event report - DICE Foundation

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event report - DICE Foundation
POST EVENT REPORT
DICE AUTMOTOVE
Dec 16, 2014
SMME, NUST H-12
Table of Contents
Introduction ............................................................................................................................................ 2
Event Committees ................................................................................................................................... 4
Event activities/ Schedule ....................................................................................................................... 7
Names & details of Guest Speakers ........................................................................................................ 8
Details of Panel Discussion ..................................................................................................................... 8
Judges...................................................................................................................................................... 8
Judging Criteria ....................................................................................................................................... 9
Winner Teams ......................................................................................................................................... 9
Participating Teams............................................................................................................................... 10
Abstracts/Summary of the Registered Projects .................................................................................... 12
Participating Industries ......................................................................................................................... 24
DICE Automotive Post Event Write-Up ................................................................................................. 25
PHOTO GALLERY.................................................................................................................................... 26
1
Introduction
DICE Foundation is a non-profit organization, registered in Michigan, USA. The term DICE stands for
Distinguished Innovations, Collaboration and Entrepreneurship. The main objective of DICE
Foundation is to foster innovation culture in the Society. NUST School of Mechanical and
Manufacturing Engineering (SMME) and DICE Foundation jointly launched DICE Automotive event
which was held on Dec 16, 2014 in SMME at NUST main campus, H-12, Islamabad, Pakistan.
DICE Automotive is an Exhibition, Symposium and Competition that aimed to bring together the
academia and Industry. Its primary objective was to act as a pragmatic and focused platform for
automotive related innovations and for collaboration among academia, industry, government,
entrepreneurs and expatriate community on all matters pertaining to the growth of automotive sector
in Pakistan. The event also focused on mobilizing expatriate community to take advantage of their
expertise and experiences for the benefit of auto industry in Pakistan; and also to act as a Think Tank
to recommend automotive related strategies.
Participation in the event was open to all industry and research organization with their products /
projects and innovations. Student teams working on any automotive related research/Innovations,
from any HEC recognized degree awarding university/institute were also encouraged to participate by
showcasing their projects from the following topics:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Automotive Design & Manufacturing techniques
Fuels, Fuel Cells for Electric / Hybrid Vehicles
Systems and Methods for Economy improvement
Emissions
Advanced Materials for Vehicles
Automotive Electronics, Controls and Instrumentation
Ergonomic design of Automotive
Vehicle Dynamics
Active & Passive Safety
Human- Machine Interfacing
Automotive CFD Design / Analysis
Performance Enhancement
Motor Sports Engineering
Others (Thermal Design, Structural Design etc.)
To encourage participation the following prizes were offered to competitors.



First Prize: Cash Prize of Rs 100, 000 along with DICE-Automotive 2014 shields to the
winning team.
Second Prize: Cash Prize of Rs 60, 000 along with DICE-Automotive 2014 shields to the first
runner-up team.
Third Prize: Cash Prize of Rs 40, 000 along with DICE-Automotive 2014 shields to the second
runner-up team.
2
In addition to the prizes given to the winners teams, Rs 15000/- amount was given as an appreciation
prize to the each of the University who took part/participated in DICE Automotive 2014. Names of
these universities are:
Sr. No.
Name of Institute
1
HITEC University
2
NED University
3
COMSATS Institute Of Information
Technology, Sahiwal
4
Swedish College, Rahim Yar Khan
5
Ghulam Ishaq Khan Institute (GIKI)
6
Muhammad
Ali Jinnah University Islamabad
7
Rachna College of Engineering and Technology
A panel of academicians from leading universities adjudicated the submitted reports. While the final
project presentation and demonstration was evaluated by a panel of judges consisting of experts from
the industry.
3
Event Committees
DICE-Automotive 2014 Steering Committee
Patron in Chief: Engr. Mohammad Asghar, Rector NUST
Chairperson-Academia DICE-Automotive 2014: Dr. Abdul Ghafoor, Principal & Dean SMME
Chairperson-Industry DICE-Automotive 2014: Mr. Usman Malik, Chairman PAAPAM
DICE Foundation Chairman: Dr. Khurshid Qureshi, President DICE Foundation, USA
Chief Organizer DICE-Automotive 2014: Dr. Shahid Ikramullah Butt, HoD Mechanical Engg,
NUST-SMME
Deputy Chief Organizer DICE-Automotive 2014: Dr. Muhammad Sajid, Deputy HoD
Mechanical Engg, NUST-SMME
PCST Chairperson: Dr. Mudassir Asrar
HEC Liaison 1: Ms. Afsheen Akhtar
HEC Liaison 2: Ms Noshaba Awais, Deputy Director R&D
British Council Liason: Mr. Mohammad Ali
Chief Coordinator:
Team:
Lecturer Ammar Tariq, NUST-SMME
Lab Engineer Usman Abdullah
Finance Manager: Mr Tahir Mehmood, Account Officer, NUST-SMME
Note that several other planning & arrangement committees was also formed to lead specific
areas for event planning and arrangement such as:
1. Invitation Committee – Academics (student projects and speakers):
Lead:
Dr Mushtaq
Team:
Lec Jamal Saeed, DBA Ali Baig, PA Ikram, LE Umair Saleem
2. Invitation Committee – Industry (sponsorship, booths, participants, and speakers)
Lead:
Dr. Khalid Akhtar / Dr. Riaz Ahmed Mufti
Team:
Dr. Sami-ur-Rehman Shah, Lec Nabeel Younis
3. Media / Advertising Committee (including brochures / flyers / Banners / etc.)
Lead:
Lec Nabeel Younis
Team:
Usman Abdullah
4
4. Finance / Budget Committee
Lead:
Dr. Amir Mubashir
Team:
5. Evaluation Committee
Lead:
Dr. Muhammad Safdar
Dr Emad Ud Din
6. Boarding & Lodging committee (out of town student teams, speakers, guests)
Lead:
Engr. Farooq Azam Khan
7. Other Event Arrangement Committee(s):
Exhibit Booth Lead: Dr. Emad-ud-Din
Team:
Dr. Riaz Ahmed
8. Lead Organizers And Event Day Management
Lead Organizers (Lec. Ammar Tariq)
S. No Name
1
Tahir Iqbal
2
Muhammad Talha Naeem Rao
Designation
Session
Lead Organizer
ME 03 B
Assistant Lead Organizer ME 04 A
3
Awais Aziz
Assistant Lead Organizer
Incharge Participants (Dr. Sami ur Rehman / Lec. Usman Bhutta)
S. No Name
Designation
1
Syed Osama Bin Ahsan
Team Lead
2
Mubashar Ahmad
3
Hassam Bashir
4
Arsalan Thaheem
5
Syed Usama Mutahir
Publicity (Lec. Nabeel Younis / LE Usman Abdullah)
S. No Name
Department
1
Saifullah
Graphics
2
Muhammad Ahmed Amaan
Graphics
ME 04 A
3
Mohsin Qadoosi
Graphics
4
Maimoon Mazhar
Graphics
5
Syed Moiz Ashraf
Publication
6
Heena Tariq
Publication
Stalls (Dr. Amir Mubashir / Lec. Adnan Hanif)
S. No Name
Designation
1
Zain Fida
Team Lead
2
Ali Azfar
3
Fasihiullah
4
Raza Tariq
-
ME 05 A
ME 05 A
ME 04 A
ME 05 A
5
Session
ME 04 A
ME 04 B
ME 04 A
ME 04 A
ME 04 A
Session
ME 04 A
ME 04 A
Session
ME 03 A
ME 03 B
ME 04 B
ME 04 A
5
6
7
8
9
10
Usama Javed
Arsalan Mohsin
Hamza Rasheed
Zain ul Abideen Ayaz
Soban Khaliq
Muhammad Hanzala Munawar
-
ME 04 A
ME 04 A
ME 04 A
ME 05 A
ME 05 A
ME 06 B
11
M Uzman Hameed
Reception (AP Naeem / Dr. Nousheen / Dr. Safdar)
S. No Name
Designation
1
Abdul Waheed
Team Lead
2
Farhan Maqbool
3
Salman Sakandar
4
Umar Mukhtar
5
Ali Zahid Khan
6
Malik Waqar Zahoor Awan
7
Syed Basil Bukhari
8
Muhammad Azeem Ali
Evaluation (Dr. Emaduddin)
S. No Name
Designation
1
Rao Muhammad Danial
2
Ayesha Siddique
-
6
ME 05 A
Session
ME 03 A
ME 03 B
ME 04 B
ME 04 A
ME 04 B
ME 05 A
ME 05 A
ME 06 B
Session
ME 05 A
ME 05 A
Event activities/ Schedule
Timing
Inaugural Session
0830 : 1300
Registration
1000 : 1015
Guests To be Seated
1015 : 1020
Tilawat
1020 : 1030
Welcome Address by Dr. Abdul Ghafoor, Principal SMME
1030 : 1040
Keynote Speech by Dr. Khurshid - Introduction to DICE 2014
1040 : 1050
Address by Chief Guest
1055 : 1105
Presentation of Souvenir to Chief Guest
1105 : 1200
Visit of the Venue by the Guests
1200 : 1230
Refreshments
1230 : 1315
Evaluation of Students Projects
1315 : 1430
Lunch/Prayer break
1430 : 1545
Presentations by Guest Speaker / Projects Evaluation
1545 : 1600
Prayer Break
1600 : 1700
Panel Discussion: How Universities can contribute in the Development of our Auto
Industry / Project Evaluation
Prayer Break
1700 : 1730
Timing
Closing Ceremony
1730 : 1745
Guests To be Seated
1745 : 1750
Tilawat
1750 : 1800
Address by Dr. Abdul Ghafoor, Principal SMME - Summary of DICE 2014
1800 : 1810
Remarks on Competition by Chief Judge
1810 : 1830
Prize Distribution Ceremony
1830 : 1840
Address by Rector NUST
1840 : 1850
Address by The Chief Guest
1850 : 1855
Presentation of Souvenir to Chief Guest and Organizing Team
1855 : 1900
Note of Thanks by MOC
1905 : 1910
Group Photo with Chief Guest
1910 : 2000
Dinner
7
Names & details of Guest Speakers
1. Mr Imtiaz Rastgar
Chief Executive Rastgar Indutries
Title of Talk: Local Automotive Industry of Pakistan
2. Mr Iftikhar Ahmad
Vice Chairman PAAPAM
Title of Talk: Role of PAAPAM in support of indigenous Automotive Part
Development
3. Dr Riaz Ahmad Mufti
Director Research SMME-NUST
Title of Talk: Role of The Academia in supporting Local Automotive Industry
Details of Panel Discussion
The convener of the Panel Discussion Dr. Sami ur Rehman Shah raised the following questions and
asked the panelist Mr. Imtiaz Rastgar, Dr. Riaz Ahmad Mufti, Dr. Khurshid Qureshi, Dr. Abdul
Waheed, Iftikhar Ahmad to give their opinion on the said topics. The topics were:
How are Universities helping the industry in Pakistan?
Has publication in research journals helped the industry in Pakistan?
What are the incentives offered to the faculty members to do projects for the industry?
This panel discussion remained continued for one hour and each panelist was given appropriate time
to come conclude. At the end, there was a brief question answer session with the audience.
Judges
1. Afaq Ahmed
General Manager
Research & Development
Atlas Honda
2. Dr. Wasim Akram
Deputy Chief Manager
NESCOM
3. Nasir Ali
Manager
AARDIC, Heavy Industries Taxila
8
Judging Criteria
The projects were evaluated on by the judges on the basis of the following judgment criteria:
Key Points
Excellent Good Average Below average
1 Potential Impact on the local industry
20
15
10
5
2 Potential impact on the economy of the country
20
15
10
5
3 Project goals are successfully achieved
10
7.5
5
2.5
4 Effectiveness of the demonstration
10
7.5
5
2.5
Winner Teams
WINNER
1st Runner Up
2nd Runner Up
Experimental and
simulated
performance analysis
of parabolic trough
collector
Solar Electric Vehicle
(Rickshaw)
Comparison of
thermos mechanical
stresses produced in
work rolls during hot
and cold rolling of
cartridge brass 1101
SMME, NUST
Naveed Ahmad
Sarhad University of
Science & IT,
Peshawar
Muhammad
Fahim
UET Taxila
9
Osama Shakeel
Participating Teams
Sr.
No.
Project Name
Institute
Team Leader
1.
Improving Aermodynamics to Boost
Fuel Economy
SMME, NUST
Quratulain
2.
Design and fabrication of low cost fuel efficient one
seater vehicle
SMME, NUST
Farooq i Azam
3.
Formula Student Car
SMME, NUST
4.
Sand Casting Process Automation by Automatic Mold
Positioning
Experimental and simulated performance analysis of
parabolic trough collector
Design and Fabriaction of Test Bed for Compressed
Air Engines (CAE)
Compressed Air Vehicle (CAV)
SMME, NUST
Yahya Khan Niazi
Hanzla Khan
SMME, NUST
Naveed Ahmad
5.
6.
7.
Ibraheem Naeem
HITEC University
Ibraheem Naeem
HITEC University
8.
Design and Manufacturing of electromagnetic clutch
and automatic transmission
HITEC University
Hydroxy Kit
HITEC University
Khuram Yousaf
College of
Electrical and
Mechanical
Engineering,
NUST
NED University
Muhammad Nouman
12. dsPIC based Engine Control Unit (ECU) powered by
LabVIEW
SEECS, NUST
Asad Hameed
13. Design, Analysis and Fabrication of a super
lightweight chasis
COMSATS
Institute Of
Information
Technology,
Sahiwal
IT & Software
iFahja Limited
Zaid Iftikhar
15. To Fabricate Compressed Air Car
Swedish College,
Rahim Yar Khan
Waleed Ahmad
16. All-Terrain Vehicle
Ghulam Ishaq
Khan Institute
(GIKI)
Muhammad Usman
Sardar
9.
10. Design and Fabrication of Vehicle
Door using Composite Materials
11. Study the behavior of spring back effect high tensile
steel sheets.
14. Mobile App based Auto Security and Safety Device
10
Saud Idrees
Hassan Karim
A. H. Khalil
17. FPGA Based Adaptive Cruise Car
Control System
COMSATS
Institute Of
Information
Technology, Isb
Muhammad
Ali Jinnah
University
Islamabad
COMSATS
Institute Of
Information
Technology,
Sahiwal
COMSATS
Institute Of
Information
Technology,
Sahiwal
COMSATS
Institute Of
Information
Technology,
Sahiwal
18. Automotive Spark Ignited Engine
Idle Speed Control System
19. Active and passive safety in the
Automobile
20. CFD Design Analysis for the sports
vehicles to decrease the failure of
the design
21. Automotive Design and manufacturing
Techniques
22. Design and Development of chassis dynamometer for
motorbike
23. Solar Electric Vehicle (Rickshaw)
25. development of standardized composite testing and
simulation procedure sandwitch structure carbon
fiber composite
26. Effect of current in EDM machining of AL 6061& its
effect on surface morphology
Ahmed Yar
Majid Nazeer
Rumeel Ahmad
Bhutta
Muhammad
Adeel
Uzair Ahmed
NED University
Sarhad University
of Science & IT,
Peshawar
SMME, NUST
24. Electronic Variable Valve Timing
Mudassar Zia
Muhammad
Fahim
M. Bilal Khalid
Faryal Khan
UET Taxila
Rubab Arshad
UET Taxila
27. Comparison of thermomechanical stresses produced
in work rolls during hot and cold rolling of cartridge
brass 1101
UET Taxila
28. Development of complex shape sheet hydroforming
UET Taxila
Faisal Qayyum
29. Determination of fretting fatigue behaviour oin
titanium
Alloy Ti-6Al-4V
UET Taxila
Zeshan Anjum
30. Obstacle avoidance hexapoid robot using tripod gate
mechanism
Rachna College
of Engineering
and Technology
Yasir Manzoor
11
Osama Shakeel
Abstracts/Summary of the Registered Projects
Electronic Variable Valve Timing (EVVTi)
The cam has been an integral part of the IC engine since its invention. The cam controls the breathing
channels of the IC engines, that is, the valves through which the fuel air mixture (in SI engines) or air
(in CI engines) is supplied and exhaust driven out. Recently due to demands for better fuel economy,
more power, and less pollution, motor engineers around the world are pursuing a radical camless
design that promises to deliver liberation from a constraint that has handcuffed performance since
the birth of the internal-combustion engine more than a century ago. Electronic Valve Train (EVT)
engine technology is soon to be a reality for commercial vehicles. In the EVT, the valve motion is
controlled directly by a valve actuator. There’s no camshaft or connecting mechanism. The future of
Internal Combustion Engine is Camless. We have decided to undertake the task to replace
mechanically operated valves system of an IC engine by Electronic Valve Train (EVT). This project
focuses to design an electronically controlled valve train to eliminate cam shaft, gear/belt drive
mechanism, improve efficiency and reduce power losses in conventional design.
External Aerodynamics of Formula Student Car-Assessment & Experimental Testing
Automakers have been interested in aerodynamics since the introduction of the Chrysler Airflow in
1934. In recent years Improvement in fuel economy has pushed aerodynamics toward the top of
automakers' priority lists, particularly in racing world where the high speed is the aim [1]. Formula
student (FS) is an engineering design competition to design, build, test and race a single seated car [2].
A competition is based on 3 static events and 5 dynamic events. To achieve success in race,all aspects
of the car must be carefully balanced [3], [4]. The objective of this work is to assess different
aerodynamic parameters which are taken into account while designing FS car, using Computational
Fluid Dynamics (CFD) tool and experimental testing.
Design, Fabrication and Testing of a Motorcycle Engine, Single Seat Prototype Racecar
Formula Student (FS) is a worldwide motorsport competition for university students, organized by
Institute of Mechanical Engineers (IMechE) and Society of Automotive Engineers (SAE) annually. It
encourages and promotes young engineers from all over the world to design, manufacture and test a
single seat prototype racecar and market it. Each car is judged through a series of static and dynamic
events, providing a perfect platform to the young engineers to test their technical and managerial
capabilities. The competition is backed by industry and high profile engineers like Patron Ross Brawn
OBE,
according
to
whom;
“The variety and Breadth of talent out there was what so exciting about the event”
Automation of Sand Casting Process by Mold Positioning
In today’s world automation is no more a fancy setup in the industry; it has become a necessity for
the industries to compete in the market. This project has been done to introduce automation in an
induction furnace based sand casting setup. Primarily there are two types of automation that can be
done, firstly is to automate the pouring of molten metal into the casting molds and second is develop
an automated system in which the casting molds automatically align themselves in front of the
induction furnace, such that the center of sprue comes directly beneath the fixed pouring point of
12
induction furnace. Much work has been done on automatic pouring system but the concept of
automatic mold alignment is relatively new, therefore this has been taken up as the core objective of
this project. Firstly a complete to the scale model in Pro-Engineer has been made of the automated
system which primarily consist of conveyors and other mechanisms which fulfill our objective;
moreover the same model has been animated to show the automated casting process. The project
has been initiated by Manufacturing Resource Centre (MRC) – SMME, therefore the model is designed
keeping in mind the requirements of MRC, the actual equipment present there, the actual dimension
of the space available and the dimensions of the equipment already present there. After making the
conceptual model and its simulation, the concept is then verified by making a small scale prototype
model and along with it a complete algorithm has also been made. The results of this is that I have
achieved an automated small scale model which fully depicts the full scale model designed earlier.
Simulated and Experimental Comparative Performance Analysis of Parabolic Trough Collector
Research in energy sector is ever-increasing due to decrease in conventional fuel reservoirs [1] and
the world needs environmental friendly and green energy solutions. Currently Pakistan is facing
pressing power crisis and need of the hour is to go for alternate energy solutions. Meteorological
conditions of Pakistan are ideal for solar thermal technology[2].And the fact is that Pakistan is located
in the 2nd highest solar rich region which receives solar irradiation around 1900-2000KWh per square
meter per annum. To extract this huge potential of solar energy for a developing country like Pakistan,
there is a vast need of research in solar thermal sector. For the propagation of Concentrated Solar
Power (CSP) technology study analysis on PTC systems is critical under particular climatic conditions.
The subject project is a step forward towards the novel design of PTC based thermal plants. PTC based
plants use specially designed parabola mirrors to concentrate the sun’s rays to receiver and transfer
thermal energy to working fluid which intern can be used for variety of applications like
 Power generation.
 Boilers are extensively used for steam generation to be used in different manufacturing
processes. CSP concentrators can be used to generate steam for industrial applications and
can replace boilers to meet thermal energy of a factory like leather industry, automobile
manufacturing parts, Textile, Pharmaceutical, chemical industry etc.
 Mini PTCs can be used for domestic water heating and space heating etc
 PTC can exclusively be used for space heating & cooling systems.
 CSP concentrators also find their applications in heat based water desalination processes.
More utilizing the CSP technology means less emissions of CO2 which helpful to get benefit from CDM
program for larger plants which is incentive based.
13
Active and Passive Safety
As we move backward we will know that in past safety opportunities in automotive were very less as
compared to present opportunities but now with the vast amount of opportunities we have huge
number of accidents due to not abiding safety cautions. What are causes? Causes are
eatures
As the time pass new safety features appears and now we are at the stage where a sensor could
control entire automotive but is costly.
Automotive Design & Manufacturing techniques
The purpose of our project is to design and manufacture light weight fuel efficient economical vehicle.
The purposes for designing and manufacturing this vehicle are: to compete in SHELL ECO-MATARHON
race and offer some vehicle which is more economical, beautiful and safer to replace bikes from the
roads of cities.
Our design has the basic purposes of:
1. Light weight
2. Fuel efficient
3. Economical
4. Safer.
The manufacturing adapted techniques are very important to get the destined design. The basic
importance in manufacturing is skilled labor our skilled worker. We chose very skilled worker in
Islamabad in contrast with our comfort. Because we have to attend classes in Sahiwal and also
manufacture our project in Islamabad.
Our project has primary importance for mode of transportation inside cities where bikes are used.
Bikes are not very safe mode of transportation. Our project is safer and also save drivers from dust
and smoke of city roads. Our project is more economical as compared to bikes and also more reliable
than bikes because of the manufacturing techniques used.
CFD in Automotive Design and Analysis
Our project “Design and Fabrication of a car for shell eco marathon” is what makes us close to the
automotive and CFD has now became a back bone of the automotive industry. From cars to airplane
to submarines everything is now evaluated and checked with what the modern world called CFD. In
fact CFD has reduced the wind tunnel testing up to 50% and this is what makes CFD a reliable yet less
expensive tool for the stimulation and analysis of automotive.
DESIGN, ANALYSIS AND FABRICATION OF A SUPER LIGHTWEIGHT CHASSIS
14
Unfortunately the Human Race is slowly & gradually cutting its own life line by continuously utilizing
Earth’s (the only known celestial body for sustaining & accommodating human life) resources,
especially in the automotive sector, in a way to benefit themselves without even realizing that it’s
haunting Earth in a devastating manner by constantly deteriorating Earth’s atmospheric & Ecological
stability which puts the existence of humanity in question for future. Until or unless some extreme
measures are taken in a quick time to mitigate this deterioration, it is possible that we would soon be
left helpless in maintaining the correct balance between the human life biological requirements and
earth’s environmental aspects which will have devastating effects not only on human life but also on
nature itself. On the other hand if possible correction measures are taken and implemented
successfully many positive results would be drawn such as the conservation of the already fast
depleting non-renewable fossil fuels reserves and a critical decrease in the vast emissions of pollutant
gases (CO, CO2 etc.) from the engines of the automobiles, in the best interests of our future
generations.
That’s what our project is all about, as we have designed, analyzed & fabricated a relatively safe and
comfortable chassis with the least possible expenditure of capital by taking into consideration several
critical aspects of the designing and manufacturing of the chassis and re-engineering it in a manner
which would be as close as possible to the optimum parameters of safety, comfortability and
lightweighting. On a lighter note it will also act as partial solution to the stressing effects of the ghost
of inflation that is at present haunting humans throughout the globe especially those living in the
Middle Eastern and Asian countries.
EFFECT OF CURRENT IN THE EDM MACHINING OF ALUMINIUM 6061 T6 AND ITS EFFECT ON THE
SURFACE MORPHOLOGY
Electric discharge machining being the non-conventional machining technique is still under
development. Throughout the world research is carried out on EDM to understand the phenomenon
involved and the results obtained. As machining process affects the surface morphology of the
specimens, electric discharge machining also produces white layer, globules of molten material,
surface cracks and voids. All of these results have detrimental effect on the specimen’s finish and life.
Thus the effect of the parameters of the electric discharge machining process needs to be discussed
on the specimen’s surface quality before putting them into service. EDM process for Aluminium alloys
is used frequently in aerospace industry. Machining of Al 6061 T6 cylinders is performed on die-sinking
EDM machine with varying electric current values to determine its effect on surface morphology in
the case of aluminum alloy. Material removal rate versus current is determined for different current
values. An attempt is made to relate the globule formation on the machined surface, with the
machining current. Scanning electron microscopy (SEM) is performed. The white layer thickness,
globule diameter and inter-globule distance are found to increase with the increase in electric current.
15
DEVELOPMENT OF COMPLEX SHAPE SHEET HYDROFORMING
In industrial practice it takes multiple steps to produce complex shaped sheet metal parts of good
tolerances and better surface finish. Sheet hydroforming can be useful process to produce complex
shaped parts of better finish and tolerances, while keeping the production rate faster and cheaper.
Yet many parts are still not manufactured by this process because many conditional parameters are
involved with change with geometry, external conditions and various other aspects. We have done
detailed analysis of deep drawing using various analytical models, experimental techniques and
numerical simulation codes has been carried out with extended hydroforming of deep drawn cups to
form complex shapes..
In the research work we tried to address several problems which occur during manufacturing of
complex shaped parts using hydroforming process. Tensile tests and anisotropy tests were conducted
to determine the detailed material properties. Initial testes were carried out to identify the process
parameters majorly affecting the process, and in final tests they were optimized to get the desired
results.
Same problem was simulated using ABAQUS StandardTM explicit package, to further develop a model
to get deep insights of the process, material properties determined earlier were helpful during
simulation and helped us make the simulation model more real time and comparable.
During deep drawing Draw Ratio (DR) greater than 2.5 were achieved by using residual stress removal
technique (annealing) and force control methods. The anisotropic behavior of sheet were analyzed
and the results of simulation and experimentation compared.
Comparison of thermomechanical stresses produced in work rolls during hot and cold rolling of
cartridge brass 1101
A process in which metal heated at elevated temperatures (above recrystallization temperature) is
passed between two rolls to flatten and lengthen the metal is called Hot Rolling
During hot rolling, the work rolls of hot rolling mill undergo severe thermomechanical stresses. These
stresses are produced due to successive heating and cooling of rolls by the heated billet and the
cooling system respectively. The thermomechanical stresses gives rise to the cracking of material on
the surface of the rolls which reduces the work roll life and also affects the quality and shape of the
billet being rolled. So it is important to study their effects so that the damage can be reduced.
In the past we have done research on the thermomechanical stresses produced in work rolls during
hot and cold rolling of cartridge brass 1101. During that research the temperature dependant material
properties of cartridge brass was experimentally determined. For the simulation, boundary conditions
were taken from a brass rolling mill. The thermomechanical stresses produced in the work rolls made
of AISI H11 Tool steel were determined using thermoplastic FEM approach in Abaqus. The effects on
the work rolls due to hot and cold rolling was compared.
Currently we are working on cracking of roll surface due to thermal fatigue. A laboratory setup to
simulate thermal fatigue and its effect on rim of H11 tool steel is being developed. Later on numerical
simulation of the same process stated above will be carried out to get deep insight of all types of
stresses which are produced during thermal cycling.
16
Determination of Fretting Fatigue Behavior in Titanium Alloy, Ti-6Al-4V
Fretting fatigue failure is a type of failure which occurs in structures and mechanical parts, typically in
riveted or bolted joints, gas turbine disc and blade dovetail joints, when they start sliding minutely
(typically from 1 to 100μm) against each other due to vibration between them or some other force.
Titanium element is widely used in aircraft, armour plating, naval ships, missiles and aircrafts after
being alloyed with aluminum, vanadium and other elements because of their high strength to weight
ratio, higher resistance to corrosion, crack and creep at higher temperatures.
This research focuses on the fretting fatigue behavior of titanium alloy, Ti- 6Al-4V specimen with
internal dovetail configuration in contact with carbide rod and evaluates fretting fatigue strength of
that specimen.
Numerical Simulation and Experimental Verification of CMOD in SENT Specimen: Application on
FCGR of Welded Tool Steel
Welding is the common permanent joining method to join or fabricating metal parts. Welding process
induced changes in the structure and residual stresses. It is very important to understand that how a
welding component behave under fatigue and how crack initiate or propagate in specimen [1, 2].
Fatigue life of welded specimen can be divided into two main categories like endurance limit and other
is Fatigue crack growth rate inside the material.
In the work on fatigue crack propagation of D6AC steel plates and laser welds, Tasy et al.[4] found that
fatigue crack growth rates (FCGRs) of the weld metal (WM) and the heat affected zone (HAZ) were
less than those of base metal (BM) for similar stress intensity factor ranges (ΔKs). They also tested the
effects of post weld heat treatment which seems to reduce the dip in the da/dN vs. ΔK curve in regions
of HAZ and WM with a corresponding increase in the post weld heat treatment temperature. Crack
propagation rate is reduces with reduction in specimen thickness and vice versa, which has to be
considered while characterizing welds in thick base metals or high strength material sheet.
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DETERMINATION OF FRACTURE ENERGY IN DELAMINATION TEST OF FIBER METAL LAMINATES.
Composite materials are becoming an important building block in almost every field like aircraft,
automobile, buildings, boats etc. due to their highly equitable qualities. However there is continuing
development over procedures to test and classify these materials. The standards used in the testing
of these materials need further understanding. In this research we intend to use Digital Image
Correlation, forthwith called DIC, to develop testing capability for the composite materials.
Digital image correlation is a novel method of calculating material properties, damage and fracture in
difficult configurations of composite materials. Inter-laminar shear strain γ13 and shear modulus G13
is calculated using digital image correlation (DIC) in a four point bending test of a glass fiber reinforced
polymer, by observing the cross section. The measurement method is verified by using some principles
of mechanics applied to the beam theory. Firstly verification is made by calculating the modulus of
elasticity of E-glass fiber by tensile test and linear strains during bending using simple beam theory
and comparing them with DIC results. Secondly a method of verifying the validity of DIC method is
proposed by confirming zero shear strain in the zone of maximum bending moment, characteristic of
a four point bend experiment.
Idle Speed Control
Project consists of a 1.3L Spark Ignited (Manufactured by Honda with i-DSi). Hardware consists of
Freescale’s Qorivva Microcontroller (dedicated for automotive power-train applications). Project
involves interfacing all the standard actuators and sensors, except crank and cam shaft position
sensors. For the sake of idle speed control, crankshaft position sensor and idle air control valve are
the sensor and actuator, respectively, are of the main interest.
All-Terrain Vehicle
In today’s world, technology has been progressing on a daily basis with a remarkable pace. We have
come so far on so many frontiers of technology that was unprecedented by even the most
accomplished minds of their time. Innovation has become the hallmark of development and the path
to success. The automotive industry is one of the biggest industries in the world which drives
innovation in the modern world. Ideas are imagined, created, refined, and implemented with such
pace in this field of technology that a worthwhile idea can potentially revolutionize the world in a
matter of days. What we are targeting is that worthwhile idea. What we have here is a brand new
concept for a suspension system with a complete set of all terrain capabilities. This design has been
implemented by us on a small scale remotely controlled all-terrain vehicle which is our project. The
suspension system is a never before implemented unique design with the capability to handle any and
all terrains it may encounter including a limited capability of handling vertical obstacles like stairs. The
robot on which we have implemented the concept is a small scale UGV with a sophisticated control
system and a powerful steering mechanism making an ideal candidate for a wide range of possible
functionalities. The robot is a highly customizable basic structure with a wide scope for applicability in
defense, rescue operations, space exploration, automotive and many other industries and has a lot of
potential to further drive innovative thinking on part of the user. The project was done in collaboration
by a set of students comprising from the fields of both mechanical and electronics engineering which
has played a great part in making it a more out of the box concept. Members from both the disciplines
bought their own unique mind set and ideals to the table setting in motion a cycle of innovative drive
in which multiple new ideas were generated in a number of areas from both fields.
Our project has been recognized for its potential on multiple platforms coming first in the Project
Exhibitions at NUTEC’14 FAST Peshawar, Academic Expo University of Swat and NOC’14 GIKI. The
appreciation received by us has further strengthened our resolve to pursue a bigger and better
platform to showcase our idea and DICE seems like the perfect opportunity for that.
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Mobile App based Auto Security and Safety Device
Existing auto security solutions (like trackers, electronic immobilisers, transponders, alarms etc) were
developed in 1980s/1990s and thieves have learnt how to bypass them. “My Smart Remote” is a
mobile app based system that provides innovative auto security, auto safety and mobile app
controlled features like AC, heater, door locks etc.
d crimes in the developed and
underdeveloped countries.
subjected to the above limitations
-theft, anti-snatching, prevention from driving in the drunk
mode. Other benefits include mobile app controlled doors lock, AC, Heater, Lights etc
ows resilience even if a thief
hacks password or jams the signals.
-snatching mechanism of MSR also provides drivers safety.
it up during a cold winter.
for free. Changing keys is as simple as changing a password
nd old cars.
– no need for keys and related issues like keys locked inside car
year.
evenue generation for the MSR system, this is despite
using very low market penetration rates.
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DESIGN AND FABRICATION OF VEHICLE DOOR USING COMPOSITE MATERIALS
Composite materials are being used stupendously in a variety of fields like Aerospace (tails, wings,
fuselages, propellers), Automotive (car bodies), Sports baseball bats, boat and scull hulls), and
Medicine (orthopedic surgery). The automotive industry is focused on developing cars with higher
safety levels, reduced fuel consumption and cost-efficient production methods. This will be
accomplished through smarter design and the continuous introduction of newer, lighter and stronger
materials. In this project we are providing a solution with the help of which, automotive parts can be
manufactured according to industrial standards. The purpose of our project is to provide a low cost
solution for replacement of vehicle parts that can be fabricated by SMEs. For prototyping purpose
vehicle door has been selected. Properties like strength, stiffness and crashworthiness of a door
manufactured using composites (E-Glass Woven reinforcement & Polyester as matrix) are compared
with that of existing steel door. VARI (Vacuum Assisted Resin Infusion) process is used in order to
achieve an enhanced Vf (volume fraction) for better specific stiffness. FE analysis (in Abaqus) along
with experimental testing for defined load cases is applied to both doors (metallic and composites) in
order to compare their properties. The applied design criterion is equal stiffness. It is observed that
by applying equal stiffness criterion, strength is enhanced (3.5 times) while weight reduction is not
significant (which is also advantageous as CG remains same and vehicle stability is not affected).
Electric Hybrid Conversion kit
Keeping in view the current energy crisis in Pakistan, transport consume almost 50 % of the total oil
consumption per year. Electric hybrid cars are the next step in conserving fuel demands. Although this
technology is old yet it is expensive. In our project we have shown that this technology can be
implemented in current cars at a quite cheaper rate with a more feasible approach. We took a 30 year
old car and some cheap electronic devices that were easily available and turned them into a replication
of the hybrid technology with a unique approach.
The first electric hybrid car was commercially introduced in the market in 1997 by Toyota
Japan and was named as Prius. Today it is the world’s cleanest in terms of emission, largest selling
commercially sold vehicle.
By installing our kit any current car can be converted into a hybrid electric car that would not
only provide a better gas mileage but would also provide people a bridge to move from the current
internal combustion cars to electric ones which are the future of automotive industry.
We have made this effort to improve fuel economy in the automobile industry.
dsPIC based “Engine Control Unit (ECU)” powered by LabVIEW
Powertrain control engineers are constantly striving to improve engine performance measures, such
as power output, fuel consumption and emission control. The engine performance becomes
increasingly important due to the demands of the government and customers. However,
accomplishing this has been challenging, since progress in one area often requires an undesirable
tradeoff in another. In modern day cars, electronics are used to regulate emissions and enhance the
driving experience [1]. In local universities, most of the research is paper-oriented or simulation based
and sometimes it has nothing to do with real world problems. This open source dsPIC based ECU
powered by LabVIEW provides a tangible working platform to students, researchers and developers
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to implement challenging complex Model-Based or Model-Free control schemes and to gain indepth
knowledge of ECU operation in real time. This ECU provides an affordable solution to beginners as
well as professionals and hobbyists. Designers can do real-time implementation, rapid prototyping,
designing and development of an ECU that comprises of all advance engine control technology.
Stock ECUs are still like a black box for most of the researchers and engineers. The user cannot do any
aftermarket modifications to it and they are preprogrammed by the company for economical fuel
settings. This aftermarket ECU also provides an alternative way to enhance the engine performance
at the cost of high fuel consumption for racing enthusiast. As an open source ECU, user can edit the
fuel/ignition maps or set of nonlinear equations and other vital tuning parameters to make it possible
to run an ordinary EFI gasoline (E10) engine 2
on alternative fuels (i.e. CNG, LPG, Methanol/M85, Ethanol/E85) more efficiently. When the engine
uses fuel mixtures, for instance alcohol with gasoline, the injector width and ignition timing should be
modified [2-4]. The tuning can be carried out via proper engine test bench equipped with
dynamometer and emission gas analyzer [5].
Solar Electric Vehicle
21st century is the era of industrialization and automation to boost the GDP (Gross Domestic Product)
of countries but with this enhancement the great risk to environment cannot be ignored.
Industrialized countries are more responsible for this environmental damage and as well as
responsible to minimize this damage. In these countries the environment protection departments are
highly powerful to avoid those projects and new technologies which damage the environment, in short
to protect their environment on any cost and at any level.
Automobile plays a pivotal role in our daily life and as well as the cause of environmental pollution. To
decrease this impact on environment world leading economical countries are inclined towards the
hybrid and solar electric vehicles to overcome this danger. These countries as well as Pakistan
subsidized and encourage their citizen to adopt these new technologies in automobile.
The main aim behind hybrid and Electric Vehicles is to reduce the pollution impact on our environment
and decrease the fuel cost of vehicle by using solar energy. The main advantage of this project will
impact on our future environmental policy and green energy utilization in daily life.
Design and fabrication of low cost fuel efficient one seater vehicle
The aim of this project is to design, build and test a gasoline powered one seater vehicle. The main
focus is fuel economy which is a major factor in the success of upcoming automobiles. As energy
demand of the world is rising, a rise in oil prices have occurred. Methods to increase fuel efficiency
are being used together with a shift towards renewable energy technology.
The main source of energy for traditional automobile engines is gasoline. The U.S. publisher Ward's,
estimate that as of 2010 there were 1.015 billion motor vehicles in use in the world and the numbers
are rising. Therefore improvement in fuel economy of automobiles is a rising conc
To achieve maximum fuel efficiency, our core focus is bent on aerodynamics, weight reduction and
engine optimization of our prototype. Our team, NUST Ecomotive, aims to be pioneers in representing
SMME, NUST at an international level competition and ultimately launch the prototype as a
commercialized road legal product in Pakistan.
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Hexapodic Surveillance Robot Biased With Solar System
Robotics is a very vast field on which a lot of research has been done and many are under process.
Scientists from all over the world trying to develop new things that can reduce human effort and can
serve mankind. The main purpose of developing this robot is to develop a user friendly device that can
be used for several purposes like surveillance, obstacle avoidance and for stair climbing mechanism
(future scope). It usually involves controlling of servo motors through Pulse Width Modulation (PWM)
technique that can be generated by Arduino UNO Board. Through properly timed switching pulses the
rotation and angle of motors are controlled, it follows a tripod mechanism for both forward and
backward movement. Surveillance is being provided with the help of a video camera that uses a
wireless transmission of signals for transferring data, besides this ultrasonic sensor is used for obstacle
avoidance purpose. The robot takes the power through a light weight 7.2V rechargeable Ni-MH
battery that has a solar charging mechanism which increases the energy efficiency of our robot. In
future one can make it as a flying robot used as a spy as well as by controlling its movement of pads
one can also make it a stair climbing robot.
Idle Speed Control
1. Introduction
Project consists of a 1.3L Spark Ignited (Manufactured by Honda with i-DSi). Hardware consists of
Freescale’s Qorivva Microcontroller (dedicated for automotive power-train applications). Project
involves interfacing all the standard actuators and sensors, except crank and cam shaft position
sensors. For the sake of idle speed control, crankshaft position sensor and idle air control valve are
the sensor and actuator, respectively, are of the main interest.
2. Background
Rigorous work on automotive engine has been carried out at Control and Signal Processing Research
Group (CASPR). Areas of the research work includes modeling (mean value, discrete event and hybrid),
observer design and fault diagnosis. Scope of the work could have not been extended to the control
because of the deficiency of proper reconfigurable engine control unit. Since engine was running on
OEM ECU, and all of the experiments were conducted using OBD – II interface. “Idle Speed Control”
loop is one of the milestones in developing the whole setup. Completion has enabled the CASPR to
carry out experiment on the said topic.
3. Project
Whole of the setup is being developed at Freescale’s PowerPC based MPC5634M microcontroller.
Selection of this microcontroller was done on the following basis I. eTPU make it possible to interface
the sensors and actuators (operating on 0/1 signals) without loading the main microprocessor II.
Dedicated architecture for power-train applications III. Presence of CAN interface, which will be useful
in final product After identification of all the sensors, calibration of each sensor was done keeping the
OBD – II as reference. However, when idle speed is only the concern in our case following are the
inputs and outputs of the system I. Engine crankshaft speed: measured from sensor having the
following arrangement a. Tooth wheel of 36-2 configuration b. Hall effect sensor II. Air flow regulating
valve (operating at 250Hz, taking PW as controlling variable) Qorivva microcontroller is interfaced to
a standard PC for data indication and storage. PC application is a Java SE based application.
Communication part of the application is a state machine which receives the data from hardware in a
cyclic manner. Data could either be viewed in gauges or in graph mode as shown in Figure 3-2 and
4. Summary
Idle speed control is one of the milestones of full project. Completion of this control loop has enabled
the CASPR to conduct experiments on idle speed control. Currently air-to-fuel ratio is being controller
in open loop mode.
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COMPRESSED AIR ENGINE
In Pakistan bikes and cars are becoming very popular means of independent transportation for short
distances however; petrol and diesel that have been the main sources of fuel in the history of
transportation are becoming very expensive for lower, middle and even upper middle class and
determinant to environment.
It is not possible to completely eliminate the use of fuel but engineers are always striving to develop
and make environmental friendly vehicles. Air - Powered Vehicle is one such attempt in this direction.
Engineers are directing their efforts and ideas to make use of air as an energy source to run the low
utility Vehicle which will make future bikes and light/small cars running with air power for daily
commuting.
Gasoline is already being considered a fuel of the past. To most of us it might not seem that way as
we fill up the gasoline on our way to work, but it is gradually depleting. Gasoline’s drawbacks are: its
tendency to pollute air and its rapidly increasing prices. Automobile manufacturers are well aware of
the problem and have started spending lot of time and money to find and develop alternative fuel for
the future which would be environmental friendly. As good as that idea might seem, some
manufacturers think compressed air could become an even better energy source.
At first glance, the idea of running a car on compressed air seems almost too good to be true. Air is all
around us, it never runs out, it is nonpolluting and best of all, air is free. But the question is how to
use it as a fuel substitute.
So a test bed was designed which can calculate all the required outputs of the engine which are then
be analyzed and further improvements can be made in the engines.
Design and Manufacturing of Electromagnetic Clutch and Automatic Transmission.
The project selected for the final year, focuses on many different aspects of the technology and the
real need of mechanism in today’s life. The electromagnetic clutch and automatic transmission of bike
is actually the mounting of electromagnetic clutch on the 72 cc engine of motor bike in order to make
it fully automatic. But the main thing is that the automation is made possible without any change of
already existing system of the engine, the gear train is the same as was once in the conventional or
manual system. The automation is made possible by the usage of electromagnetic clutch and stepper
motor and the micro controller.
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Participating Industries
1. HYBRID ENGINEERING PVT LTC
2. PAAPAM
3. TROSOL (TOJANS PAKISTAN)
4. ZIC OIL
5. INTERNATIONAL POLYMER INDUSTRY (IPI)
6. RENEWABLE STAR
7. SPEL
8. INFINITY ENGINEERING
9. SUBWAY
10. IT & Software (iFahja)
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DICE Automotive Post Event Write-Up
On the 16th December 2014, the School of Mechanical and Manufacturing Engineering in collaboration
with the DICE foundation held its first ever DICE Automotive 2014 event.
DICE Automotive 2014 formally started with the recitation from the Holy Quran and was followed by
a welcome address by the principal SMME, Dr. Abdul Ghafoor who highlighted the importance of
technological advancement and industrial growth in today’s day and age.
The event continued its course with interesting talks by the Chairman of DICE Foundation Dr. Khurshid
and the Chief Guest Mr Zibber Moinuddin. The inauguration was followed by the evaluation of all 34
projects that were all innovative and ground-breaking. The event had a vast turn out with students
from all over NUST attending in large numbers and taking an enthusiastic interest in the various
projects being presented. Said students then actively participated in the panel discussion that focused
on universities involvement in the development of our auto Industry.
After a short break, the results were announced and the prizes were distributed to the most deserving
projects, though the judges disclosed that the decision was indeed a tough one. The chief guest for
the closing ceremony Mr Imtiaz Rastgar expressed his views in the expansion of the automotive
industry in Pakistan which was followed by a closing address by rector NUST, Engr. Mohammad
Asghar, bringing the event to its end.
DICE Automotive 2014 was an endeavor that truly explored how devastating a progressive stock-still
can be for Pakistan and will act as a pioneering step for similar events in the future. The SMME faculty
will keep working with the DICE foundation to initiate further projects over the course of the coming
years.”
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PHOTO GALLERY
Keynote speech by Chief Guest
Presentation of the souvenir to Chief Guest
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Opening ceremony
Projects being evaluated
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SMME, FS project member
Presentation of the winner shield
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Presentation of the runner up shield
Presentation of the 2nd runner up shield
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Symposium
Closing ceremony
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