30 | ENDEAVOUR ENGINEERING AND IT EXHIBITION - Program Guide 2017

MECHANICAL ENGINEERING

Mechanical engineering focuses on turning energy into power and motion. Using human and material resources, this discipline looks at the design, construction, operation and maintenance of machines and devices to create a more efficient world.

MUR-E chassis Nimo Li, Brad ZhuChassis is primarily responsible for the design, optimisation and manufacture of the electric car’s main frame, which is a steel spaceframe. This is executed with heavy use of finite element analysis. Chassis is also responsible for the design and manufacture of the car’s steering mount, managing driver ergonomics and the overall safety of the driver and car appropriately.

MUR-E steering and suspension Prateek Gupta, Menqi Yan, Timothy WongThe steering and suspension team is broadly responsible for steering linkages and dynamic handling of the electric car. Specifically, this team is responsible for the design and manufacture of a system tailor-made for amateur drivers, which regulates and controls tyre contact to maximise cornering performance. These responsibilities are met through the use of high technical knowledge of springs, anti-roll bars and geometric principles.

MUR-E brakes, drivetrain and thermal systems

Nitin Jayswal, Barry Yang, Zhao Li, Tashdid TahmidThis team is primarily responsible for the design and manufacture of the brakes, drivetrain and thermal systems of the electric car. Specifically, the team designed and implemented a brake system, pedal box and all drivetrain components linking the gearbox and the rear wheels. Its thermal system is concerned with maintaining the car’s motor, inverter and accumulator temperature within a range that allows for optimal performance of the car.

MUR coordination Andrew Pham, Nisha Nijhar, Luke BofingerCoordination oversees the project management of both MUR’s combustion and electric vehicles, and manages all non-technical aspects of both projects. This includes organising finances, procuring sponsorship, improving faculty relations, expanding marketing efforts and holding events.

MUR-C integration Buddhi Mendis, Samuel Vuillermin, Tim MurphyIntegration is the technical management team for the combustion car. Responsibilities include producing a reliable, driveable and well-tested car, computer-aided design management and verification to ensure Formula SAE rules compliance while maintaining a safe environment throughout the project, and managing manufacture, fabrication and procurement of components.

MUR-C brakes and drivetrain Brendan Giang, Ahmed Fayyaz, Umar Ashraf, Bilal AbdullahThis team implemented and tested the brakes and drivetrain system of the combustion car. This entails the development of a drivetrain that can efficiently transmit power from the engine to the wheels whilst balancing performance needs, and a braking system that is characterised by controlled and effective deceleration. Also within the scope of the team is the design and implementation of a pedal box, as well as a clutch and gear selection mechanism.

MUR-C engine Andrew Zammit, Kenneth Huang, Zhen Vhen Chang, Shamit DahakeThe engine team is primarily responsible for selection, maintenance and optimisation of the combustion car’s engine, as well as managing the cooling, lubrication and fuel systems of the car. This team is also responsible for the car’s overall wiring loom design as well as the data logging system, all sensor systems and wireless communications between the car and track crew.

MUR-C chassis Albert Chang, Shengjie Yu, Somesh KaushalChassis is primarily responsible for the design, optimisation and manufacture of the combustion car’s main frame - this year, a carbon fibre monocoque. This is executed with heavy use of finite element analysis and vast knowledge of composite materials. Chassis is also responsible for design and manufacture of the car’s steering mount, managing driver ergonomics and the overall safety of the driver and car appropriately.

MUR-C steering and suspension Jay Honey, Zac EvansSteering and Suspension is broadly responsible for steering linkages and dynamic handling of the combustion car. Specifically, this team is responsible for the design and manufacture of a system tailor-made for amateur drivers, that regulates and controls tyre contact to maximise cornering performance. These responsibilities are met through the use of high technical knowledge of springs, anti-roll bars and geometric principles

MUR-C aerodynamics Andrew Chak, Harrison TraversAerodynamics is responsible for the design, optimisation and manufacture of a full carbon fibre aerodynamics package for the combustion car. The package includes a front wing, rear wing, body kit, and undertray. The team meets its responsibilities with a heavy reliance on computational fluid dynamics and track validation.

Design and build of low noise airfoils

Mark Thomas, Daniel Link, Sinu Sen, Michael KellyWith the recent upsurge in unmanned aerial vehicles (UAVs), concerns about noise pollution in residential areas are becoming increasingly relevant. This project conducts research into the existing literature on noise reduction techniques by aiming for a meaningful reduction in tip vortices and trailing edge wake via the implementation of serrated trailing edges. Following a theoretical basis for serration design, a series of configurations are to be tested at low Reynolds number and static RPM against a reference NACA 6409 aerofoil. Rapid prototyping of the reference and varied rotors will be completed using a 3D printer. Experimental results involve the produced sound pressure level (dB) and Power Spectral Density analysis, where a noise reduction in the range of sensitive human hearing (1-4 kHz) and maintained lift performance are the key criteria of a successful design.

Noise reduction in high aspect ratio slot jets

Edward Rasmussen, James Gregory, Blagoj Josifovski, Ben AndersonJet mixing noise arises from turbulent structures which form at the interface between high velocity flow from a jet outlet and the ambient air. While considerable research has gone into reduction of this noise in circular jets, no such study exists for the quasi-2D flows from rectangular jets at high aspect ratios. Serrated nozzle outlets are known to break up the aforementioned structures, resulting in less audible noise to the human ear. This project tested a number of 3D printed serration profiles on a 200x1mm slot jet, and analysed the resulting noise distributions relative to a flat profile. This research has its principal application in commercial hand dryers found in public restrooms.

Wakes evolution analysis for wind turbine blade design

He Yang, Yifan Lyu, Gu Zhang, Xiang YangThe current design of wind-turbine blade is not reliable in storm conditions. In order to improve the blade design, simplified two-dimensional wind-turbine blades will be placed in the wind tunnel then the measurements of velocity and drag will be carried out. Based on that, analysis and improvements will be made.

Development of a musculoskeletal model of child’s neck

Peixuan Wu, Wankai Chen, Huanxin ZhangMusculoskeletal modelling is used to evaluate muscle and joint loading since it is difficult or impossible to perform such measurements on human subjects non-invasively. At present, little is understood about the function of the neck in children. Children are particularly vulnerable to head and neck injury during motorcycle and bicycle accidents. The objective of this study is to adapt an existing musculoskeletal model of an adult to the anatomy of a child to perform simulations of human movement using an open-source software package (OpenSim, StimTK). The muscle and joint force data output will provide insights into neck function in children, and indicate how head and neck injury may be prevented.

Computational fluid dynamics modelling of a dual rotor blade system

Isabella Filmer, Lukas MichelComputational fluid dynamics, more specifically, ANSYS Fluent, has been used to simulate air flow through a dual (coaxial) rotor blade system of a helicopter. Prior research has focused on single rotor systems, with limited research conducted on coaxial systems. With the proposal of this technology to be used in future military applications, the performance of helicopters with additional rotors requires further understanding and research. This project examines the performance of dual rotor systems when compared to single rotor systems in common flight scenarios (including hover and forward flight).

Visualisation of impinging supersonic jet flow under varying jet structures

Yifan Zhang, Xinbei Dou, Yan He, Yiou ChenThe objective of the project is to visualise the property changes in supersonic impinging jet flows with different jet structures using OpenFOAM, a software for fluid simulation. Jets with infinite lips would have a stagnation zone in its flow cells and that low speed zone does not appear in jet flows with thin jet lips. This project seeks to reform and find out the stagnation zone formation mechanism, especially its relationship with lip thickness and stand-off distance, and investigate its importance to acoustic feedback phenomena in impinging jet flow.

3D printed bones for patients (foot bone)

Weitao Chen, Zhi Liao, Jingyuan JiangThis project aims to help people suffering from sesamoid bone fractures. Sesamoid bone fractures can cause long-term disability for athletes and non-athletes. While a 3D printed bone graft could help people with sesamoid bone fractures, no precedent exists. In order to maximise bone graft benefits and reduce possible hazards, this project carried out simulations of the stress distribution for the human foot system around the sesamoid bone with different graft methods and subjects.

Improved manufacture of vibrating rollers for printing

Jordan Ignatiadis, Jen Zen HoThe team was tasked with improving the process by which banknotes and passports are printed. Currently, the manufacturing process involves cutting rollers with a hand lathe. This can cause offsets of several millimetres leading to difficulties in meeting customer requirements. Due to the precision required in the banknote industry this can often mean unacceptable spoilage. We have developed a novel and innovative approach by utilising a digital design format to manufacture the rollers to micrometre precision. This has the potential to greatly decrease the time and cost involved in manufacturing the rollers while satisfying stringent accuracy requirements.

The Grand Bridge Challenge Junlin Ci, Xu Han, Thomas Touma, Chen YangThe ‘Grand Bridge Challenge’ project seeks to analyse, design and construct a bridge passing over a varying muddy to dry creek bed of offset elevation. The bridge is designed to be easily construct by a single, average sized human; mobile within reason if necessary and able to support masses of up to roughly 700kg of live weight. The client also specifically requires sufficient width allowance to pass a ride on lawn mower across. The span shall be from two to three metres, depending on the varying creek bed spans.

MB sports drivetrain analysis Lincoln Reeves, Jens Orda, Gonzalo Bueno del AmoThe 2015 MB F21 Tomcat was one of the first boats to use a V-Drive. Providing many advantages such as a more compact design and better weight distribution, the original design featured a drivetrain-coupling arrangement which regularly faced critical material failure.

This project provides a redesigned coupling arrangement and drivetrain keyway, ensuring the originally intended infinite life span of the V-Drive coupling and allowing for easier disassembly. Additionally, an insight into national standards of keyways in pleasure craft design is provided, pointing out the origin of the designs flaw.

FREO2 Aqua Kevin Rassool, Katrina Bigelow, Drishtant Kapur, Andy Fu, Shahed Mahmood SyedFREO2 Foundation is a not-for-profit health technology start-up and has developed a world first electricity-free oxygen concentrator, FREO2 Siphon, designed to treat pneumonia in developing countries, the number one infectious disease killer of children in the world. To explore further applications for this technology, the FREO2 Foundation has formed a partnership with Green Camel, an innovative aquaculture company in Sydney to evaluate the feasibility of using FREO2 Siphon to provide oxygen for their barramundi farm. This student project has been awarded the ‘2017 Science and Innovation Award’ for aquaculture and secured funding from the Department of Agriculture to construct and install a prototype of FREO2 Siphon at the Green Camel facility. More information can be found at freo2.org.

Underwater image-based surface scanner

James Ogilvie, Michael Henning, Ye Tian, Matthew ViccarsThere are an estimated 90,000 ships in service globally, consuming up to 8% of the world’s oil production. Biofouling, (the build-up of marine organisms), increases drag on a ship’s hull, which in extreme cases is estimated to increase fuel use by up to 80%. Presently biofouling levels are only crudely estimated, however hull cleaning is expensive and companies must balance the cost of cleaning over the resultant fuel saving, likely resulting in sub-optimal management. This project is developing a low cost, high accuracy, 3D image based underwater surface scanner which a diver can use to assess a hull’s condition without putting the ship into dry dock. This represents the next step in improved biofouling management helping to increase shipping efficiency, save fuel and reduce emissions.

Modelling and control of cavity oscillations

Michael Xie, Shiqing Zhang, Lu Zhou, Riyan ZhousFlow past a cavity will produce acoustic waves. In aerospace applications, these oscillations, if left uncontrolled, can lead to fuselage damage. However, the complexity of cavity oscillations poses a dilemma when attempting to control them. On one hand, models derived from first principles can accurately describe the phenomenon, but are difficult to analyse for control. On the other hand, empirical models are easier to analyse, but do not capture the physics, ultimately limiting the effect of controlling oscillations. This project aims to use accurate numerical simulations to develop a model that remains simple enough for quick and practical control.

Multicopter Project 2017 Matthew Churcher, Qin Xu, Jun GaoOur project is to design and build a retractable power tether system for a multicopter to be used for telecommunications purposes.

Thermodynamic analysis of dolar PV systems

Randika Yasas Dewage, Yi Xu, Zhengshen ChenThe project entails the completion of a solar panel test system being built over the last two years, which will be used to study the performance of the solar panel, and thereafter for coursework purposes as a laboratory session.

Western BACE: Night sky cooling and solar heating optimisation

Sathia Smith, Sam ColemanThe Night Sky Radiation Cooling and Solar Heating (NSRCSH) system has been designed to provide structural mass tempering for the Western Business Accelerator & Centre of Excellence (WBACE) in Melton, Victoria.

To assist the building’s main heating, ventilation and cooling (HVAC) systems, the NSRCSH system circulates cooled water during summer nights and heated water during winter days, through solar collectors on the roof and radiant piping embedded in the concrete slab.

As the system was installed as a trial and is yet to be tested, it is unknown whether any improvements to occupant comfort levels or energy savings for the building have been achieved. The optimisation project investigates the range of factors that affect the performance of the system and seeks to confirm the best working parameters to achieve optimum system efficiency.

Self-levelling hydrofoil sailing boat

Callum Castles, Nikhildev Mulakkal, Tam Hong, Yuliang LiuHydrofoils are wing-like structures that are mounted underneath the hull of sail boat. As the sail boat increases in speed, the hydrofoil will generate sufficient lift to raise the hull out of the water. This results in reduced wetted area, reduced drag, and increased speed performance of the sail boat. Due to changing sailing conditions such as wind direction, wind speed, and sea waves, hydrofoils require an active control mechanism that is either human or automatically operated in order to maintain optimum lift conditions so that the hull is sufficiently raised above water. The objective of this study is to design and build (scale prototype) hydrofoils for a sail boat that is self-levelling for optimum lift and has no moving parts to reduce the complexity of a self-levelling automated control system.

Energy intensity at Melbourne Zoo

Vivekananthan Karthikeyan, Muhammad Waqas, Haseeb Ahmed, Kunal GheekThis project conducted an energy audit of Melbourne Zoo with data collected and aligned to Zoos Victoria’s Hardcat Fixed Asset Management software. The data collected will then be used to produce heat maps with energy intensity of buildings and exhibits in the zoo. The current transformers will be used to validate the physical audits conducted. Thermal imaging will be conducted to investigate specific high consumption area. This information will then be used to expedite energy efficiency projects and serve as an internal and external benchmark for the various types of facilities in the zoo.

Tethered drone Wenqi Cai, Jovan Lazarov, Qiancheng WeiThis project intended to design, develop and build a medium-altitude hovering multicopter. This multicopter will be powered by a tether from the ground, with the aim to keep the multicopter hovering for long periods of time. The purpose is to provide an alternative to permanent mobile phone towers presenting a lower cost, in rural and remote less-technologically-developed countries.

Design of a 3D printed porous femoral implant

Alistair Jones, Steven DespotellisHip replacement surgery is one of the most common types of medical procedures worldwide, numbering in excess of 45,000 per year in Australia alone. Current implants use materials such as titanium that are much stiffer than bone, resulting in stress shielding, a phenomenon that causes bone resorption and a failure rate of nearly 50% after 10 years. This project explores the use of additive manufacturing to combat this issue by creating a porous implant with reduced stiffness. This project will focus on the optimal application of a lattice micro-structure to a femoral implant. The micro-structure is being developed in parallel by a biomedical engineering capstone project (Project name: Design and optimise microstructure of a porous femoral stem for hip implants using finite element analysis, see Biomedical Engineering list).