection, experimental design, performance of tests, data analysis and interpretation). Variables affecting performance could include fly ash content, geometry, loading rate and direction, previous exposure to heat, and moisture. The student will define the scope of work such that the influence of some of these factors will be determined during the experimental programme. 101. INVESTIGATE THE CONFORMITY OF A PSEUDO ESPI CONFIGURATION FOR NDT PURPOSES

INTERNAL SUPERVISOR AND PROPOSED BY: D Findeis Electronic Speckle Pattern Interferometry (ESPI) is an optical non destructive testing technique which can be used to inspect objects for surface and subsurface defects. By modifying a conventional Digital Shearography setup a pseudo-ESPI method can be achieved. Using purpose made inspection samples allowing for repeatable load applications, the aim of this project is to thoroughly investigate the pseudo ESPI technique and determine its conformity with conventional ESPI. To this end the results obtained need to be quantified in order to make meaningful deductions.

102. USING OPTICAL NDT TECHNIQUES AND ACOUSTIC EXCITATION TO INSPECT COMPOSITES FOR DEFECTS INTERNAL SUPERVISOR AND PROPOSED BY: D Findeis

Optical NDT techniques including ESPI and Digital Shearography are used to inspect manufactured components for surface as well as sub-surface defects. One of the key elements in the inspection process is to suitably stress the object to reveal the defects. The aim of this project is to investigate the use of PZT based acoustic object excitation as a suitable technique to inspect composite panels for defects. You will be required to design and if possible manufacture a set of suitable composite panels with integrated defects and then test them using the available optical interference techniques using acoustic stressing methods. As a reference stressing method, thermal stressing techniques will also be applied. You will be required to draw conclusions from the results obtained and determine the suitability of the suggested stressing method. 103. ON BOARD VIDEO CAMERA MONITORING OF CANOEIST TO IMPROVE PERFORMANCE

INTERNAL SUPERVISOR : D Findeis PROJECT PROPOSED BY: B Moolenschot PROJECT PRE-ALLOCATED TO: B Moolenschot (MLNBRE005)

Video recording of canoeists is a technique employed to analyse and improve the performance of canoeists. The methods offered are based on land based high zoom cameras and fixed position on-board cameras. In an attempt to improve this technique further, this project aims to develop an on-board camera recording mechanism and system which allows the video operator to record the canoeist from many angles via a camera mounted on an adjustable boom at the front of the canoe. The boom must have pan and tilt functionality and the canoeist must always remains centred and focussed in the picture. 104. DESIGNING A COLLAPSIBLE KAYAK

INTERNAL SUPERVISOR : D Findeis PROJECT PROPOSED BY: R Arnold PROJECT PRE-ALLOCATED TO: R Arnold (ARNROB004)

The aim of this project is to design a collapsible kayak based on an existing single seat kayak shape. The final design needs to be light enough to be carried as a backpack. The design has to be biased more towards speed than stability, but has to be rigid and strong enough to handle turbulent waters. 105. INVESTIGATE THE ABILITY TO DETECT RESIDUAL STRESSES IN BEAMS USING OPTICAL NDT TECHNIQUES

INTERNAL SUPERVISOR AND PROPOSED BY: D Findeis Residual stresses are introduced into many components due to the manufacturing process. Digital Shearography (DS) is an optical inspection technique used to record the rate of displacement of an object in response to an applied force. Using DS, investigate the displacement behaviour of simply supported beams made from different materials with induced residual stresses. In particular attempt to quantify any possible changes to the displacement profile of stress free beams and beams containing residual stresses. For these investigations a purpose designed rig to hold the simply supported beams and apply repeatable loads has to be manufactured. 106. OPTIMIZATION OF A THERMAL ROCK STORE AIR-CONDITIONING SYSTEM

INTERNAL SUPERVISOR : D Findeis PROJECT PROPOSED BY: B Bonthuys PROJECT PRE-ALLOCATED TO: B Bonthuys (BNTBER002)

Sustainable building design focuses on using sustainable renewable energy where possible. A thermal rock store used as an air-conditioning system for a building is one such application. In this configuration a rock store placed in

the basement of the building is used during daytime to cool air prior to it entering the building. During the night time, the process is reversed and cool night air is used to remove energy from the rock store which accumulated during the daytime. The aim of this project is to investigate all aspects of the rock store contributing to its performance and using theoretical performance values to verify the experimental results obtained from a scaled down version using dimensional analysis. 107. ANALYSIS OF PRODUCTION AND QUALITY FUNCTIONS OF A REAL WORLD ORGANISATION AND

RECOMMENDATIONS FOR IMPROVEMENT INTERNAL SUPERVISOR AND PROPOSED BY: C Shaw

Quality pervades the whole company and effects all the functional departments within it. Quality systems are usually procedure based and are meant to ensure that defined quality levels are consistently maintained. In this project you will be required to conduct a study in a real world production facility, as part of the project you will:

Produce an outline test schedule for a new product

Produce a high level outline design of the production line. Include incoming QA and production testing.

Carry out a simple target yield analysis of the line. Make recommendations taking into account organisational constraints. Pre/Co-requisite courses: MEC4054Z 108. AN INVESTIGATION OF THE CONSTRUCTS OF MANAGEMENT OF ENGINEERS IN INDUSTRY

INTERNAL SUPERVISOR AND PROPOSED BY: C Shaw Managers hailing from an engineering background are considered to have a higher failure rate in management than any other functional area despite an increasing demand for engineering management. This project entails a research design using the Repertory Grid Technique in order to determine the constructs of management of engineers in industry. Qualitative research sampling procedures will be used to identify suitable candidates to survey in industry. The purpose of the project is to determine if and to what extent, variation exists in the constructs of engineering management in these groups and to compare these with self reports of constructs of effective management from the same group. The project will require preparation in the form of becoming competent in the use of the Repertory Grid Technique and qualitative research methods and sampling. Pre/Co-requisite courses: MEC4042Z 109. ANALYSIS AND DESIGN OF A MAINTENANCE MANAGEMENT SYSTEM FOR AN INDUSTRIAL CONCERN

INTERNAL SUPERVISORS: C Shaw & K Balchin PROJECT PROPOSED BY: C Shaw

This project is a qualitative research study which entails an assessment and recommendations for improvement of an existing maintenance management system in a company to be identified. Pre/Co-requisite courses: MEC4054Z 110. COMMISSION AND TEST A DIESEL CVCC

INTERNAL SUPERVISOR AND PROPOSED BY: M Perumal A Constant Volume Combustion Chamber (CVCC) has been developed at the Sasol Advanced Fuels Laboratory for the investigation of Diesel Spray and Combustion. This combustion bomb has many desirable features such as large sapphire windows for optical access, multiple ports for instrumentation and injector configuration and a system whereby a mixture of acetylene, nitrogen and oxygen are first combusted to simulate diesel engine like conditions into which fuel can be sprayed. Although the device has been used in the past for fuel spray studies, the measured results from experiments have shown some deviation from prediction. It is thus desired to re-commission and calibrate the bomb, investigate some

of the sources of uncertainty and either quantitatively define these or reduce their effect by modifications to the device or the operating procedure. This will require a substantial amount of testing under both combusting and non-combusting conditions to establish repeatability of the device and comparison to published results of combustion chambers at other research facilities. 111. KNOCK-LIMITED COMPRESSION RATIO OF WOOD-GAS

INTERNAL SUPERVISORS: A Yates & G Floweday PROJECT PROPOSED BY: A Yates

The gasification of wood and other renewable energy feedstocks to produce synthesis-gas (mixture of hydrogen and carbon monoxide) is becoming an attractive research area in the energy industry as an alternative to use of dwindling gas reserves. It is common knowledge that the conversion of spark-ignition engines to run on wood-gas involves a significant power loss due to the lower energy content of the gas and its volumetric displacement of intake air. (Wood-gas is a high octane mixture of carbon monoxide and hydrogen produced from the gasification of wood.) It is also common knowledge that some of the power loss can be compensated by taking advantage of the high octane of the gas by raising the compression ratio of the engine or turbo-charging. A maximum compression ratio of about 12:1 is the typical literature recommendation. However, there is a recent observation from the manufacturers of the Gasification Experimenters Kit (GEK) that they were able to successfully operate an ex-diesel engine that had been converted to spark-ignition on wood-gas with a compression ratio of 17:1. In-house research at the Sasol Advanced Fuels Laboratory has shown that certain fuel types (which would include woof-gas) can be induced to exhibit apparently high octane behaviour under certain operating conditions. It has also been shown that auto-ignition (knocking) can be “softened” by the presence of high concentrations of inert gas (which is also a feature of wood-gas). The aim of this project is to investigate the knock-limited behaviour of wood-gas to gain greater understanding of these anecdotal data. A portable gassifier is currently being designed and built and will be available for use in conjunction with a variable compression-ratio engine (Ricardo E6). The student will need to build the gas-carburettor to enable tests to be conducted and then characterise the wood-gas fuel w.r.t. knock limited compression ratios at Maximum Brake Torque (MBT) spark timing and knock limited spark timing at slightly higher compression ratios. Pre/Co-requisite courses: MEC4092F (Internal Combustion Engines) 112. CFR ENGINE MODIFICATION FOR HIGH OCTANE FUEL TESTING

INTERNAL SUPERVISOR AND PROPOSED BY: G Floweday The octane rating of gasoline (petrol) fuels is done using a special spark ignition test engine called a Cooperative Fuels Research (CFR) engine. This test engine essentially works by changing the (variable) compression ratio of the engine until the engine starts to knock (auto-ignition of the unburned fuel and air mixture in the endgas region) and reaches “standard knock intensity” as measured by a calibrated knockmeter. Blends of the Primary Reference Fuels (PRFs) iso-octane and n-heptane are then run at the same compression ratio and the ratio of these fuels is varied until the same knock intensity is reached. The two PRFs are used to define the octane scale with iso-octane being defined as 100 octane and n-heptane being defines as zero octane. The octane of a blend of the two PRFs is then defined by the volumetric percentage of iso-octane in the blend. So, for example, a 95 octane gasoline will reach standard knock intensity at a compression ratio “x”, which is the compression ratio at which a 95% iso-octane and 5% n-heptane blend PRF will run at standard knock intensity. The CFR engine uses a simple carburettor to atomise the test fuel and facilitate its evaporation in the inlet air stream. The air-fuel ratio is adjusted during testing to produce maximum knocking and is typically slightly rich of stoichiometric. Most test fuels can be tested easily in this manner. However some high octane fuels of interest, such as methanol and ethanol, are difficult to test because their stoichiometric air-fuel ratios are outside of the adjustment range of the CFR engine carburettor’s mixture adjustment screw. The carburettor therefore requires modification in order to allow higher fuel flow rates and enable testing of these interesting fuels.

In addition to this, these two fuels also have very high latent heat of vaporisation. Since the Motor Octane Number (MON) octane test method requires the fuel-air mixture temperature to be controlled to 422K, significant heating power is required in the CFR engine’s inlet manifold to achieve and maintain this temperature set point. The standard heating element is not powerful enough to maintain the temperature set point for ethanol and methanol. This heating element also then requires modification in order to test these high octane fuels. Pre/Co-requisite courses: 3rd year Thermofluids & IC engines 113. CONCEPT DEVELOPMENT ON A PERFORMANCE FUEL ADDITIVE FOR GASOLINE ENGINES

INTERNAL SUPERVISOR AND PROPOSED BY: G Floweday The relationships between fuel composition, air-fuel ratio and the ratio of specific heats (gamma) of the air-fuel mixture are well known and documented. The importance of gamma on the pressure and thermal history during compression and on the thermal efficiency of an internal combustion engine is also well known. Scope therefore exists to investigate the effect of fuel composition and fuel additives on the power output and efficiency of an engine via the effect on the value/s of gamma. A recent CFD engine modelling project indicated that fuel composition dependent latent heat of vaporisation (temperature drop from fuel evaporation) effects are essentially smudged out by cylinder wall heat transfer during the intake stroke. The effect of gamma on thermal development by nominally adiabatic compression of the mixture by the piston during the compression stroke was found to be far more significant. It would therefore seem that the gamma effects of different fuels can have significant effect on engine power output and efficiency. It stands to reason then that this effect could be manipulated by changing the fuel composition and/or through the use of fuel additives. This project aims to investigate this issue using thermodynamic engine modelling techniques. If successful, this project could result in a real modification to the composition of Sasol’s synthetic fuel products. Pre/Co-requisite courses: MEC4092F (IC engines) & MEC3044S (Thermofluids III) 114. RE-DESIGN AND PERFORMANCE MAPPING OF A SMALL ROOTS BLOWER SUPERCHARGER

INTERNAL SUPERVISOR : G Floweday PROJECT PROPOSED BY: D Humphris PROJECT PRE-ALLOCATED TO: D Humphris (HMPDAV005)

Engine downsizing and boosting (using turbochargers or superchargers) is a strong trend in the engine development programmes of automotive engine manufacturers. The aim of this project is to re-design and conduct performance mapping on a supercharger that was recently built for use on a single cylinder (300 cc) Briggs & Stratton engine. This is the engine that was used for the Mini-Baja competition vehicle. The engine will need to be assessed regarding its suitability and robustness for inlet boosting. This will entail reverse engineering of key components and assessment of boost limits. Boosted air flow rate requirements will also require definition. An existing mini-roots blower from a previous project will then be modified/re-designed and tested to map out its performance and determine its suitability for the B&S engine. Test data proving the suitability of the compressor will be obtained by driving the compressor with an electric motor. The design for incorporation on the B&S engine may be considered if the student demonstrates strong performance on this project. Pre/Co-requisite courses: 3rd year Thermofluids & IC engines 115. COMPUTATIONAL MODELLING OF THE EFFECT OF IN-CYLINDER TEMPERATURE GRADIENT ON OCTANE

RATING IN THE CFR ENGINE INTERNAL SUPERVISOR AND PROPOSED BY: M Perumal

Knock in spark ignition engines is highly undesirable and potentially damaging, thus placing design and operation constraints on the engine. It is caused by auto-ignition of the unburned fuel-mixture before it is consumed by the flame front of normal combustion. Therefore the chemistry of the fuel being used is one of the key factors influencing whether knock will occur or not. The standard rating of a fuel’s resistance to knock is Octane Number, which is measured in standardised tests in the CFR engine.

Since Octane number is such a critical fuel specification, the Octane rating tests and the CFR engine have been the subject of on-going research at the Sasol Advanced Fuels Laboratory. Most recently, a multi-zone engine combustion model has been developed and a CFD study of the intake process including the effects of fuel evaporation has been performed. It is now required to consolidate the results of these two modelling studies. The student will be required to implement the Multi-zone model in Matlab, including possible improvements to the sub-model and critically analyse the results the results of the previous modelling studies. Using the initial conditions obtained from the CFD model, the RON and MON tests will be simulated and compared to experimental data. The Multi-zone model can then be used to investigate the effects of fuel evaporation and in-cylinder temperature gradient on Octane rating for various fuels. Pre/Co-requisite courses: MEC4092F & MAM3080F (MEC4045F is recommended) 116. NDT DETECTION OF FATIGUE CRACKING IN DIAMOND DRILL PIPE USING AN EDDY CURRENT SYSTEM

INTERNAL SUPERVISOR AND PROPOSED BY: R Tait

A key feature of the lucrative offshore diamond mining enterprise, in which De Beers Marine have a large stake, is the structural integrity of the so called ‘drill pipe’ through which sea bed gravel –and diamonds- are airlifted to the ship. These drill pipes often develop corrosion-fatigue cracks which if allowed to develop through to complete failure can have disastrous consequences for the mining operation. This project is concerned with the “manufacture” of realistic circumferentially oriented corrosion fatigue type cracks in representative pipeline steel (on a quarter scale), and their subsequent detection using eddy current NDT methods (which have already been developed as part of an MSc project). Pre/Co-requisite courses: MEC 4035 fracture Mechanics 117. FITNESS FOR PURPOSE OF SASOL FUEL WELDED PIPELINE

INTERNAL SUPERVISOR AND PROPOSED BY: R Tait SASOL are in the process of installing a new large 26 inch fuel pipeline which is joined by butt welding. The implications of any leaks, cracking or failures are extremely serious and are to be avoided at all costs. In a contributory effort to monitor the safety and “fitness for purpose” of the line, a fracture mechanics assessment is in order. This would require samples of pipeline which includes welded samples incorporating not only parent plate pipe material, but also weld metal and heat affected zone sections. This project sets out to measure the fracture toughness of these three material regions and types, in an effort to provide reliable data in the event of some defect developing and a fracture mechanics assessment being required , with reliable actual fracture toughness data, and known applied stresses. Pre/Co-requisite courses: MEC 4035 Fracture Mechanics 118. RESIDUAL STRESS RELIEF BY VIBRATORY STRESS RELIEF (VSR)

INTERNAL SUPERVISOR AND PROPOSED BY: R Tait PROJECT PRE-ALLOCATED TO: S Rivett (RVTSEA001)

Although welding or other fabrication or manufacturing techniques can lead to severe residual stresses, of the order of the yield stress, post weld heat treatment (PWHT) is only occasionally applied. An alternative technique due to VSR is used but the understanding of the detailed mechanism of stress relief is not well understood. This project is a research attempt to understand VSR by using rolled or weld clad steel beams into which residual stresses have been induced, and subject them to controlled vibration, and monitor the effect on residual stress, distortion and other metallurgical parameters, as a function of frequency, amplitude, location and VSR time. Pre/Co-requisite courses: MEC 4035 Fracture Mechanics

119. HIGH TEMPERATURE MECHANICAL PERFORMANCE OF TITANIUM ALLOY INTERNAL SUPERVISOR : R Tait PROJECT PROPOSED BY: R Tait, S George & R Knutsen

Manufacture by laser sintering of polymers or fine powder offers remarkable flexibility as layers can be built up at 100 micron layer increments. Consequently very complex shapes can be achieved and minimum machining is required. For very complex parts such laser sintering may be a viable alternative to conventional casting, forging and machining. The process does, however, result in significant residual stresses as well as surface roughness and some porosity, all of which can impair mechanical properties. Modern laser sintering can use titanium powder to form high quality aircraft parts but the process is still at the development stage, even though densities of more than 99% are claimed. The potential for high strength lightweight aircraft parts is very promising as there is generally good high temperature performance as well. This project is targeted at students with a Materials interest, to measure the high temperature strength and stiffness characteristics of such a laser fabricated alloy as a function of temperature, to 1000C, as well as at a reasonable range of strain rates, using the new Gleeble machine in the Materials Engineering lab. Correlation of properties with microstructure and porosity will be investigated. 120. FATIGUE OF TI 6-4 TITANIUM ALLOY USING SMALL COMPACT TENSION SPECIMENS

INTERNAL SUPERVISOR AND PROPOSED BY: R Tait Manufacture by laser sintering of polymers or fine powder offers remarkable flexibility as layers can be built up at 100 micron layer increments. Consequently very complex shapes can be achieved and minimum machining is required. For very complex parts such laser sintering may be a viable alternative to conventional casting, forging and machining. The process does, however, result in significant residual stresses as well as surface roughness and some porosity, all of which can impair mechanical properties. The fatigue behaviour of such Ti6-4 alloys fabricated by laser sintering can depend heavily on the interlayer bonding, as this method could lead to lines of weakness between sintered layers or even very poorly sintered layers. This project then endeavours to measure the fatigue behaviour in the form of a “Paris equation” of such sintered material in two orientations, both across the grain (sintering direction) and also with the grain direction. Such fatigue data would be invaluable in the assessment of fatigue lives of components made of such material. Pre/Co-requisite courses: MEC 4035 Fracture mechanics 121. FRACTURE TOUGHNESS OF TI 6-4 TITANIUM ALLOY USING SHORT ROD METHODS

INTERNAL SUPERVISOR AND PROPOSED BY: R Tait Manufacture by laser sintering of polymers or fine powder offers remarkable flexibility as layers can be built up at 100 micron layer increments. Consequently very complex shapes can be achieved and minimum machining is required. For very complex parts such laser sintering may be a viable alternative to conventional casting, forging and machining. The process does, however, result in significant residual stresses as well as surface roughness and some porosity, all of which can impair mechanical properties. The fracture toughness of such Ti6-4 alloys fabricated by laser sintering can depend on the interlayer bonding and this project is targeted at measuring the fracture toughness of such material as a function of orientation. In particular, laser sintered cylindrical products would be formed, with the forming axis both longitudinal and transverse. From such cylinders “short rod” fracture toughness specimens would be machined and tested to assess the standard fracture toughness of such material and compare it to bulk material, and also assess its “fitness for purpose” Pre/Co-requisite courses: MEC 4035 Fracture mechanics

122. EFFECT OF SHOT PEENING ON RESIDUAL STRESS OF A SINTERED TITANIUM ALLOY INTERNAL SUPERVISOR AND PROPOSED BY: R Tait

South Africa is seriously considering an effort to produce titanium products using rapid proto-typing methods, rather like laser sintering from titanium alloy powder to near net shape. This has obvious advantages, since titanium is very expensive and is also very difficult to machine. It is already finding application in prostheses in the human body because of its bio–compatibility, but there is also a move to use the material more widely in aeronautical and aero-space applications, because of its high strength and low density. However the microstructure, properties and structural integrity of a laser powder sintering route is not clear nor has the material been extensively tested for these features.

This project is concerned with the fatigue life enhancement of the material as a function of shot peening the surface. Such shot peeing would induce extensive compressive residual stress into the surface and (as long as surface roughness is not impaired) potentially significantly improve fatigue performance. The project is concerned with creating high residual stresses, by shot peening, in previously annealed titanium 6-4, and then measuring these residual stresses as a function of shot peening intensity and coverage. An attempt at micro–structural understanding of the results is also anticipated as an aid in assessing its viability for aero-nautical applications. 123. EXPLORING MECHANICAL ENGINEERING STUDENTS’ INTEREST IN SOCIAL/CIVIC RESPONSIBILITY ISSUES AS

PART OF A CURRICULUM RE-DESIGN PROCESS INTERNAL SUPERVISOR AND PROPOSED BY: B Kloot

The purpose of this project is to gauge undergraduate students’ interest in issues with a view of feeding into the curriculum re-design process currently underway in the EBE Faculty. There are three parts to this project:

1. A quantitative survey exploring the reasons why students choose to study Mechanical Engineering. It is envisaged that both first- and second-year students will be surveyed. Of particular interest in this study are the categories that Jawitz and Case (1998) call reasons of ‘social identity’ or what Reed and Case (2003) refer to as ‘social/civic responsibility’. Determining whether any trends can be discerned in the results is important, and of particular interest is whether the relatively high proportion of black* and female students mentioning social/civic responsibility reasons appears to increase or decrease with time;

2. Qualitative group discussion/s with students will follow with a view of exploring students’ understandings, ambitions and knowledge of the opportunities available in the world of work. Another topic to be explored is the extent to which students are prepared to get involved in community work during their undergraduate degree. This part of the project will follow a participatory research design where the facilitator (in this case the research project student) also shares knowledge about issues of social justice and community involvement.

3. The final phase of this project is a curriculum design component – the student must propose a number of curricula options and recommend the most suitable given the results from parts 1 and 2 above. Although detailed curriculum design is not expected, a rough outline of the content and outcomes of the proposed curriculum that speaks to ECSA’s requirements in terms of the impact of engineering on society is required.

References 1. Jawitz, J. and J.M. Case. 1998. Exploring the reasons given by South African students for studying

engineering, International Journal of Engineering Education, 14(4) pp. 235–240. 2. Reed, B.I. and J.M. Case. 2003. Factors influencing learners’ choice of Mechanical Engineering as a career,

African Journal of Research in SMT Education, 7 pp. 73–83. * The term ‘black’ here refers to students belonging to the African, ‘coloured’ and Indian population groups 124. EFFECT OF A GEYSER BLANKET AND HOT WATER CYLINDER ORIENTATION ON ENERGY EFFICIENCY

INTERNAL SUPERVISOR AND PROPOSED BY: B Kloot It has been estimated that hot water cylinders (geysers) account for between 20–45% of energy supplied to the residential sector. A demand-side management strategy for reducing the energy consumption of hot water cylinders involves insulating the cylinder with a geyser blanket. This project investigates the combination of the effect of having a geyser blanket with geyser orientation (vertical or horizontal). In other words, it explores to what extent a

geyser blanket improves efficiency on a horizontal geyser compared to a vertical geyser, if at all. The results will hopefully allow recommendations to be made for energy savings to the electricity sector. 125. SAFE PARAFFIN STOVE

INTERNAL SUPERVISOR AND PROPOSED BY: B Kloot The Paraffin Safety Association of South Africa (PSASA) reports that at least 4 000 people die in fires caused by paraffin stoves every year. About 20 million South Africans are forced to cook on dangerous, sub-standard paraffin stoves, and most are not aware of the risks. The aim of this project is to design a safe, functional and cost-effective paraffin stove to try to reduce the number of fires that occur and therefore the number of fire-related deaths. 126. AIRCRAFT FUEL SLOSHING TANK – LATERAL ACCELERATION

INTERNAL SUPERVISORS AND PROPOSED BY: A Malan & C Redelinghuys Commercial transonic aircraft such as the A-range developed by Airbus, are continually being refined and enhanced in the interest of efficiency and safety. New generation long haul aircraft are using larger outer board fuel tanks, and with the fuel at take-off being close to 50% of the aircraft weight, flight induced sloshing loads are a key design consideration. So called baffles are placed in the tanks in order to control the loads induced on the airframe. Computational Fluid Dynamics (CFD) has become a strategic tool in the aerospace industry, and is today showing promise for fuel sloshing load calculations. Such tools must however be validated by comparison to experimental data prior to application. This project involves the design, build and commissioning of a scale model tank complete with baffle to experimentally investigate aerospace sloshing. The tank is to induce roll-type manoeuvre loads at low frequencies i.e. 0.2Hz. The baffle is to be instrumented with a strain gauge to measure sloshing induced strain, and the tank-walls with devices from which sloshing induced loads may be measured and a number of locations. 127. AIRCRAFT FUEL TANK BAFFLE DESIGN

INTERNAL SUPERVISOR AND PROPOSED BY: A Malan PROJECT PRE-ALLOCATED TO: D Merrick (MRRDAN008)

Commercial transonic aircraft such as the A-range developed by Airbus, are continually being refined and enhanced in the interest of efficiency and safety. New generation long haul aircraft are using larger outer board fuel tanks, and with the fuel at take off being close to 50% of the aircraft weight, flight induced sloshing loads are a key design consideration. So-called baffles are placed in the tanks in order to control the loads induced on the airframe. Computational Fluid Dynamics (CFD) has become a strategic tool in the aerospace industry. This is as it offers unprecedented engineering insights while being cost effective. This project entails using a modern sloshing CFD tool Elemental to design the baffle configuration for a representative transonic aircraft tank geometry. The design objectives include minimize required baffle structure while offering adequate reduction to induced fuel slosh loads. Pre/Co-requisite courses: MEC4045F 128. 1D MODELLING OF ARTERIAL FLUID-STRUCTURE-INTERACTION

INTERNAL SUPERVISORS AND PROPOSED BY: A Malan & D Reddy The human body contains complex vascular networks, the modelling of which is a key area of research today. It requires accounting for the fluid dynamics associated with blood flow, in conjunction with arterial expansion and contraction. Using compliant 3D Computational Fluid Dynamics (CFD) models remains prohibitively expensive, while 1D models have shown considerable promise. This project involves the development of a 1D CFD model which describes the flow of an incompressible fluid interacting with an elastic arterial wall. The model is to be discretized, and computer code written by which it may be solved. Accuracy and efficiency is to be estimated, followed by application to modelling a case of pulsating flow in an artery with scar tissue.

Pre/Co-requisite courses: MEC4045F 129. THE CATAPULT: ROMAN TERROR WEAPON

INTERNAL SUPERVISOR AND PROPOSED BY: A Malan In their days as the super power, the Romans developed a weapon with unrivalled range and fire-power: the catapult. The version of this machine to be considered in this project, consists of a rotating flexible arm, which is pin-jointed at one end and has a movable payload (projectile) which slides along the flexible arm. Even though the romans were famous at the time for their understanding of dynamic systems, what has been a mystery for more than a thousand years, is what the optimal rotating-arm position of release is, as well as the resulting effect of the arm’s flexibility. This project entails the design of an optimal machine as follows: • Use dynamics (as per the Engineering undergraduate dynamics course) and solid mechanics to formulate equations that describe the weapon. • Develop a Matlab code to describe the dynamics of the catapult using the above identified equations. • Apply an optimization algorithm to find the optimal position of release. • Build a scale model of the catapult and verify calculations. This project is only for those who have a keen interest in history as well as having serious fun with mathematics. 130. AIRCRAFT FUEL SLOSHING TANK – HIGH ACCELERATION LOW FREQUENCY MECHANISM

INTERNAL SUPERVISORS AND PROPOSED BY: A Malan & C Redelinghuys Commercial transonic aircraft such as the A-range developed by Airbus, are continually being refined and enhanced in the interest of efficiency and safety. New generation long haul aircraft are using larger outer board fuel tanks, and with the fuel at take-off being close to 50% of the aircraft weight, flight induced sloshing loads are a key design consideration. So-called baffles are placed in the tanks in order to control the loads induced on the airframe. Computational Fluid Dynamics (CFD) has become a strategic tool in the aerospace industry, and is today showing promise for fuel sloshing load calculations. Such tools must however be validated by comparison to experimental data prior to application. Particularly low frequency high acceleration cases (0.2Hz, 3g) result in severe slosh loads yet very little experimental data is available. This project involves the design, build and commissioning of a mechanism such as to demonstrate its potential for low frequency high acceleration slosh experimental set-up. 131. WATER PROPELLED ROCKET: MODELLING AND EVALUATION

INTERNAL SUPERVISOR AND PROPOSED BY: A Malan Water propelled rockets are finding increased industrial application due to their inherent safety, short time intervals required to recharge and being exceptionally environmentally friendly. Of importance to effective operation is the optimal water-air ratio, as this is critical to determining flight height achievable. The aim of this project is to develop an effective Computational Fluid Dynamics (CFD) model to numerically model a water propelled rocket as well as build a simple rocket. The model is to quantify the dynamics of the thrust as well as the drag on the fuselage, in order to predict launch height achievable. For validation purposes, a simple rocket composed of a 2 litre bottle fuselage with fins for stability is to be designed and launched and the height achieved compared to predictions. Stability tests are to be carried out in the low speed wind tunnel. 132. WATER PROPELLED ROCKET LAUNCH MECHANISM

INTERNAL SUPERVISOR AND PROPOSED BY: A Malan

Water propelled rockets are finding increased industrial application due to their inherent safety, short time intervals required to recharge, and being exceptionally environmentally friendly. Of importance to effective operation are the release mechanisms, as it is to allow for both pressurisation of the rocket, as well as fast and effective release.

The aim of this project is the design of a cost effective launcher for a water-propelled rocket. Of importance are speed of release, weight implications (it is to be portable and add minimum weight to the rocket), safety, stable vertical launch and cost effectiveness. Construct various concept designs, select the most appropriate and perform a detailed design complete with manufacture cost estimate. Furnish production drawings of your design. 133. DEVELOPMENT OF A 6 LEGGED WALKING ROBOT

INTERNAL SUPERVISOR : T Booysen PROJECT PROPOSED BY: W Fong PROJECT PRE-ALLOCATED TO: W Fong (FNGWAI001)

The first prototype of a 6 legged robot was built in 2009 and incorporated 12 motors to produce a walking motion. In 2010 a second version was designed and built that had 18 motors, 3 on each leg. In 2011 the robot was further developed and is now made of aluminium and uses Dynamixel RX motors. The 2011 robot is controlled using Java and Python and the motors tend to fail due to torque overloads. This year the control software needs to be modified in order to use Labview. Both the motors and wireless link between the robot and host machine need to be run exclusively in Labview. The user interface needs to be refined so that proper testing of existing walking patterns can be done. If the robot continues to overload the motors, a change in control or mechanical design needs to be investigated. Pre/Co-requisite courses: MEC4053Z in 2012 134. BEARING FOR A ROTATING HINGE ARTIFICIAL KNEE

INTERNAL SUPERVISOR: G Vicatos PROJECT PROPOSED BY: S Tenim PROJECT PRE-ALLOCATED TO: S Temin (TMNSEV001)

The artificial knee, in patients who have received such an implant, has an increased stability when it can rotate in addition to the flexion that can provide. In this way, there are no stresses built up between the stems, the bone cement and the bone. This extra degree of freedom is provided by a universal type bearing, which is enclosed within the femoral part of the knee. However, in certain cases, there is very little space to ensure that such a bearing can be secured inside the artificial knee component, and a special locking mechanism needs to be designed. The task is to investigate the parameters involved for such a design, such as the ergonomics of the knee, the space available, the design of the bearing which can provide the necessary movement and the locking mechanism. Design, build and test a prototype of the locking mechanism. Set an experimental procedure, to measure the “pull out” force and the endurance of the bearing. 135. DESIGN, BUILD AND TEST A SHAKER TABLE

INTERNAL SUPERVISORS: G Nurick & V Balden PROJECT PROPOSED BY: V Balden & K McMahon PROJECT PRE-ALLOCATED TO: K McMahon (MCMKIM002)

The student will design, build and test a scale model of shaker table. The student will then alter various parameters and measure the response of the tables. Those parameters include table mass, suspension member angle, eccentric drive, motor speed and suspension member stiffness. The student will also produce simple mathematical models and finite element analysis of the table to explain the observed behaviour. Pre/Co-requisite courses: FEM

INDIVIDIUAL LABORATORY/RESEARCH PROJECT – 2012

PROJECT PROPOSALS MEC4061Z

Please select five projects from the distributed list and return this completed form to A/Prof C von Klemperer (Room 204) by mid-day on Thursday 26 April 2012. NAME: ………………………………… STUDENT NUMBER: ……………………

PROGRAMME: (Circle one)

MECHANICAL or ELECTRO-MECHANICAL

SELECTION

PROJECT NUMBER

1

2

3

4

5.

If you have a pre-allocated project please put project number in selection 1 and write “Pre-allocated” next to it. Project Submission by 12h00 on Tuesday 23 October 2012. As well as a hard copy of your project report, an electronic copy on a CD-Rom disc must also be submitted with your name, year and project title on it. SIGNED: ………………………….. DATE: ………………………………………