Case Studies

Torque converter multiplies the torque when there is a substantial difference between engine and transmission rotational speed. Thus, providing an equivalent of a reduced gear. Moreover, the continuous development of transmission for various combat vehicles has led to the need for developing a design procedure for torque converter for various power ratings. In this project, torque converter design methodology is finalized and a standalone program - SASTCD.exe is developed using available open source software. The proposed design code for the development of torque converter facilitated better understanding of the flow field inside the converter to minimize the flow losses leading to improved overall performance of torque converter. This research project has resulted in to development of highly competent code for design of different ranges of torque converter.

This research is aimed at Kinematic and Dynamic Analysis with Trajectory Planning and FEA of the Arm Assembly of Mobile Manipulator mounted on an Armed Tank. The mine detection manipulator system mounted on an reconnaissance tank comprises of two serial manipulators working together as a dual-arm cooperative manipulator and carries the GPR, vapor detection and LIDAR sensors, the former two sensors detects for the presence of mines buried underneath the ground surface and the latter measures the distance from ground.
The operation of the mine detection manipulator involves detection of mines while the tank is in the motion by swinging the sensor assembly linearly sideways to increase its coverage area while also maintaining the optimal ground clearance by dynamically adapting to the unpredictable terrain. During off duty the manipulator assembly is fold and rest on the tank for its safety and deployed to its ready pose when needed.

In this work, optimization of a brushless direct current (BLDC) generator design was undertaken by carrying out an electromagnetic and computational fluid dynamic study. The studies were carried out for different loading-overloading conditions and angular speeds, keeping in consideration the required electrical and thermal parameters, firstly for the initial design and then for optimized designs. In the initial phase, transient electromagnetic simulations were done using Ansys Maxwell to estimate power output, flux densities, heat losses et al. In the next phase, steady state conjugate heat transfer simulations using frozen rotor method for rotating domains were carried out in Ansys CFX using the heat loss values obtained from electromagnetic study in the first phase. The results from conjugate heat transfer were obtained in the form of temperature and flow parameters. After a thorough study and comparison of the results for different designs, obtained in the two phases, it was seen one of the optimized designs showed better electromagnetic, thermal and flow parameters as compared to the initial design and satisfied all the optimum electrical and thermal parameters.

All aircraft components are vulnerable to bird impact and hence, it becomes necessary for the components to be designed against bird impact. In spite of the experimental technique being a foolproof method of testing a component after preliminary design, the huge cost and time involved renders the technique, impractical. Hence it is required to develop a reliable methodology using finite element analysis to simulate the bird hit event. Bird impact on aircraft is a soft body impact, which is very much different from elastic impact. Accurate numerical solution demands the proper selection of the parameters such as the shape of bird projectile, density of a bird material and length to diameter ratio, before simulating the bird impact analysis. This project investigates the influence of impact angle and impact velocity in the structural response. Two different size of bird has been simulated as hemispherical ended projectile with gelatine as material. Simulation has been performed in LS-Dyna.

A safety helmet is a type of helmet predominantly used in workplace environments, such as construction sites/mining industries, to protect the head from injury by falling objects, impact with other objects, debris, bad weather and electric shock. Helmet inner construction consist of suspension that spreads the helmet's weight over the top of the head. It also provides a space between the helmet's shell and the wearer's head so that if an object strikes the shell, the impact is less likely to be transmitted directly to the skull. Sometimes the helmet shell has a mid-line reinforcement ridge, which strengthens it against impact. At RUAS-Techno Centre Engineering, a safety helmet for one of the private industry is designed by the consideration of safety, aesthetics and sturdy look with cost effectiveness.
Latest trends and need for safety helmets was gathered from market survey. More than 5 concepts are generated and finally the above shown concept was finalized. Impact and penetration test were simulated as per as BIS standard using FEA tool-LS-Dyna and designed helmet shows satisfactory results for standard test procedure. Materials(HDPE+EVA+Talc powder) for safety helmet construction was also suggested by keeping cost effectiveness criteria.

The Guide Vane Mechanism is used to control the airflow through the aircraft engine. The mechanism consists of an actuation system and three individual stages. The actuation system consists of two actuators (master and slave). An individual stage of GM system consists of vanes, which are distributed radially around the circumference of the engine, which each of vane connected to an actuating lever. All of the actuating levers are connected to the actuating ring through spherical bearings. The actuating ring rotates about the axis of the engine by connectors from the actuation systems. As the actuating ring is rotated, all of the vanes should rotate an equal amount.
The Guide Vane Mechanism is subjected to various loading conditions. Hence it is very important to evaluate the structure of the GM through various analyses. Kinematic analysis, Link length optimization, Dynamic analysis & Finite element Analysis of Guide Vane Mechanism for the given different input condition was carried out.

The helicopter borne under-slung assembly is composed of a system of concentric transmitter, bucking and receiver coils in tubular housings all held in place by a system of suspension and radial ropes. In flight, the entire assembly is in equilibrium under aerodynamic and gravitational loads. The assembly thus is likely prone to aero-elastic instabilities such as buffeting.
Dynamic aero-elastic characteristics such as flutter are known to depend on the underlying modal characteristics in coupled flow. For vortex-shedding phenomena however, in-vacuo modal characteristics typically govern the associated critical flow speeds. Accordingly the present study is aimed at obtaining modal solutions of the under-slung assembly in-vacuo.
The FE solutions have been satisfactorily correlated with hand estimates of modal frequencies wherever feasible. Both FE solutions and hand estimates have been obtained to fulfill wind tunnel test requirements.