Box Design Research Articles

Structure design and multiobjective optimization of CFRP/aluminum hybrid crash box

AbstractTo improve the crashworthiness and reduce vehicle weight, a crash box made of carbon fiber reinforced plastics (CFRP)/aluminum (Al) hybrid materials was introduced in the paper. Quasistatic axial compression tests and numerical simulations were conducted for pure Al tubes and CFRP/Al hybrid tubes. The simulation models were validated and were further employed to investigate the effects of geometry, aluminum tube thickness, fiber wrapping angle and CFRP layers on the crashworthiness of the hybrid crash box under axial loading and 30° oblique collision. The multiobjectives were taken to obtain the optimal geometrical dimensions, aluminum tube thickness, wrapping angle, and the number of layers. The crashworthiness of the optimal CFRP/Al hybrid crash box was compared with that of original aluminum crash box. It was found that the mass of the crash box was reduced by 35.21%, while the specific energy absorption (SEA) and mean crushing force (Fmean) were increased by more than 18% and 46%, respectively. The paper was aimed to provide some references for the design and optimization of composite crash box.

Analysis and Design of Box Girder and T-Beam Bridge Superstructure - A Comparative Study

Bridges are the most important component of transportation system of any country due to their ability of accelerating the development of the nation. Design of bridge highly depends on its function, nature of soil strata where it is constructed and the material used to construct it. Extensive growth of population and traffic leads to many changes in the use and development of different types of bridges. Box and T-beam girders are most commonly used superstructure in case of bridges. In this research work, analysis and design of box and T beam girder has been performed using SAP2000 in order to find out the most suitable type of bridge superstructure. The main objective of this study is to compare the structural behavior, optimization of materials used in each component and cost comparison of box and T beam girder bridge. Previous research in this regard is based upon working stress method but this research follows limit state design. Detailed comparison shows that box girder is more suitable as compared to T beam girder even for shorter span in terms of structural stability and cost efficiency.

Effect of Design and Surface Treatments on Fracture Resistance of Zirconia Inlay-Retained Fixed Dental Prosthesis After Thermo-Mechanical Cycling: An in vitro study

Objective: This study evaluated the effect of preparation designs and surface treatment on the fracture resistance of zirconia inlay retained fixed dental prosthesis (IR-FDPs). Material and Methods: Twenty secondary premolar and twenty secondary molar were used in this study. Twenty zirconia IR-FDPs were constructed, divided into two main groups, ten specimens each, according to abutment preparation (box & tube shape), each main group was subdivided into two sub groups according to surface treatment (Air abrasion & MDP primer surface treatment). The IR-FDPs were cemented using dual cure resin cement, then the specimens were subjected to thermo-mechanical cyclic loading (TMCL). The fracture resistance was measured. Results: The results showed that there was no statistically significant difference between air abrasion and MDP for both designs (box & tube shape).The effect of design,showed that there was statistically significant difference for both surface treatments between tube and box design where box design showed higher fracture resistance than tube design for both surface treatments. Conclusion: Inlay retained fixed dental prosthesis (IR-FDPs) with box shape provide more fracture resistance than with tube shape. The air abrasion surface treatment shows similar fracture as the MDP primer surface treatment.

Surface temperatures of non-incubated eggs in great tits (Parus major) are strongly associated with ambient temperature.

Temperature is one of the best investigated environmental factors in ecological life-history studies and is increasingly considered in the contexts of climate change and urbanization. In avian ecology, few studies have examined the associations between thermal dynamics in the nest environment and its neighbouring air. Here, we placed avian nests and non-incubated eggs inside nest boxes at various air temperatures that ranged from 0.3 to 33.1 °C, both in the field and in laboratory conditions. We measured how the design of the boxes, their compass orientation and their location in more or less urbanized environments affected the surface temperature of nests and eggs. We also assessed whether covering the eggs with lining material influenced their surface temperature. Overall, across all performed tests, we found that the surface temperature of nests and eggs strongly reflected the air temperature measured outside of the nest boxes. While the design of the nest boxes had little influence on the temperature of nests and eggs, orienting the nest boxes to the north or to the west significantly decreased their surface temperature. The presence of lining material also kept eggs slightly warmer when air temperatures were low. Altogether these results suggest that non-incubated eggs are not well protected against extreme air temperatures prior to the onset of incubation. From an evolutionary point of view, producers of ectotherm eggs need therefore to time egg-laying appropriately in order to avoid unfavourable thermal nest environments.

Design of a 720-mm Square Direct Shear Box and Investigation of the Impact of Boundary Conditions on Large-Scale Measured Strength

Large-scale direct-shear equipment is described and experimental results are presented showing the influence of test boundary conditions on direct shear strength. The equipment was constructed at the University of Newcastle in 2013 for testing square samples up to 720 mm and applying vertical loads up to 4 MPa. Its boundary conditions were modified in 2017 to better comply with the testing philosophy in standards. The main modifications introduced include full compensation for normal load eccentricity induced in the original arrangement and the introduction of a system that would allow the installation of a seamless gap between shear box halves before shearing. Additional modifications considered the restriction of unwanted carriage spinning during lateral displacement and reduction of frictional force between the specimen and the vertical walls of the box. After the modifications were introduced, implementing a careful method for sample construction, repeatability of the friction angle at large displacement in the range of 1° was achieved among single tests. Further equipment improvement strategies were identified.

Design and Construction of a New Metering Hot Box for the In Situ Hygrothermal Measurement in Dynamic Conditions of Historic Masonries

The main purpose of the HeLLo project is to contribute to data available on the literature on the real hygrothermal behavior of historic walls and the suitability of insulation technologies. Furthermore, it also aims at minimizing the energy simulation errors at the design phase and at improving their conservation features. In this framework, one of the preliminary activities of the study is the creation of a real in situ hot box to measure and analyze different insulation technologies applied to a real historic wall, to quantify the hygrothermal performance of a masonry building. Inside this box, ‘traditional’ experiments can be carried out: recording heat flux, surface temperature, and air temperatures, as well as relative humidity values through the use of a new sensing system (composed of thermocouples and temperature/relative humidity combined sensors). Within this paper, the process of development, construction, and validation of this new metering box is exhibited. The new hot box, specifically studied for historic case studies, when compared to other boxes, presents other advantages compared to previous examples, widely exemplified.

Opening the discussion on a closed intubation box

BackgroundAirway management for patients with COVID-19 poses a significant infection risk to clinicians. As such, some providers have adopted the "COVID intubation box", a cuboid barrier which which separates the clinician from the airway. While this device has limitations, there is promising evidence on its effectiveness. AimTo summarize the history, evidence, and limitations of the popular intubation box design. Furthermore, we share our modified design and experiences from airway simulations. MethodsUsing our prototyping and validation facilities, our team designed and iteratively improved our device to arrive at a final design. The expert panel, consisting of anesthesiologists, infection control staff, and emergency clinicians, trialed the device using airway simulation mannequins and provided feedback. ResultsOur final device features a dome shape, increased height, wider arm port diameter, additional side port for assistants, and drapes to reduce viral escape. Feedback from simulations was overall positive, especially noting that the height and arm port diameter facilitated arm motion within the box. The infection control team preferred the unique dome shape for safe disinfection. ConclusionOur intubation box overcomes several challenges and criticisms of the popular intubation box. This device is an important harm reduction tool for clinicians during this COVID-19 pandemic.

Design, Construction, and Effectiveness of Electrical Outlet Box with Built-in High and Low Voltage Cut-off and Power-on Delay Circuit

The electrical outlets installed in houses and buildings have no means of protection to prevent the plugged-in electrical appliances from the risk of being hit by the voltage fluctuations, and sudden loss and recurrence of electricity. This study designed and constructed an electrical outlet box that disconnects the appliance from the power source when high and low voltage levels occurs. It also delays the connection to the power source at normal voltage level. It comprises a plastic enclosure securing therein the interconnections of a power supply circuit, a high and low voltage cut-off circuit, a power-on delay circuit, a relay driver circuit, a double pole double throw relay switch, and electrical outlet. The variable alternating current transformer was used to apply the high and low voltage levels to the electrical outlet box where the industrial fan was plugged. Results showed that the electrical outlet box disconnected the industrial fan from the power source at 231 and 199 V. Also, there was a four-minute waiting period before the industrial fan was connected to the power source when the 201-229 V was applied. Therefore, this device is effective in preventing appliances from being hit by voltage fluctuations and sudden loss and recurrence of electricity.

Alkyl β-D-xyloside synthesis from black liquor xylan using Aureobasidium pullulans CBS 135684 β-xylosidases immobilized on spent expanded perlite

The crude β-xylosidase from Aureobasidium pullulans CBS 135684 was immobilized on the surface of the modified spent expanded perlite via (3-aminopropyl) triethoxy-silane and glutaraldehyde cross-linking reaction. Over 80% of the initial free enzyme activity was detected on the bound enzyme. The immobilized β-xylosidase (204.7 ± 6.5 U g-1 of perlite) exhibited transxylosylation activity when sugars from black liquor xylan hydrolysate and a variety of alcohols (C1-6) were used as donor and acceptor molecules, respectively, yielding a number of alkyl xylosides. The synthesized hexyl xyloside exhibited some interesting properties comparable with those of a commercial hexyl glucoside, including an antioxidant activity (IC50 = 8.9 ± 2.0 mg mL-1), wetting time (43 s), and critical micelle concentration value (252 mmol L-1). Optimization for hexyl xyloside synthesis was performed via statistical analysis using a Box and Behnken design. The maximum predicted yield of hexyl xyloside (499.0 ± 1.1 mg g-1 xylan hydrolysate) was obtained with 10% (w/v) xylan hydrolysate, 10 U g-1 immobilized β-xylosidase, and 13% (v/v) hexanol at 70 °C, pH 6.0 for 4 h, and it was validated by the following experimental yield (498.9 ± 4.8 mg g-1 xylan hydrolysate). The maximum production yield remained relatively stable after the immobilized enzyme was reused for 12 cycles with a 471.5 ± 15.1 mg g-1 hexyl xyloside yield (94.4% of the first cycle). Thus, the immobilized β-xylosidase has a high potential as a robust catalyst for application in alkyl xyloside production.

A Study on the Shipping Box Design of Online Stores- Based on Both Graphic and Sustainable Characteristics -

A Study on the Shipping Box Design of Online Stores- Based on Both Graphic and Sustainable Characteristics -

Assessment of the Feasibility and Acceptability of Using Water Pasteurization Indicators to Increase Access to Safe Drinking Water in the Peruvian Amazon.

.Approximately two billion people lack access to microbiologically safe drinking water globally. Boiling is the most popular household water treatment method and significantly reduces diarrheal disease, but is often practiced inconsistently or ineffectively. The use of low-cost technologies to improve boiling is one approach with potential for increasing access to safe drinking water. We conducted household trials to evaluate the feasibility and acceptability of water pasteurization indicators (WAPIs) in the Peruvian Amazon in 2015. A total of 28 randomly selected households were enrolled from a rural and a peri-urban community. All households trialed two WAPI designs, each for a 2-week period. Ninety-six percent of participants demonstrated the correct use of the WAPIs at the end of each trial, and 88% expressed satisfaction with both WAPI models. Ease of use, short treatment time, knowledge of the association between WAPI use and improved health, and the taste of treated water were among the key factors that influenced acceptability. Ease of use was the key factor that influenced design preference. Participants in both communities preferred a WAPI with a plastic box that floated on the water’s surface compared with a WAPI with a wire that was dipped into the pot of drinking water while it was heating (77% versus 15%, P < 0.001); we selected the box design for a subsequent randomized trial of this intervention. The high feasibility and acceptability of the WAPIs in this study suggest that these interventions have potential to increase access to safe water in resource-limited settings.

The virtual core - modelling and optimization of core manufacturing and application

Development and manufacturing of high quality cast parts with tight dimensional requirements depend to a large extent on the stability and application of the sand cores. The core-sand is based on a complex granular multi-material system, where curing of an organic or inorganic system bond the grains into a porous core. The chosen combination of sand and binder determines the thermo-mechanical properties of the core. The paper provides an overview of current modelling capabilities along the life cycle of sand cores. A detailed analysis of the production steps is presented as well as the resulting properties linked to the application in the casting process. Several questions and some answers are given to the understanding of core related defects and how simulation can bridge the gap between core production and application of cores in the casting process. Today, process simulation of sand core production is an accepted tool for core box design and prediction of robust production conditions. The first modelling step is core shooting where expanding air is the driving force for sand flow from a core shooting machine into the core box. Coupled two phase flow modelling of air and granular material is required to represent the process sufficiently. The final process step in core manufacturing is core curing and moisture transport where porous media gas flow modelling is applied. Phase transformations as well as the relevant transport phenomena and the complete heat balance in case of thermally controlled processes need to be considered. During casting the deformation of the bonded sand material is generally governed by thermal expansion, phase transformation and the location of core prints. For long thin walled cores, buoyancy forces due to density differences between the cast material and the bonded sand material can play an important role due to creep effects in the organic binder systems. For inorganic systems moisture content and moisture transport during casting are affecting the mechanical behaviour, such as bending strength. The paper presents a detailed overview of a recent implemented soil plasticity model which is calibrated for different binder systems and sand types. The data are based on comprehensive mechanical tests to provide temperature, moisture and time dependent input data for the shown examples. This includes new steps and future challenges in modelling the anisotropy of printed sand cores and digitalization of the foundry in general.

Design of an ATV Gear Box

The main objective of the project was to design and fabricate a drive train for an intercollegiate competition called BAJA SAE. The motive to get into this project was to learn more about an All-Terrain Vehicle (ATV), studying about different parameter which would affect the drive train of the vehicle. All the possible options were considered while making the drive train. After discussions alternative options were taken neglected and the main option was chosen. It was decided that the transmission would be automatic, consist of a continuously variable transmission (CVT) couples with a two staged gearbox which is then couples with the half shaft. The whole system was tested thoroughly and it performed well.

Characteristics of deformation pattern and energy absorption in honeycomb filler crash box due to frontal load and oblique load test

A crash box design is developed to enhance the crash box’s abilities to absorb crash energy. Previous research has developed the crash box by adding filler material. Adding the filling material to the crash box will increase energy absorption. Aluminum honeycomb has a combination of lightweight mass and an ability to absorb crash energy. The addition of filler material to the crash box will also reduce the possibility of global bending in the crash box. The method of study is a computer simulation using ANSYS Academic software ver 18.1. This research used circular, square and hexagonal cross-section variations, which reached the same cross-sectional area design. Geometry model for the crash box and honeycomb filler is defined as crash box thickness (tc) 1.6 mm, honeycomb filler thickness (t) 0.5 mm for single layer and 1 mm for double layer and crash box length (l) 120 mm. The materials used were AA6063-T6 for crash boxes and AA3003 for honeycomb fillers. The test model consisted of two types, namely frontal load and oblique load test. The impactor velocity (v) is set to 15 m/s. The impactor and the fixed support are modeled as a rigid body, while the crash box is assumed as an elastic body. Observations were done by using the characteristics of deformation pattern and the absorption amount of produced energy due to the given loading model. Based on the deformation pattern results, it can be found that in the crash box model with square and hexagon honeycomb filler, the occurred deformation pattern was concertina, while the crash box with circular honeycomb filler was the mixed mode in the frontal load test. Regarding the oblique loads, the crash box remains to collapse the global bending on all models. Simulation results with the frontal load test model found that the crash box with circle-shaped honeycomb has the highest energy absorption while the crash box with hexagonal honeycomb filler has the highest Specific Energy Absorption (SEA). In the oblique load test, it was found that the crash box with hexagonal honeycomb filler has the highest energy absorption and SEA. By comparing the hexagonal crash box model with and without honeycomb filler, it is noted that the hexagonal crash box with honeycomb filler has higher Crash Force Efficiency

An approximate approach on the buckling analysis of a composite lattice cylindrical panel

This paper defines the modified effective stiffness considering the direction-dependent mechanical properties to an intersection of ribs and mode shape function of a composite lattice cylindrical panel. It subsequently presents an approximate method based on the continuous model of conducting a buckling analysis of the composite lattice cylindrical panel with various boundary conditions under uniform compression. This method considers the coupled buckling mode as well as the global and local buckling modes. We verify the validity of the present method by comparing the results of the finite element analysis. In addition, parametric and sensitivity analyses are performed to investigate the effects of the design parameters on the buckling characteristics based on the present method. The results allow a database to be obtained on the buckling characteristics by design parameters. Finally, the present method is applied to optimizing a composite lattice cylindrical panel for wing box design to minimize the mass. Consequently, it is concluded that the present method is very suitable for an optimization involved in the buckling analysis of composite lattice cylindrical panels due to their relative simplicity and computational efficiency.

Standardization of process parameters for the production of bulky raw silk using cocoon entanglement method

Production of bulky raw silk is preferred for weaving sarees in Indian context. It was thought to increase the speed of movement of cocoons by incorporating suitable device so that entanglement in filaments will take place resulting in different structure of bulky silk yarn. CSTRI has developed a mechanism to rotate the inner vessel keeping the outer vessel constant; thus, the water would not be spilled during the rotation of the vessel in the reeling process. In order to standardize the process parameters viz., basin (rotation of vessel) speed, reel speed, and the number of cocoons reeled for the production of bulky raw silk by cocoon entanglement using Box and Behnken design of experiment. The studies conducted reveal that the average denier, size uniformity, and size deviation are significantly influenced at 1% level on the above process variables. Further, it was observed that the basin speed and reel speed should be in the ratio of 2:1. The basin speed of 150 rpm with reel speed of 75 rpm and 30 cocoons has imparted required bulkiness in the yarn and having characteristics suitable for production of bulky silk fabric which can be used for exclusive end uses.

Thickness effect study on the crushing characteristics of aluminum and composite tubes: Numerical analysis and multi-objective optimization

Since lightweight and energy-absorbing materials have an effective role in occupant safety during accidents, the use of aluminum or composite tubes and their optimum designs are of great importance in crashworthiness. In this study, numerical simulation of crushing and multi-objective optimization of aluminum and composite cylinders are performed to evaluate the effects of tube thickness on the objective functions (the specific energy absorption and the peak force). Besides, the effects of annealing and tempering of ductile aluminum alloys (Al 6061) are investigated. The results show that annealing of ductile aluminum alloys yields a significant reduction in objective functions. With the same thickness of the aluminum and composite shell, the composite tube exhibits proper results in terms of both peak load and energy absorption. Finally, it seems that in the design of crash boxes, a thicker composite tube leads to more appropriate results than aluminum shell.

Development of a solar heat assisted egg incubation system

This study is an attempt to provide the poultry industry with an appropriate technology suited for small to medium scale production. The main strategies implemented to enhance energy efficiency were solar assisted heating of the incubation space and intermittent operation of the ventilation device. The study revealed that 72.6% of electrical energy was conserved by using the proposed system. If the prototype was used for balut production, payback period for initial investment is just 10.5 month and annual income would be 3.3 times compared with the income from a conventional system. Response surface methodology was used to characterise the incubation system using a Box and Behnken Design. Response variables were electrical energy consumption and evaporation of water in the incubator. Parameters used in the modelling work were incubator temperature setting, tank water temperature and ventilation port opening. Mathematical models that were generated by the statistical software, Design Expert ®, had a good fit and were validated and was found to be 94% and 98% accurate for predicting electrical energy consumption and evaporation of water, respectively. Numerical optimisation revealed the ideal region of operation for system for incubating duck eggs was at 0% ventilation port opening, incubator temperature setting of 37.5-38°C and tank water temperature of 47.5-60°C. The solar heat collector assisted egg incubation system promotes energy efficiency, utilizes a renewable energy resource, and can also be considered an environmentally sound technology. This study presents tremendous potential for adoption not just for balut production but also for the entire poultry industry.

Pemetaan Arah Desain Rice box untuk Pengguna Di Indonesia

In 2011 and 2016, the author had been designed a rice box based on user aspect. The result indicated the change of rice box product design in form of dimension/ load capacity. This indication then followed by continued study in order to find the comprehensive design of rice box development. This research is focused on design mapping based on design direction of rice box that had been done in 2011, 2016 and 2019, also perceptual mapping method on existing rice box products. The aim is to find the tendency user preference to rice box design. The result showed that the significant value for user preference is rice box with capacity of 12 kg and slowly leave the rice box with capacity of 30 kg. This study also argued that there is an implication of rice consumption changing. The result is hopefully could become the reference in rice box design based on mapping result that can be applied by industrial stakeholder.

CFD MODELLING OF FORMULA STUDENT CAR INTAKE SYSTEM

Formula Student Car (FS) is an international race car design competition for students at universities of applied sciences and technical universities. The winning team is not the one that produces the fastest racing car, but the group that achieves the highest overall score in design, racing performance. The arrangement of internal components for example, predicting aerodynamics of the air intake system is crucial to optimizing car performance as speed changes. The air intake system consists of an inlet nozzle, throttle, restrictor, air box and cylinder suction pipes (runners). The paper deals with the use of CFD numerical simulations during the design and optimization of components. In this research article, two main steps are illustrated to develop carefully the design of the air box and match it with the suction pipe lengths to optimize torque over the entire range of operating speeds. Also the current intake system was assessed acoustically and simulated by means of 1-D gas dynamics using the software AVL-Boost. In this manner, before a new prototype intake manifold is built, the designer can save a substantial amount of time and resources. The results illustrate the improvement of simulation quality using the new models compared to the previous AVL-Boost models.The results illustrate the improvement of simulation quality using the new models compared to the previous AVL-Boost models.