Designs, Volume 8, Issue 2 (April 2024) – 19 articles

NiCoCrAlY high entropy alloy (HEA) coating (47.1 wt.% Ni, 23 wt.% Co, 17 wt.% Cr, 12.5 wt.% Al, and 0.4 wt.% Y) was deposited on a stainless steel subtract by atmospheric plasma spraying (APS). The as-deposited coating was about 300 μm thickness with <1% porosity. The microstructure of the coating consisted of dispersed secondary phases/intermetallics in the solid solution. The stress–strain behaviour of this coating was investigated in micro-scale with the help of in situ micro-pillar compression. The experimental results show that yield and compressive stress in the cross-section of the coating was higher (1.27 ± 0.10 MPa and 2.19 ± 0.10 GPa, respectively) than that of the planar direction (0.85 ± 0.09 MPa and 1.20 ± 0.08 GPa, respectively). The various secondary/intermetallic phases (γ′–Ni₃Al, β–NiAl) that were present in the coating microstructure hinder the lattice movement during compression, according to Orowan mechanism. In addition to that, the direction of the loading to that of the orientation of the phase/splat boundaries dictate the crack propagation architecture, which results in difference in the micro-mechanical properties. Full article

In the era of the competitive environment, the improvement in current products is ensured through activities aimed at increasing a product’s quality level and, consequently, reducing the amount of waste. The dynamically changing production environment and sudden changes in customer expectations force us to take precise and well-thought-out development steps. Furthermore, it is important to anticipate favourable product changes to prepare for market changes over time. This is still an open problem. The aim of this study was to develop a method to predict the quality of potential product prototypes resulting from the proposed modifications of the product features. This methodology takes into account current customer expectations. The method was created based on the principles of creating Quality Function Deployment (QFD) in the context of taking into account current and future customer expectations regarding product features. This is a new approach to analysing product quality within the principles of the traditional QFD method. The originality of the study is the technique used in the method to estimate the expected values of product features and their importance (weights), taking into account current customer expectations. Its originality is also manifested in drawing conclusions supporting the decision-making process of product improvement, because it involves ensuring the pro-quality modification of selected features of current products in the order that is most advantageous from the customer’s point of view. The use of the proposed method allows for the analysis of the impact of modifying the current value of a product feature. The method is illustrated with an example of a vacuum cleaner for home use. However, the proposed method can be applied to the design of any product to predict products that will meet customer expectations. Full article

A significant number of individuals in the United States use assistive devices to enhance their mobility, and a considerable portion of those who depend on such aids require assistance from another individual in performing daily living activities. The introduction of robotic grippers has emerged as a transformative intervention, significantly contributing to the cultivation of independence. However, there are few grippers in the fields, which help with mimicking human hand-like movements (mostly grasping and pinching, with adoptive force control) to grasp and carry objects. Additionally, the data are not available even on how many Activities of Daily Living (ADL) objects they can handle. The goal of the research is to offer a new three-fingered gripper for daily living assistance, which can both grasp and pinch with adaptive force, enabling the capabilities of handling wide-ranging ADL objects with a minimal footprint. It is designed to handle 90 selective essential ADL objects of different shapes (cylindrical, irregular, rectangular, and round), sizes, weights, and textures (smooth, rough, bumpy, and rubbery). The gripper boasts a meticulously engineered yet simple design, facilitating seamless manufacturing through 3D printing technology without compromising its operational efficacy. The gripper extends its functionality beyond conventional grasping, featuring the capability to pinch (such as holding a credit card) and securely hold lightweight objects. Moreover, the gripper is adaptable to grasping various objects with different shapes and weights with controlled forces. In evaluation, the developed gripper went through rigorous load tests and usability tests. The results demonstrated that the users picked and placed 75 objects out of 90 daily objects. The gripper held and manipulated objects with dimensions from 25 mm to 80 mm and up to 2.9 kg. For heavy-weight objects (like books) where the centroid is far apart from the grasping areas, it is difficult to hold them due to high torque. However, objects’ textures have no significant effect on grasping performance. Users perceived the simplicity of the gripper. Further investigation is required to assess the utility and longevity of grippers. This study contributes to developing assistive robots designed to enhance object manipulation, thereby improving individuals’ independence and overall quality of life. Full article

In many applications, such as space navigation, metrology, testing, and geodesy, it is necessary to measure accelerations with frequencies ranging from fractions of a hertz to several kilohertz. For this purpose, optomechanical sensors are used. The natural frequency of such sensors should be approximately ten times greater than the frequency of the measured acceleration. In the case of triaxial acceleration measurements, a planar design with two sensors that measure accelerations in two perpendicular in-plane directions and a third sensor that measures out-of-plane acceleration is effective. The mechanical characteristics of the existing designs of both in-plane and out-of-plane types of sensors were analyzed, and the improved designs were elaborated. Using numerical simulation, the dependencies of the natural frequency level in the range from several hertz to tens of kilohertz on the designs and geometric parameters of opto-mechanical accelerometers were modeled. This allows one to select the accelerometer design and its parameters to measure the acceleration at the assigned frequency. It is shown that the opto-mechanical accelerometers of the proposed designs have reduced dissipation losses and crosstalk. Full article

The environmental impact of wind turbine rotor blades, both during manufacturing and at the end of their life cycle, can be significant. The aim of this study was to define and test a methodology for recycling the waste resulting from their production. Particles of waste from the mechanical machining of rotor blades, which were made up of a glass fibre/epoxy matrix mixture, were used to produce toe caps for use by the footwear industry. The addition of 1 wt.% of particles improved the mechanical properties of the epoxy matrix, with a 5.50% improvement in tension and an 8% improvement in stiffness. Characterisation of the laminates, manufactured by hand lay-up technique, revealed that in the three-point bending tests, the additive laminates showed improvements of 18.60% in tension, 7.50% in stiffness, and 10% in deformation compared to the control laminate. The compression test showed that the additive glass fibre toe cap had greater resistance to compression than the control glass fibre toe cap, with a reduction in deformation of 23.10%. The toe caps are suitable for use in protective footwear according to European standard EN ISO 20346:2022. They guaranteed protection against low-velocity impacts at an energy level of at least 100 J and against compression when tested at a compression load of at least 10 kN. Full article

This work presents the study of the thickness vs. stiffness relationship for different materials (PMMA and PEEK) in patient-specific cranial implants, as a criterion for the selection of biomaterials from a mechanical perspective. The geometry of the implant is constructed from the reconstruction of the cranial lesion using image segmentation obtained from computed axial tomography. Different design parameters such as thickness and perforations are considered to obtain displacement distributions under critical loading conditions using finite element analysis. The models consider quasi-static loads with linear elastic materials. The null hypothesis underlying this research asserts that both biomaterials exhibit the minimum mechanical characteristics necessary to withstand direct impact trauma at the implant center, effectively averting critical deformations higher than 2 mm. In this way, the use of PMMA cranioplasties is justified in most cases where a PEEK implant cannot be accessed. Full article

Indonesia is situated on the Ring of Fire, which causes a lot of earthquakes. On the 28 September 2018, there was an earthquake in Palu, Sulawesi Island, Indonesia, which was one of the strongest shakings since 1980. Surprisingly, most traditional houses in Sulawesi survived. There has been some research on adapting traditional house structures to modern residential buildings. The limited availability of wood and complicated construction make adapting wood structures to current conditions challenging. The purpose of this study is to analyze space organization in ten traditional South Sulawesi house designs. A possible evacuation route can be found through the analysis as the first space for expeditiously escaping from an earthquake. In addition, modernizing the layout of a traditional South Sulawesi house and introducing it to local people was easy since they were familiar with the design. A deep analysis of spatial organization and its interrelations can help develop realistic designs, plans, and knowledge, thus improving the quality of residential projects. A descriptive qualitative method was used as a research method. Data were collected from field observations, brief interviews, and literature reviews. In order to analyz thee data, ORA-LITE was used to redraw the data and create the charts. It was found that different cultures have different evacuation spaces, in this case the Bugis tribe and the Toraja tribe. A corridor and kitchen were the most strategically located areas that could possibly be used for evacuation. Considering the differences in culture among tribes, designing evacuation spaces based on local culture was important. A recommendation based on this finding can also be made to the government of South Sulawesi in the design of residential houses. Full article

Numerical modeling tools are essential in aircraft structural design, yet they face challenges in accurately reflecting real-world behavior due to factors like material properties scatter and manufacturing-induced deviations. This article addresses the potential impact of digital twins on overcoming these limitations and enhancing model reliability through advanced updating techniques based on machine learning. Digital twins, which are virtual replicas of physical systems, offer a promising solution by integrating sensor data, operational inputs, and historical records. Machine learning techniques enable the calibration and validation of models, combining experimental inputs with simulations through continuous updating processes that refine digital twins, improving their accuracy in predicting structural behavior and performance throughout an aircraft’s life cycle. These refined models enable real-time monitoring and precise damage assessment, supporting decision making in diverse contexts. By integrating sensor data and updating techniques, digital twins contribute to improved design and maintenance operations by providing valuable insights into structural health, safety, and reliability. Ultimately, this approach leads to more efficient and safer aviation operations, demonstrating the potential of digital twins to revolutionize aircraft structural analysis and design. This article explores various advancements and methodologies applicable to structural assessment, leveraging machine learning tools. These include the utilization of physics-informed neural networks, which enable the handling of diverse uncertainties. Such approaches empower a more informed and adaptive strategy, contributing to the assurance of structural integrity and safety in aircraft structures throughout their operational life. Full article

Total knee arthroplasty (TKA) stands out as one of the most widely employed surgical procedures, establishing itself as the preferred method for addressing advanced osteoarthritis of the knee. However, current knee prostheses require refined design solutions. This research work focuses on a computational analysis of both the mechanical behavior of a knee joint implant and the bone remodeling process in the tibia following implantation. This research study delves into how specific design parameters, particularly the stem geometry, impact the prosthesis’s performance. Utilizing a computed tomography scan of a tibia, various TKA configurations were simulated to conduct analyses employing advanced discretization techniques, such as the finite element method (FEM) and the radial point interpolation method (RPIM). The findings reveal that the introduction of the implant leads to a marginal increase in the stress values within the tibia, accompanied by a reduction in the displacement field values. The insertion of the longest tested implant increased the maximum stress from 5.0705 MPa to 6.1584 MPa, leading to a displacement reduction from 0.016 mm to 0.0142 mm. Finally, by combining the FEM with a bone remodeling algorithm, the bone remodeling process of the tibia due to an implant insertion was simulated. Full article

Lung cancer is identified by the uncontrolled proliferation of cells in lung tissues. The timely detection of malignant cells in the lungs, crucial for processes such as oxygen provision and carbon dioxide elimination in the human body, is imperative. The application of deep learning for discerning lymph node involvement in CT scans and histopathological images has garnered widespread attention due to its potential impact on patient diagnosis and treatment. This paper suggests employing DenseNet for lung cancer detection, leveraging its ability to transmit learned features backward through each layer continuously. This characteristic not only reduces model parameters but also enhances the learning of local features, facilitating a better comprehension of the structural complexity and uneven distribution in CT scans and histopathological cancer images. Furthermore, DenseNet accompanied by an attention mechanism (ATT-DenseNet) allows the model to focus on specific parts of an image, giving more weight to relevant regions. Compared to existing algorithms, the ATT-DenseNet demonstrates a remarkable enhancement in accuracy, precision, recall, and the F1-Score. It achieves an average improvement of 20% in accuracy, 19.66% in precision, 24.33% in recall, and 22.33% in the F1-Score across these metrics. The motivation behind the research is to leverage deep learning technologies to enhance the precision and reliability of lung cancer diagnostics, thus addressing the gap in early detection and treatment. This pursuit is driven by the potential of deep learning models, like DenseNet, to provide significant improvements in analyzing complex medical images for better clinical outcomes. Full article

Cyber-physical systems, cloud computing, the Internet of Things, and big data play significant roles in shaping digital and automated landscape manufacturing. However, to fully realize the potential of these technologies and achieve tangible benefits, such as reduced manufacturing lead times, improved product quality, and enhanced organizational performance, new decision support models need development. Game theory offers a promising approach to address multi-objective problems and streamline decision-making processes, thereby reducing computational time. This paper aims to provide a comprehensive and up-to-date systematic review of the literature on the application of game theory models in various areas of digital manufacturing, including production and capacity planning, scheduling, sustainable production systems, and cloud manufacturing. This review identifies key research themes that have been explored and examines the main research gaps that exist within these domains. Furthermore, this paper outlines potential future research directions to inspire both researchers and practitioners to further explore and develop game theory models that can effectively support the digital transformation of manufacturing systems. Full article

This article focuses on modelling and validating a groundbreaking magnetorheological braking system. Addressing shortcomings in traditional automotive friction brake systems, including response delays, wear, and added mass from auxiliary components, the study employs a novel brake design combining mechanical and electrical elements for enhanced efficiency. Utilizing magnetorheological (MR) technology within a motor–brake system, the investigation explores the influence of external magnetic flux from the nearby motor on MR fluid movement, particularly under high-flux conditions. The evaluation of a high-magnetic-field mitigator is guided by simulated findings with the objective of resolving potential issues. An alternative method of resolving an interaction between an electric motor and a magnetorheological brake is presented. In addition, to test four configurations, multiple absorber materials are reviewed. Full article

The authors of this article analyze the existing methods and models of technological preparation of machine-building industries. The structure of a three-level simulation model with network-centric control, the structures of individual elements of the simulation model, and the process of simulation modeling are described. The criteria for choosing a rational option for the processing technological route have been determined. During this research, a simulation program was implemented in C++. It allows you to select the optimal scenario for the operation of a production site based on two criteria: time and cost. The volume of implementation is about 2 × 10³ lines of code. A diagram of the modeling algorithm for the implemented program and a description of the classes and their interactions are given in the article. The developed simulation model was tested at a machine-building enterprise using the example of the “Pusher” part, manufactured under single-unit production conditions. The technological equipment used for the manufacture of this part was formed in the form of input data of the simulation model. The results of simulation modeling for the selected part are described. For each variant of the technological processing route, the values of variable costs and the duration of the production cycle were determined. Full article

Cities are complex systems requiring urban design models that balance order and disorder. Collective creativity initiatives engage citizens in these processes, empowering bottom-up approaches that prioritize people and social well-being within urban development. This paper investigates an ‘Urban Laboratory’ as a case study, examining the potential of collective creativity to address urban complexity. The successful and ongoing project ‘El Campo de Cebada’ in Madrid, Spain, demonstrates how a community transformed a vacant lot into a vibrant social hub. The phases of this study include case selection, data collection, data analysis, and presentation of the results. This study identifies key enabling factors, including agents, management, social dynamics, infrastructure, and actions. These insights offer a methodological framework for designing future collaborative, resilient, and inclusive urban spaces, addressing the complex needs of communities within our cities. Full article

This paper presents an experimental campaign conducted next to the Condoroma dam, in Perú, at 4075 m a.s.l. The tests carried out in this paper were conducted in a 21 m long channel located at the toe of Condoroma dam. The setup consisted of a series of standard profile spillways with a vertical upstream face of up to five different dimensionless heights (P/H_d) ranging from 0.5 to 2. The experimental results indicated that, the P/H_d ratio influences the discharge coefficients in Condoroma, and P/H_d ≥ 1 values are recommended for the design of the spillway profile. In addition, for all the P/H_d ratios studied, the discharge coefficients adjusted to the Condoroma altitude were lower than those reported by classical formulations used in conventional spillway designs. Finally, a generalized equation is proposed to estimate the discharge coefficient for standard spillways located in dams at similar elevations above sea level. Full article

LNG ISO tank containers are a solution for bulk liquefied natural gas (LNG) delivery to the outer islands of Indonesia that are not connected to the gas pipeline network. The design of an ISO tank frame must consider two critical parameters, strength/rigidity and weight saving, which affect the operational performance of the distribution process. The current investigation aims to numerically optimize the design of the structural frame of a 40 ft LNG ISO tank for a mini LNG carrier operation using a topology optimization framework. Two design solutions are used in the topology optimization framework: reducing the strain energy and mass retained. Mass retained was selected as the objective function to be minimized, which was assumed to be 60–80%. The proposed frame design is tested using three operational loading scenarios, including racking, lifting, and stacking tests based on the ISO 1496 standard. The convergence mesh tests were initially evaluated to obtain the appropriate mesh density in the finite element analysis (FEA). The simulation findings show that the topology optimization method of the frame design resulted in an improved design, with an increase in the strength-to-weight saving ratio. A promising result from the optimization scenario demonstrates weight savings of about 18.4–37.3%, with experienced stress below the limit criteria. It is found that decreasing mass retained causes a significant stress increase in the structural frame and ISO corner castings, especially in the stacking load. The critical recommendation in the frame design of the LNG ISO tank can be improved by eliminating the saddle support and bottom frame and increasing the thickness of the vertical frame. Full article

The aim of this review paper is to collect and discuss the most relevant and updated contributions in the literature regarding studies on new or non-conventional technologies for propulsion–airframe integration. Specifically, the focus is given to both evolutionary technologies, such as ultra-high bypass ratio turbofan engines, and breakthrough propulsive concepts, represented in this frame by boundary layer ingestion engines and distributed propulsion architectures. The discussion focuses mainly on the integration effects of these propulsion technologies, with the aim of defining performance interactions with the overall aircraft, in terms of aerodynamic, propulsive, operating and mission performance. Hence, this work aims to analyse these technologies from a general perspective, related to the effects they have on overall aircraft design and performance, primarily considering the fuel consumption as a main metric. Potential advantages but also possible drawbacks or detected showstoppers are proposed and discussed with the aim of providing as broad a framework as possible for the aircraft design development roadmap for these emerging propulsive technologies. Full article

Thermal comfort is increasingly recognized as vital in healthcare facilities, where patients spend 80–90% of their time indoors. Sensing, controlling, and predicting indoor air quality should be monitored for thermal comfort. This study examines the effects of ventilation design on thermal comfort in hospital rooms, proposing four distinct ventilation configurations, each with three airflow rates of 9, 12, and 15 Air Changes per Hour (ACH). The study conducted various ventilation simulation scenarios for a hospital room. The objective is to determine the effect of airflow and the diffuser location distribution on thermal comfort. The Reynolds-Averaged Navier–Stokes (RANS) equations, along with the k–ε turbulence model, were used as the underlying mathematical representation for the airflow. The boundary conditions for the simulations were derived from the ventilation standards set by the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) and insights from previous studies. Thermal comfort and temperature distribution were assessed using indices like Predicted Percentage Dissatisfaction (PPD), Predicted Mean Vote (PMV), and Air Diffusion Performance Index (ADPI). Although most of the twelve scenarios failed to attain thermal comfort, two of those instances were optimal in this simulation. Those instances involved the return diffuser behind the patient and airflow of 9 ACH, the minimum recommended by previous studies. It should be noted that the ADPI remained unmet in these cases, revealing complexities in achieving ideal thermal conditions in healthcare environments. This study extends the insights from our prior research, advancing our understanding of ventilation impacts on thermal comfort in healthcare facilities. It underscores the need for comprehensive approaches to environmental control, setting the stage for future research to refine these findings further. Full article