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.
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.
Bachelor Degree of Mechanical and Manufacturing
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.
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.
A Study on Sustainability of a Multipurpose Cooker by Using SolidWorks Sustainability Analysis
This study focuses on designing and assessing the sustainability of a multipurpose cooker to meet the growing demand for eco-friendly, energy-efficient kitchen appliances. Using SolidWorks Sustainability tools, the research evaluates material selection, thermal efficiency, and environmental impact through lifecycle analysis. Key metrics such as carbon footprint, energy consumption, air acidification, and water eutrophication are analyzed. The study balances environmental benefits with production costs, comparing design alternatives to identify the optimal solution for performance and sustainability. The findings aim to reduce waste, enhance recyclability, and promote durable, safe, and cost-effective cooker designs, contributing to sustainable engineering practices.
Characterisation of Cassava Peel-Derived Silica at Varied Combustion Temperatures: Identifying the Optimum for Filler Applications
This study looks at the possibility of using cassava peel, which is a common waste product from agriculture and industry, as a long-term source of high-purity silica by controlled burning (400–800 °C) and acid leaching. FTIR, SEM, and TGA were used to look at the structural and thermal properties of the silica that was taken out. The results showed that silica made at 600–700 °C had the best properties, such as high purity, an amorphous structure, and better thermal stability. The cassava peel-derived silica had the same physical and chemical properties as commercial silica, showing that it could be used as a cheap, environmentally friendly filler for polymers. This also shows how useful agricultural waste can be in developing sustainable materials engineering.
Bachelor of Mechanical Engineering with Honours
Mohamad Firdaus Dzilikhram Bin Mohamad Fatahiyudin
Development of Small-Scale Hydro Energy Harvester using Piezoelectric Sensor
This project presents the development of a small-scale hydro energy harvester that utilizes piezoelectric technology to convert mechanical energy from water movement into electrical energy. The main objective is to explore a renewable energy solution suitable for powering low-energy devices, particularly in rural or off-grid areas where access to conventional electricity is limited. The energy harvester prototype was designed and fabricated using water-powered mechanisms to simulate different types of water motion, including artificial waves, flowing water, and falling water. A supporting circuit system was implemented to collect, rectify, and store the generated electrical energy. The system’s performance was evaluated based on the effectiveness of each water condition in generating electricity through mechanical interaction with the piezoelectric element. The results demonstrated that the type and intensity of water movement significantly influence the efficiency of energy harvesting. Among the tested scenarios, falling water showed the most promising performance due to the greater mechanical force exerted. This study confirms the feasibility of utilizing hydro-based piezoelectric systems for micro-energy harvesting applications. In conclusion, the developed prototype offers a practical and sustainable approach for generating renewable energy on a small scale. It holds potential for powering low-power electronic devices, environmental sensors, or Internet of Things (IoT) modules, contributing to the advancement of green energy technologies.
Analytical Study to Produce The Green Hydrogen Via Wind Energy in Malaysia
The study explores the possibility of generating green hydrogen using wind power in Malaysia. It revolves around incorporating wind-driven electrolysis as one of the hydrogen production avenues that comply with the decarbonization targets in Malaysia. The issues facing integration of wind and hydrogen are severe wind speed, a deficiency of special turbine technologies and a know-how gap, which are mentioned. The process will include the modelling of wind turbines and hydrogen plant, gathering data on wind profiles of cities chosen in Malaysia, and simulations with MATLAB Simulink to evaluate the rates of production. Findings indicate that there is a potential of introducing hybrid renewable system to increase the reliability and efficiency of hydrogen generation, despite the moderate wind climate in Malaysia. The results present knowledge to develop a local green hydrogen structure.
Green hydrogen, Wind energy, Renewable energy, Electrolysis,MATLAB Simulink, Malaysia.
BACHELOR OF MECHANICAL ENGINEERING TECHNOLOGY (PLANT) WITH HONOURS
The Impact of an Upgraded Ventilation System on Thermal Comfort in the Newly Renovated UTHM’s Badminton Hall
This study investigates the impact of an upgraded natural ventilation system on thermal comfort within the newly renovated Universiti Tun Hussein Onn Malaysia (UTHM) badminton hall. Achieving sufficient thermal comfort is crucial for occupant performance and well-being, as athletic activities like badminton require a high metabolic rate. Previous assessments indicated that the original ventilation system failed to maintain appropriate indoor environmental conditions. This study aims to evaluate whether the upgraded system, which includes additional exhaust fans, improves thermal comfort. The findings showed that 90% of respondents experienced thermal conditions, with an average TSV of +0.5, that were within or close to the acceptable PMV range of -0.5 to +0.5. Compared to earlier studies, objective measurements indicated a reduction in extreme temperature fluctuations and a moderate improvement in air velocity. However, inadequate airflow persisted in certain localized areas. In conclusion, the upgraded ventilation system has contributed to improving the thermal comfort standards of the UTHM badminton hall. These results provide valuable insights for future enhancements in similar indoor environments and reinforce the importance of proper ventilation design and air flow in naturally ventilated sports facilities.
Geometric Influence on Microstructure and Mechanics in Welded A36 Mild Steel
Welding is widely employed in manufacturing due to its cost-effectiveness and mechanical reliability. However, heat from welding alters the base material's microstructure, especially in the Coarse Grain Heat-Affected Zone (CGHAZ). This study investigates the effect of plate geometry on the microstructural evolution and mechanical properties of A36 mild steel welded under constant heat input. Specifically, two sets of welded plates with identical thicknesses (6 mm) but different lengths (Set A: 109mm, Set B: 198mm) were subjected to mechanical and microstructural analysis. The key tests included tensile testing, hardness testing, and optical microscopy. Results showed significant variation in cooling rates and mechanical performance due to geometric differences. Set A exhibited higher tensile strength and hardness due to faster cooling, while Set B showed improved ductility but coarser microstructures. This research emphasizes the crucial role of plate length in thermal behavior and structural performance during welding.
Microstructure Analysis of Laser Welded Ferritic Stainless-Steel Interconnect for Solid Oxide Fuel Cell
Solid Oxide Fuel Cells (SOFC) require durable and thermally stable interconnect materials, and ferritic stainless steels like AISI 430 have emerged as a strong candidate due to their cost-effectiveness and good oxidation resistance. In this study, laser welding was used to join AISI 430 stainless steel plates, aiming to maintain structural integrity while minimizing thermal distortional important factor in fuel cell stack assembly. Microstructural analysis was carried out across the weldment, focusing on the fusion zone (FZ), heat-affected zone (HAZ), and base metal (BM). The weld metal exhibited a structure of ferrite while the HAZ showed distinct grain growth and refinement patterns depending on heat input. Fine precipitates and microstructural changes at the grain boundaries were also observed, which could influence the electrical and mechanical performance of the interconnect in long-term SOFC operation. These findings contribute to a better understanding of how laser welding affects the internal structure of ferritic stainless steels and support efforts to optimize welding techniques for high-temperature fuel cell applications.
Impact Analysis of a Lattice Structure Based Design of Motorcycle Helmet Liners Using Finite Element Modelling
The fact that the number of motorcycle accidents is increasing in Malaysia means there is an urgent need of high-quality helmet designs that could offer better protection of head injuries caused by intense type of collision. In this research, the finite element analysis or FEA in ANSYS Workbench used to study the protective behavior of the foam-filled lattice core sandwich structure motorcycle helmet as compared to the traditional expanded polystyrene (EPS) liner structure of a motorcycle helmet. The study methodology entails extensive three dimensional finite element modeling of the traditional, as well as lattice core-filled helmet design including significant assignment of material properties, meshing, and boundary conditions that allow full three dimensional finite element modeling simulation of a realistic, three dimensional, 5 m/s, linear, side-region impact condition with dynamic loading, or appropriate ligament modeling and characteristics of the headform. The results of the simulation proved the excellent performance of the lattice core-filled helmet design a total of 75.9 percent decrease of deformation (0.19415 m to 0.046752 m), 97.9 percent decrease of equivalent elastic strain (2.2006 m/m to 0.046752 m/m), and much better stress management where stress dissipated fast when it reaches a peak equivalent stress of 132.92 MPa and quickly reduced against the sustained 16.176. Foam-filled lattice core helmets demonstrate significant enhancements in motorcycle crash protection through superior energy absorption, structural integrity, deformation resistance, and stress dissipation, thereby establishing a quantitative foundation for advancing future helmet safety standards.
Impact of Sintering Temperature on Silica Water Filter Fabricated via Cold Isostatic Pressing
This study investigates the effect of sintering temperature on the properties and performance of silica water filters fabricated using the Cold Isostatic Pressing (CIP) method. Silica samples were compacted using CIP and sintered at three temperatures: 1000°C, 1100°C, and 1200°C. Scanning Electron Microscopy (SEM) was used to observe the microstructure and grain bonding. Physical properties such as porosity, density, shrinkage, and water absorption were evaluated to understand the influence of sintering conditions. Filtration performance tests were conducted to assess the efficiency of each sample. The findings aim to identify the optimal sintering temperature for producing high-performance silica water filters with improved structural integrity and filtration efficiency.
Numerical Investigation of Crash Energy Distribution of Lightweight Vehicle at Medium and High-Speed Impacts
This study investigates how crash energy is distributed in a lightweight vehicle during frontal collisions at 45 km/h and 90 km/h using Finite Element Analysis (FEA) in ANSYS. As there is an increased demand of fuel efficient and environmentally supporting vehicles, the usage of lightweight materials such as aluminum is on the rise. Although these materials add to functioning and productivity, the problems in accidents emerge. The simulation findings indicated that during medium speeds, light weight vehicles are crashworthy, yet during high speeds severe deformation and concentration of stress undermines structural strength. The paper emphasizes the importance of hybrid materials and advanced design reinforcements aiming at the equilibrium between effectiveness and safety of the occupants.
Crash Energy Distribution, Lightweight Vehicle, Finite Element Analysis (FEA), Vehicle Crashworthiness
Effect of Reynolds Number on Minor Loss Coefficient of a T-Strainer
Loss coefficient is very important to determine minor loss occur in the piping system. This project is carried out because there is no information for the T-strainer loss coefficient. So, this project is done to determine the value of loss coefficient for T-strainer. To determine T-strainer loss coefficient at different Reynolds number, the apparatus needs to be design and fabricated. The result shows that at low Reynolds number (Re < 20000), minor loss coefficient value is inversely proportional to the value of Reynolds number while at high Reynolds number (Re > 25000), the value of minor loss coefficient almost constant. To determine the optimal link between the Reynolds number and the value of the minor loss coefficient at low Reynolds number, the correlation and regression methods were used. The outcome demonstrates that the best correlation between the Reynolds number and the value of the minor loss coefficient was found is the cubic equation. However, the quadratic relationship graph pattern is more preferable than the cubic relationship graph pattern. The value of R and R-squared are 0.9902, 0.9804 respectively. At high Reynolds number, the loss coefficient for T-strainer is 13.37.
Effect of Composition on the Properties of Silica Foam Produced by Slurry Method
This study explores the fabrication of silica foam derived from rice husk-based silica for potential use in water filtration systems. Silica served as the primary material, while polyethylene glycol (PEG) and carboxymethyl cellulose (CMC) were employed as binders in the slurry formulation. The investigation focused on the influence of different silica compositions, specifically 45 wt.%, 50 wt.%, and 55 wt.% at a constant sintering temperature of 1200°C. The resulting foams were characterized through morphological analysis using Scanning Electron Microscopy (SEM), density and porosity measurements following ASTM C20 standards, and compressive strength testing in accordance with ASTM C773-88. Pore sizes ranged from 237.12 µm to 452.08 µm. Foam analysis revealed an inverse relationship between density and porosity. The optimal density (0.5591 g/cm³) was recorded at 50 wt%, while maximum porosity (69.61%) occurred at 45 wt.%. Compressive strength peaked at 55 wt.% (0.162 N/mm²), indicating sufficient mechanical integrity. The findings underscore the significance of slurry composition, curing, and application methods in achieving optimal structural and mechanical properties. Overall, the replication method proved effective in producing silica foams with promising characteristics for sustainable and efficient water filtration applications.
Surface Integrity Study of AISI D2 Steel Using Powder Mixed RBD Palm Oil-Based Dielectric Fluid in Electrical Discharge Machining Process
A series of regulated electrical discharges between an electrode and a workpiece immersed in a dielectric fluid removes material from the workpiece during Electrical Discharge Machining (EDM). The dielectric fluid plays a crucial role by aiding cooling, stabilizing sparks, and removing debris, all of which influence machining performance. This study examines the surface integrity of AISI D2 steel machined using a copper electrode with biodegradable Refined, Bleached, and Deodorized (RBD) palm oil, both with and without nano aluminum oxide (Al₂O₃) powder, in comparison with conventional kerosene-based dielectric fluids. The experiments varied peak current (10A, 20A, 30A) and pulse durations (50 µs, 100 µs, 150 µs), focusing on surface roughness (Ra), recast layer thickness (RL), and microhardness (MH) as key responses. The findings reveal that adding nano-alumina powder to both kerosene and RBD palm oil significantly improves surface finish and reduces recast layer thickness, with kerosene with powder achieving the thinnest RL and lowest Ra. Although kerosene generally produces a smoother surface, RBD palm oil with powder demonstrates comparable effectiveness while providing a more sustainable alternative. Microhardness near the machined surface increased across all dielectrics due to thermal effects and rapid solidification, with powder-mixed fluids aiding in controlling heat distribution and stabilizing discharges. These results indicate that powder-mixed RBD palm oil is a practical and environmentally friendly substitute for petroleum-based fluids in EDM, maintaining machining quality while aligning with global sustainability goals
Effect of Design of Uniform Packing Characteristic to Improve Cooling Tower Performance
An experimental study of the effect of uniform packing design on cooling tower performance is presented in this thesis, with a focus on contrasting a newly developed Uniform Packing New Design (UPND) with a Previous Packing Design (UPPD) and a Non-Uniform Packing (NUP) configuration. Thermal performance is assessed under a range of operating conditions, including inlet water temperatures of 35°C, 43°C, and 50°C, and water flow rates ranging from 25 to 200 kg/h, using a laboratory-scale cooling tower apparatus (Model HE 152). The primary factors that were looked at were the tower characteristic (KaV/L) and the cooling efficiency. The results show that the UPND does much better than the UPPD in all tested conditions. The tower characteristic values were 0.35, 0.39, and 0.37, which is an improvement of 52%, 86%, and 76%, respectively. UPND also showed better cooling efficiency across the tested temperature range, with values of 64.59%, 57.05%, and 54.89%, which was up to 54.3% better than UPPD. The better performance is due to better contact between water and air, a more even flow distribution, and the removal of thermal dead zones in the packing structure. NUP worked best at certain liquid-to-gas (L/G) ratios, but UPND worked well and consistently over a wider range of L/G ratios (0.20 to 1.70), showing that it can handle changing load conditions. The study finds that the uniform packing design not only improves heat rejection and thermal stability, but it also fits with sustainable energy goals by lowering entropy generation and fan energy use. These results show that UPND is a practical and high-performance option for industrial cooling systems. They also help make cooling tower technologies that are more efficient, reliable, and good for the environment.
Uniform packing,Cooling efficiency, Packing design,Heat rejection,Tower characteristic.
Mechanical Engineering, Thermal Systems, Energy Engineering
Field Study of Car Discs Brake Temperature at Highway Exit Using Infrared Thermography
This study investigates the thermal performance of Proton car disc brakes under real-world driving conditions on the PLUS Highway using infrared thermography. The primary objective was to capture and record the operating temperature of Proton car disc brakes using infrared thermography, while also analyzing the temperature distribution and thermal behavior under real-world highway driving conditions, including frequent braking events at toll plazas. Using the FLIR T640 infrared thermography camera, real-time temperature data were collected at various times of the day, considering the impact of environmental factors such as ambient temperature and humidity. The results revealed significant temperature variations, with higher temperatures recorded during peak traffic, raising concerns about brake fade, disc warping, and potential wear. The study emphasizes the importance of thermal management in braking systems, proposing design improvements to enhance heat dissipation and reduce wear. This research provides valuable insights into the behavior of Proton car disc brakes in highway conditions and contributes to improving vehicle safety and brake system performance. Additionally, the study highlights the need for further research into alternative materials and cooling techniques for automotive braking systems to address the challenges posed by heat accumulation.
Fire Safety Assessment at Block G2 FKMP, Universiti Tun Hussein Onn Malaysia
Fire safety awareness and preparedness among Malaysian university students remain a key concern, as many studies have found gaps in training, infrastructure, and behavioral readiness despite current safety measures and awareness efforts. This study reveals numerous significant factors influencing fire safety preparation among university inhabitants, including limited participation in fire drills, lack of fire extinguisher training, insufficient awareness of emergency procedures, and inadequate visibility of safety signage and equipment. The emphasis of this study is specifically on tenants of Block G2 under the Faculty of Mechanical and Manufacturing Engineering (FKMP) at University Tun Hussein Onn Malaysia (UTHM), Parit Raja. The purpose is to examine the level of fire safety knowledge, preparedness, and the effectiveness of present fire safety measures. Data was obtained from 102 respondents through structured questionnaires and processed using SPSS software version 27. The findings of the ANOVA analysis revealed no significant differences (at p = 0.05) in fire safety awareness across demographic variables such as age, year of study, gender, department, and role. However, Pearson correlation analysis indicated high statistical connections (r > 0.5, n = 102, p < 0.05) between knowledge of fire alarms, frequency of fire drills, and evacuation confidence, demonstrating that these factors strongly affect readiness. It is intended that the findings of this research would assist FKMP in strengthening fire safety culture and emergency response preparation among students and staff. Based on the results, proposed treatments include enhancing fire safety training programs, increasing the frequency of fire drills, improving the visibility of safety signage, and adding digital alert systems to strengthen overall campus safety management.
Faculty of Mechanical and Manufacturing Engineering
Development of Integrated Renewable Energy Harvesting System
Malaysia has a lot of potential for solar, wind, and wave energy because of its tropical environment and long coastline, however the output of the current systems, when installed separately, is uneven because of weather fluctuations. This project suggests and constructs an integrated renewable energy harvester system designed for Malaysia's coastal circumstances, driven by the demand for a more reliable and sustainable energy solution. With power management and storage to guarantee continuous output, the system includes thin-film solar panels, a Savonius wind turbine, and a point absorber wave mechanism. The prototype was tested in real-world settings using locally sourced materials, and under ideal circumstances, it produced a peak output of roughly 14.6 V and 1.07 W. The findings support the viability, economics, and environmental compatibility of such a hybrid system for reliable renewable energy production in coastal areas.