Air manifold optimization

Air manifold optimization

A request was made to optimize a manifold that is creates a screen of moving air to take away smoke out of the air. A constant flow distribution is desired at the blower and suction manifold. Due to geometric constraints the air cannot be blown or sucked perpendicular to the outlet and inlet region. The angled geometry creates a non-uniform flow throughout the manifold system. Aerodynamic shaped fins and ratios between certain areas are inserted to create the required inlet and outlet velocity profile. Design 30% Simulation 50% Post-processing...
The engineering of a boat sculpture

The engineering of a boat sculpture

I was asked by Asher Kelman, the artist of the sculpture, to help with the engineering of a boat sculpture. A project that was still in the starting phase. Initially my tasks where the flow simulations, calculating the pressure at the boat, sail and its frame and the engineering of the internal frame construction. This quickly led to the engineering of the whole sculpture. A sculpture that will be 31 ft high and 17 ft long! A most impressive sculpture that will be located at the sculpture garden in Los Angeles. The sailboat´s hull was planned to be made of wood, with a steel internal frame for strength. However due to the extensive costs and time of making the hull out of wood, this has changed to a steel rim. Steel is the main material used in this sculpture. The selection of steel is of most importance, different composition of steel can have different mechanical and chemical properties, with all a different price. Some parts required a higher strength, less elastic strain and other parts require a No 8. polished stainless finish. One of the points of attention is the corrosion resistance of the sculpture. The sculpture will be located close to the coast, where the air is humid and contains a high level of salt. As salt breaks down, the chloride ion of the salt increases the conductivity of the electrolyte and therefore increasing the galvanic corrosion. A most used combination of galvanized carbon steel and stainless. Where the contact between both steel is separated with composite washers and bushings, this to avoid electric potential difference between the...
Non-linear dynamic analyses of rolling steel sheet

Non-linear dynamic analyses of rolling steel sheet

A simulation setup has been made to find the acting forces on a roller for bending sheet metal. This machine is going to be used in a machine factory in Bulgaria. This to help a previous project colleague getting started with the further dynamic simulations. SheetRolling Design 30% Simulation...
Redesign and FEM optimization of a staff connector

Redesign and FEM optimization of a staff connector

A company that designs, develops and manufactures equipment for jugglers and other artist alike. A connector unit to add 4 fire staffs to a main staff was developed and new design changes had been made, however the new design did not work and I was contacted to provide FEM strength calculations for the current design and find the solution to make it work. Also if the new solution was proven to be successful a new design needed to be made. The general idea is a connector unit existing out of 2 parts, that can be screwed together into one piece to hold the staff and the fire staffs. The first concept was screwed together by two bolts, however the new concept should allow to connect the two parts with a hook mechanism, so you only need one bolt to screw the parts together. A simulation has been made and a new concept including a different material choice has been provided. Design 60% FEM 30% Engineering...
Engineering a cutting blade design for a robotic lawn mower

Engineering a cutting blade design for a robotic lawn mower

The scope of this project was the design and engineering of a cutting blade and guard design to fit on newly developed robotic lawn mower. At the start of the project a set of requirements were noted. 1. Blade and guard fits within existing frame with minimal modification. 2. A 7″ blade. 3. Blade accelerates to cutting speed within 2s. 4. Blade stops within 0.5s. (Ideally faster.) 5. Blade has linear speed of 7000 to 19,000 feet per minute. 6. The blade should generate enough lift to lift wet grass. 7. The blade should mulch grass clippings. 8. The guard should not accumulate excessive clippings. 9. Rocks and other debris are not thrown with excessive force and are contained. 10. Blade does not get tangled up in tall grass. 11. Cutting height can be manually controlled from 1″ to 4″. 12. We would prefer a quieter and more energy efficient system. 13. Blades should be very low cost to manufacture. I suggest injection molding using nylon with 50% glass fiber and not requiring any inserts. 1 month of heavy cutting would be an acceptable blade life. (More is great too.) The last significant requirement is that I want a blade that is as intrinsically safe as possible. According to these requirements 3 concepts have been designed, engineered, developed and tested. Some of the requirements where conflicting with each other and had to be slightly changed to achieve the required results. The final blade has a low mass moment of inertia, good cutting properties, low energy consumption and grass mulching capabilities. While the guard is protecting the blade and is...