Research Progress in Mechanical and Manufacturing Engineering
Research Progress in Mechanical and Manufacturing Engineering (RPMME) is a single-blind peer-reviewed Periodical which publishes 2 times a year (February and September), focuses on the publication of original and innovative research results that contribute to clarify mechanical and manufacturing engineering.
Repetitive Bending and Straightening of Sheet Metal: Effects on Microstructure and Mechanical Performance
This project investigates how the Repetitive Bending and Straightening (RBS) process affects the strength and internal structure of galvanized iron. The main goal was to compare the grain size and mechanical strength of the metal before and after undergoing 3 and 5 cycles of bending. To do this, the grain size was measured using a microscope, and the strength was tested using a tensile testing machine. The results showed that as the number of bending cycles increased, the grains (original) to 7.68 um inside the metal grew larger, increasing from 4.22 um (5 cycles). The tensile tests revealed that the original unbent metal was the strongest, with a maximum stress of 335.63 N/mm². Overall, the study concludes that this bending process made the material weaker and caused the grains to expand, rather than improving its strength.
Repetitive Bending and Straightening (RBS)
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia (UTHM),
Copyright (c) 2026 Research Progress in Mechanical and Manufacturing Engineering https://creativecommons.org/licenses/by-nc-sa/4.0
Development of Directly Recycled AA6061 Aluminium Composite Reinforced with Graphite Using Casting (Foundry) Method
Aluminum alloy AA6061 is widely used in engineering applications due to its favorable strength-to-weight ratio, corrosion resistance, and good machinability. With an increasing emphasis on sustainability and energy efficiency, secondary recycling of aluminum has become a crucial alternative to primary production, which is highly energy-consuming. This study investigates the development of directly recycled AA6061 aluminum composites reinforced with graphite using a casting (foundry) method. Recycled AA6061 chips were reinforced with different graphite volume fractions (5%, 10%, and 12.5%) and fabricated through controlled casting conditions. The mechanical and physical properties of the composites were evaluated through tensile testing, Vickers microhardness measurements, and density analysis. Microstructural characteristics were examined using optical microscopy, scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS). The results indicate that incorporating graphite improves microhardness and reduces density, thereby contributing to the lightweight characteristics of the material. An optimum graphite content was observed to enhance tensile strength, whereas excessive graphite addition led to particle agglomeration, increased porosity, and weakened interfacial bonding. Microstructural analysis confirmed grain refinement and successful incorporation of graphite within the aluminum matrix. Overall, the findings demonstrate that graphite-reinforced recycled AA6061 composites produced via casting offer a promising and sustainable approach for lightweight engineering applications, provided that the reinforcement content and processing parameters are carefully optimized
Numerical Analysis of Bumper System Performance in Low and Medium Speed Impacts
This study uses Finite Element Analysis (FEA) to analyze the performance of bumper systems in low and medium-speed crashes. The study's goal is to determine how well lightweight materials like aluminum alloy and magnesium alloy absorb impact energy during collisions at speeds of 20 and 40 km/h, respectively. ANSYS was used tosimulate frontal impacts on bumpers against a structural steel wall. The findings demonstrate that, while both materials performed well at low speeds, aluminum alloy outperformed magnesium alloy at medium speeds, demonstrating superior energy absorption and structural integrity. The findings indicate that additional design modifications, such as hybrid materials or reinforced constructions, could increase bumper performance and safety in normal driving circumstances.
Crashworthiness, Lightweight material and Energy absorption
Bachelor Degree of Mechanical and Manufacturing
Improvement on the Design of a Palm Fruit Lifting Device for Truck
The oil palm sector, particularly in Malaysia, is a vital contributor to the global supply; however, harvesting and loading fresh fruit bunches (FFBs) onto trucks is still a labor-intensive operation that causes serious musculoskeletal diseases in workers. This project overcomes the limitations of an earlier lifting device design done by Wan Sayyidil Athir, which was determined to be extremely heavy at 370.56 kg, with a lifting speed of 0.78 m/s that didn’t achieve the targeted speed at around 1 m/s, and was unsuitable for remote locations due to its reliance on a stable electrical supply. This study focuses on three key improvements: a lightweight design with a target weight under 250 kg, an engine-driven power system for plantation areas that are weak in electrical supply, and a flexible, foldable structure for easier storage and transport. The design process included the creation of 3D models, motion simulations, and detailed engineering drawings using SolidWorks software, following a modified George E. Dieter design method. The results of this project include an improved lifting device utilizing a power transmission system with an engine and gearbox to achieve a lifting speed of 0.96 m/s, meeting user expectations for efficiency. This project successfully achieves its objectives by enhancing the device’s field-adaptability and providing a more portable solution for actual plantation settings.
Effect of Reynolds Number and Temperature on Water Heater Loss Coefficient
The Loss coefficient of the heater determines how much pressure drop occurs as fluid flows through it. Accurate estimation of the loss coefficient of the heater is essential for optimizing thermal system performance. A higher loss coefficient of the heater indicates greater resistance to flow, which can reduce system performance. To determine the effect of Reynolds Number and temperature on water heater loss coefficient, an experimental apparatus was designed and fabricated to measure pressure differences and flow rates across a water heater system. Tests were conducted based on two different conditions which is temperature constant, different volumetric flowrate and different temperature, constant volumetric flowrate. The experimental findings demonstrate that the heater’s loss coefficient exhibits a direct proportionality to the Reynolds number. This relationship suggests that flow regime and velocity play a dominant role in determining the hydraulic resistance of the heater. In contrast, variations in fluid temperature were observed to have no measurable influence on the loss coefficient. This indicates that thermal effects, within the tested range, do not significantly alter the fluid’s interaction with the heater geometry. This outcome highlights the dominance of flow dynamics over thermal influences in determining hydraulic resistance. These findings provide a useful basis for optimizing heater design and improving efficiency in thermal fluid systems.
Characterization and Analysis of Bottom Ash Derived from The Combustion of Empty Fruit Bunch (EFB) for Potential Fertilizer
The palm oil industry generates large quantities of Empty Fruit Bunch (EFB), creating challenges in waste management and environmental sustainability. Combustion is commonly used to reduce EFB volume but the resulting bottom ash is often discarded despite its potential nutrient. This study investigates the characteristics of bottom ash produced from the combustion of EFB pellets to assess its suitability for potential fertilizer applications. EFB pellets were combusted at 200 °C, 300 °C, and 400 °C for 60 minutes inside a combustion chamber under controlled laboratory conditions. Thermogravimetric analysis (TGA) was conducted to evaluate the thermal decomposition behavior of raw EFB, while scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM–EDX) and X-ray diffraction (XRD) were used to analyze ash morphology, elemental composition, and mineralogical phases. The results indicate that increasing combustion temperature enhances mineral crystallinity and reduces residual carbon content. The bottom ash contained essential plant nutrients such as potassium, calcium, magnesium, phosphorus, and silicon, with progressive formation of thermally stable mineral phases at higher temperatures. Among the conditions studied, combustion at 300 °C produced ash with balanced mineral composition and limited sintering, indicating favorable characteristics for agricultural application.
Assessment of Power and Torque Delivery Profiles in a Small-Displacement Engine Following Bore Modifications
This project focuses on the repair, calibration, and performance evaluation of a motorcycle chassis dynamometer to ensure accurate and reliable engine testing, specifically for the Yamaha Y15ZR. The dynamometer initially exhibited mechanical wear, sensor malfunctions, and calibration drift, resulting in inconsistent torque, power, and RPM readings. Through systematic troubleshooting and covering mechanical realignment, electrical repairs, and sensor recalibration in the system was restored to proper working condition. A calibrated testing setup was then used to establish baseline engine performance data, followed by comparative tests using two different flat-top ceramic pistons (57 mm and 63mm). The use of ceramic pistons, known for high thermal resistance and low heat conductivity, allowed the study to examine variations in combustion efficiency, heat transfer characteristics, and emission behavior across different piston sizes. Preliminary results show improved combustion stability and measurable changes in power output and exhaust temperature corresponding to piston diameter. Overall, this project provides a functional dynamometer platform and meaningful insights into how piston geometry and material influence motorcycle engine performance, supporting future tuning, research, and development efforts
Chassis dynamometer, Piston size, Motorcycle performance.
BACHELOR OF MECHANICAL ENGINEERING WITH HONOURS
Design Analysis of a Foldable Wheel Clamp
This project aims to design and develop a foldable wheel clamp that addresses the common limitations of traditional immobilization devices, such as excessive weight, bulkiness, and lack of adjustability. Conventional clamps, typically constructed from heavy steel or cast iron, are cumbersome to transport and often damage alloy wheels during installation and removal. To overcome these shortcomings, the proposed design incorporates lightweight, high-strength materials, an ergonomic form factor, and a telescopic adjustment mechanism compatible with wheel diameters ranging from 14 to 18 inches. A scissor-type folding mechanism enables compact storage, while a linear actuator automates deployment, achieving full extension in approximately 5 seconds. Rubberized contact pads are integrated to prevent wheel surface damage during clamping. The design methodology encompasses conceptualization, functional decomposition, material selection, and iterative validation using Computer-Aided Design (CAD) and Finite Element Analysis (FEA). The concept was evaluated through a weighted decision matrix prioritizing security, portability, and ease of use. Results indicate that the foldable wheel clamp offers significant improvements in robustness, weight reduction, and ergonomic handling, thereby decreasing the time and physical effort required for deployment. Primarily intended for law enforcement and parking enforcement applications, the design presents a modern, user-centric solution for vehicle immobilization. Future work may explore integration with smart locking systems and field validation of the motorized deployment mechanism under real-world conditions.
MUHAMMAD IZZUDIN BIN MOHD BAKRI MOHDBAKRI
Comparative Study of Different Packing Designs in Counterflow Wet Cooling Towers
This study presents a comprehensive comparative analysis of three polyvinyl chloride (PVC)-based packing designs non-uniform film fill (NNU), double S-wave fill (DSW), and expanded wire mesh (EWM) in a counter-flow wet cooling tower. The research addresses gaps in existing literature, which often evaluates single packing types under idealized conditions, leading to suboptimal selections in industrial applications and increased energy and water consumption. NNU features irregular film paths promoting adaptive flow and turbulence for enhanced heat and mass transfer; DSW incorporates dual S-waves to optimize surface area, improve water distribution, and minimize pressure drop; while EWM provides intermediate turbulence via its expandable mesh structure for flexible airflow. Experiments were conducted using the SOLTEQ HE152 bench-top cooling tower at inlet water temperatures of 35°C, 43°C, and 50°C, with water flow rates varied from 25 to 200 kg/h under constant airflow. Key performance indicators, including tower characteristic (KaV/L or NTU), cooling efficiency, and energy consumption, were evaluated against liquid-to-gas (L/G) ratios. Results demonstrate that NNU achieves the highest average tower characteristic values (0.4036 at 35°C, 0.4873 at 43°C, and 0.5322 at 50°C) due to its adaptive flow paths. DSW exhibits superior cooling efficiency at lower temperatures (average 74.00% at 35°C) and the lowest energy consumption across all regimes (322.13 W at 35°C, 663.85 W at 43°C, and 774.74 W at 50°C), attributed to optimized surface area and reduced pressure drop. EWM performs well at intermediate temperatures but shows greater variability. Efficiency decreases while energy consumption increases with rising L/G ratios and temperatures. This research provides empirical guidelines for packing selection to optimize thermal performance, reduce operational costs, and align with Sustainable Development Goals (SDGs) related to energy efficiency (SDG 7) and water conservation (SDG 6).
Indoor Air Quality Assessment in an Aging Educational Building: A Case Study of the ICRC Office, UTHM
Indoor air quality (IAQ) plays an important role in maintaining occupant health, comfort, and productivity, particularly in office environments. Aging buildings are often associated with ventilation limitations and deteriorated systems that may contribute to indoor pollutant accumulation. This study presents an IAQ assessment conducted at the Industry Community and Relations Centre (ICRC) Office, Universiti Tun Hussein Onn Malaysia (UTHM), an educational building established in 1999. The assessment involved walkthrough inspection, physical measurements using sensor-based instruments, subjective evaluation through an occupant questionnaire survey, and comparison with the Industry Code of Practice on Indoor Air Quality (ICOP IAQ 2010) guidelines and previous IAQ data. The subjective assessment focused on occupants’ perceptions of indoor comfort and the occurrence of IAQ-related symptoms during working hours. Key physical parameters evaluated include air temperature, relative humidity, and air movement, while chemical parameters include carbon dioxide, carbon monoxide, ozone, formaldehyde, particulate matter, and total volatile organic compounds. Most parameters were within acceptable limits; however, particulate matter (PM₁₀) exceeded the ICOP IAQ 2010 limit of 0.15 mg/m³, with concentrations of 0.328 mg/m³ on Day 1 and 0.220 mg/m³ on Day 2. Elevated PM₁₀ levels are likely influenced by infrequent housekeeping activities and carpeted flooring. Correlation analysis indicated an association between increased particulate matter levels and reported symptoms such as fatigue and headaches, suggesting potential Sick Building Syndrome (SBS) conditions. The findings highlight the importance of continuous IAQ monitoring and proper maintenance of ventilation systems in aging educational buildings.
CHE MUHAMMAD NAQEB BIN CHE BAHARUM CHE BAHARUM BIN CHE BUSU
Enhancing Resource Use Efficiency (RUE) in Indoor Vertical Farming Systems (PACER)
Indoor vertical farming systems offer high productivity but require efficient management of resources. The effect of inefficient management of resources will lead to increase in operational cost and reduce sustainability. This study aim to evaluate and enhance Resource Use Efficiency (RUE) in indoor farming system operated at PACER UTHM. The methodology involved conducting water, energy, nutrient and Carbon Dioxide audits. Performance are analyzed relative to crop yield, the indicator involved are Water Use Efficiency (WUE), Energy Use Efficiency (EUE), Nutrient Use Efficiency (NUE) and Carbon Dioxide Use Efficiency (CUE). The finding shows that WUE is 1.3052, while EUE is 0.1717. NUE obtained are 11.1935 and CUE are 45.8351. The outcomes provides insight into sustainable indoor farming practices and support the development of more efficient resource controlled environment.
Indoor Vertical Farming; Resource Use Efficiency; Energy Management; Hydroponic Systems; Controlled Environment Agriculture; Sustainability Assessment
Mechanical Engineering; Agricultural Engineering; Sustainable Engineering
PROF. MADYA Dr. AKMAL NIZAM BIN MOHAMMED
Energy Audit and Energy Efficiency Improvement Proposal for Pejabat Pembangunan dan Penyenggaraan (PPP), UTHM
Since Malaysia's building industry contributes significantly to the country's energy consumption, energy efficiency is a top national concern. The Sustainable Energy Management System (SEMS) is presently being implemented by Universiti Tun Hussein Onn Malaysia (UTHM) in order to enhance its energy performance. This study focuses full on carrying out an energy audit at the Pejabat Pembangunan dan Penyenggaraan (PPP) building, where issues with inefficient and unmonitored energy usage have been found. This study evaluates the energy consumption patterns of the PPP building and investigates major inefficiencies across key systems, including lighting, and MVAC system. The data were collected through a walkthrough audit and the UTHM energy monitoring system known as ENERGY SCADA. The walkthrough audit provided information on equipment type, operating conditions, and usage behavior, while the SCADA system supplied real-time measurements of power, cost, and energy trends throughout the year. Analysis of the data collected helps to reveal the building’s energy consumption and overall energy performance. The result from the audit indicates opportunities for improvement and the unnecessary energy consumption. This study supports PPP's efforts to improve operational efficiency by identifying consumption trends, inefficiencies, and possible low-cost or high-impact alternatives. The PPP Building Energy Index (BEI) is 74.20 kWh/m2/year below than the standard of MS 1525:2019. This indicate PPP energy consumption is not exceed the standard. The findings of PPP BEI also support UTHM's larger sustainability objectives in reducing energy consumption systematically and act as a baseline for upcoming energy audits in UTHM.
Pejabat Pembangunan dan Penyenggaraan (PPP)
Computational Fluid Dynamics (CFD) Analysis of Electrolyte Flow Over Electroplating Surfaces with Integrated Flow Straighteners
Electroplating is a critical process in semiconductor manufacturing, where the uniformity of metal deposition is directly governed by the distribution of electrolyte flow. Non-uniform flow often leads to current density variations and coating defects; therefore, this study utilizes Computational Fluid Dynamics (CFD) to optimize the design of integrated flow straighteners within a rectangular electroplating cell. Using the Shear Stress Transport (SST) k-ω turbulence model, a parametric analysis was conducted to evaluate the hydrodynamic effects of varying blade quantities and blade thicknesses. Flow uniformity was quantified using the Coefficient of Variation (CV) of velocity magnitude across the cathode surface. The results indicated that flow uniformity is non-linearly dependent on geometric parameters, with an optimal configuration identified at 23 blades and a blade thickness of 3.25 mm, achieving a minimum CV of 0.050. Furthermore, a dimensionless design correlation based on the Open Area Ratio, ∅ was formulated, revealing a theoretical optimum ratio of approximately 0.37. This finding establishes that the balance between flow guidance and blockage is the governing factor for uniformity, providing a robust, scalable engineering protocol for designing highprecision electroplating systems.
Investigation of Processing Parameters on the Mechanical and Physical Properties of AA6061 Chip-Based Forged Parts Using MLR-GA Method
Solid-state recycling of aluminium offers an energy-efficient and environmentally friendly alternative to conventional melting-based methods. This study investigates the influence of processing parameters on the mechanical and physical performance of AA6061 chip-based forged components using Multiple Linear Regression (MLR) and Genetic Algorithm (GA) techniques. Aluminium chips produced by high-speed milling were consolidated through hot press forging at temperatures of 450°C, 500°C, and 550°C, with holding times of 60, 120, and 180 minutes. Tensile testing was conducted to assess the mechanical properties, with the ultimate tensile strength (UTS) selected as the main response variable. In addition, density testing was carried out to evaluate the physical properties of the forged samples. The MLR models successfully established correlations between forging parameters and UTS, while GA optimization identified the most favourable conditions for superior mechanical properties. The results showed that a higher forging temperature of 550°C and a longer holding time of 180 minutes improved the bonding between chips, resulting in higher UTS. The highest UTS was achieved at 550°C, 180 minutes, and a chip surface area of 73.77 mm². These findings highlight the potential of optimized solid-state recycling to produce high-quality aluminium components, thereby supporting sustainable manufacturing and efficient resource utilization in materials engineering.
CFD Analysis of Empty Fruit Bunch Drying System in Biomass Processing Application
The global shift towards biomass energy reflects the growing recognition of its potential to provide clean and renewable energy while reducing carbon emissions and promoting environmental sustainability. Empty Fruit Bunch (EFB), a by-product of the palm oil industry, has emerged as a promising biomass fuel source; however, its high moisture content significantly reduces combustion efficiency, necessitating an effective drying process. This study examines the heat transfer and thermal characteristics within a drum dryer system used for EFB drying, aiming to determine the optimal inlet air temperature and velocity for efficient moisture removal. A three-dimensional model of the EFB drum dryer was designed using SolidWorks, and computational fluid dynamics (CFD) simulations were performed using ANSYS software. The inlet air temperature ranged from 120°C to 250°C, with a volume flow rate between 0.105 m³/s and 0.185 m³/s. Results indicate that increasing both inlet temperature and air velocity enhances the outlet air temperature, whereas the inlet flow rate mainly influences the outlet velocity. The highest outlet temperature achieved was 64.17°C, suggesting that the tested operating conditions were insufficient to achieve optimal drying efficiency. These findings provide valuable insights for scaling up the system under modified operating parameters or reducing the dryer length to minimize heat loss and improve drying performance.
Copyright (c) 2025 Research Progress in Mechanical and Manufacturing Engineering https://creativecommons.org/licenses/by-nc-sa/4.0
Bridging the Gap: A Short Review of BSCF Composite Materials for Intermediate Temperature SOFC
Barium Strontium Cobalt Ferrite (BSCF) is highly regarded as the top choice for solid oxide fuel cell (SOFC) cathodes because of its exceptional catalytic activity in oxygen reduction and superior mixed electrical and ionic conductivity. This abstract provides an overview of recent research efforts focused on the synthesis, characterization, and performance evaluation of BSCF composite materials operating at intermediate temperatures. Various synthesis methods, including solid-state reaction, sol-gel and mechanical milling are discussed, along with characterization techniques such as X-ray diffraction (XRD) and scanning electron microscopy (SEM). Issues related to BSCF composites, such as chemical stability and long-term performance, are discussed, along with recommendations for future research to overcome these obstacles and enhance the commercialization of IT-SOFCs using BSCF composite materials.
The Flow Characteristic Of Simulation For Newly Developed Disposable Inhaler Spacer Geometry
Pressurized metered-dose inhalers (pMDIs) are widely used for airway disease treatment, but incorrect usage reduces their efficiency, with much of the drug depositing in the oropharynx. Spacer devices were developed to slow aerosol particles and improve lung deposition. This study compares four spacer designs using Computational Fluid Dynamics (CFD) in SolidWorks 2024, focusing on outlet velocity and pressure. Results showed that WT-Model 4 provided the most efficient and uniform airflow distribution, with velocities ranging from 0.361–1.874 m/s (average 1.628 m/s) and stable outlet pressures around 101324.84 Pa, indicating improved aerodynamic performance and drug delivery potential.
Computational fluid dynamics analysis of inhaler spacer design for improved asthma drug delivery
The Flow Characteristic of Newly Developed Disposable Inhaler
Newly Developed Disposable Inhaler Spacer Geometry
Design of Vibration Energy Harvester using Piezoelectric Sensor
This project explores the development of a vibration-based energy harvester utilizing piezoelectric sensors to convert mechanical energy into electrical energy for powering low-energy devices such as LED lighting. The primary aim is to design and evaluate a sustainable, compact system capable of capturing energy from environmental vibrations—simulated through a vibration motor—and storing it efficiently. The methodology involved integrating piezoelectric sensors with electronic components including Arduino UNO, LM7812 voltage regulator, bridge rectifier, relay module, and a 12V battery. Circuit design and prototyping were conducted using Arduino IDE, Fritzing, and SketchUp. The system was tested at various motor speeds (1000–6000 RPM), revealing a direct correlation between vibration intensity and electrical output. An array of eight piezoelectric sensors connected in parallel generated voltages up to 6V and currents up to 320 µA at peak conditions, successfully reaching the threshold to trigger energy storage and lighting. Results demonstrated improved charging rates and system efficiency with increased motor speeds and sensor counts. The project concludes that piezoelectric-based energy harvesting systems, when carefully designed and safeguarded, offer promising solutions for smart, low-power urban applications. The findings support further development toward scalable, environmentally friendly energy sources integrated within public infrastructure.
Fabrication and Characterisation of Eutectic Cast Alloy from Aluminium and Copper Wastes
This project investigates the fabrication and characterisation of aluminium-copper (Al–Cu) eutectic cast alloys using recycled metal waste materials. The primary aim was to explore the viability of repurposing scrap aluminium and copper into hypoeutectic (15% Cu), eutectic (33% Cu), and hypereutectic (40% Cu) alloy compositions. The methodology involved material collection, alloy preparation, casting, and mechanical and microstructural characterisation using hardness testing, impact resistance, optical microscopy, SEM, and EDX. Despite following precise fabrication processes, results showed that the intended compositions were not fully achieved due to copper impurity, equipment limitations, and inadequate homogenisation during melting. All specimens exhibited similar aluminium-rich microstructures and low mechanical performance, with hardness values averaging around 75–95 HV and minimal presence of the θ-phase. The lack of distinction in mechanical and structural characteristics among the samples indicates a significant deviation from the target eutectic and hypereutectic structures. This highlights the importance of material purity and process control when using waste materials for advanced alloy development. Nonetheless, the study demonstrates a foundational approach to sustainable alloy production through metal recycling, with recommendations for future improvements.
Indoor Air Quality Monitoring through Internet of Things System: A Case Study at UTHM-Fraunhofer IEM Innovation Lab
Indoor air quality (IAQ) significantly influences occupant health, comfort, and productivity, particularly in high-occupancy academic environments. This study develops an Internet of Things (IoT)-based system for real-time IAQ monitoring at Room G1 035B, UTHM-Fraunhofer IEM Innovation Lab, addressing limitations of traditional offline monitoring methods. The objectives are to investigate the interplay between IAQ, IoT technology, and mechanical ventilation and air conditioning (MVAC) systems; design a functional real-time IAQ monitoring system; and assess IAQ conditions in the selected laboratory. The system, utilizing an ESP32 microcontroller with DHT22, SGP30, and GP2Y1010AU0F sensors, was programmed via Arduino IDE and integrated with the ThingSpeak cloud platform for data storage and visualization. Data was collected over five days (June 28 to July 2, 2025), comparing ventilated weekdays and non-ventilated weekends. Results demonstrated the system’s ability to detect environmental fluctuations, with MVAC operations influencing pollutant levels and revealing energy inefficiencies due to overcooling. The system offers a scalable, cost-effective solution for real-time IAQ monitoring, providing actionable insights for healthier indoor environments.
Mechanical Ventilation and Air Conditioning (MVAC)
Innovative Redesign of an Umbrella Using Quality Function Deployment (QFD) and Theory of Inventive Problem Solving (TRIZ)
Umbrellas are essential tools for weather protection, yet many existing designs lack portability, ease of use, and adequate coverage; particularly for university students who require compact, reliable, and user-friendly solutions for daily mobility. One of the most critical issues identified is the need for umbrellas that are lightweight and foldable for easy carrying and storage, especially in backpacks or bags. The objectives of this project are to identify customer requirements for umbrellas, evaluate the importance of these requirements and the performance of existing umbrella designs, and propose design improvement using the Quality Function Deployment (QFD) and Theory of Inventive Problem Solving (TRIZ) methods. Data were collected through pilot interviews and a questionnaire survey involving 100 university students to capture users' requirements. Based on the survey analysis, the top three prioritized customer requirements were: (1) lightweight and foldable for easy carrying and storage, (2) smooth operation, and (3) sufficient coverage to keep users and their belongings dry. The integration of QFD and TRIZ effectively translated the user requirements into technical specifications and guided innovation in the design process. As a result, a new umbrella concept was proposed, featuring a head-mounted design for hands-free operation and full coverage, along with lightweight materials and an enhanced opening mechanism. The final design was developed using SolidWorks software. This study demonstrates that combining QFD and TRIZ offers a structured and effective approach to user-centered product innovation.
Theory of Inventive Problem Solving (TRIZ)
Crashworthiness Analysis of Hierarchical Multi-Cell Circular Structures Made of Recycled Aa6061 Aluminium Alloys for Sustainable Automotive Crash Box
The crashworthiness of automotive structures is crucial for vehicle safety, particularly in reducing impact forces during collisions. Hierarchical multi-cell (HMC) crash box designs, made from recycled AA6061 aluminium alloys, offer superior energy absorption and lightweight properties. However, many existing designs lack thorough evaluation under dynamic axial impact conditions, which may affect energy dissipation and structural integrity. This study analyzes stress distribution, deformation behavior, and key metrics such as Specific Energy Absorption (SEA) and Peak Crushing Force (PCF) in both traditional and HMC crash boxes under axial impact. The methodology includes 3D modeling using ANSYS Workbench and Finite Element Analysis (FEA) simulations. Results show that the conventional crash box design recorded a peak deformation of 0.031302 meters and a peak crushing force (PCF) of 4246 N, while the HMC design achieved a peak deformation of 0.022479 meters and a PCF of 3417.5 N. This indicates that the HMC design absorbed impact energy more efficiently, resulting in 6.7% less deformation and a lower peak crushing force. Additionally, the HMC crash box demonstrated a higher Specific Energy Absorption (SEA) of 6962.8 J/kg, compared to 5611.8 J/kg for the conventional crash box, further proving that the HMC design provides better energy dissipation and enhanced crashworthiness. This research introduces an innovative HMC crash box design from recycled AA6061 aluminium alloys, enhancing energy dissipation, material efficiency, and structural resilience for safer, sustainable automotive components.
A Machine Learning Framework for Predictive Maintenance of Centrifugal Water Pumps using Remaining Useful Life Estimation
Water pumps play a crucial role in various industrial, agricultural, and municipal applications. However, their efficiency and reliability are often compromised by unexpected failures, resulting in costly downtime. Traditional maintenance strategies like corrective and preventive maintenance have limitations in accurately predicting failures. This study explores the use of machine learning (ML) techniques, particularly Support Vector Machines (SVM), K-Nearest Neighbors (KNN), and Long Short-Term Memory (LSTM), to develop a predictive maintenance system that estimates the Remaining Useful Life (RUL) of centrifugal water pumps. MATLAB is used for data preprocessing, feature extraction, model training, and deployment. Sensor data is analyzed using statistical and frequency-domain techniques to extract health indicators, which are then used to train and validate predictive models. The results demonstrate the model's capability to accurately forecast pump failures, allowing timely interventions and reduced maintenance costs. This research highlights the potential of ML based predictive maintenance systems to enhance reliability and efficiency in pump operations.
Identify the Optimal Sensor Location: Analysis of Flue Gas Behavior in Stack by Using CFD Simulation
Industrial flue gas emission consists of harmful substance such as carbon monoxide (CO), carbon dioxide (CO₂), nitrogen oxides (NOₓ), sulfur dioxide (SO₂), which contribute to air pollution, climate change, and health risks. Effective emission monitoring is essential to reduce environmental impact and comply with air quality regulations. However, the accuracy of in-situ gas sensors largely depends on proper placement within the exhaust stack, as poor positioning in turbulent or unstable flow regions can result in inaccurate readings. This study aims to analyze flue gas flow behavior within an L-shaped industrial exhaust stack and determine the optimal sensor placement using Computational Fluid Dynamic (CFD) simulation. The geometry was created in SolidWorks and imported into ANSYS Fluent 2024 R1 for steady state analysis using the standard k-epsilon turbulence model. Key flow parameters such as velocity, pressure, and gas interaction with sensor geometry were examined. The stack consists of a 4-meter horizontal section, a 12-meter vertical section, and a 2-meter diameter. Four sensor locations 2 m, 4 m, 6 m, and 8 m from the outlet were tested to evaluate flow stability and suitability for sensor installation. Simulation results showed that the sensor location at 10 meters from the bend which is 2 meters before the outlet offered the most stable flow conditions, with an average velocity of 10.75 m/s and a pressure difference of only 59.5 Pa across the sensor. This minimal pressure drop indicates low flow disturbance caused by the sensor, helping maintain continuous and reliable contact between the flue gas and the sensor surface. These favorable flow characteristics support the accuracy of gas detection and confirm this location as optimal for in-situ sensor deployment. Overall, the findings demonstrate the effectiveness of CFD in guiding sensor placement strategies for enhanced emission monitoring in industrial stack systems
Real-Time Running Performance Analysis and Optimization with YOLOv8-Based AI Vision and Random Forest Classification
In this project, it was proposed to introduce an AI-enabled solution that identifies a running posture in real-time delivered through video analysis. The system employs the YOLOv8n-pose model to identify 17 anatomical keypoints in every video frame, which allows extracting three most important biomechanical properties: stride ratio, knee angle, and cadence. These characteristics are subsequently used to categorize every frame into Good or Not Good posture by a Random Forest classifier based on manually and semi-automatically labeled data. The model was also very accurate, as its precision had a value of 0.98, recall had 1.00, and F1- score was 0.99. Six running video tests were used to test the system and its results included CSV files, biomechanical graphs, and posture summaries. This study shows how non-invasive and low-cost solution can be applied instead of traditional motion capture that can be used in athletic training and rehabilitation tasks.
Transforming Silica Water Filter Waste into Sustainable Fertiliser
This study examines the reuse of silica waste from water filters combined with coffee powder as a sustainable fertilizer. Spinach was selected to evaluate the effects of silica ratios at 0%, 10%, 20%, and 30% on plant growth and soil pH. The combination of 20% silica with 30% coffee powder yielded the tallest plants and the highest number of leaves. Soil pH remained neutral, indicating the stability of the amendment. The findings suggest that this low-cost formulation can improve crop performance. This method also promotes sustainable waste management by repurposing industrial and organic residues.
Optimizing Cooling Tower Length Fan Blade Standardization in Biodiesel Plants: Approach to Cost Savings and Efficiency Improvement
Cooling towers play a crucial role in dissipating heat from industrial processes, especially in biodiesel plants where thermal management is essential. However, the diversity of fan blade lengths currently in use results in increased maintenance complexity, higher inventory costs for spare parts, and inconsistent energy performance. This study addresses the challenge of optimizing cooling tower fan blade design by proposing a standardized blade length that can deliver a balance between operational efficiency and cost-effectiveness across biodiesel facilities. The main objectives of this research are to investigate the performance of standard cooling tower designs, to develop a new blade length configuration, and to evaluate its efficiency compared to existing setups. To achieve these goals, three different blade lengths 0.7 m, 1.0 m, and 1.5 m were analyzed using Computational Fluid Dynamics (CFD) simulations conducted in ANSYS Fluent. The simulations measured critical parameters such as generated torque, airflow velocity, and energy consumption under constant rotational speed (500 RPM). A systematic comparison was made to determine the best-performing design in terms of both energy output and cost savings. Results indicated that the 1.5 m blade length demonstrated the highest efficiency with the lowest cost per unit airflow, generating a torque of 8107.30 Nm and a power consumption of 424.42 kW. Conversely, the 0.7 m and 1.0 m blades offered reduced torque and airflow, but showed potential for further optimization through aerodynamic enhancements. Despite its superior performance, the longer blade increases operational and material costs, which must be weighed against energy benefits. In conclusion, while standardizing to a 1.5 m blade offers the best performance, the study highlights the importance of balancing energy efficiency with maintenance simplicity and cost. The findings provide strategic insights for biodiesel plants seeking to streamline operations and enhance system sustainability. This research also lays the foundation for broader standardization efforts in industrial mechanical systems.
ANSYS, CFD, meter, simulations, Fan Blade, Cooling Tower, Length Blade
The Effect of Clay Content Towards the Processing of Polypropylene Nano clay Samples in Practical Injection Molding
This study investigated the effect of nano clay content (3%, 4%, and 5%) on the mechanical properties of polypropylene (PP) nanocomposites produced via injection molding. Samples were processed at temperatures of 160–170°C, an injection pressure of 73 MPa, and injection times of 5–7 seconds. Tensile testing revealed that the 3% nano clay formulation achieved a maximum tensile stress of 28.696 N/mm² and a strain of 16.732%, indicating a balance between strength and elasticity. The 4% nano clay samples exhibited superior mechanical performance with a maximum tensile stress of 33.5 MPa, while the 5% formulation showed reduced strength (29.1 MPa) due to increased viscosity and poor dispersion. The study concludes that 4% nano clay offers the optimal balance of mechanical performance and processability for industrial applications.
Polypropylene nanocomposites, nano clay, injection molding, tensile properties, processing optimization, filler dispersion, melt viscosity, mechanical performance, polymer processing, thermal stability.
Mechanical Engineering Materials Science Polymer Engineering Manufacturing Engineering
The Efficiency Performance of CNC Milling Machine with Vibration Sensor
For the purpose of to determine the operational effectiveness and surface finish quality of a CNC milling machine fitted with a vibration sensor, this study analyses its performance. The variations in machine behaviour under various cutting parameters have been studied by integrating a real-time vibration monitoring system in order to identify the factors that result in excessive tool wear, chatter, and surface roughness. Early identification of inefficiencies and possible faults was made possible by the vibration sensor's data, which offered useful details about the dynamic stability of the milling process. The findings show that vibration analysis is a dependable technique for improving cutting conditions, process control, and the overall precision and productivity of CNC milling operations.
Effect of Polyethylene Glycol (PEG) & Polyvinyl Alcohol (PVA) Concentrations on the Mechanical Behavior and Microstructure of Sintered Hydroxyapatite for Biomedical Use
The increasing number of road accidents has led to a growing demand for effective bone repair materials. Hydroxyapatite (HAp), a bioceramic that closely resembles the mineral component of natural bone, is widely used for this purpose. To enhance its mechanical properties, water-soluble binders such as polyethylene glycol (PEG) and polyvinyl alcohol (PVA) are commonly incorporated into HAp. This study was conducted with three main objectives: to characterise the fundamental material properties of Hydroxyapatite (HAp), to examine the role of binder composition (specifically PEG and PVA) in the fabrication of HAp composites, and to assess the mechanical properties of HAp composites with varying binder concentrations. Four samples were prepared using dry mixing and compaction methods, with PEG and PVA concentrations ranging from 1% to 5% by weight. Among the prepared samples, Sample 3—containing 3% PEG and 3% PVA—demonstrated the best overall performance. It exhibited high hardness (515.998 HV), moderate porosity (5.6467%), excellent yield strength (16.1356 N/mm²), and a strong crystalline structure, indicated by an intensity count of 2100. These findings reveal that the ratio of PEG to PVA significantly affects the mechanical strength, porosity, and surface quality of HAp composites, making Sample 3 particularly promising for bone replacement applications.