RESEARCH REPORT 2001 - 2002 · RESEARCH REPORT 2001-2002 Approximately 25 postgraduate and postdoctoral researchers have been associated with MIRC since 1989; many of these people

RESEARCH REPORT

2001 - 2002FACULTY OF

ENGINEERING & ARCHITECTURE

DEPARTMENT OF

MECHANICAL ENGINEERING

University College Dublin

DEPARTMENT OF


The Department is housed in a purpose-built Engineering building at Belfield that was completed in

1989. This provides a range of modern teaching, laboratory and office facilities to the Department. Both

the teaching and the research laboratories are well equipped, with considerable expenditure on both

equipment and instrumentation in recent years. The present intake of undergraduate students (partly by

direct entry from 2001) is 66-70. Approximately 50 postgraduate students are enrolled for either Masters

or Doctoral degrees by research. The staff of the Department comprises 18 academic staff, as well as 12

technical staff, and 2 administrative staff. The Department offers one primary degree in Mechanical

Engineering, which is of four year’s duration. In addition to an M.Sc. in Technology Management which is

run in conjunction with the Faculty of Commerce, the Department offers a taught part-time Masters in

Industrial Engineering for engineering and other technology professionals who wish to strengthen their

management competencies. Participants on this course normally have a number of years work

experience since completing their primary degree. Areas covered on this course include Operations

Management and Human Resources, Information Technology and Systems Engineering.

Further information on this course can be obtained from the programme webpage at

www.ucd.ie/~mecheng/mie.

The Department is active in both basic and applied research programmes in a number of important

areas. There are five broad research themes within the Department, namely, (i) Bioengineering, (ii)

Manufacturing & Industrial Engineering, (iii) Materials, (iv) Mechanics, and (v) Energy Conversion. The

range of project activities in each of these areas is described in this report. Additionally, there are three

Technology Centres in the Department, which complement various of the research activities, namely AMT

Ireland, the Materials Ireland Research Centre and the National Heat Treatment Centre.

Head of Department

Professor Dr.-Ing Gerald Byrne,

Chartered Engineer

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2001-2002

ACADEMIC STAFF & RESEARCH INTERESTS

Eamonn Ambrose

BE, MBA – College Lecturer:

Production and Operations Management; Supply Chain Management;

E-business Technology Management.

Barry Brophy

BE, MEngSc, MISTC – Assistant Lecturer (September 2000 – August

2002):

Cognitive processes involved in communication of technical concepts;

Next generation refrigeration systems for road transport of food;

Tool breakage detection in automated drilling using neural networks.

David J. Browne

BE, MSc (Oxon), DPhil (Oxon), CEng, MIEI, MIM – Lecturer:

Non-ferrous metallurgy; Numerical modelling of alloy solidification: grain

nucleation and growth, heat transfer, front tracking, natural convection;

Experimental studies of alloy solidification: evolution of macrostructure,

interface heat transfer in casting processes, semi-solid processing of

aluminium alloys; Gradient and composite materials; Plastic deformation

of metals; Microgravity experimentation.

Gerald Byrne

BSc(Eng) (Dub), MSc, MA (Dub), Dr-Ing (TUBerlin), FIAE, FSME, CEng,

EurIng, FIEI, FIMechE, FIEE, Hon M VDI, Active member CIRP

Professor of Mechanical Engineering:

Precision and ultra-precision machining science; Machine tool technology;

Temperature measurement in machining; Sensors for tool condition

monitoring; Integrated manufacturing processes; Process chains.

Alun J. Carr

BSc (Newcastle), PhD (Newcastle), MIM – College Lecturer (sabbatical

leave January – August 2002):

Development of technical ceramics and interstitial alloys for structural

wear and biomedical applications; Design of test methods for studying

abrasive wear; Development and testing of coatings for biomedical

applications; Thermal fatigue of ceramics.

David N. Collins

Dip Met (Flintshire), MSc (Aston), CEng, MIM – College Lecturer:

Ferrous metallurgy; Alloy and tool steels; Ductile irons; Heat treatment

and surface hardening processes; Effects of composition and processing

parameters on micro-structure and performance of these alloys.

Patrick T. Connolly

BE, MEngSc, FIEI, CEng, EurIng – College Lecturer:

Manufacturing information systems; Flexible automation; Data

acquisition; Computer aided design and manufacture.

Gerard F. Cummings

ME, PhD, CEng, MIEE, PE, FIEI, EurIng – Senior Lecturer (Until September

2002):

Computer numerical control and flexible manufacturing; Operations

management; Production and operations planning and control; Discrete

and continuous modelling and simulation of industrial engineering and

production systems.

Donal P. Finn

BE, MEngSc, PhD (Dub), CEng, MASHRAE, MIEI – College Lecturer:

Heat transfer; Building energy eystems: free/evaporative cooling,

radiative cooling; Refrigeration and heat pumps: control and optimisation,

transient system response evaluation, multi-evaporator systems;

Particulate drying: heat transfer mechanisms, process modelling.

David FitzPatrick

BA, BAI, DPhil – College Lecturer:

Musculoskeletal mechanics; Medical device technology; Design.

Michael D. Gilchrist

BE, MEngSc, PhD (Sheffield), FInstP, FIMechE, FIEI, FIMMM, CPhys, CEng –

Senior Lecturer:

The mechanical performance of viscoelastic and anisotropic material

systems (including structural engineering materials, composites and

biological tissue); Head impact biomechanics; Processing and

performance of polymer matrix composites; Mechanics and

mechanism of fracture, damage and failure of materials; Experimental

and computational modelling.

Donal Hughes

BE, MEngSc, MIE – College Lecturer and Director of Master of Industrial

Engineering (MIE) Programme:

Production management; Industrial systems; Industrial engineering;

Production systems design; Project management.

Neal Murphy

BE, MEngSc – College Lecturer:

Computational methods in solid mechanics, particularly finite element and

finite volume formulations; Dynamic fracture mechanics; Simulation of

rapid crack propagation in brittle polymers, particularly pipe-grade

polyethylene at low temperatures and PMMA at room temperature.

William J. O’Connor

BE, PhD, CEng, FIEI – Senior Lecturer (sabbatical leave October 2001 to

September 2002):

Control of flexible mechanical systems; Novel application areas of the

Transmission Line Matrix modelling method, especially in mechanics,

acoustics, computational fluid mechanics, diffusion and magnetostatics;

Software for the design of acoustic devices; Design of special-purpose

sensors, including sensors for moisture content, fluid density, relative

humidity, fluid level in sealed containers, and counting people.

Garret E. O Donnell

BSc(Eng) (Dub), MIEI, MSME, MInstP – Assistant Lecturer (from September

2002):

Machine tool technology; Machining technology; Automation; Sensors and

algorithm development for tool condition monitoring; Artificial intelligence

in decision making; Discrete and continuous simulation.

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DEPARTMENT OF


Malachy J. O’Rourke

BEng (QUB), PhD (QUB), MAIAA – College Lecturer:

Transonic Aerodynamics: control of shock boundary layer interactions;

Boundary layer control methods: suction, injection, passive vortex

control jets, porous plate and passive cavity; Hemodynamics:

abdominal aortic aneurysms, development of surgical devices; Radial flow

turbomachinery: secondary flows and wake development due to rotation

and curvature, wake mixing.

Peter T. O’Neill

BE – College Lecturer:

Quality control and the application of statistical methods to industrial

problems; Operations research; Information systems; Computer graphics.

William J. Smith

BE, PhD, MIEI, AMSAE – College Lecturer:

Theoretical and experimental analysis of gas flow, fuel injection, combustion

and pollutant formation in internal combustion engines; Engine condition

monitoring; Second Law analysis of thermal systems and cycles.

David J. Timoney

BE, MEngSc, PhD, CEng, FIEI, MSAE, CDipAF – Senior Lecturer:

Internal combustion engines and exhaust emissions; Hydrogen as an

automotive fuel; Energy in transport; Combined heat and power; Transport

refrigeration.

Sean Timoney

BE, MEngSc, MIEI, MSAE, FIMechE – Senior Lecturer (leave of absence

September 2000 – August 2001):

Automotive design; Vehicle suspension design effects on handling,

stability ride and road damage; Component fatigue; Gear design;

Experimental and computer-aided stress analysis; Noise and vibration

measurement, modal analysis, sound intensity.

EMERITUS STAFF

Michael Hayes

PhD (Brown), DSc, MRIA – Emeritus Professor:

Finite deformation of elastic solids; Wave propagation in finitely deformed

elastic and viscoelastic materials; Deformations of Bell constrained

materials; Theory of bivectors; Wave propagation in crystals; Kinematics

of finite strain and straining.

Desmond F. Moore

BE, MS (MIT), PhD (Penn), DSc, EurIng, CEng, FIMechE, FIEI, MASME,

MSTLE – Emeritus Professor:

Tribology of elastomers and rubber like materials; Fundamental energy

and tribology relationships; Viscoelasto-hydrodynamics and micro-

lubrication; Impact and crashworthiness of collapsible structures;

Thermodynamic energy degrading.

RESEARCH STAFF

Mr Eamonn Ahearne, Materials Ireland Research Centre

Mr Micheal Armstrong, AMT Ireland

Prof. Jurek Banaszek, Visiting Researcher (from March 2001), Warsaw

University of Technology

Mr Derry Dillon, AMT Ireland (until May 2002)

Prof. Takeshi Fujimoto, Visiting Researcher (from May 2002),Yuge National

College of Maritime Technology

Mr David Heeran, AMT Ireland (July – October 2002)

Mr Martin Hussey, Materials Ireland Research Centre

Ms Barbara Ann McCabe, AMT Ireland (until August 2001)

Dr Ciaran McNally, Materials Ireland Research Centre, Department of Civil

Engineering

Mr Graham Thomas, Materials Ireland Research Centre

Mr Kieran Ryan, AMT Ireland

Mr James Ryder, AMT Ireland

Advanced Manufacturing Technologies (AMT - Ireland)Director: Donal Hughes

AMT Ireland was established under the Programmes for Advanced

Technology (PAT) and is a partnership between Enterprise Ireland, the

Universities and Irish Industry. AMT Ireland’s role is to support research in

advanced manufacturing technology within the universities and to ensure

that the results of this research are transferred to Industry in Ireland.

There are AMT centres located in Cork, Limerick, Galway and UCD.

The AMT Ireland Centre located within the Mechanical Engineering

Department at UCD is a centre of excellence in Manufacturing Systems

Design and Operation. It interfaces with Industry through collaborative

research projects and also by offering consulting services within its field

of expertise. Areas of research interest include automation systems

integration; total preventive maintenance (TPM); business excellence

model; world class manufacturing; new product introduction; competitive

benchmarking; product data management.

Materials Ireland Research Centre (MIRC)Director: Michael Gilchrist

The Materials Ireland Research Centre at UCD was established in 1989 as

one of the Programmes for Advanced Technology. Its objectives are to

undertake and support Research & Development for Irish industry and for

appropriate international organisations: this is accomplished through

short, medium and long-term project activities. MIRC-UCD is sister to five

other centres in Trinity College, University of Limerick, Polymer

Development Centre Athlone, and Enterprise Ireland Glasnevin.

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RESEARCH REPORT

2001-2002

Approximately 25 postgraduate and postdoctoral researchers have been

associated with MIRC since 1989; many of these people have

subsequently been employed within Irish and international research and

industrial environments. Research ranging from fundamental science

through to applied engineering is conducted across a spectrum of specific

materials areas including metals processing, concrete and cementitious

materials, polymer matrix composites, surface engineering, precision

grinding/polishing, bioengineering and biological materials. This addresses

both materials, products and processes. Research activities are funded

directly by Irish and international industry, and by Irish, European and

international organisations and research agencies. In addition to

conducting short and medium-term industrial contract research, the

Centre also serves to facilitate the transfer of expertise and technology to

industry (SMEs and MNCs).

National Heat Treatment CentreDirector: David Collins

Founded in 1995 under the Technology Centres Programme, this Centre,

which is self-financing, acts as a central resource for the heat treatment

and tooling industries. The Centre is equipped with a wide range of modern

facilities, including vacuum, fluidised bed, controlled atmosphere furnaces, a

range of quenching, deep cryogenic treatment and ancillary equipment. As

well as Research and Development, the Centre provides technical

assistance, testing and investigation facilities, courses, and also undertakes

specialised sub-contract heat treatment on a semi-commercial basis, which

is the main source of its income. Recent research has concentrated on

specialised heat treatment of tooling materials, including deep cryogenic

treatments and fluidised bed thermochemical surface treatments.

BIOENGINEERINGAJ Carr, DP FitzPatrick, MD Gilchrist, M O’Rourke

Research within bioengineering involves an interdisciplinary group of

engineers, material scientists, biochemists, anatomists, veterinary

surgeons and medical practitioners. The main research themes are:

(i) biomaterials – experimental and theoretical modelling of the

fundamental relationship between the physiology and the mechanics of

bone, (ii) musculoskeletal mechanics – combining experimental and

theoretical analysis of joint kinematics and biomechanics to evaluate the

performance of joint replacements, spinal implant technology and soft

tissue reconstruction on clinical outcome, (iii) medical imaging – applying

novel analysis techniques to raw image data, allowing the analysis of

contact geometries articular surfaces as well as the development of

patient-specific computational models, and (iv) biomechanics of head

impact – the use of computational mechanics methods to simulate impact

events and to identify the consequent clinical trauma.

The Degradation Characteristics of a Resorbable Polymer and

Their Application to Long Bone Fracture Fixation

DP FitzPatrick & L Balfe

Resorbable polymers have traditionally found biomedical application in the

areas of sutures and fracture repair. Emerging applications such as tissue

engineering and drug delivery also rely heavily on the use of these

polymer families, and as such, on the reliable and accurate determination

of their degradation characteristics. To utilise existing, and future,

resorbable polymers to their full potential it is necessary to fully

understand their degradation characteristics.

To further this objective, in-vivo and in-vitro degradation of resorbable

polymers has been investigated by many authors, however, there has been

no standardisation of test method, sample size or geometry. As a result,

comparison of results between studies is very difficult. This study proposes

a standardised degradation test protocol, based on ASTM standards, to

determine the degradation characteristics of resorbable polymers. It is

hoped that the protocol will be adopted by other researchers in the field,

thereby providing the opportunity to consolidate the available information

on the time-dependent mechanical performance of these polymers.

Evaluating Ergonomic Simulation Software

DP FitzPatrick & L Coffey

Ergonomic Simulation Software (ESS) is increasingly used in the design and

development of workplace environments, allowing identification of possible

sources of work related injury. Within the algorithms for the ESS models,

assumptions are made as to the type and form of motion that can occur

within the body. It is hypothesised that the level of simplification introduced

during this process has a significant influence on the accuracy of the data

produced. However, no standardised means exists to determine the accuracy

to which such software can simulate the normal kinematics of an individual.

An easily implemented test environment is defined, based on a series

of six tasks, representing movements of increasing complexity. The results

for the measurement and simulation are presented by comparing the time

dependent joint angles subtended by human subjects to those produced

through two ESS algorithms. The results provide a unique insight into the

level of simulation error encountered for a given task simulation. Detailed

analysis of the kinematics highlighted a number of areas in which both

ESS models appeared to be deficient. In particular, simplified modelling of

shoulder and spinal kinematics resulted in a significant influence on the

simulated kinematics of the upper limb.

Comparison of Asian and Caucasian Knee Anthropometrics

DP FitzPatrick & N Rooney

Success of Total Knee Arthroplasty (TKA) relies upon the correct sizing and

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DEPARTMENT OF


positioning of the prosthetic implants. It is therefore important to quantify

the key dimensional variables of the knee so that an accurate anatomical

dataset is available for use in prosthesis design and as an aid to surgical

technique. Incorrect sizing can cause prosthesis loosening, incorrect soft

tissue balancing and uneven stress distribution across the tibiofemoral

joint area. Accounting for variation in implant size is a critical step when

developing a range of implant sizes to meet the needs of the world-

wide market.

Previous studies of knee anthropometrics have used insufficient

sample sizes, typically 30, with low confidence in results. This study uses

linear intraoperative data collected from TKA patients and 3-D data from

CT imaging to develop a statistically significant understanding of the

dimensional changes that occur within a given patient population.

Sponsors: DePuy International Ltd & Enterprise Ireland

Spinal Disc Mechanics

DP FitzPatrick & B Heidari

The primary objectives of this work are to assess the potential influence

of collagen fibre imbalance within the Annulus Fibrosus (AF) on the

progression of Adolescent Idiopathic Scoliosis (AIS) deformity and

to model the progression of AIS deformity due to collagen fibre imbalance

in the intervertebral disc in the thoracic region during rapid growth.

A number of aetiological factors have been proposed for idiopathic

scoliosis. Some have indicated a contribution from the intervertebral disc,

but the specific influence of the AF has yet to be effectively modelled.

A mathematical model has been developed from first principles to

determine the contribution of AF imbalance to vertebral rotation and

overall deformity of thoracic spine. Combined rotational (due to the AF

imbalance) and translational (due to the rapid growth) movements were

applied to a simplified model of the thoracic spine, using a three-

dimensional transformation matrix approach.

Alterations of the ratio of clockwise to counterclockwise fibres in the

interverterbral disc (from unity to 0.85) demonstrated a considerable

influence on the spatial curvature. The three-dimensional model

illustrates the initiation and progression of the scoliotic deformity during

adolescent growth and suggests that imbalance in collagen fibre direction

within the AF of the interverterbal disc contributes to the progression of

the spinal deformity. The influence is not governed by the rate of increase

in height, being a constant for any given fibre ratio.

Sponsor: Enterprise Ireland (PRP 2000)

Reconstructing Real World Head Injury Accidents

Resulting from Falls

MD Gilchrist, K O’Riordain & M Doorly

Mechanical impact is the leading cause of injury, death and disability in

people aged under 45 in the USA, Europe and increasingly so in Third

World countries. Head impact injuries account for approximately half of all

deaths due to mechanical trauma, but account for the majority of cases of

disability after injury. In addition to the huge human cost to society, the

financial cost of hospitalisation, care and rehabilitation of head injured

people has been estimated to be as high as $33 billion per year in the US

alone. In Ireland, falls are the single greatest cause of hospital admissions

for both males and females across most age groups, with head injuries

occurring in approximately a quarter of fall admissions. The objective of

this programme of research is to reconstruct real life head injury

accidents resulting from falls using multibody dynamics simulations, with

the aim of relating predicted impact velocities, forces and accelerations to

injuries sustained. Reconstructing such real life accidents offers new

insights in understanding the mechanisms of head injury and establishing

human tolerances to head injury.

Cycling accidents constitute a significant percentage of non-fatal road

accidents within Ireland’s urban environment. The National Roads

Authority is statutorily charged with collating all road accident facts within

Ireland and while these records do not discriminate between serious and

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Three-dimensional reconstruction of knee geometry from CT data for use in theanalysis of knee anthropometrics

Scoliotic curve pattern changes due to collagen fibre imbalance (r=0.95 & 0.80).Left: DY= 5%, Right: DY= 20%. Dashed line: normal thoracic spine; solid line:thoracic spine with r=0.95, solid surface: thoracic spine with r=0.80.

RESEARCH REPORT

2001-2002

minor injuries, such information can be obtained by cross-reference

against hospital records. The objective of this project is to obtain a

statistically reliable perspective on Irish cycling accidents and to

reconstruct the biomechanics of a representative selection of such

accidents. This information will ultimately help to better understand the

causative mechanisms of particular injuries that cyclists would sustain

and will suggest how Ireland’s future infrastructural development could

usefully be improved for the cyclists of tomorrow.

Sponsors: UCD (President’s Research Award),

PRTLI (Urban Institute Ireland), Materials Ireland.

Collaboration: Beaumont Hospital (JP Phillips & PM Thomas).

Three-Dimensional Finite Element Modelling of

Human Head Impact Events

MD Gilchrist & T Horgan

The head is one of the most frequently injured body regions and

neurotrauma constitutes one of the major causes of death in accidents.

Simple two-dimensional models can be used to indicate the qualitative

effects of a head impact but three-dimensional models are necessary to

obtain more accurate quantitative insights. In order to investigate the

mechanisms of injury a three-dimensional finite element (3DFE)

representation of the human head complex is necessary to simulate the

transient occurrence of simple pedestrian accidents. This project has

developed and validated such a 3DFE model of the human head.

The constitutive properties and physical geometry of the model were

validated (against the results of published cadaveric and in-vivo

experiments) for transient frontal and occipital impact conditions using a

variety of linear and nonlinear material properties. By simulating identical

impact scenarios with a range of different finite element models it has

been possible to investigate the influence of model topologies. Results

indicate that careful modelling of the cerebrospinal fluid (depth/volume)

and skull thickness (including cortical/trabecular ratio) is necessary if the

correct intracranial pressure distribution is to be predicted.

Sponsors: Enterprise Ireland (Basic Research Grant), UCD (President’s

Research Award), Materials Ireland.

Collaboration: University of Strasbourg (R Willinger & D Baumgartner).

A Fully Automated System for Generating Three-dimensional

Finite Element Models of Biological Structures

MD Gilchrist & B Canton

Biomechanics research depends largely on using accurate computational

simulations to predict the response of the human body to mechanical

forces. Developing appropriate three-dimensional finite element (3DFE)

models of biological objects, which have highly irregular geometries, is

both time consuming and a subjective task. The objective of this project

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Initial position of woman immediately prior to falling from chair

Initial position of cyclist prior to hitting road obstruction and sustaining a fall

Layered 3DFE head model used to simulate impacts and neural damage

Computed tomography brain scan of a person who sustained extraduralhaematoma (indicated by arrow) from a fall

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is to develop a rapid, accurate and automatic system for developing such

models. Minimal user interaction and an ability to create a mesh from a

CT dataset in a matter of minutes were two desired characteristics of this

system. The finite element meshes that this system generates have a

geometry that is patient specific, based on CT scans of the object.

The system generates a hexahedral mesh comprising a user specified

number of material classes. An automatic image segmentation system

was developed in MATLAB. This used a combination of thresholding and

seeding to produce an accurate segmentation of the image. A further

automatic series of morphological operations ensure that the image data

will generate a well-structured and connected FE mesh. In contrast to

traditional meshing systems, the newly developed system is flexible to a

wide range of input objects and geometries. Current work is aimed at

evaluating the functionality of the system and the quality of resulting

meshes. Initial results suggest the accuracy of meshes compares

favourably with those of less automatic systems.

Sponsors: IRCSET (Research Scholarship), UCD (President’s Research Award).

Collaboration: Catholic University Leuven (J Vander Sloten & C Van Lierde).

Computational, Biomechanical & Biochemical Studies of Blunt

Head Impact Trauma

MD Gilchrist & C Gallagher

The objective of this project is to establish quantitative levels of severity

associated with focal impact injuries to the frontal, temporal and occipital

cortex of the intact brain using computational biomechanical models in

combination with experimental in-vivo biochemical measurements.

This will be achieved by developing a biologically motivated,

experimentally testable biomechanical model for evaluating the effects

of head impact on discrete brain regions. In conjunction with these

laboratory experiments, a three-dimensional finite element model will

simulate the full-field stress, strain and strain rate fields throughout the

neural tissue due to various impact events. By correlating microdialysis

data and other indices of neurotrauma, such a model may be useful in

establishing a biochemical threshold for intervention and predicting

clinical course and outcome of different types of brain lesion.

Sponsors: IRCSET (Research Scholarship), PRTLI (National Neuroscience

Network and Conway Neuroscience).

Collaboration: Department of Human Anatomy & Physiology (WT O’Connor

& A Smyth).

Design, Manufacture and Testing of a Prototype Wheelchair for

People with Special Seating Needs

MD Gilchrist & J Tiernan

The goal of this project has been the design of an armchair with the

added functionality of a wheelchair for immobile people who are heavily

dependent on others for every aspect of their care. A person may be

dependent on others for any number of reasons, including age and a

range of debilitating conditions. By incorporating features that allow for

easy transfer and positioning of patients, it is expected that this working

prototype design will act as an aid in reducing the incidence of pressure

sore development. The prototype chair design also aims to provide a less

traumatic and more dignified patient-transfer method than the hoisting

method currently in use. The design incorporates a vertical-height

adjustment mechanism and a tilt-in-space mechanism, which is a key

factor in the prevention of pressure sores, since this acts to take pressure

off the ischial tuberosities and redistribute it over the back. Another cause

of pressure sores, shearing, is significantly reduced by a novel back

recline mechanism that enables the back support translate in line with the

patient’s back while the support is being reclined. A significant

feature of the design is the frame structure, where the wheelbase of

600mm comprises large wheels located at the centre-point of the chair

with four castors at the extremities. This configuration proves highly

stable, offering manoeuvrability far superior to conventional wheelchairs.

Sponsors: Materials Ireland, National Rehabilitation Hospital.

Collaboration: Department of Electronic & Electrical Engineering (AM de

Paor), Royal Hospital Donnybrook (C Leonard).

MANUFACTURING & INDUSTRIAL ENGINEERINGE Ambrose, G Byrne, P Connolly, G Cummings, D FitzPatrick, DF Moore,

GE O Donnell

The Advanced Manufacturing Science (AMS) Research Group is working in

the area of advanced manufacturing processes. The objective of the

group is to develop reliable and reproducible manufacturing processes

such that engineering surfaces of a defined integrity can be economically

produced in a clean environment. The sensors and algorithms for process

and tool condition monitoring are also under investigation.

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Typical 3DFE skull model generated automatically from CT data

RESEARCH REPORT

2001-2002

Adding Value to the Supply Chain Through B2B E-Commerce

E Ambrose

With the growing importance of Supply Chain Management, the importance

of purchasing and its strategic role in the business is being increasingly

recognised. The inexorable growth of e-commerce has intensified the interest

in supply chain issues and particularly eprocurement. While the business-to-

consumer (B2C) e-commerce has largely been seen as a passing fad,

business-to-business (B2B) e-commerce is showing continued growth.

A wide range of e-commerce models has evolved, some in specific

industries, others spanning a range of generic products. These models

create value in a variety of ways - enabling low-cost high-speed

transactions, global search and specification matching functionality,

industry sector collaboration and information sharing. The ownership of

these e-commerce sites varies from buyer consortia through industry

sector hubs to third party service providers. The academic and business

worlds have yet to concur on the future shape of the eprocurement

environment, leaving practitioners with little guidance.

This research will examine the development of various B2B

e-commerce models internationally, and identify the various means by

which each model adds value to the supply chain. This will involve

developing a new classification of e-commerce models, which will be

verified across a range of industry sectors. The work will provide guidance

to buyers and suppliers in identifying the opportunities for generating

savings or developing new business through e-commerce activity.

Sponsor: National Institute of Technology Management, UCD.

Collaboration: Warwick Business School, University of Warwick, UK.

E-procurement of Maintenance, Repairs and Operating Supplies

in a Manufacturing Organisation

E Ambrose

The procurement of maintenance, repairs and operating (MRO) supplies is

not well understood by purchasing practitioners, and its importance to a

business is usually underestimated. This project examines the nature and

importance of MRO purchasing, from the perspective of the buying

organisation, and focuses on indirect purchases only i.e. excluding raw

materials and capital expenditure.

A model for the effective management of MRO purchasing is

developed, encompassing the purchasing process, the organisation of the

purchasing function and the purchasing channels available. The model

provides a means to assess the relevance of electronic procurement

(e-procurement) in MRO purchasing, addressing what is currently

perceived as the burning issue for purchasing managers.

As a preliminary validation of the model, a case study of a major

multinational manufacturer in Ireland was carried out to assess the

effectiveness of the procurement of MRO items, and to identify

opportunities for e-procurement.

Sponsor: Smurfit Business School, UCD.

Process Monitoring of Flexible Machining Centres

G Byrne & GE O Donnell

The term process monitoring can be regarded as an enhancement of tool

condition monitoring, incorporating information related to the cutting tool,

process, workpiece and machine tool. Based on a summary of the state of

the art it can be said that (a) existing monitoring systems are not performing

to a satisfactory level and (b) there is an absence of transferable technology

from research institutes due to the complexity of the solutions developed and

the lack of robustness to factors in the manufacturing environment.

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Positioning of MRO supplies within a two-dimensional procurement portfolio

Process reliability and alarm frequency during 80 hours

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This research work is particularly concerned with identification and

quantification of the factors that affect the monitoring system performance

in the manufacturing environment, and the subsequent development of

more robust sensor technology. Comprehensive investigations were carried

out in production facilities resulting in a quantitative and qualitative analysis

of the influences affecting the performance of monitoring systems.

The application of process monitoring to flexible machining centres

was the main focus of the research work as these machining centers

typically carry out a large variety of machining operations on a large

variety of workpiece types. This level of flexibility/variation is particularly

challenging for sensor technology and decision algorithms. A sensor

integrated motor spindle was developed within the project and used to

measure torque and 3 components of force. These integrated force

sensing elements provided high quality process information, including

very high quality information regarding the condition of the spindle.

This processing framework for the sensor integrated motor spindle is a

topic of further ongoing research.

Sponsor: European Commission (BE3565-COMPRO).

Collaboration: Robert Bosch GmbH, Scania CV AB, COMAU Mechanical

Systems, IDEKO, A. I. E., Hüller Hille GmbH, Kistler Instrumente AG, IPK

Berlin and ARTIS GmbH.

Condition Monitoring in Manufacturing: An Assessment of the

Level of Knowledge and Implementation in Irish Manufacturing

Industry

G Byrne & GE O Donnell

At present, there are substantial difficulties in diagnosing or predicting

equipment problems with the types of advanced manufacturing

equipment used in high volume and flexible production, e.g. CNC machine

tools, automated assembling machines etc. This is due to the relative

complexity of the manufacturing processes and the difficulty of monitoring

all significant process variables. Therefore there is a necessity for the use

of automated data acquisition, signal processing and decision making

techniques generally referred to as condition monitoring. Much of the

research work in the area of condition monitoring considers advanced

signal processing algorithms such as wavelets and advanced knowledge

based systems such as neural networks for decision making. Integration

of these techniques into the computer integrated manufacturing (CIM)

environment is both necessary and feasible using open system

architectures. Open systems are advantageous in providing ease of

access to information, and interoperability (multi platform software)

reduces the cost of installation.

The rate of development of manufacturing equipment and the

sophistication of the technology involved in condition monitoring can

result in a knowledge gap between developer/researcher and end user.

The main purpose of this research work is to address this knowledge gap.

This study is reviewing the state of the art of condition monitoring in

industrial practice and the state of the art in research. A survey of the

level of knowledge and implementation of condition monitoring in Irish

manufacturing industry has been piloted. The survey targets specific

manufacturing sectors that dominate the Irish manufacturing landscape

such as Engineering Components, Finished Pharmaceuticals, Food

Manufacture, Semiconductor, Computer Peripherals, Biomedical Devices,

Furniture and Glass Manufacture. Publication of a final report

summarising the state of the art, the results of the survey, and the

inclusion of case studies is intended.

Sponsor: AMT Ireland.

Collaboration: AMT Ireland, A consortium of manufacturing companies is

being negotiated.

Investigating Silicon Wafer Temperature Variations during

Chemical Mechanical Polishing (CMP)

G Byrne & B Mullany

Chemical Mechanical Polishing (CMP) is the process used for wafer

planarisation in the semiconductor industry. The process relies on both

chemical and mechanical interactions between the wafer, the pad and an

abrasive loaded slurry to successfully remove material from the wafer

surface. Since an explanation for the precise manner in which the

chemical and the mechanical aspects interact to planarise a wafer is

still somewhat elusive, there remains a need for fundamental research

in CMP.

Process temperatures and thermal gradients across the wafer have

not received much attention. However, it would be of considerable

interest to have knowledge in this area as both chemical reaction rates

and slurry viscosity will be affected by changes in temperatures. This

research program uses radiation thermometry to investigate the thermal

gradients across a 4-inch wafer during polishing. An infra-red thermal

imaging camera captures the thermal gradients at the pad wafer interface

and subsequent analysis provides information on the effects of changing

various process parameters and polishing pads.

A thermal image of the wafer, polishing pad and the loading arm is

shown below and is typical of the results recorded. The graph depicts the

difference in the average wafer temperature when polished on three

different polishing pads, a soft grooved pad, a soft non-grooved pad and a

hard polishing pad. The applied load was 14.4 kPa, platen speed = 143

rpm, wafer speed = 7 rpm and the slurry supply rate was 140 ml/min at

22˚C. The maximum and minimum temperatures at a particular wafer

radius are indicated on the graph by the error bars. Differences between

the results for each of the pads can be attributed to the polishing pad

grooves and the different pad materials. The large difference between the

8

RESEARCH REPORT

2001-2002

maximum and minimum temperature values indicates that significant

temperature variations can exist across the wafer during polishing.

Sponsors: Intel Ireland Ltd., Enterprise Ireland.

Collaboration: National Institute of Standards and Technology, USA

(C. Evans); University of California at Berkeley, USA (D. Dornfeld).

The Effect of Conditioning on Polishing Pad Wear in Chemical

Mechanical Polishing

G Byrne & BJ Hooper

For successful manufacture of complex integrated circuits, high levels of

wafer planarity are required. Chemical mechanical polishing (CMP) is

used for this purpose on the wafer surface, however, the level of planarity

is influenced by the polishing pad properties. During polishing, pad

deterioration causes reduced removal rates and poorer planarity. SEM

examination has shown that this is caused by plastic flow of the pad

material, leading to glazed areas on the pad surface. Conditioning by

diamond abrasives is used to regenerate the pad surface by breaking up

these areas but this induces pad wear. As some areas of the pad

experience higher levels of glazing, it is necessary to locally vary

conditioning density. The conditioning profile dictates the travel of the

conditioning arm over the pad and hence the conditioning density

experienced at each point.

This work concerns the effect that different levels of conditioning

density across the pad have on both geometric pad wear and pad surface

characteristics, such as roughness and percentage glazing. A model was

developed to determine the conditioning density resulting at each point on

the pad. Geometric pad wear, surface roughness, and percentage of

glazing were determined experimentally on pads of known conditioning

history. By comparing experimental results with the conditioning density

data, its influence on pad properties could be seen (below). This provides

a baseline simulation for future research. Gaining a better understanding

of the influence of conditioning and its effect on pad wear is essential to

future process optimisation. In turn this will enable a reduction in overall

operating costs.

Sponsors: Intel Ireland Ltd., Enterprise Ireland.

Collaboratuion: University of California at Berkeley (D. Dornfeld), USA.

Machining Hardened Steels

G Byrne & J Barry

The influence of inclusion content on the rates and mechanisms of

alumina/TiC and CBN/TiC tool wear was assessed for the machining of

hardened steels. A sixfold variation in the wear rate of alumina/TiC

cutting tools was observed in the machining of BS 817M40 steel

(equivalent to AISI 4340) subjected to varying heat treatment conditions

and of 52 HRC. In machining steels containing Ca-bearing mixed oxide

inclusions, a reaction between inclusionary deposits and the alumina

phase of the tool is the dominant wear mechanism. In machining low-Ca

9

Thermal image of the polishing pad, wafer and loading mechanism taken duringthe chemical mechanical polishing of a thermal oxide wafer

SEM micrograph showing plastic flow leading to glazing on worn pad

Top: conditioning densities for two different conditioning profilesBelow: experimental geometric wear results for same conditioning profiles

Variations in wafer temperature due to polishing on different polishing pads.Error bars indicate the max. and min. temperatures at a particular wafer radius.

DEPARTMENT OF


steels, or steels with a very low inclusion content, plastic deformation and

grain spallation are the dominant mechanisms. In machining of BS

817M40 steel subjected to three different heat treatment conditions, a

fourfold variation in the wear rate of CBN/TiC cutting tools was observed.

Irrespective of wear rate, the dominant wear mechanism is based on the

preferential wear of the CBN phase through a complex chemical reaction,

the rate of which appears to be partly determined by the aluminium

content of the steel.

Regarding the mechanisms of material removal: examination of the

quick-stop specimens reveal the primary metallurgical instability resulting

in sawtooth chip formation to be adiabatic shear. Adiabatic shear initiates

at the tool tip and propagates partway to the free surface. Catastrophic

failure in the upper region of the primary shear zone occurs through

either of two mechanisms: ductile fracture or large strain plastic

deformation, under severe and moderate cutting conditions, respectively.

Prior to the onset of sawtooth chip formation, there is a transition in the

structure of the free surface of continuous chips, from the lamellar

structure to what has been termed a ‘fold’ structure. The relationship

between chip formation and Acoustic Emission is also discussed, for both

hardened steels and Ti6Al-4V.

White layers, in the surfaces machined with unworn and worn cutting

tools, were examined using transmission electron microscopy (TEM).

The primary characteristics of the surface white layer are; a fine cell size,

between 10-100nm, the presence of retained austenite, the volume

fraction of which increases with increased flank wear and the presence of

extremely fine carbides. The similarity between the structure of the

surface white layers and that of adiabatic shear bands indicates that

the surface generation in hard machining is essentially an adiabatic

shear process.

The Development of an Evaluation Algorithm for Integrated

Production Chains

G Byrne & A Corcoran

Analysis of automotive production chains has revealed that many

manufactured components are subject to high levels of stand-by (non-

production) time. Stand-by times represent a gross inefficiency to the

manufacturer, as component lead times are extended. Furthermore,

components in stand-by require storage space and thus increase the

necessary process workspace considerably. Integrated manufacture is

a production methodology that arose from the idea of concurrent

engineering. By integrating multiple production processes into one

station, a component can be formed by numerous processes

simultaneously. Such integration has been observed to reduce lead times

and yield a significant return-on-investment.

The integration of production processes is cost intensive. Integrated

production models have been developed that evaluate the economic

feasibility of integration. It is proposed herein, to develop the state-of-

the-art of such models by developing an algorithm that determines the

technical feasibility of integrating production processes. It is intended

that the model also incorporate qualitative analysis of auxiliary factors and

an existing state-of-the-art economic algorithm.

Sponsor: Enterprise Ireland.

Collaboration: Daimler Chrysler AG.

The Integration of Laser Processing into

Conventional Machining Centres

G Byrne & E Kennedy

The rationale for integrating high power lasers into conventional

machining centres is to implement the principle of integrated

manufacturing so that diverse operations can be carried out on a

component in a single clamping. Two areas where lasers can be utilised

in manufacturing are being studied: laser hardening and laser assisted

machining. In laser assisted machining, a high power laser beam is used

to selectively soften the workpiece ahead of an approaching conventional

cutting tool. With laser hardening, hardening of the workpiece can be

done in combination with other operations such as cutting, milling and

forming thus eliminating the need for a subsequent hardening process.

There are a number of benefits associated with each of these concepts

which are being explored in relation to specific industry applications over

the course of the project.

The primary goal of the project is to develop a centre of expertise in

U.C.D. for the transfer of laser-integrated technology to Irish manufacturers.

Laboratory experimentation and mathematical modelling is being carried

out to develop application specific data to demonstrate that components

of high quality, conforming to industry standards and cost constraints can

be produced.


10

Integration of multiple processing technologies into single machining centre

RESEARCH REPORT

2001-2002

Dynamic Behaviour of Materials in Machining

G Byrne & M Cotterell

The mechanics of chip formation during orthogonal cutting are being

investigated using high speed photographic techniques. Cutting tests are

conducted on a conventional CNC lathe. A CCD camera with a long distance

microscope lens is focused on the primary and secondary shear zones. The

dynamic components of the cutting force are monitored using a PVDF

piezoelectric force sensor. The force signal triggers a short duration (less than

1ms) high intensity flash at various stages of the chip formation cycle. An

infrared thermal imaging system with a microscope lens attachment is used

to measure temperatures in the primary and secondary shear zones. Models

for the prediction of the onset of chip segmentation and segmentation

frequency are being evaluated for various materials including titanium alloy

(Ti6Al4V), stainless steel (SS 316) and hardened bearing steel (AISI 52100).

The models consider the thermal aspects of the cutting process, the frictional

characteristics of the tool-chip interface and incorporate constitutive models

of material behaviour at elevated temperatures and high strain rates.

Collaborators: Cork Institute of Technology, Enterprise Ireland.

Clean Machining Processes

G Byrne & M Cotterell

In many cases, modern manufacturing processes are not adequately

clean. In material removal operations, problems arise from the disposal of

process residuals such as cutting fluids, grinding sludge, contaminated

filters, wet chips etc. Hard machining offers significant advantages over

grinding as a finishing operation in terms of greater flexibility, lower

energy consumption and lower environmental loading. However, there are

some concerns about the effects of machining on the surface integrity of

engineering components and their subsequent performance.

The aim of this project is to develop a model of the microstructural

evolution of an engineering component due to finishing operations.

Rough grinding, or machining with worn tools, results in significant

microstructural alterations to the surface layers of the workpiece

material. Plastic deformation results from mechanical loading and phase

transformations due to the elevated temperatures involved. In this project,

the effects of finish machining on the surface integrity of hardened AISI

4340 and AISI 52100 steels are investigated. A finite element

thermo-mechanical model is proposed and this is coupled with material

constitutive models in order to predict the resulting microstructure, the

hardness profile and the residual stress profile of the surface layers.


Collaboration: Cork Institute of Technology.

Performance Evaluation of PVD Coated Cemented

Carbide Cutting Tools

G Byrne & K Tuffy

Physical Vapour Deposition (PVD) is an advanced plasma deposition

technique for the application of coatings onto engineering components.

In this project titanium nitride (TiN) is deposited on cemented carbide tool

inserts (CNMG 432) using two PVD techniques known as magnetron

sputtering (MS) and HYBRID plasma. The research work will compare the

mechanical performance of inserts coated using the two deposition

systems. One evaluation of insert performance will be obtained from tool

life studies in the dry turning of AISI 1040 carbon steel. The study will also

include a detailed analysis of the wear behaviour during machining.

11

The Hembrug Super Microturn CNC machine on which the research is conducted

Laser hardening of a crankshaft

Temperature distribution during orthogonal cutting of SS316 modelled usingAdvantEdge

DEPARTMENT OF


Determination of the optimum machining parameters of the coated inserts

based on the Taguchi method is currently being carried out

considering tool life, cutting forces and surface roughness.

The optimum coating thickness that yielded the longest tool life

according to the ISO 3685 criteria was a 3.5µm thick coating. Coatings

up to 7.5µm thick were deposited but as the coating thickness increases

so does the compressive stress in the coating resulting in poor

mechanical performance. X-ray diffraction (XRD) of the coatings was

carried out revealing that the coating grew with a strong (111) orientation

as the thickness increased. Coating adhesion was assessed using the

Rockwell indentation test. Coating thickness was determined using

optical profilometry and scanning electron microscopy (SEM). Results

show that the uncoated tools are inadequate for machining without the

aid of coolant and at high cutting speeds. The coated tools perform well

during dry cutting and there is a dramatic increase in tool life.


Collaboration: Surface Engineering Group, Enterprise Ireland (D. Dowling).

Material Removal Mechanisms in Nanogrinding of Silicon

G Byrne & E Ahearne

This project is concerned with the general objective of extending the

capabilities of grinding technology to produce high quality surfaces in

monocrystalline silicon. Silicon is the main substrate material used in

microfabrication of integrated circuits. The substrate must meet extreme

form and finish specifications which, for the next generation of 300mm

diameter substrates includes: total thickness variation of less than one

micron over the substrate area, site flatness of less than 130 nm and

surface finish of less than 0.1 nm Ra. Ultra-precision grinding and polishing

technologies enable the realisation of these specifications. While much of

the research will apply generally, the specific grinding operation of interest

is “backgrinding” of the substrate after microfabrication. This operation is

critical as the surface quality after grinding determines the substrate

strength and, accordingly, production yields in subsequent processing.

Surface quality improvement is also of fundamental interest for the

production of ultra-thin integrated circuits for “smart card” applications.

The project is considering recent research into the fundamental

phenomena in fixed abrasive finishing (grinding) of silicon with particular

reference to the effect of process parameters on the ductile-brittle

transition. Recent technological developments in relation to the total

machine system will also be appraised including: high loop stiffness,

machine tools with high dynamic damping, electrolytic in-process

dressing (ELID) and ultra-precision control systems. The project is also

uniquely considering the effect of grinding tool design and production

parameters through collaboration with the project sponsor.

Sponsors: Element 6, Atlantic Diamond.

Collaboration: Cranfield University.

Laser Drilling of Aerospace Components

G Byrne, L Sexton & A Corcoran

Due to continuing advances in jet engine efficiency, components are

exposed to ever-increasing combustion and exhaust gas temperatures.

Air plasma sprayed Thermal Barrier Coatings (TBCs) protect jet engine

components (Cobalt/Nickel base superalloys) from direct exposure to the

corrosive temperatures. The TBC is affixed to the superalloy substrate by

an intermediate bond coat thus producing a multi-layer material system.

A laser drilling technique has been developed, to generate cooling holes in

multi-layer systems, for use in the aerospace industry. The purpose of

12

Graph showing tool life achieved vs. coating thickness

Cross section of TiN coating clearly showing columnar growth typical ofmagnetron sputtering

Cranfield’s Tetraform high loop stiffness grinding machine

RESEARCH REPORT

2001-2002

such cooling holes is to provide a protective film of cool air over the

surface of the component, that further shields it from high temperature

exhaust gases. The cooling holes are required to conform to strict

standards stipulated by the original engine manufacturer. Two pulsed

Nd:YAG lasers were used to study the parameters affecting hole

generation in TBC coated superalloy materials. Thorough investigation into

the negative effects of percussion laser drilling on material interfaces,

hole geometry, and the negative effects on the individual microstructures

such as remelt-layer and microcracking, has led to the development of an

optimised percussion drilling process. Percussion laser drilling represents

a significant time saving in comparison with more traditional hole

generating techniques such as laser trepan drilling and EDM. Through

further experimentation at acute angles, the percussion drilling process is

being integrated into a product development plan for the repair of TBC

coated nozzle guide vain components as SIFCO (Ireland) Ltd. The final

phase of this research into the laser drilling of aerospace components is

concerned with the development of a more suitable laser barrier material

for the aerospace industry. Laser barrier materials are required to protect

the intricate inner-channels of turbine blades and nozzle guide vanes from

laser radiation as it breaks through in the hole drilling process.

Collaboration: SIFCO (Ireland) Ltd., DaimlerChrysler AG, Ulm, Germany.

Laser Surface Treatment Technologies for Enhanced

Competitiveness in European Industries (LASCLAD)

G Byrne & L Sexton

This project promotes the advantages of laser surface treatment technologies

(including cladding and surface alloying) of components, or discrete areas of

components, for repair and engineering industries. This technology enables

alloy layers to be deposited with minimal pre-processing and post-processing

on steel or other substrate surfaces. Localised treatment causes reduced

distortion of the component and minimises the heat affected zone. The result

is a wear and corrosion resistant surface applied in a specific region in a

shorter time and at lower cost to comparative techniques. Furthermore,

recent adaptation of the process has led to a novel method to directly build

components from CAD data, which offers a means of rapid prototyping or

rapid production of the appropriate metal or alloy.

Sponsor: Sifco (Ireland) Ltd.

Collaboration: University of Liverpool.

Investigation of the Dimensional Stability of Rapid Tooling

Processes

G Byrne & P Dunne

The process and materials limitations of rapid prototyping systems have led

to the development and industrial application of rapid tooling techniques.

These techniques allow prototypes to be manufactured in final materials by

injection moulding. Enhanced silicone moulding is one such process, which

offers a rapid, low cost route to the manufacture of thermoplastic

prototypes in a metal impregnated rubber mould. During the moulding

cycle, the mould deforms under the high pressures and temperatures

experienced and components produced suffer significant tolerance

deviations. A theoretical model of the system has been developed using

finite element techniques to allow prediction of the tolerance deviations.

The model is two dimensional with the rubber material represented by an

Ogden hyperelastic function. The model is subjected to thermal and

pressure loads which are predicted independently using moulding

simulation techniques. The diagram below shows the pressure profile in the

mould cavity over the moulding cycle. The model has highlighted that areas

close to the gate of the mould are most affected during the moulding cycle

with maximum tolerance deviations occurring in these areas. Research is

continuing on development of the model and comparison of predicted

results with experiment.

Sponsors: AMT Ireland.

Colaboration: Queen’s University of Belfast, University of Sunderland.

13

Blown powder laser cladding process using reflective dome to enhance absorptionof laser energy into molten material

Predicted pressure profile in mould cavity during filling (stages 1-2) and packing(stages 3-4)

The StarDrill/Cut 150 Nd:YAG high power laser system. The motion system can beseen on the right with the laser above. On the left are the power supply andcontrollers for the system

DEPARTMENT OF


Acoustic Emission and Surface Integrity

G Byrne & M Woulfe

Monitoring systems applied to the machining process should ensure that

components are produced to the required dimensional accuracy and

surface quality. To date, monitoring systems fall short of achieving this

objective. Acoustic Emission (AE) sensors are increasingly used to monitor

the AE signals from the turning process. In this work, AE signals in the 100-

900 kHz range are investigated for a range of cutting speeds and feeds in

the turning process. The results indicate that AE levels rise above those

predicted by the established theory as the quality of the surface decreases.

Further research is required to investigate the possibility of monitoring the

surface in-process without extensive modification of the machine tool.

Collaboration: Kistler AG (Switzerland), Technical University Berlin (IWF),

University of California, Berkeley, USA.

Micro-Tribology

DF Moore

A fundamental understanding and exposition of the nature of contact

between a sliding elastomer and a textured substrate is being developed,

with particular attention to micro-events. Both micro-friction and

micro-lubrication for dry and lubricated conditions respectively are

being considered.

The deformation pattern of elastomeric material about a macro-asperity

exhibits complex frequency-stiffening, temperature-softening and local

viscoelastic effects. It appears that according as the scale of events is

diminished to sub-micron dimensions, the surface stiffening effect is

greatly enhanced about micro-texture elements, even at moderate sliding

speeds of engineering interest. At the same time, local viscoelastic effects

on a micro-level become negligible. The elastomeric sliding material

appears to exhibit a stratified stiffening profile across its thickness, with

maximum effect at the sliding interface itself. This stratification is the net

result of an apparent stiffening due to dynamic frequency indentation

from the micro-texture, and the actual temperature softening from energy

dissipation, both predominant at the sliding interface.

This profoundly affects the nature of the frictional mechanism and

explains the apparent convergence of micro-adhesion and micro-hysteresis

conceptual modelling. In practical terms, the harshness and scale of

micro-texture remain the key elements in determining friction levels. In

the presence of a lubricant, effective micro-lubrication in contrast

necessitates the complete absence of harshness in the micro-texture.

Apart from sliding speed, the key variable now becomes micro-reservoir

lubricant capacity in the void spacing between micro-texture elements.

Significantly, it also appears that the very nature of elastohydrodynamic

fluid film entrainment is altered because of surface stiffening. Effective

micro-lubrication can be significantly enhanced on an apparently smooth

substrate by introducing crazing or micro-cracking at the manufacturing

stage. These observations shed new light in particular on the design and

nature of micro-lubrication in ball- or roller-bearing races, and on the

mechanism of micro-slip in tyres and elastomeric seals.

The Impact of Product Life Cycle and Innovation Strategy on

Corporate Performance

DP FitzPatrick & B Dattee

Increasingly more rapid advances in technology are contributing to the

concatenation of product life cycles. In industries with a fast rate of

evolution, new products with better technology are replacing products

based on conventional technology at increasingly faster rates. Rapid

acceleration of the product life cycle in response to technology push/

market pull ultimately increases a company’s dependence on a smaller

number of products, therefore increasing its overall business risk.

This project has focussed on identifying the dynamics that lead to life

cycle acceleration and has used a research approach that integrates

diffusion models, utility theory, technology assessment methods and

business simulation. A simulation model has been developed which

operates on three levels: an analytical model of an industry technological

evolution, a System Dynamics model of technological innovation diffusion,

and a System Dynamics model of the firm’s performance.

The model allows the level of technological innovation to the market

diffusion, through the use of product attribute levels and risk-adjusted

utility. Thus, the model can replicate diffusion and substitution effects

leading to the acceleration of technology life cycles. Partial validation

14

A quick-stop specimen produced from the low alloy tool steel of 56HRC.Thearrows indicate the primary shear band which originates at the tool tip

RESEARCH REPORT

2001-2002

of the model has been achieved through the use of data from the

development of public switching technologies and the DRAM industry.

The research has demonstrated the need for coherence between the

innovation strategy, the firm’s capabilities and its market environment.


Collaborative Design - Analysis of Web-based Technology Use

and Effectiveness

DP FitzPatrick & B O’Doherty

Currently SMEs in Ireland are involved in global scale design efforts in

many different sectors. The concept of “lean design” is beginning to gain

the momentum that lean manufacturing enjoyed in previous years. The

cost of the design process is exaggerated by the difficulties of

communicating between various parts of an often international design

team. The project has the following high-level objectives:

• A review the current collaborative design tools available. These

include design tools, real time Internet collaboration tools, design

project management tools and combinations thereof.

• A review of the current collaborative design processes used within

a number of industry sectors for different size organisations.

• A compilation of the findings from the software tools review and

business process review and best practice recommendations for

different industries/company sizes.

The project has shown that the range of software tools which offer the

benefit of increased collaboration to product development groups is wide

and growing. However the level of usage of such tools is markedly low

in a sector which has a number of well established communication

requirements. Many of the identified problems associated with product

development have potential solutions based on the appropriate use of

Internet technologies but the level of understanding and knowledge of

these solutions is low among Irish SMEs.


Aerospace Supply Chain Business Processes

DP FitzPatrick & K O’Brien

The subcontract repair process in the aerospace industry would benefit

hugely from e-commerce development. The large number of parts and

interacting suppliers, over 3 million parts from thousands of suppliers in

the case of a Boeing 747, suggests that significant gains in efficiency

could be realised if the subcontract repair process could be systemised.

Ths project is concerned with the detailed mapping of the supply chain

interfacing business processes from a selected number of Maintenance

Repair and Overhaul (MRO) organisations. The primary objective is to

develop a prototype B2B e-commerce solution.

The development and documenting of process mapping methodologies

has enabled detailed process maps to be developed for the collaborating

companies, selected to form a cross-section of the aerospace

industry and includes a regional airline, a base maintenance

organisation, a piece part supplier and a component repair organisation.

The business process review has concentrated on the Engineering,

Planning/Operations and Materials departments of the organisations

concerned. The results have enabled a generic process map for the

aerospace industry to be developed.


Collaboration: Faculty of Commerce, UCD (M. McDonnell).

E-Commerce Technology in the Aerospace Industry - Capability

Assessment and E-Commerce Solution Development

DP FitzPatrick & D Sexton

This project examines the existing technological initiatives within the

Maintenance, Repair and Overhaul (MRO) sector of this industry and hopes

to identify a set of recommendations and an e-commerce prototype for the

future technological progression of the Irish MRO companies. The two

primary objectives of the project are to provide a set of recommendations

based upon the review of the existing technical infrastructure, and to

develop a prototype for a commercial message brokering system tailored

to the individual needs of the aerospace MRO industry.

The use of IT solutions in the Irish aerospace industry varies from

company to company. Some of the factors that influence the level of IT

usage within companies include the IT policies of parent companies and

their competitors, the availability of relevant IT solutions and the expertise

within the companies themselves. In general, autonomous companies

tended to have a lesser level of systemisation within their processes while

subsidiaries of larger companies used the initiatives and methodologies of

the parent companies. Some of the companies visited have necessitated

solutions that fall between two stools in terms of functionality and this

has led to a need to complement existing applications by developing

15

Acceleration engine model demonstrating the increase in product sales withsuccesive generations of technology until a saturation effect occurs with the fourthgeneration, resulting in a marked fall in new sales

DEPARTMENT OF


systems in-house. It is hoped that this project will provide a direction for

the industry to follow in order to successfully compete in the New

Economy with a set of recommendations accompanied by a sample

prototype of a tailored e-commerce system.



Distributed Industry Systems in the Aerospace Sector -

Technology Audit and E-Commerce Solution Specification

DP FitzPatrick & E Kearney

The project examines the methods currently used by airlines to calculate

the inventory spend and how they manage this inventory, specifically

rotable inventory components, including in-house inventory management

methods and the range of third party solutions which exist. The objective

of the project is to specify a web-based solution which can calculate

inventory quantities for fleet-wide service levels which minimize cost and

calculate the optimum points to store this inventory in the airlines

operational network.

The project has shown that, through the application of management

science techniques, airlines can reduce capital investment on rotable

inventory, by as much as 50% without compromising fleet service levels.

They can also increase the efficiency of this inventory by applying

management science solutions to the distribution problem. More efficient

distribution of inventory will also impact airlines revenue by reducing the

number of grounded aircraft, increasing aircraft dispatch reliability and

increasing customer goodwill. A web-based system would allow real-time

traceability of all rotable components and dynamic reallocation of

inventory when parts are withdrawn from stock.


MATERIALSDJ Browne, AJ Carr, DN Collins, MD Gilchrist, MA Hayes, DF Moore,

N Murphy

Over the period covered by this report, there has been very active

research taking place into the science and engineering of materials. In

addition to basic research covering metal alloys, polymers, ceramics and

composites, the Department and the Materials Ireland Research Centre

have been working with industrial partners in applied R&D projects.

Particular expertise of the academic staff members include phase

transformations in alloys, mechanics of composite materials, development

and characterisation of new materials, and computer modelling and

simulation of materials processing and behaviour.

The Department’s materials laboratories include a solidification

laboratory, a ceramics laboratory, a plastic injection moulding facility, an

alloy heat treatment centre, and a metallography laboratory. Facilities

exist in the Department for static and dynamic mechanical testing, high

strain rate testing, diffraction studies of structure, corrosion and fatigue

testing, and quantitative microstructural evaluation. Also available within

the University is a well-equipped electron microscopy facility.

Solidification of Metal Alloys: Modelling the Evolution of

Microstructure

DJ Browne

A novel computer model of the development of grain structure during

alloy solidification in a shape casting process has been developed.

The non-equilibrium kinetics of nucleation and growth of crystals in the

melt are treated computationally via a front-tracking algorithm, whereby

the moving crystal boundaries are tracked across a fixed grid. The new

model has been used successfully to predict the temporal advance of a

front of columnar crystals in a mould, and has been verified by

comparison with results from the well-known enthalpy method.

In the undercooled liquid ahead of such a front, equiaxed solidification can

occur. The nucleation and growth of equiaxed grains in such a zone have

been modelled, and preliminary results agree with experimental findings.

Sponsors: Materials Ireland.

Collaboration: University of Oxford (JD Hunt).

Microgravity Solidification

DJ Browne, J Banaszek

Funded by the European Space Agency, Professor Jerzy Banaszek of the

Institute of Heat Engineering, Warsaw University of Technology, joined UCD

for a two-year period to work on the development of a computer model in

which the effects of natural convection, in the liquid phase, on the

structure of a freezing alloy could be simulated. Such natural convection

occurs on earth due to density gradients in a fluid, in turn caused by

spatial, thermal or compositional variations. In microgravity conditions (for

16

Prediction of the growth of two “twin” equiaxed grains during alloy solidification;position every 1 s after nucleation; Al-2wt.%Cu; h=0.05 W/cm2K; initial alloy liquidtemperature Ta=675oC. Axes show distance from mould corner

RESEARCH REPORT

2001-2002

example on board the International Space Station), such convection does

not occur, and diffusion dominates; under such conditions the model of

Browne and Hunt (see above) can be used. The effects of convection on

columnar solidification have been ascertained via a new numerical model.

The front-tracking microstructural evolution model is now being coupled

to a model of convection heat transfer. ESA have extended the UCD

funding to 2006, which will enable completion of this work.

Sponsors: European Space Agency and Materials Ireland.

Investigation of Thermal Boundary Conditions in Casting

Processes

DJ Browne, N Coone & M Hussey

Using an inverse computer model developed in the Department, the heat

transfer at the interface between a solidifying alloy and its mould, in a

casting process, has been characterised. This has been completed for

the ceramic moulds used in investment casting, and also for metallic

(permanent) moulds and sand moulds. The solidification of Al, Pb and Fe

alloys has been studied. Via design of experiments, the effects of process

variables, such as alloy preheat and freezing range, on the interface heat

transfer coefficients have been determined. The results of this work have

been used as boundary conditions in simulations of alloy solidification in

castings, both for commercial processes and for research experiments.

Sponsors: Enterprise Ireland.

Collaboration: Ecole Centrale de Nantes (M. Jacot) and NMRC-Cork (D

O’Mahoney).

Direct Thermal Method of Rheocasting

DJ Browne, M Hussey & AJ Carr

Experimental studies in the UCD Solidification Laboratory led to the

invention of a new casting process to produce a microstructure of

globular (non-dendritic) primary phase in an alloy. This is a rheocasting

process, but unlike competing technology, no special device to stir the

material (electromagnetically or mechanically) during its solidification or

external thermal management system is required. Rather the design of

the experimental geometry and choice of materials leads to a situation

wherein the alloy in a simple mould is held nearly isothermally for

prolonged periods. This isothermal environment leads to the surface

energy-reducing ripening of the solid morphology, forming globular

shapes. Because of the absence of external intervention in the natural

progress of solidification in this process, it was given the name Direct

Thermal Method. Its invention has been met with considerable

enthusiasm in both industrial and academic circles.

Sponsor: Materials Ireland.

Collaboration: Dublin City University (D Brabazon) and INSA, Rouen

(L Legendre).

Optimising Moulding Conditions to Improve the Quality of

Injection Moulded Parts

MD Gilchrist & F O’Dowd

It is increasingly important that products that are manufactured using high

cost and high energy content materials be done so using environmentally

efficient processes. Injection moulding offers the potential to manufacture

plastic and reinforced-plastic products in a single operation to net shape

17

Flow pattern and the solidus and liquidus isotherms (which bound the grey mushyzone) for solidification with natural thermal convection

Columnar and equiaxed grain structure in a typical casting

Direct Thermal Method (DTM) of rheocasting: schematic of apparatus

Microstructure of DTM cast A356 aluminium alloy

DEPARTMENT OF


geometries. The quality of an injection-moulded part is affected by many

factors, including part geometry, material properties and processing

conditions. Due to the large number of processing parameters involved in

injection moulding a comprehensive investigation of their main effects

and interactions is vital to the understanding of the process and also in

achieving optimum part quality. In this project the main influencing factors

that have been varied are flow rate (fill time), melt and mould

temperatures, injection pressure, cooling time, packing pressure, part

thickness and material type. The influence that these variables have on

the shrinkage and strength of an injection moulded component was

analysed using a design of experiments approach. Based on analysis of

variance (ANOVA), the best condition set, which gives the best response

(minimum, maximum, or close to an average value), are obtained.

Sponsors: Enterprise Ireland (PRP2000), EU (Thematic Network), PRTLI

(Urban Institute Ireland), Royal Irish Academy.

Collaboration: ENSAM-Paris (D Baptiste).

A Theoretical Study of the Tensile Test for Highly Anisotropic

Composite Materials

MD Gilchrist & M Lévesque

Various standard procedures (ISO 527 parts 4&5 and ASTM D3039) exist

for measuring the tensile strength of composite laminates. However,

situations can arise when these standards fail to produce acceptable

results. In such cases, the standards provide no guidance for modifying

the specimen to improve the quality of results when unacceptable failures

occur. The aim of this research has been to analyse the precise stress

field in a tensile test specimen when measuring the tensile strength in the

fibre direction of a unidirectional composite material. This theoretical and

experimental analysis has shown that:

• increasing the value of E22,t and ν12t and decreasing the value of G13,t

will decrease the peak intensities of the parasitic stresses and the

failure index in the test material,

• the most influential tab engineering constant on the parasitic stress

field in the test material is E11,t and

• the clamping force should be kept as high as possible without

inducing compressive failure of the test material.

Sponsor: Enterprise Ireland (Applied Research Grant).

Collaboration: Ecole Polytechnique, Montreal (B Fisa).

Design and Performance of a Composite Seat for

Civil Aircraft Applications

MD Gilchrist, G Byrne & M Levesque

The objective of this project has been to develop a systematic procedure

that can be used for the design & manufacture of lightweight composite

seat frames in civil aircraft. The motivation for this research is the

demand for increased passenger and flight capacity, achieved through

weight reduction, in the latest and next generations of commercial

aircraft. Within an Irish context, specific opportunities exist for

manufacturing high added-value niche products (viz. sub-structural

components) for supply into the competitive international aeronautics

industry. This present project has directly assisted in this endeavour by

reducing the weight of current seats through innovative design

modifications. The results that have emanated from this project are (i)

the development of a unique experimental facility that can be used to

determine the structural performance (and compliance with FAA

regulations) of different seat frame designs, and (ii) the creation of a

computer simulation tool that can be used to predict the behaviour

of alternative seat frame designs (different materials and composite

stacking sequences).

Sponsors: Enterprise Ireland (Applied Research Grant), Carbofast.

A Micromechanical Model for Non-Linear Viscoelastic Particle

Reinforced Polymeric Composite Materials

MD Gilchrist

A theoretical model has been developed to predict the mechanical

behaviour of reinforced polymers where the matrix is nonlinear viscoelastic.

The model is based on knowledge of the microstructure of the composite

material and on the mechanical behaviour of each constituent phase,

namely glass bead-reinforced polypropylene. The beads are assumed to

be randomly distributed throughout the matrix. The glass is assumed to

be linear elastic (isotropic) while the matrix is assumed to be nonlinear

viscoelastic (isotropic). The polypropylene is assumed to obey a

generalised 3D form of Schapery’s behaviour law.

Simulations of the behaviour accurately predict the mechanical

response under constant stress rates of loading: the material becomes

stiffer as the volume fraction of reinforcement increases. In addition, the

stress-strain curves become increasingly linear as the reinforcement

18

Predicted variation of injection pressure during injection moulding process

RESEARCH REPORT

2001-2002

volume fraction increases.The composite material behaves less as a

nonlinear viscoelastic material and more like a linear elastic material as

the volume fraction of reinforcement increases.

Sponsors: Enterprise Ireland (PRP2000), Royal Irish Academy

(Ulysses Grant).

Collaboration: ENSAM-Paris (D Baptiste, M Lèvesque & K Derrien).

Experimental Studies in Micro-displacement Characteristics of

Rubber Adhesion

DF Moore and T Fujimoto

In this research three rubbers of varying hardness and hysteresis are

subjected to an increasing tangential shear force in a purpose-built precision

laboratory rig. Pre-slip transient micro-displacement characteristics are

established for both dry and lubricated contact conditions. During

subsequent micro-slip, peak and quasi-static friction coefficients are

measured and the phenomenon of macro stick-slip is identified.

Sponsor: Japanese Ministry of Education.

Dynamic Fracture Simulation of Brittle Polymers Characterised

by Microcrack-dominated Failure Mechanisms

N Murphy

A wealth of experimental evidence on the dynamic fracture of some brittle

polymers such as PMMA indicates that their primary failure mechanism is

the formation and coalescence of microcracks. Associated observations

include attempted branching from the initial fracture plane, variation of

macroscopic roughness of the fracture surface, oscillations in crack

velocity and a substantial increase in the energy dissipation of the crack

with increasing velocity. For this class of materials, the model of a single

crack tip is inappropriate and further insight may only be made by

exploring alternative modelling techniques. In this work, a non-linear

elastic Finite Volume formulation is adopted for the two-dimensional

transient stress analysis. The finite normal and shear cohesive strengths

and separation energies of the material are incorporated into the

formulation and the fracture behaviour emerges as a natural outcome of

the solution of the resulting initial-boundary value problem.

Sponsors: Enterprise Ireland (International Collaboration Programme),

British Council.

Collaboration: Imperial College, London (A Ivankovic).

MECHANICSMD Gilchrist, WJ O’Connor, SS Timoney

Ultrasonic Detection of Embedded and Surface Defects in

Thin Plates Using Lamb Waves

MD Gilchrist & M Conry

Conventional ultrasonic NDT&E relies mainly on through-thickness wave

propagation. For plate-like sections, this is a very slow process. The present

research is focused on exploring an alternative form of propagating waves.

Lamb waves are waves that propagate longitudinally along a plate (as

opposed to transversely through the plate thickness). At least two

propagating (Lamb) modes can exist at any given frequency. These modes

are classified as either symmetric or anti-symmetric. The lowest order

symmetric mode is denoted So and this is the mode which has been used in

this work. The characteristic equation governing the phase-velocity for

Lamb waves is dependent upon the frequency of the wave, the elastic

constants of the plate material, and the plate thickness. For anisotropic

plates, for example fibre-reinforced composites, the frequency-velocity

relation is highly dependent on the propagation direction. This dependence

is illustrated in the two dispersion curves shown. Both curves are

calculated using the same material properties for a unidirectional fibre-

reinforced composite plate, but with different propagation directions.

Sponsors: Materials Ireland, Enterprise Ireland (Basic Research Grant and

International Collaboration Programme).

Collaboration: Trinity College Dublin (LJ Crane), Polish Academy of

Science, Gdansk (WM Ostachowicz).

Prediction and Detection of Critical Defects in Engineering Structures

MD Gilchrist

This project simulates the propagation of an acoustic wave within a

delaminated beam in order to use the known fact that material

19

Propagation normal to fibres

Propagation parallel to fibres

DEPARTMENT OF


discontinuities affect the propagation of elastic waves in solids.

The change in certain material characteristics, such as a local change in

stiffness or inertia caused by a crack or the presence of material

damage, affects the propagation of transmitted elastic waves and thus

modifies the received signal. Wave frequencies associated with the

highest detection sensitivity depend, among other things, on the type of

structure, the type of material, and the type of damage. This research

uses spectral finite elements to detect small delaminations in

beam-like structures.

Sponsors: Enterprise Ireland (International Collaboration Programme),

Royal Irish Academy.

Collaboration: Polish Academy of Sciences, Gdansk, Poland (WM

Ostachowicz).

Wave-based Position Control of Flexible Mechanical Systems

WJ O’Connor & C Hu

A successful new approach to the old problem of positioning flexible

mechanical systems, such as gantry cranes or long, light, flexible robot

arms, has been developed. The crane trolley (or actuator) must attempt to

reconcile two apparently conflicting requirements: position control

(despite elasticity) and active vibration (or swing) damping. Previous

approaches based on, for example, input shaping, active modal damping,

or wave absorption, typically have been open-ended, giving an asymptotic

approach to the final rest position. By contrast, the new control strategy

stops the load dead, exactly at target, in a finite time, after a single

smooth transit (without swings) and no overshoot.

Using ideas based on mechanical waves, the gantry controller learns

from the previously unknown dynamic response in the first part of the

motion exactly how to terminate the motion. In a sense, the system itself

serves as the controller “model”. The controller is self-adapting, needs no

system model, needs minimal sensor information, minimal computation

overhead and no adjustment for load changes. Furthermore, the trolley (or

actuator) can be speed-limited or force-limited without even marginally

impairing the vibration control performance. The analytical results

have been confirmed by numerical simulation and by experimental

measurement.

Sponsor: Enterprise Ireland (Basic Research Grant).

Dynamics of Musical Instrument Plates

WJ O’Connor & T Hanson

Although a violin’s sound is produced by a complex interaction of many

effects, all agree that the way the plates vibrate is crucial. Violinmakers

(“luthiers”) often measure the mode shapes and frequencies of

unassembled violin plates and then try to “tune” them, by thinning certain

areas, to get mode shapes and frequency relationships as close as

possible to some perceived ideal, despite the idiosyncracies of any given

piece of tonewood.

From the perspective of dynamics, plate thinning has the main effect of

changing the local bending-stiffness and mass-density over some area of

a plate. Most experts agree that three vibration modes, numbered 1, 2

and 5, are particularly important. A common strategy is to use thinning to

try to get them to have the right shapes and harmonic frequency

interrelationships. For many reasons this is much easier said than done.

User-friendly software is being developed to make it easy to analyse the

vibration of a real plate and to predict the effects of a proposed tuning

strategy before actually thinning the wood, and so to tell the craftsman

(a) where to thin and (b) when he has reached the optimum and therefore

should stop.

The work has wider application not just to many other musical

instruments but generally to problems involving vibrating beams or plates.

20

Transverse acceleration at the free end of a delaminated cantilever beam

An actuator controls the position of a remote load through an intermediate flexible system

Software predicts mode shape and frequency of vibration, in this case for auniform beam with ends free

RESEARCH REPORT

2001-2002

The Application of TLM to the Design of Acoustic Devices

WJ O’Connor

TLM (Transmission Line Matrix) is an inherently stable time domain

numerical technique for solving variants of the wave and related

equations. Its application areas include electromagnetics, thermal

diffusion, and acoustics. TLM is characterised by its close relationship to

the physical processes being simulated. In other words, the modelling

process conceptually resembles the actual propagation process. The

calculations required are very simple, and may be implemented efficiently

on a computer. This project is concerned with the development of a user-

friendly TLM acoustic modelling software application. As a design tool it

provides an attractive alternative to time-consuming prototype testing of

acoustic devices. Of particular interest is acoustic device design is the

mechanical-acoustical interaction between sound waves and membranes,

as found for example in microphones and loudspeakers. A condenser

microphone is an example of where this interaction is of importance.

TLM Applied to CFD

WJ O’Connor & F O Cleirigh

Computational fluid dynamics (CFD) models the mechanics of flow.

The basic CFD variables are pressure and velocity, as in acoustics.

But CFD is broader. The acoustic wave equation, which the basic TLM

method can solve, makes certain approximations that are no longer valid

for most fluid dynamic problems. For this reason the basic TLM algorithm

has to be modified and developed. Firstly an extra pressure gradient

associated with the convective acceleration term in Euler’s equation of

fluid mechanics was incorporated into the TLM model. Then the effects of

viscosity were studied and incorporated. The end result is a completely

new way of solving the Navier-Stokes equations of fluid mechanics which

has many of TLM’s attractive features, including complete modelling of

time transients and a very close relationship between the model and the

physics of the problem.

The Fundamentals of TLM

WJ O’Connor & A Kennedy

There is ongoing research into the fundamentals of the TLM (Transmission

Line Matrix) numerical modelling method. One area of interest is

modelling waves in moving media, where the wave speed is direction

dependent. A successful model has been developed and analysed. A

second area concerns the time-domain dynamics of TLM.

Numerical Solution of PDEs by Impulse Propagation

and Scattering (IPS)

WJ O’Connor

Impulse propagation and scattering (IPS) is a development of the

Transmission Line Matrix (TLM) numerical modelling technique to solve a

range of important partial differential equations of mathematical physics.

The primary dependent variable is modelled throughout space and time

by impulses that can be considered as sample values of the variable.

Space is discretised by a series of nodes, interconnected by transmission

lines, along which the impulses propagate during each time increment.

At the nodes the impulses undergo a scattering process that obeys

fundamental conservation laws. By varying the scattering algorithm

and/or the nature of the propagation, the method provides a numerical

solution technique for a wide and growing range of PDEs. The method has

many attractive features.

Sensors

WJ O’Connor

Work is continuing on the design and development of a variety of sensors

for special purposes. Sensors recently studied include a sensor for

measuring the moisture content of solid fuel, the relative humidity of

exhaled breath, the density of fluids, and the mode shapes of vibrating

plates. Already developed are sensors for measuring the fluid level in

sealed containers and for counting people.

21

TLM software models laminar flow around a square obstacle in a pipe

Relative motion between source and wave medium modelled by TLM

DEPARTMENT OF


Vehicle Roll Control

SS Timoney, P Christian & C Begley

In order to provide good vehicle ride behaviour, a relatively soft vehicle

suspension is desirable. A consequence of using soft suspension is that

the vehicle roll stiffness is reduced leading to higher roll angles in

cornering maneuvers. Anti-roll bars or similar devices are often used to

increase the vehicle roll stiffness. Soft suspension may also result in more

severe vehicle pitch oscillations. The use of devices such as anti-roll bars

tends to degrade the performance of an independent suspension system.

The anti-roll bar increases the suspension stiffness, even in the absence

of body roll, when the wheels on opposite sides of the vehicle are moving

in different directions in response to uneven terrain, thus reducing the

independence of the wheel movements.

This project is intended to bring a patented idea for vehicle roll control

to the stage where it is ready to be installed in a test truck. The project

addresses the mechanical and hydraulic design of the system and will

simulate the total vehicle system behaviour with and without the control

system present. It will also encompass the design and testing of a control

system for the suspension.

Sponsor: Enterprise Ireland (Innovation Partnership).

Racing Car Yaw Response

SS Timoney & C O’Kane

The response of a racing car to steer inputs is characterized by two

degrees of freedom namely the yaw response (rotation) and the lateral

acceleration response (translation). This response must combine rapid

transients with stability at high speed. The aim in all motor racing is to

optimize this response under the constraints of cost, mass, moment of

inertia, packaging, etc. Active yaw control is currently being developed

as a safety feature in the automotive industry to improve the high-speed

stability and low-speed maneuverability of vehicles. In the racing

environment, the challenge is to produce a system that improves dynamic

performance under race conditions. Similar constraints apply, although

their relative importance differs.

Four-wheel steering (4WS) has been investigated in the literature for

some time. This project aims to apply the improvement in dynamic

response available from 4WS to a small racing car.

ENERGY CONVERSION(DP Finn, MJ O’Rourke, WJ Smith, DJ Timoney)

The Energy Conversion Research Centre was established in 1987 and

acts as a focus for faculty activities in the fields of:

• Internal Combustion Engines

Spark Ignition & Diesel Combustion,

Alternative Fuels.

• Power Plant and Power Generation

Combined Heat & Power Systems,

Steam and Gas Turbine Modelling.

• Building Energy Systems

Refrigeration & Air Conditioning,

Heat Pumps,

Evaporative / Radiant / Displacement Cooling,

Water Heating Boilers.

• Energy and the Environment

I.C. Engine Exhaust Pollutant Formation,

External Costs of Power Generation,

Energy Usage in Transport.

• Heat Transfer and Fluid Dynamics

Drying of Particulate Materials,

Compact Heat Exchanger Technology,

Computational Heat Transfer and Fluid Dynamics.

Response Characteristics of Vapour Compression Cycles subject

to Non-Uniform Operating Conditions

DP Finn & K Grant

Multi-temperature vapour compression systems are frequently utilised in

transport refrigeration containers and consist of two or more evaporators

in conjunction with a single compressor-condenser unit. Although multi-

temperature systems are designed to provide independent cooling of

separate compartments in a single container, they are usually subject to

highly non-uniform operating conditions that makes independent

temperature control particularly challenging. In this project, a custom

designed multiple-evaporator test facility capable of examining the

dynamic behaviour of multi-temperature vapour compression systems has

been developed. The test facility is based on three evaporators in parallel,

a compressor-condenser unit that utilises either a reciprocating or scroll

compressor and a choice of throttling mechanisms to include

thermostatic, stepper motor or modulated pulse expansion valves. In

addition, the facility is capable of direct optimisation of the vapour

compression cycle by real-time control of evaporator throttling, suction

line pressure regulation and compressor capacity regulation. To facilitate

development and testing of control and optimisation algorithms, a model

capable of simulating both steady state and dynamic performance of the

multi-temperature experimental facility has been developed. Typical

operational sequences representative of steady state and transient

behaviour of transport refrigeration systems are tested and evaluated

using the experimental facility and are compared with simulated

predictions of the model.

22

RESEARCH REPORT

2001-2002

Sponsor: Enterprise Ireland (Basic Research Grant).

Transient Modelling and Optimisation of Multi-Evaporator

Refrigeration Cycles

DP Finn & A Stack

This research focuses on modelling multiple-evaporator transport

refrigeration systems under transient operating conditions.

Multi-evaporator systems are extensively used in urban transport

refrigeration where flexible modular cooling is required. An approach

which combines dynamic modelling, stability analysis and experimental

validation is being followed. A discrete multi-zone control volume

approach is utilised for modelling the condenser and evaporators. All

other major refrigeration components including compressor, expansion

valves, receiver, pressure-regulating valves are modeled using time-

dependent differential equations. The model is implemented using

MATLAB. Component models are validated individually and are then

combined to give an overall system model. Overall model predictions are

further validated using experimental data obtained from a purpose-built

multi-evaporator test rig for transient and non-uniform operating conditions.

Sponsors: Enterprise Ireland (Basic Research Grant)

Evaporator Performance Optimisation using Algorithm Controlled

Throttling Devices in Vapour Compression Systems

DP Finn & K Toumanguelov

Recent developments in refrigerant expansion devices include pulse and

stepper motor electronic throttling valves. In this research, evaporator

heat transfer performance subject to electronic throttling devices is

examined under steady and transient conditions. For both devices,

refrigerant expansion is controlled by custom-designed algorithms, which

have been developed from first principles and implemented by means of

a Building Energy Management System. Evaporator heat transfer

performance subject to control by different devices is benchmarked

against standard reference throttling devices. Extensive experimental

testing under steady state and transient conditions demonstrate the

importance of algorithm design and tuning in achieving optimisation of

evaporator heat transfer.

Sponsors: Cylon Controls Ltd. and CIBSE.

23

Schematic representation of multi-evaporator experimental test facility

Experimental and simulated temperatures during step load change to a singleevaporator in a multi evaporator system

Transient and steady evaporator response to PID control in a pulse electronicexpansion valve

24

DEPARTMENT OF


Analysis and Optimisation of Evaporative Cooling in

Building Energy Applications

DP Finn & BM Costelloe

Evaporative cooling has had limited application in maritime, temperate,

climates due to the low levels of cooling water availability which result

when low temperature (5 to 8˚C), convection based, building cooling

systems are used. However, the success of high temperature radiant

cooling, in the form of chilled ceilings, has prompted a review of

evaporative cooling in maritime, temperate, conditions. In order to

maximize evaporative cooling availability, however, in this application, it is

necessary to achieve low wet bulb temperature approach conditions, at

viable levels of primary energy consumption. The focus of this research

is to examine how the combination of radiant systems with evaporative

cooling will perform under maritime-type climate conditions.

An instrumented experimental test facility has been constructed and

testing to date has indicated that evaporative cooling can provide a

significant proportion of the total annual cooling requirement. Results from

experimental research into the energy performance of an

evaporative cooling test facility are compared with typical energy

efficiencies of conventional, refrigeration based, building cooling systems.

A significant potential for improved energy performance has been found.

Sponsors: Enterprise Ireland and CIBSE.

Process Analysis of the Artificial Drying of Milled Peat

DP Finn & D Hanratty

Artificial drying of milled peat is typically carried out in large scale shell

and tube process heat exchangers. The objective of this research is on

process optimization associated with the drying of different milled peat

types. Work to date has focused on developing drying correlations that

link drying parameters such as drying rate, drying duration, etc., with

various peat physical properties as well as process parameters. This has

been achieved by experimental testing using fluidised drying as well as

process simulation models. By monitoring differential absolute humidity

across the fluidised bed throughout a test, the process of moisture

removal from a sample could be examined. This process is presented as

drying characteristic curves. A significant finding of this work is that the

drying characteristic of a blend appears to be an average of the

characteristics of its constituent peat types. This could be used to improve

the planning of blend make-up at Bord na Móna plants.

Sponsors: Enterprise Ireland and Bord na Mona.

Analysis and Optimisation of Secondary Circuit Multi-Evaporator

Refrigeration Cycles

DP Finn, DJ Timoney, J Carroll & R Kelehan

The overall aim of this project is to design and test a prototype multi-

temperature refrigeration system that uses secondary-loop refrigerant

circuits. Unlike direct expansion vapour compression systems, secondary

loop systems utilise a primary refrigeration cycle to cool a single-phase

coolant which is then circulated to cool separate compartments in

an independent manner. Although secondary loop systems may

exhibitertain thermodynamic penalties, it is envisaged that they also

address some of the significant control and defrost issues associated with

the current multi-temperature units. A thermodynamic transient model of

the secondary system has been developed thereby facilitating validation

and design optimisation of different prototypical secondary systems.

Sponsors: Enterprise Ireland and Themo King Ltd.

Collaboration: University of Illinois at Urbana Champaign, USA (P Hrnjck).

Influence of Urban Pollution on the Effectiveness of Natural

Ventilation for Low Energy Heating and Cooling of Commercial

and Institutional Buildings

DP Finn & J Horan

Building energy is responsible for approximately 40% of EU energy

consumption and associated emissions. Air conditioning occupies a

Evaporative cooling test facility

Fluidised bed test rig

Direct expansion multi evaporator vapour compression system in transport refrigeration application

RESEARCH REPORT

2001-2002

significant portion of this figure and is projected to increase over the

coming decades. Natural ventilation has recently emerged as an

innovative alternative low energy concept for heating and cooling of

commercial and institutional buildings. However, in urban environments,

ambient air pollution is perceived to have a detrimental effect on the

effectiveness of natural ventilation systems, thereby acting as a barrier

to its adoption. This project aims to examine the sensitivity of the internal

building environment to external urban microclimate parameters such as

wind speed, wind direction, pollution, noise and other urban parameters,

with the aim of establishing correlations that will assist with the design

of natural ventilation systems. A combination of computational fluid

dynamics and experimental testing will be utilised. The outcome of this

research will be used to formulate guidelines and best practice codes on

the use of natural ventilation solutions thereby improving the uptake of

this technology in future building energy solutions.

Sponsor: Urban Institute Ireland.

Collaboration: Department of Geography (G. Mills).

Knowledge-based Predictive Control and Optimisation of Night

Ventilation in Low Energy Passively Cooled Buildings

DP Finn & D Connolly

This project aims to develop novel predictive algorithms for real-time

control and optimisation of night ventilation cooling systems in building

energy applications. Night ventilation involves pre-cooling of the building

fabric during nocturnal hours by circulating cool external air through the

building. This stored resource is used during the subsequent daytime

period to condition the building. Night ventilation systems offer the

potential to eliminate the use of energy intensive refrigeration-based

water chillers. Optimisation of night ventilation systems has to date

proven to be very difficult and involves weeks and sometimes months of

pre-building commissioning before satisfactory performance can be

achieved. This project aims to address this shortcoming by developing

novel self-learning predictive routines aimed at automated commissioning

and improved real-time control. In this way these developments will

increase the uptake by architects and engineers of this promising concept.

Sponsor: Urban Institute Ireland.

Collaboration: School of Architecture (P. Kenny).

Optimisation of Radiative Cooling in Mixed-Mode

Building Energy Systems

DP Finn & C Ruane

The use of radiant cooling panels in conjunction with low energy building

energy systems (eg, evaporative cooling, displacement ventilation) has

been the subject of considerable interest in recent years. However, to

date little work has been carried out that focuses on the design and

optimisation of radiant cooling panels in building energy applications. The

aims of the proposed research project are (i) design of a high

efficiency radiant panel which optimises radiant and convective heat

transfer using computational design tools, (ii) assessment of the

performance of such panels in mixed mode operation (eg, natural

ventilation, displacement ventilation), (iii) verify any computational

predictions by an experimental test programmme. This will be achieved

by a combination of CFD analysis and laboratory testing.

Design and Evaluation of a Variable Intake System for a Formula

Student Engine

W Smith & A Bates

This project aims to design and develop a variable-length intake runner

system for a Formula Student race engine. The performance of such an

engine is highly dependent on the geometry of the intake system, as this

exerts a strong influence on both the magnitude of the engine torque

peak, and the engine speed at which that peak will be attained. The

implementation of a variable-length intake runner system allows

the torque peak to be maintained over a wide range of engine operating

conditions, enhancing both the absolute performance of the vehicle and

its driveability.

The project involves a tightly coupled programme of experimental and

theoretical experimentation, integrating data obtained from UCD’s engine

test facility with the predictions of commercial and in-house simulation

codes. Information derived from this programme will inform the

parametric design of the variable intake system. Detailed mechanical

design will lead to the production of a variable-length intake runner

system, which will be tested and evaluated on the Formula Student

race engine.

25

Velocity streamlines in a naturally ventilated building using CFD aanalysis

Night ventilated buildings

DEPARTMENT OF


Design, Analysis and Implementation of a Suspension System for

a Formula Student Racing Car

W Smith, W Carroll, C O’Kane & S Clancy

The lateral grip, traction, braking performance and transient response of a

Formula Student race car are heavily dependent on the configuration,

geometry and mass of the tyres, wheels, springs, dampers and links

that constitute the suspension system. Design and development of an

optimised suspension design is therefore critical if the car is to perform

well in competition. The project involves a comprehensive review and

analysis of potential design solutions, leading to the definition of an

appropriate outline performance specification for the Formula Student

suspension system. Based on that specification, kinematic analysis is

employed to devise a physical mechanism that approximates the required

performance, while minimising attendant mass, cost and volume. This is

followed by detailed mechanical design involving material selection, finite-

element analysis and component integration. Finally, the complete system

is manufactured and installed on the Formula Student racing car, its

performance recorded using on-board data acquisition and compared

with the predictions of the theoretical models.

Analysis and Evaluation of Gear-ratio Selection Mechanisms for a

Formula Student Car

W Smith & D Halpin

Formula Student engines are typically based around a motorcycle unit,

with an integrated clutch and gearbox. On the motorcycle, gear ratio

selection is performed using a foot-operated rod linkage combined with a

hand-operated clutch, and such a mechanism is not appropriate for use in

a Formula Student car. This project examines the relative performance of

hand-operated rod linkage, hand-operated push-pull cable linkage, and a

semi-automatic solenoid-operated linkage, using either a foot-operated or

hand-operated clutch. The objective is to design and implement each of

these systems, and to evaluate performance in terms of shift duration,

shift repeatability, system weight and cost, packaging constraints and

driver satisfaction. The characteristics of the gear selector drum within

the gearbox are also analyzed, and modified to better suit the Formula

Student application.

In parallel with this mechanism evaluation programme, a dynamic

model of the Formula Student power train is created and combined with

measurements of on-track performance to optimize choice of gear ratio

and final-drive ratio for specific track characteristics and conditions.

This power train code also models the effects of changes in engine torque

curve, tyre characteristics, and vehicle mass distribution, and

constitutes an important part of the feedback loop for the engine

development programme.

A further extension of the programme will aim to integrate the power

train code with the vehicle dynamic model to yield a comprehensive

full-vehicle model to assist further refinement of the design.

Sponsor: Jordan Grand Prix

Design and Development of a Lightweight Body Structure for a

Formula Student Race Car

W Smith & N O’Toole

A key objective when designing a Formula Student racing car is to

minimise the overall mass of the vehicle. At the same time, there are

strict requirements concerning the strength and stiffness of the vehicle

structure in order to protect the driver. Suspension and drive-line

performance are also strongly influenced by the stiffness of the structure

in torsion and in bending. The objective therefore is to design the body

structure such that weight is minimised while the safety and performance

requirements are satisfied or exceeded. The structure should also be

cheap and easy to manufacture and to repair, provide adequate space for

the driver, and neatly accommodate ancillary items.

These conflicting requirements are best resolved using a space-frame

structure fabricated from steel tubing. Optimisation of the solution

requires the extensive use of 3-D solid modelling and finite element

analysis (FEA), and careful analysis of the load lines associated with the

range of static, dynamic, and impact loads associated with aggressive

driving of the car.

Combustion and Emissions Formation Processes in Spark

Ignition Engines with Multi-Constituent Fuels

DJ Timoney & B Tapley

Use of small amounts of hydrogen as a fuel supplement permits operation

of spark ignition engines at very lean air-fuel ratios and this can yield

significant emissions and efficiency benefits. A partial-oxidation (POx)

reforming reactor can be used for on-board hydrogen generation, using a

hydrocarbon fuel feed from a liquid storage tank. This system generates a

hydrogen-rich gas stream which also includes several other, less

26

RESEARCH REPORT

2001-2002

desirable, ingredients such as CO, CO2, CH4, C2H2, C2H6, H2O and N2.

A steady state test program was carried out on a Rover K16, 1.6 litre

4-stroke spark ignition engine, where measured quantities of H2, CO2

and H20 were mixed into the intake air stream whilst the gasoline was

supplied through port fuel injectors, operating under computer control.

The experimental results indicate that the addition of supplemental

hydrogen (at 5% energy fraction) can yield increased rates of combustion,

improved combustion stability, and reduced exhaust emissions,

particularly under lean burn conditions. This experimental data was

subsequently used to further validate the UCD-developed thermodynamic

cycle simulation computer model (SPARK37) which predicts engine gas

flows, power output, efficiency and exhaust emissions quantities.

Sponsors: Flogas (Ireland) Ltd. and Enterprise-Ireland / Irish American

Partnership.

Application of On-Board Gasoline Reforming to S.I. Engines:

Prediction of Performance and Emissions Under

Transient Conditions

DJ Timoney, WJ Smith & A Drew

Significant strides have been made in the prediction of engine

performance and emissions under steady operating conditions. In

practice, however, the great majority of mobile engine operation involves

unsteady (or transient) operation, where prediction of performance and

emissions is considerably less well understood. Partial Oxidation systems,

supplied with hydrocarbon fuel are being considered for hydrogen

production during the warm up stage of an engine. Most parameters are

transient during this stage and as a result the products of partial oxidation

and the engine-out emissions will vary greatly with time. The

effectiveness of this technology therefore depends greatly on what occurs

during these transients. The principal aim of this project is to formulate a

simulation of a more complete system - which is capable of predicting

the effects of partial oxidiser operating conditions on engine out

emissions. The present work focuses particularly on the effect of unsteady

pressure waves in the intake system during transient operation, and their

influence on trapped air - fuel ratio, internal exhaust gas recirculation and

volumetric efficiency. An existing single-cylinder engine simulation code

(SPARK37) is being expanded to incorporate multi-cylinder capability and

is being integrated into a Simulink-based transient vehicle demand

model. The combined model will be capable of predicting the performance

and exhaust emissions from a vehicle engine during typical operation.

Evaluation of Options for Reducing Irish Diesel Particulate

Emissions - Utilising Measurement and Modelling Methods

DJ Timoney & SO’Sullivan

Exhaust emissions from newly manufactured vehicles and diesel engines

are heavily regulated by EU Directives but very little data is currently

available to indicate quantities of diesel particulates emitted from actual

vehicles in service. This is especially the case for older, poorly maintained

diesel vehicles still in service on Irish roads. This project aims to refine

and use a novel measurement device to collect real world particulate

emissions data from a variety of used vehicles, with a view to identifying

and targeting heavy polluters. The data gathered will then be used, in

combination with localised pollution dispersion modelling techniques, to

determine the peak doses of particulate matter to which city pedestrians

might typically be exposed. This and other data will be used subsequently

in cost-benefit analyses - to evaluate alternative policy options aimed at

reducing emissions and improving Irish urban air quality.

Sponsors: Urban Institute Ireland and EPA ERTDI Doctoral Scholarship Programme.

27

Rover K16 test engine installation

Effect of supplemental hydrogen addition on rates of combustion in a spark ignition engine at 2000 rev/min, part load

Partial oxidization (POx) system used for on-board hydrogen production

Diesel exhaust flow splitter - for on-board particulate measurement usingparticulate filter.

DEPARTMENT OF


A Novel Diagnostic Method for Emissions Control in Diesel Engine

Combustion Systems

DJ Timoney & C Lyons

This project is aimed at developing and validating a computational

scheme which accepts data obtained from high speed sampling of

instantaneous cylinder pressures in a 4-stroke diesel engine as input, and

computes (i) rates of heat release due to combustion, (ii) rates of in-

cylinder nitric oxide (NOx) formation, and (iii) rates of particulate

formation. This involves the formation of simplified theoretical

representations, which are adequate to describe the temporal and some

spatial variations of in-cylinder gas composition and temperature. It is

envisaged that this computational method could be employed in real-time

combustion and emissions control strategies. Comprehensive engine

tests have been carried out on a modern automotive diesel engine and

that the resulting trends are being used to verify the results estimated

by the computational scheme.

Sponsor: IRCSET (Basic Research Grant).

Collaboration: CMT-Motores Térmicos, Universidad Politecnica de Valencia,

Spain.

Planning for Airport Demand and Accommodation: An Integrated

Planning Methodology for Assessment of Airport Capacity

DJ Timoney, W Hynes & MJ Bannon

The expected consequences of the continued forecast growth in

worldwide air travel will be a need for the provision of extensive and

expensive additions and improvements to the aviation industry’s basic

infrastructures, more efficient airport terminals and runways, enhanced air

traffic control systems to ensure greater passenger safety while reducing

aircraft delays, and improvements in landside access to and egress from

airport complexes. In order to allow for informed decision making

concerning investment in airport infrastructure, whilst ensuring that the

utilisation of associated resources are maximised, there is a need for a

clear unambiguous statement of airport capacity, and an identification of

the difference between airport capacity demand and airport capacity

supply. This project has developed and implemented an integrated

approach and methodology for the assessment of capacity of the entire

airport system, to enable the orderly planning and development of an

airport complex. This methodology should allow for the establishment of

clear definitions of airport capacity “demand” and “supply”.

Collaboration: Aer Rianta / Dublin Airport.

Life Cycle Energy Accounting in Road Design

DJ Timoney & P Gahan

The objectives of this project are to facilitate and encourage road designers

to consider the energy implications when they are planning new roads

and/or realigning existing roads. The project will look at all aspects of

road design and the energy implications involved in them. Route selection,

route design and construction on specific new road projects will have

their energy use quantified and the projection of energy usage by vehicles

using the road will be evaluated. The project should allow the use of

energy in road construction to be reduced by quantifying what energy is

used and identifying potential energy efficiencies. It will also demonstrate

how energy usage by vehicles can be reduced by designing roads that

facilitate energy efficient driving.

Collaboration: Waterford County Council (Ireland), VTI (Swedish National

Road and Transport Research Institute), Infrasoft Solutions Ltd (UK),

ENGIVIA - Consultores de Engenharia, SA (Portugal), Agência Municipal de

Energia do Seixal (Portugal), Gaudriot SA (France) and CDV - Transport

Research Centre (Czech Republic).

PUBLICATIONS

JOURNALSBarry, J. and Byrne, G.

Cutting tool wear in the machining of hardened steels Part I: Alumina/TiC

cutting tool wear. Wear, 247: 139-151, 2001.

Barry, J. and Byrne, G.

Cutting tool wear in the machining of hardened steels Part II: cubic boron

nitride cutting tool wear. Wear, 247: 152-160, 2001.


Observations on chip formation and acoustic emission in manufacturing

Ti-6AI-4V alloy. International Journal of Machine Tools and Manufacture,

41: 1055-1070, 2001.

Barry, J. & Byrne, G.

TEM study on the surface white layer in two turned hardened steels.

Materials Science and Engineering A, 325: 356-364, 2002.


The mechanisms of chip formation in machining hardened steels. Journal

of Manufacturing Science and Engineering, 124 (3): 528 – 535, 2002.


Cutting tool wear in the machining of hardened steels Part I: Acoustic

28

RESEARCH REPORT

2001-2002

emission during saw-tooth chip formation. Journal of Engineering

Manufacture, 215 (11): 1549-1559, 2001.


Cutting tool wear in the machining of hardened steels Part II: Acoustic

emission during continuous chip formation with a non-overlapping cutting

arrangement. Journal of Engineering Manufacture, 215 (11): 1561-1570,

2001.


Chip formation, acoustic emission and surface white layers in hard

machining. CIRP Annals 2002, 51 (1) 65 – 70, 2002.

Boulanger, P. and Hayes, M.

On shearing, stretching and spin. Theoretical and Computational Fluid

Dynamics, 15: 199 - 229, 2002.

Brabazon, D., Browne, DJ. and Carr, AJ.

Mechanical stir casting of aluminium alloys from the mushy state:

Process, microstructure, and mechanical properties. Materials Science

and Engineering A, 326 (2): 370-381, 2002.

Brophy, B., Kelly, K. and Byrne, G.

AI-based condition monitoring of the drilling process. Journal of Materials

Processing Technology, 124: 305-310, 2002.

Browne, DJ. and O’Mahoney, D.

Interface heat transfer in aluminum investment casting. Metallurgical and

Materials Transactions A, 32 (12): 3055-3063, 2001.

Conry, MJ., Crane, LJ. and Gilchrist, MD.

Rayleigh-Lamb wave detection of two-dimensional defects in metal

plates. Zeitschrift fur Angewandte Mathematik und Mechanik, 81 (S4):

S975-S976, 2001.

Corcoran, A., Sexton, L., Seaman, B., Ryan P. and Byrne, G.

The laser drilling of multi-layer aerospace material systems. Journal of

Materials Processing Technology, 123 (1): 100-106, 2002.

Destrade, M. and Hayes, M.

Circularly-polarised plane waves in a deformed Hadamard material. Wave

Motion, 35: 289 – 309, 2002.

Gilchrist, MD., Hartman, AM., Owende, PMO. and Ward, SM.

Full scale accelerated testing of bituminous road pavement mixtures. Key

Engineering Materials, 204-205: 443-452, 2001.

Gilchrist, MD., O’Donoghue, D. and Horgan, T.

A two dimensional analysis of the biomechanics of frontal and occipital

head impact injuries. International Journal of Crashworthiness, 6 (2): 253-

262, 2001.

Hartman, AM., Gilchrist, MD. and Nolan, D.

Wheeltracking fatigue simulation of bituminous mixtures. International

Journal of Road Materials and Pavement Design, 2 (2): 141-160, 2001.

Hartman, AM., Gilchrist, MD., Owende, P., Ward, S. and Clancy, F.

In-situ accelerated testing of bituminous mixtures. International Journal of

Road Materials and Pavement Design, 2 (4): 337-357, 2001.

Hartman, AM., Gilchrist, MD. and Walsh, G.

Effect of mixture compaction on indirect tensile stiffness and fatigue.

ASCE Journal of Transportation Engineering, 127 (5): 370-378, 2001.

Hayes, M. and Saccomandi, G.

Finite amplitude waves superimposed on pseudoplanar motions for

Mooney Rivlin viscoelastic solids. International Journal of Non-Linear

Mechanics, 37: 1139 1146, 2002.

Hooper, BJ. Byrne, G. and Galligan, S.

Pad conditioning in chemical mechanical processing. Journal of Materials

Processing Technology, 123 (1): 107-113, 2002.

Miodownik, MA., Smereka, P., Srolovitz, DJ. and Holm, EA.

Scaling of dislocation cell structures: diffusion in orientation space.

Proceedings of the Royal Society of London A, 457: 1807-1819, 2001.

Moore, DF.

On the micro-tribology of elastomeric contacts. International Journal of

Applied Mechanics and Engineering, 7 (3): 903 – 910, 2002.

Murphy, C. Byrne, G. and Gilchrist, MD.

The performance of coated WC drills when machining carbon fibre-

reinforced epoxy composite materials. Journal of Engineering

Manufacture: Proc. IMechE Part B, 216: 143-152, 2002.

O’Connor, WJ.

Wave speeds for a TLM model of moving media. International Journal for

Numerical Modelling, 15 (2): 195-203, 2002.

O’Connor, WJ.

TLM model of waves in moving media. International Journal for Numerical

Modelling, 15 (2): 205-214, 2002.

29

DEPARTMENT OF


O’Connor, WJ. and Clune, FJ.

TLM-based solutions of the Klein-Gordon equation (Part I). International

Journal for Numerical Modelling, 14: 439-449, 2001.

O’Connor, WJ and Clune, FJ.

TLM-based solutions of the Klein-Gordon equation (Part II). International

Journal for Numerical Modelling, 15 (2) 215-220, 2002.

O’Donnell, G., Young, P., Kelly, K. and Byrne, G.

Towards the improvement of tool condition monitoring systems in the

manufacturing environment. Journal of Materials and Processing

Technology, 119: 133-139, 2001.

Owende, PMO., Hartman, AM., Ward, SM., Gilchrist, MD. and O’Mahony, MJ.

Minimising distress on flexible pavements using variable tire pressure.

ASCE Journal of Transportation Engineering. 127 (3): 1-9, 2001.

Rackard, SM., Carr, AJ., Callanan, JJ. and Bellenger, CR.

An avian model of limb deviation induced by periosteal surgery. Research

in Veterinary Science, 73: 237-241, 2002.

Sexton, L., Lavin, S., Byrne, G. and Kennedy, A.

Laser cladding of aerospace materials. Journal of Materials Processing

Technology, 122 (1) 63-68, 2002.

Tancred, DC., Carr, AJ. and McCormack, BAO.

The sintering and mechanical behavior of hydroxyapatite with bioglass

additions. Journal of Materials Science: Materials in Medicine, 12: 81-93,

2001.

Tiernan, J., Gilchrist, MD., dePaor, AM. and Leonard, C.

A review of seating principles in the context of a prototype design project.

Posture and Mobility, 15 (Spring): 5-11, 2002.

Tikare, V., Miodownik, MA. and Holm, EA.

Three dimensional simulation of grain growth in the presence of mobile

pores. Journal of the American Ceramics Society, 84(6): 1379-1385, 2001.

Thomas, PM., O’Riordain, K., Phillips, JP., Kumar, R. and Gilchrist, MD.

A novel approach to computer modelling in head injury. Irish Journal of

Medical Science, 171 (3, S2): p. 73, 2002.

BOOKS AND BOOK CHAPTERSByrne, G.

Engineering as a Career – A Detailed Guide to the Engineering Profession

in Ireland, 2002.

Gilchrist, MD.

Use of advanced composite materials in the construction of suspension

push-rods for a Formula one racing car. Handbook of Composite Blends

and Polymers, Vol. 2, Chapter 3, pp. 81-102. Kulshreshtha, A. & Vasile, C.

(Eds.), Rapra Technology Ltd., UK, 2002.

Miodownik, MA.

Normal grain growth. The Encyclopaedia of Materials Science and

Technology, Elsevier Science Ltd., Oxford, Vol.4, pp. 3636-3641, 2001.

Miodownik, MA.

Zener pinning. The Encyclopaedia of Materials, Science and Technology,

Elsevier Science Ltd., Oxford, Vol.10, pp. 9855-9859, 2001.

O’Sullivan, S. and Timoney, DJ.

Diesel particulate emissions and air quality - The Irish context.

Achievement and Challenge Rio+10 and Ireland, Edited by F. Convery & J.

Feehan, UCD Environmental Institute, Part 3: Transport, Energy, Urban, pp.

288-296, 2002.

Ridgeway, O., Timoney, DJ. and Convery, FJ.

Integrating environment and tourism in Ireland – Environmental

implications of air access transport to Dublin, in Tourism and the

Environment: Sustainability in Tourism Development, Edited by N.

Andrews, F. Convery, S. Flanagan & J. Ruddy, Dublin Institute of

Technology, pp. 19-37, 2002.

CONFERENCE PROCEEDINGSBanaszek, J., Browne, DJ. and Furmanski, P.

Some aspects of modelling of binary system solidification on a fixed grid.

Proceedings of the Third International Conference on Transport

Phenomena in Multiphase Systems, Baranów Sandomierksi, Poland, June

24-27, (Eds. ME Poniewski, TM Wójcik, R Pastuszko), pp. 201-209, 2002.

Boulanger. P. and Hayes, M.

Energy flux in elasticity and electromagnetism. Proceedings of IUTAM

Symposium on mechanical and electromagnetic waves in structural

media, (R. C. McPhedran, L. C. Botten and N. A. Nicorovici, eds.) Kluwer,

Dordrecht, pp. 89 – 100, 2001.

Brophy, B., Kelly, K. and Byrne, G.

Anomaly Detection in Drilling Using Neural Networks. Proceedings of the

18th International Manufacturing Conference (IMC-18), pp.321-329, UCD,

September 2001.

Browne, DJ., Banaszek, J. and Hunt, JD.

Front tracking on a fixed grid versus enthalpy approach in modelling of

30

RESEARCH REPORT

2001-2002

binary alloy solidification. Proceedings of the ASME International

Mechanical Engineering Congress and Exhibition, New Orleans, USA,

paper IMECE2002-32871, 2002.

Browne, DJ. and Hunt, JD.

Modelling of moving boundaries in multi-phase systems: a front-tracking

approach. Proceedings of the Third International Conference on

Transport Phenomena in Multiphase Systems, Baranów Sandomierksi,

Poland, June 24-27, (Eds. ME Poniewski, TM Wójcik, R Pastuszko), pp.

227-232, 2002.

Byrne, GD. and Gilchrist, MD.

Design and performance of a lightweight composite seat for civil aircraft

applications. Proceedings of the 19th International Manufacturing

Conference, pp. 33-42, August 28th – 30th, Belfast, UK, 2002.

Byrne, G., O’Donnell, GE., Kelly, K. and Kirchheim, A.

An integrated sensing solution for the monitoring of a flexible machining

centre. Proceedings of the 18th International Manufacturing Conference

(IMC-18), pp. 331-340, UCD, September 2001.

Carr, AJ., FitzPatrick, D., Hennessy, RJ., Lawlor, GJ. and Lee, TC.

The application of a 3D hand-held laser scanner to human joint modelling.

Proc IMechE ‘Comrade in Arms’, London, April 2001.

Coone, N., Browne, DJ., Hussey, M. and O’Mahoney, D.

Investigation of thermal boundary conditions for computer simulation of

investment casting. Proc.19th International Manufacturing Conference,

Queen’s University Belfast, 28th-30th August, pp. 773-781, 2002.

Costello, B. and Finn, DP.

Energy reduction by enhanced evaporative cooling of buildings in

maritime climates. Renewable Energy in Maritime Climates REMIC

Conference, Belfast, N. Ireland, 2001.

Finn, DP. and Costello, B.

Evaporative cooling systems in deep-plan office buildings. CLIMA2000,

Naples, Italy, Sept. 2001.

Healy, M., O’Rourke, MJ. and Raghunathan, SR.

Further investigations of passive vortex control jets for shock boundary

layer interactions. 1st AIAA Flow Control Conference, St. Louis, Missouri,

24-26, AIAA-2002-2732, 2002.

Hussey, MJ., Browne, DJ., Brabazon, D. and Carr, AJ.

A direct thermal method of attaining globular morphology in the primary

phase of alloys. Proceedings of the 7th International Conference on Semi-

Solid Processing of Alloys and Composites, Tsukuba, Japan, pp 575-580,

September 2002.

Hussey, MJ., Browne, DJ. and Carr, A.

Production of aluminium alloys suitable for semi-solid metal processing:

new direct thermal method. Proc. 18th International Manufacturing

Conference, UCD, 5th-7th September, pp. 209-218, 2002.

Levesque, M., Byrne, G. and Gilchrist, MD.

Design & performance of a light weight composite seat for civil aircraft

applications. Proceedings of the Institute of Materials 6th international

conference on Deformation and Fracture of Composites, Paper P28, April

4th – 5th, Manchester, UK, 2001.

Levesque, M., Byrne. G and Gilchrist, MD.

Design and performance of a lightweight composite seat for civil aircraft

applications. Proceedings of ECCM-10, Paper No. 188, June 3rd – 7th,

Bruges, Belgium, 2002.

Mullany, B. and Byrne, G.

The effect of slurry viscosity on chemical mechanical polishing (CMP) of

Silicon Wafers. Proceedings of the 18th International Manufacturing

Conference (IMC-18), pp.113-122, UCD, September 2001.

Murphy, C., Byrne, G. and Gilchrist, MD.

A qualitative investigation of the drilling induced damage of carbon fibre-

reinforced epoxy composites. Proceedings of the 18th International

Manufacturing Conference, pp. 193-202, September 5th – 7th, Dublin,

Ireland, 2001.

Murphy, N. and Ivankovic, A.

A numerical and experimental investigation of dynamic fracture of poly

(methylmethacrylate). Proceedings of 10th Annual Conference of the

Association of Computational Mechanics in Engineering, Swansea, pp.

177-183, April 2002.

O’Connor, WJ.

TLM models of a heavy gantry crane. Proceedings, International TLM

Workshop, Warsaw, Poland, October 1-2, pp 3/1 - 3/7, 2001.

O’Connor, WJ.

The time-domain dynamics of 2-D TLM. Proceedings, International TLM

Workshop, Warsaw, Poland, October 1-2, pp.9/1 - 9/11, 2001.

O’Connor, WJ.

Gantry crane control: a novel solution explored and extended. ACC02,

American Control Conference, Alaska, May 2002.

31

DEPARTMENT OF


O’Connor, WJ.

Numerical solution of partial differential equations by impulse propagation

and scattering. XV International Scientific Conference “Mathematical

methods in engineering and technology, Tambov, Russia, June 5-7, 2002.

O´Connor, WJ. and Wilde, E.

Modelling acoustic transducer surface waves by Transmission Line Matrix

method. 19th CADFEM-User´s meeting, Berlin, 17-19, Oct. 2001.

O’Connor, WJ. and Hu, C.

A simple, effective position control strategy for flexible systems.

International Federation of Automatic Control, 2nd IFAC Conference on

Mechatronic Systems, December, Berkeley, California, USA, 2002.

O’Dowd, F., Walsh, O., Locufier, A. and Gilchrist, MD.

Design and optimisation of a customised compression moulding machine

for composites manufacturing. Proceedings of the 19th International

Manufacturing Conference, pp. 387-397, August 28th – 30th, Belfast, UK,

2002.

O’Mahoney, D., Browne, DJ. and Hussey, M.

Effect of experimental uncertainty on the accuracy and stability of a new

inverse method for heat transfer in solidification. Proceedings of 35th

ASME National Heat Transfer Conference, Anaheim, CA, USA, Paper No.

NHTC2001-20165, June 2001.

O’Riordain, K., Thomas, PM., Phillips, JP. and Gilchrist, MD.

Applications of multibody dynamics to the simulation of head impact

biomechanics. Proceedings of International Conference on Computation in

Engineering & Science, August 19th – 24th, Puerto Vallarta, Mexico, 2001.

O’Riordain, K., Thomas, PM., Phillips, JP. and Gilchrist, MD.

Analysis of traumatic head injury using multibody dynamic computational

techniques. Proceedings of 5th International Symposium on Computer

Methods in Biomechanics & Biomedical Engineering, October 31st –

November 3rd, Rome, Italy, 2001.

O’Rourke, MJ., Healy M, and Raghunathun, SR.

Computational experiment investigating passive vortex control jets for

shock/boundary layer interactions. 31st AIAA Fluid Dynamics Conference

and Exhibit, Anaheim, CA, AIAA-2001-3028. 11-14 June 2001.

O’Rourke MJ., Kyle DA. and Raghunathun, SR.

Implementation of turbulence models for shock/boundary layer interaction

in Transonic Flow. 31st AIAA Fluid Dynamics Conference and Exhibit,

Anaheim, CA, AIAA-2001-2856, 11-14 June 2001.


Diesel particulate emissions and air quality - The Irish context. Rio+10

Achievement and Challenge Conference, 18pp, 10-14 September, 2001.

Owende, PMO., Ward, SM., O’Mahony, MJ., Hartman, AM. and

Gilchrist, MD.

Variable tyre pressure for control of damage on low volume roads with

peat soil subgrade. Proceedings of IUFRO 03.09, September 9th – 14th,

Quebec City, Canada, 2001.

Raghunathan, SR., O’Rourke, MJ. and Healy, M.

The concept of passive vortex control jets for shock boundary layer

interactions. CEAS Aerospace Aerodynamics Research Conference,

Cambridge, 10-12 June 2002.

Sheridan, JT., Byrne, G., Connolly, P., Glennon, B., Heneghan, C.,

FitzPatrick, D., Finn, D., Gilchrist, M., Kieran, P., McLoughlin, F.,

Mulkeen, B., Murphy, N., O’Connor, W., O’Dowd, R., O’Malley, M.,

O’Rourke, M. and Reilly, R.

Optics education within engineering at UCD. Proceedings of the SPIE

Optics and Photonics Technologies and Applications, Vol. 4876, September

5th – 6th, Galway, Ireland, 2002.

Stack, AJ. and Finn, DP.

Modelling and validation of a multi-evaporator vapour compression cycle

subject to non-uniform loading in transport refrigeration applications.

Proceedings of the Ninth International Refrigeration Conference, Purdue

University, West Lafayette, Indiana, USA, July 2002.

Thomas, PM., O’Riordain, K. Phillips, JP. and Gilchrist, MD.

Mathematical reconstructive modeling applied to intra and extra-axial

head injury resulting from standing falls. Proceedings of the Congress of

Neurological Surgeons, 52nd Annual Meeting, September 21st – 26th,

Philadelphia, USA, 2002.

SEMINARS AND CONFERENCE ABSTRACTSBalfe, L. and FitzPatrick, DP.

Characterisation of the degradation characteristics of a resorbable polymer.

Proc. Bioengineering in Ireland (7), p. 31, 2001.

Banaszek, J., Browne, DJ. and Rebow, M.

Computer simulation of transport phenomena during solidification of one-

component and binary systems. Paper delivered at the Annual Symposium of

the Irish Society for Scientific and Engineering Computation, UCD, May 2001.

Browne, DJ.

A Model of columnar and equiaxed growth using a front-tracking

32

RESEARCH REPORT

2001-2002

technique, Research Seminar, Department of Materials, University of

Oxford, March 2001.

Browne, DJ.

Modelling of the columnar to equiaxed transition in solidification

processing, European Space Agency, Space Research and Technology

Centre, Noordwijk, The Netherlands, December 2001.

Browne, DJ.

Progress at UCD on modelling of alloy solidification and the effects of

gravity. European Programme on Life and Physical Sciences in Space,

Department of Enterprise, Trade and Employment, Kildare Street, Dublin,

January 2002.

Browne, DJ.

The columnar to equiaxed transition: review of theory and experiment,

Corus plc, Swinden Technology Centre, Rotherham, UK, March 2002.

Browne, DJ.

The columnar to equiaxed transition in solidification processing : theory,

experiment and modelling, Research Seminar, Institute of Process and

Power Engineering, Cracow University of Technology, Poland, June 2002.

Browne, DJ.

Multiscale materials modelling: atoms to aircraft, Department of

Mathematical Physics, October 2002.


Modelling of alloy solidification - heat conduction and interface tracking.

Paper delivered at the Annual Symposium of the Irish Society for Scientific

and Engineering Computation, UCD, May 2001.


An interface tracking model of columnar and equiaxed growth in castings,

European Space Agency HQ, Paris, July 2001.

Byrne, G., O’Donnell, G, and Kelly, K.

Technical Report Summary: COMPRO – Compensation for Stochastic

Deviations in Process Monitoring for Flexible Production Systems. CIRP

January 2001 Scientific Technical Committee ‘C’ Meeting, Paris, 25th

January 2001.

Coffey, L. and FitzPatrick, DP.

Validation of ergonomic simulation software. Proc. Bioengineering in

Ireland (7), p. 20, 2002.

Conry, M., Crane, LJ. and Gilchrist, MD.

NDE of defects in thin plates using ultrasonic Lamb waves. Proceedings of

the Annual Symposium of the Irish Society for Scientific and Engineering

Computation (ISSEC) meeting,

p. 21, May 18th – 19th, Dublin, 2001.

Drew, A., Smith, WJ, and Timoney, DJ.

Numerical simulation of one-dimensional unsteady gas flows in reciprocating

engine inlet manifolds. Irish Society for Scientific and Engineering Computation

Annual Symposium, National University of Ireland, Galway, May 24-25, 2002.

FitzPatrick, DP., Byrne, S., Russell N., Kenny, P., Harty, J. and

McCormack, D.

Modes of failure and pull-out strengths of Isola and Colorado 2 pedicle hooks:

a biomechanical study. Proc. Bioengineering in Ireland (7), p. 12, 2001.

Horgan, T. and Gilchrist, MD.

Finite element modeling of the biomechanics of head impact. Proceedings

of the 7th Biomechanics in Ireland Conference, p. 19, January 27th –

28th, Arklow, 2001.


Mesh generation challenges in modeling highly irregular biomechanical

systems. Proceedings of the Annual Symposium of the Irish Society for

Scientific and Engineering Computation (ISSEC) meeting, p. 11, May 18th

– 19th, Dublin, 2001.


Finite element analysis of traumatic brain injury due to inpact: Model

development. Proceedings of the 8th Biomechanics in Ireland Conference,

p. 50, January 26th – 27th, Sligo, 2002.

Kent, J., Faulkner, A. and FitzPatrick, D.

Engineering body parts: A sociological approach to developments in

tissue engineering, Proc. ESA Annual Conference, University of Helsinki,

p.107, 2001.

Lyons, C., McNally, C. and Timoney, DJ.

Development of a three zone heat release model for direct injection diesel

combustion analysis. Irish Society for Scientific and Engineering

Computation Annual Symposium, National University of Ireland, Galway,

May 24-25, 2002.

McCullough, J., FitzPatrick, D.P and O’Rourke, MJ.

Development of abdominal aortic aneurysm models for flow visualisation.

Proc. Bioengineering in Ireland, p.12, 26-27 January 2002.

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DEPARTMENT OF


Mullaney, B., Byrne, G. and Evans, C.

An overview of infra-red thermal images taken during chemical mechanical

polishing (CMP). CIRP Scientific Technical Committee ‘G’ Meeting, Paris,

25th January 2001.

Mullett, H., King, J., O’Rourke, K. and FitzPatrick, D.

Occipito-cervical fusion: a biomechanical analysis of initial construct

stiffness of five implant systems. Proc. Bioengineering in Ireland (7),

p.11, 2001.

O’Connor, WJ.

A gantry crane problem solved exactly. Symposium of Irish Society for

Scientific and Engineering Computation, National University of Ireland,

Dublin, 18-19 May 2001.

O’Connor, WJ.

Tuning mode shapes and frequencies of violin plates. Symposium of Irish

Society for Scientific and Engineering Computation, National University of

Ireland, Dublin, 18-19 May 2001.

O’Connor, WJ.

Wave-based position control of flexible mechanical systems, Research

Seminar, Georgia Institute of Technology, Atlanta, December 2001.

O’Connor, WJ.

Position control of flexible mechanical systems. Taiwan National

University, May 2002.

O’Connor, WJ.

Position control of flexible mechanical systems. Dalian University of

Technology, China, May 2002.

O’Connor, WJ.

Position control of flexible mechanical systems. Shenyang Institute of

Automation, China, May 2002.

O’Connor, WJ.

Position control of flexible mechanical systems. Tsingua University,

Beijing, China, May 2002.

O’Riordain, K., Thomas, PM., Phillips, J.P and Gilchrist, MD.

The simulation of head impact biomechanics using multibody dynamics.

Proceedings of the Annual Symposium of the Irish Society for Scientific &

Engineering Computation (ISSEC) meeting, p.13, May 18th - 19th, Dublin,

2001.

O’Riordain, K., Thomas, PM., Phillips, J.P and Gilchrist, MD.

Reconstruction of head injury accidents using computational methods.

Proceedings of the 8th Biomechanics in Ireland Conference, p.49, January

26th – 27th, Sligo, 2002.


Development of an on-road measurement system for particulate

emissions from diesel-engined vehicles, Urban Institute Research Forum,

Trinity College Dublin, March 28th 2001.

O’Toole, G., Salih, E., FitzPatrick, DP. and O’ Rourke, SK.

Bone sialoprotein improves implant pull-out strengths by osteoinduction.

Proc. Bioengineering in Ireland (7), p. 35, 2001.

Rackard, SM., Bellenger, CR., Carr, AJ. and Callanan, JJ.

Analysis of an avian model of limb deviation induced by periosteal

surgery. Proceedings of the 7th Biomechanics in Ireland Conference, p. 6,

January 27th – 28th, Arklow, 2001.

Tapley, B. and Timoney, DJ.

Combustion and emissions formation processes in spark ignition engines

with multi-constituent fuels. Proc. 5th Annual Sir Bernard Crossland

Symposium and Postgraduate Research Workshop, University of Ulster,

Jordanstown, p. 109, March 13th 2002.

Tapley, B. and Timoney, DJ.

Simulation of gas flows, combustion and pollutant formation in spark

ignition engines with supplemental hydrogen fuelling. Irish Society for

Scientific and Engineering Computation Annual Symposium, National

University of Ireland, Galway, May 24-25, 2002.

Thomas, PM., O’Riordain, K., Phillips, JP., Kumar, R. and Gilchrist, MD.

Head impact angular velocity associated with parenchymal brain injury.

Poster presention at Annual Meeting of Irish Neurological Association, May

17th – 18th, Dublin, 2002.

Tiernan, J., Gilchrist, MD., de Paor, AM. and Leonard, C.

The design and product development of a prototype mobile chair to assist

in transfers and positioning of the elderly and infirm. Proceedings of the

7th Biomechanics in Ireland Conference, p. 27, January 27th – 28th,

Arklow, 2001.

LECTURES HOSTED IN DEPARTMENTDr A Saidi (Lund University of Technology, Sweden), Numerical

investigation of some convective heat transfer and fluid flow problems

with relevance to gas turbines, February 2001.

34

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RESEARCH REPORT

2001-2002

Mr G Anderson (Reynard Motorsport North America), The design of single-

seat racing cars, February 2001.

Dr D Wood (Denis Wood Associates, Dublin), Accident investigation: A

perspective on forensic engineering, April 2001.

Dr C Simms (TNO International, Detroit, USA), The application of Madymo

to human body modelling, April 2001.

Prof M Krane (Purdue University, USA), Macrosegregation during

solidification in direct chill casting of aluminium alloys, May 2001.

Prof P Furmanski (Warsaw University of Technology, Poland), Basic

aspects of modelling of transfer phenomena during alloy solidification,

February 2002.

Dr D Baumgartner (University of Strasbourg, France), Human head

tolerance limits against impact for specific injury mechanisms: Numerical

and experimental head injury simulations, March 2002.

Dr M Rebow (Warsaw University of Technology, Poland), Application of

particle image velocimetry, true colour image processing and process

tomography in phase change problems of pure substances and binary

mixtures - present state and future possibilities, April 2002.

CONFERENCES AND CONTINUING EDUCATION COURSESDr MD Gilchrist was Chairman of the Annual Symposium of the Irish

Society for Scientific & Engineering Computation, at which thirty four

lectures were delivered by Irish and international speakers, UCD, May

18th – 19th, 2001.

Dr GF Cummings was Chairman of the 18th International Manufacturing

Conference, IMC-18, UCD, September 5th – 7th, 2001.

Prof G Byrne was Chairman of the CIRP UK/AMT Ireland Workshop on

Future Direction for R&D in Manufacturing Engineering in Ireland and the

UK, UCD, 3rd and 4th May 2002.

Ph.D. THESESBrabazon, D.

Processing and Properties of Rheocast Alloys, 2001.

Browne, DJ.

Modelling Columnar and Equiaxed Growth, D.Phil. thesis, University of

Oxford, 2002.

Duignan, B.

Optimised Trajectory Control of Redundant Robotic Manipulators, 2001.

Dunne, P.

An Investigation into the Dimensional Accuracy of Injection Moulded

Components Produced in a Silicone Rubber Mould, 2001.

Mullany, B.

Chemical Mechanical Polishing of Oxide Coated Silicon Wafers, 2001.

M.Eng.Sc. THESESBalfe, L.

Analysis of Time-Dependant Properties of Resorbable Biomaterials, 2002.

Coffey, L.

A Biomechanical Validation Study of Ergonomic Simulation Software,

2002.

Goulding, C.

Development of a Modular Combined Cycle Simulation Model, 2001.

Corcoran, AJ.

Laser Drilling of Aerospace Materials, 2001.

Grant, K.

Design of an Experimental Test Facility to Examine the Use of Electronic

Control in Multi-Evaporator Vapor Compression Systems, 2002.

Hickey, J.

Experimental Investigation into the Artificial Thermal Drying of Milled Peat,

2001.

Hooper, BJ.

Effect of Conditioning on Polishing Pad Wear in Chemical Mechanical

Planarization, 2001.

Kyle, DA.

Turbulence Modelling for the Computation of Transonic Aerofoil Flows, 2001.

Murphy, C.

Drilling of Carbon Fibre-Reinforced Epoxy Composites with Titanium

Nitride and Diamond-Like Carbon Coated Tungsten Carbide Drills, 2001.

O’Riordain, K.

Reconstruction of Real World Head Injury Accidents Resulting from Falls

Using Multibody Dynamics Modelling, 2002.

Stack, A.

Transient Modelling and Experimental Verification of Multi-Evaporator

Vapour Compression Systems in Transport Refrigeration Applications, 2001.

Tiernan, J.

Design, Manufacture and Testing of a Prototype Wheelchair for People

with Special Seating Needs, 2001.

Department of Mechanical Engineering

University College Dublin, Belfield, Dublin 4, Ireland.

Tel. +353 1 716 1787 Fax. +353 1 283 0534 Email. [email protected] Web. www.ucd.ie/~mecheng/

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RESEARCH REPORT 2001 - 2002 · RESEARCH REPORT 2001-2002 Approximately 25 postgraduate and postdoctoral researchers have been associated with MIRC since 1989; many of these people