Engineering Technology Department Theses and Dissertations

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https://hdl.handle.net/1805/26267

Information about the Purdue School of Engineering and Technology Graduate Degree Programs available at IUPUI can be found at: http://www.engr.iupui.edu/academics.shtml

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Elliptic Integral Approach to Large Deflection in Cantilever Beams: Theory and Validation
(2024-08) Shah, Arpit Samir; Dalir, Hamid; Tovar, Andres; Koskie , Sarah
This thesis investigates the large deflection behavior of cantilever beams under various configurations and loading conditions. The primary objective is to uset an analytical model using elliptic integrals to solve the second-order non-linear differential equations that govern the deflection of these beams. The analytical model is implemented in Python and compared against Finite Element Analysis (FEA) results obtained from ANSYS, ensuring the accuracy and reliability of the model. The study examines multiple beam configurations, including straight and inclined beams, with both free and fixed tip slopes. Sensitivity analysis is conducted to assess the impact of key parameters, such as Young’s modulus, beam height, width, and length, on the deflection behavior. This analysis reveals critical insights into how variations in material properties and geometric dimensions affect beam performance. A detailed error analysis using Root Mean Square Error (RMSE) is performed to compare the analytical model's predictions with the FEA results. The error analysis highlights any discrepancies, demonstrating the robustness of the analytical approach. The results show that the analytical model, based on elliptic integrals, closely matches the FEA results across a range of configurations and loading scenarios. The insights gained from this study can be applied to optimize the design of cantilever beams in various engineering applications, including prosthetics, robotics, and structural components. Overall, this research provides a comprehensive understanding of the large deflection behavior of cantilever beams and offers a reliable analytical tool for engineers to predict beam performance under different conditions. The integration of Python-based numerical methods with classical elliptic integral solutions presents a useful approach that enhances the precision and applicability of beam deflection analysis.
Design, Analysis and Implementation of the Power Train of an Electric Race Car
(2024-05) Bhargava, Ayush; Dalir, Hamid; Tovar, Andres; Agarwal, Mangilal
The automotive industry has witnessed a significant transformation in recent years, largely driven by the emergence of electric powertrains. These systems offer a cleaner and more efficient alternative to traditional internal combustion engines, marking a pivotal shift towards sustainability in the transportation sector. At the heart of electric vehicles (EVs) lies the powertrain, a complex assembly of components tasked with converting electrical energy into mechanical power to propel the vehicle. In the context of electric race cars, the design and optimization of the powertrain are of utmost importance to achieve high performance on the track. The powertrain typically consists of four major components: the motor, inverter, battery, and gearbox. Each of these components plays a critical role in ensuring the efficient conversion and utilization of electrical energy to drive the vehicle forward. The process of designing an electric race car powertrain begins with a thorough understanding and explanation of each component's function and contribution to overall performance. This foundational understanding serves as the basis for subsequent analysis and optimization efforts. Central to the design process is the selection and configuration of the motor and battery, two key components that heavily influence the vehicle's performance characteristics. To facilitate this decision-making process, engineers leverage specialized software tools such as OptimumLap, MATLAB, and Simulink. OptimumLap allows engineers to input relevant parameters of the race car, such as its drag coefficient and frontal area, to gain insights into its aerodynamic performance. By conducting simulations on specific race tracks, such as the Adelaide circuit, engineers can generate valuable data representing the vehicle's performance in terms of lap times and speed. MATLAB's Grabit tool is then utilized to extract velocity data from the simulation results, providing crucial input for further analysis. This data is used to create a comprehensive table of values representing the vehicle's velocity profile under different conditions. Finally, engineers develop a Simulink model to simulate the operation of the electric powertrain under various scenarios. This model allows for the extraction of critical performance metrics and parameters, enabling engineers to optimize the motor and battery configuration to meet the specific requirements and constraints of the race car.
Vibrating Plate Design: Exploring Dynamic Requirements
(2024-05) Ahire, Meehir Mohan; Dalir, Hamid; Agarwal, Mangilal; Tover, Andres
This study encompasses the design and dynamic analysis of a previously used compact, portable vibrating plate machine. Utilizing Siemens NX 2021 for the precise modeling of the machine's components, the design prioritized simplicity and functionality, resulting in a 450 mm x 450 mm aluminum alloy structure, suitable for a wide range of research applications. A detailed modal analysis, conducted to ascertain the system's natural frequencies, revealed six predominant modes, ensuring operational frequencies of 110 Hz to 130 Hz were strategically avoided to mitigate resonance risks. Complementing this, harmonic response analysis evaluated the system's behavior under an applied cyclic load, confirming the suitability of the chosen actuator, model VL181206-160H, which provides optimal vibrational force without overstressing the machine. The findings affirm the machine's capability to perform efficiently within the target frequency range, with the design and selected actuator offering a robust solution for consistent and safe vibrational analysis, essential for field and laboratory applications.
Electric Sports Car Preliminary Design (Performance Envelope)
(2024-05) Alsyoof, Mohammad; Dalir, Hamid; Tovar, Andres; Anwar, Sohel
Car design is a complex task because of how highly integrated system of systems it is. Fine designed car models take years of design and optimization and are usually done by specialty teams who are dedicated to each sub-system. This thesis delves into designing a simplified electric race car from scratch with focus on the performance envelope of it. First, a 3D CAD model was done using SolidWorks. That section deals with spatial engineering and strategic placement of major car components for best performance. Having most of the parts in place gives a rough estimate of CoG (Center of Gravity) location, which is needed for vehicle dynamics analysis, which are discussed later in the report. The target for this project car is to have innovative aerodynamics features which might not have been used before because of bulky internal combustion engines restricting available space. One of them is an airfoil-like fascia which makes the center part of the car act as a one big wing. That is believed to give a significant reduction in drag loads on the car. The approach for aerodynamics design and analysis started with a model representing the car’s OML (Outer Mold line) which was simulated separately using Siemens StarCCM+. After understanding the car’s body aero behavior, a rear wing was added to provide extra rear downforce for better handling and stability. The rear wing design was explained in detail. Unfortunately, due to time restrictions as well as software access issues, the aerodynamic analysis of the full car with rear wing is left for future work. After having an estimate about aero loads acting on the car, vehicle dynamics analysis could start. The first subject studied in vehicle dynamics was front-view suspension geometry analysis. Taking the available packaging and geometry into consideration, a 2D model was done in SolidWorks to optimize camber gain. This analysis gave the motion ratio of the front and rear pushrod suspension system which was needed to analyze the performance of the one-eighth car model, ½ car pitch model, and ½ car roll model. These models gave insights into the decision-making process for spring and damping rates to reach a good balance between performance and comfort. This project acts as a hub for further development and studies related to car design.
Rectilinear Performance Model For An Electric Indycar
(2024-05) Singh, Hemant Brijpal; Dalir, Hamid; Tovar, Andres; Agarwal, Mangilal
This motorsport thesis explores the complete electrification of an IndyCar by simulations. Initial research was conducted on stock IndyCar specifications, and concurrently, a sequential approach was developed for MATLAB-based simulations to generate comprehensive results. The study aims to integrate extensive insights gained from courses such as Vehicle Dynamics, Aerodynamics, Data Acquisition, and Electric Powertrains, alongside practical experience from racing internships. The goal is to comprehend the impact of this conversion on engineering parameters. The analysis specifically emphasizes the engineering aspects, with a particular focus on the longitudinal dynamics of the vehicle through quarter-mile simulations.
Advances in Vehicular Aerodynamics
(2024-05) Dave, Deepam; Dalir, Hamid; El-Mounayri, Hazim A.; Tovar, Andres; Anwar, Sohel
This article-based research traces the evolution and advancements of vehicular aerodynamic concepts and emphasizes on the significance of vehicle aerodynamics for high-performance vehicles. The thesis further explores the scope of integrating advanced vehicle aerodynamic concepts into consumer vehicles. The thesis aims to point out the significant improvements achieved with the integration of active aerodynamic concepts in terms of both vehicle performance as well as efficiency figures for consumer vehicles. Additionally, exploring the scope for the development of these advanced active aerodynamic systems as third-party modifications is the secondary objective of the presented research. The thesis also highlights the development and integration of unique active aerodynamic systems featured in performance vehicles and analyzes the performance gains achieved using MATLAB program-based simulations supported by a graphical representation of analyzed output data. The study of Active aerodynamic systems for both performance/track-oriented and consumer vehicles remains the primary emphasis for the presented thesis.
Cellulose Nano Fibers Infused Polylactic Acid Using the Process of Twin Screw Melt Extrusion for 3d Printing Applications
(2023-05) Bhaganagar, Siddharth; Dalir, Hamid; Agarwal, Mangilal; Zhang, Jing
In this thesis, cellulose nanofiber (CNF) reinforced polylactic acid (PLA) filaments were produced for 3D printing applications using melt extrusion. The use of CNF reinforcement has the potential to improve the mechanical properties of PLA, making it a more suitable material for various 3D printing applications. To produce the nanocomposites, a master batch with a high concentration of CNFs was premixed with PLA, and then diluted to final concentrations of 1, 3, and 5 wt% during the extrusion process. The dilution was carried out to assess the effects of varying CNF concentrations on the morphology and mechanical properties of the composites. The results showed that the addition of 3 wt.% CNF significantly enhanced the mechanical properties of the PLA composites. Specifically, the tensile strength increased by 77.7%, the compressive strength increased by 62.7%, and the flexural strength increased by 60.2%. These findings demonstrate that the melt extrusion of CNF reinforced PLA filaments is a viable approach for producing nanocomposites with improved mechanical properties for 3D printing applications. In conclusion, the study highlights the potential of CNF reinforcement in improving the mechanical properties of PLA for 3D printing applications. The results can provide valuable information for researchers and industries in the field of 3D printing and materials science, as well as support the development of more advanced and sustainable 3D printing materials.
Tire Deformation Modeling and Effect on Aerodynamic Performance of a P2 Race Car
(2021-08) Livny, Rotem; Dalir, Hamid; Borm, Andy; Finch, Chris
The development work of a race car revolves around numerous goals such as drag reduction, maximizing downforce and side force, and maintaining balance. Commonly, these goals are to be met at the same time thus increasing the level of difficulty to achieve them. The methods for data acquisitions available to a race team during the season is mostly limited to wind tunnel testing and computational fluid dynamics, both of which are being heavily regulated by sanctioning bodies. While these methods enable data collection on a regular basis with repeat-ability they are still only a simulation, and as such they come with some margin of error due to a number of factors. A significant factor for correlation error is the effect of tires on the flow field around the vehicle. This error is a product of a number of deficiencies in the simulations such as inability to capture loaded radius, contact patch deformation in Y direction, sidewall deformation and overall shifts in tire dimensions. These deficiencies are evident in most WT testing yet can be captured in CFD. It is unknown just how much they do affect the aerodynamics performance of the car. That aside, it is very difficult to correlate those findings as most correlation work is done at WT which has been said to be insufficient with regards to tire effect modeling. Some work had been published on the effect of tire deformation on race car aerodynamics, showing a large contribution to performance as the wake from the front tires moves downstream to interact with body components. Yet the work done so far focuses mostly on open wheel race cars where the tire and wheel assembly is completely exposed in all directions, suggesting a large effect on aerodynamics. This study bridges the gap between understanding the effects of tire deformation on race car aerodynamics on open wheel race cars and closed wheel race cars. The vehicle in question is a hybrid of the two, exhibiting flow features that are common to closed wheel race cars due to each tire being fully enclosed from front and top. At the same time the vehicle is presenting the downstream wake effect similar to the one in open wheel race cars as the rear of the wheelhouse is open. This is done by introducing a deformable tire model using FEA commercial code. A methodology for quick and accurate model generation is presented to properly represent true tire dimensions, contact patch size and shape, and deformed dimension, all while maintaining design flexibility as the model allows for different inflation pressures to be simulated. A file system is offered to produce CFD watertight STL files that can easily be imported to a CFD analysis, while the analysis itself presents the forces and flow structures effected by incorporating tire deformation to the model. An inflation pressure sweep is added to the study in order to evaluate the influence of tire stiffness on deformation and how this results in aerodynamic gain or loss. A comparison between wind tunnel correlation domain to a curved domain is done to describe the sensitivity each domain has with regards to tire deformation, as each of them provides a different approach to simulating a cornering condition. The Study suggests introducing tire deformation has a substantial effect on the flow field increasing both drag and downforce.In addition, flow patterns are revealed that can be capitalized by designing for specific cornering condition tire geometry. A deformed tire model offers more stable results under curved and yawed flow. Moreover, the curved domain presents a completely different side force value for both deformed and rigid tires with some downforce distribution sensitivity due to inflation pressure.

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