Theses (Department of Mechanical Engineering)
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Theses collection of the Faculty of Engineering.
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Tétel Korlátozottan hozzáférhető Development of a risk management framework for engineering projects in the automotive industryAuwal, Abdullahi; Andrea, Emese Matkó; DE--Műszaki KarThis thesis presents a comprehensive framework for managing risks in automotive engineering projects, with a specific focus on braking systems. It effectively integrates established quality tools like FMEA, APQP, ISO 9001, and IATF 16949 to identify, assess, and mitigate failure modes throughout the product lifecycle. The work also introduces the AIAG-VDA Action Priority system as a more accurate method for prioritizing risks compared to the traditional RPN approach. Notably, the thesis explores the innovative integration of artificial intelligence for real-time monitoring, anomaly detection, and predictive maintenance, showing foresight into future industry trends. Case-based FMEA on braking system components strengthens the practical application of the proposed framework. Overall, the thesis is technically sound, forward-looking, and highly relevant to modern automotive quality and safety practices.Tétel Korlátozottan hozzáférhető Predictive Maintenance based on Diagnostics for Reliable Manufacturing on Forging MachineAbdul Rehman, Muhammad; Bodzás, Sándor; DE--Műszaki KarThis thesis topic, provided by Howmet-Köfém Kft is based on achieving reliable manufacturing using advance technologies to enhance the maintenance efficiency. Relevant literature from well-known scholars was explored to check for work that is done previously in this field with goal of finding possible gaps that can be studied further. In first step the Production on forging press was studied and analyzed thoroughly to understand the basics of forging presses and involved steps. Based on understanding of process weak points in process were established which could cause downtime due to failure, most prominently hydraulic system which is the main driving force of press. Then Multiple tools were investigated to check their application and efficiency on forging press. Also, possibility of how these tools can be integrated in order to achieve industry 4.0 goals ware explored. Vibration Sensor was selected, and it was subjected to tests and trails in order to check its efficiency and reliability on forging press during the operational time. Measurements were taken twice to verify the accuracy of results obtained. The results extracted from measurements and analysis were evaluated and recommendations are given to incorporate in policies and procedure to further enhance the efficiency.Tétel Korlátozottan hozzáférhető Numerical Simulation of the Bolted connection of a Hydraulic cylinder Cap and FlangeChinedu, Kingsley; Huri, Dávid; DE--Műszaki KarThe study of bolted connection stiffness has been a subject of interest since the early 1970s, which primarily focuses on axial and lateral stiffness. However, the moment stiffness of bolted connections, particularly in precision engineering applications like ball screw bearing support blocks, has not been thoroughly explored. This gap in knowledge often leads engineers to rely on rules-of-thumb or previous designs, which may not yield in the most efficient outcomes. In the fast-paced world of engineering design, there is a pressing need for analytical models that can rapidly inform and guide the development of high-performance machine elements. This thesis presents a comprehensive analytical model that addresses the axial stiffness of bolted connections. The model’s accuracy is validated through both numerical methods and experimental testing. This in turn enables a more informed selection process during the design phase, ultimately leading to improved machine performance and efficiency. This thesis aimed to show the growing difference in the different modelling techniques (Analytical and Numerical) in precision engineering, using the bolted joints of hydraulic cylinders. Analytical calculations have serveral limitations, as these calculations can rely on simplified assumptions (e.g. uniform load distribution, idealized boundary conditions, linear material behaviour, etc.) These assumptions could pose limitations, either overestimating or underestimating real-world conditions as seen in my thesis. The analytical calculations struggles with complex geometries (in my case an irregularly shaped cylinder cap and flange), and they more often than not require simplifications that could ignore key details of a geometry design. The analytical calculations assumed that all bolts experience identical loads, which is not realistic, as it overlooks issues like stress concentration and uneven forces. It often assumes linear material properties, ignoring factors like plastic deformation, creep or even, thermal expansion. Numerical Analysis on the other hand, takes into account all these details and provides us with a more accurate precise geometry calculation, that can greatly improve the field of engineering, picking up where the analytical modelling stops. Numerical modelling provides us with stress and deformation maps, bolt-by-bolt load distribution results, and key insights into areas prone to failure. This level of detailing allows engineers to focus attention on critical regions of the design not seen in the analytical modelling. Numeric modelling not only identifies problems but also serves as a “What If” factor for analysis to greatly improve designs.Tétel Korlátozottan hozzáférhető Geometric Design and Manufacturing Analysis of Fine Blanking Press Tool for SprocketShamsher, Tamzid; Bodzás , Sándor; DE--Műszaki KarThe thesis has been a complete guide for designing, testing and maintenance of the fine blanking tool. Design of the sprocket for the motor bike is done in the first chapter. On the consecutive chapters design of the fine blanking tool, its finite element analysis and maintenance of the tool has been discussed. For the fine blanking tool proper material has been selected and afterwards, by the help of finite element analysis the materials and the geometry have been tested to ensure the manufacturing tool can be used in real life. In the last chapter various predictive and preventive maintenance techniques have been discussed which can help to enhance the tool life. In conclusion, all the chapters of this thesis have been done precisely, and several outcomes have been achieved. Depending on which various material and structural changes in the tool have been made.Tétel Korlátozottan hozzáférhető Examination of the production of a pharmaceutical company including a development plan for maintenanceAmir, Shazil; Laczkó, Gábor; DE--Műszaki KarThis Thesis investigates production issues in the pharmaceutical industry, using Searle Pharmaceuticals Pakistan as a case study. Challenges such as high defect rates, extended cycle times, equipment downtime, and supply chain disruptions impact product quality and revenue. The research explores efficiency improvements through IoT, predictive analytics, lean manufacturing, and maintenance strategies, while ensuring compliance with GMP standards. It emphasizes stock control, optimal environmental conditions, and employee training using AR and VR to enhance performance. Recommendations focus on adopting innovations and best practices to boost operational reliability, competitiveness, and quality assurance. These insights aim to benefit not only Searle but also other pharmaceutical manufacturers.Tétel Korlátozottan hozzáférhető Lattice Optimization of Camera Drone FramesJonas, Calvin; Al Kentar, Rashwan; DE--Műszaki KarThis thesis explores the application of lattice optimization, through honeycomb and tetrahedral structures, to develop light yet resistant camera drone frames. Through the use of the structures for their strength-to-weight ratio and additively manufacturability, the project aims to improve drone performance in terms of flight duration, maneuverability, and stability of the camera. Through the use of topology optimization and structural simulation, the thesis evaluates how such lattice structures distribute loads, absorb impact, and resist vibration during flight. Using SolidWorks for 3D modeling and ANSYS for modeling, finite element analysis (FEA) and modal analysis, the study applies topology optimization techniques to strategically place material only where needed, enhancing the frame’s mechanical performance while minimizing mass. This thesis explores the application of lattice optimization—more specifically The honeycomb lattice, which has excellent in-plane stiffness and energy absorption, is applied to flat frame sections, while the tetrahedral lattice offers isotropic strength that is well suited for three-dimensional structure regions. The thesis concludes with design recommendations that unify both lattice types according to functional zones in the frame, and emphasizes the role of manufacturing constraints, material properties, and multi-objective optimization in bringing high-performance drone structures to fruition.Tétel Korlátozottan hozzáférhető COMPRESSION TESTING AND ELASTICITY LIMIT CURVE GENERATION OF 3D PRINTED CELLULAR STRUCTURESTahmid, Ahnaf; Balogh, Gábor; DE--Műszaki KarThis thesis investigated how different infill patterns and densities affect the compressive behavior of 3D printed Thermoplastic Polyurethane (TPU) structures. The study started with a literature review, followed by detailed chapters covering failure types, sample preparation, compression testing, and result analysis. Common failure modes in 3D printed structures are categorized into mechanical, structural, print quality, and material-specific issues, primarily caused by improper parameters or incompatible designs. These insights guided the accurate preparation of samples in the next phase. Cylindrical specimens were designed according to ASTM D575-91 using SolidWorks and printed using an FDM printer with six different infill patterns and two density levels. In total, 36 samples were tested under compression of 2 mm and 10 mm using the INSTRON 68TM-10 machine. Data such as maximum force, displacement, and dimensional changes were recorded. Stress-strain curves were generated to show how different infill settings impacted compressive strength. Error functions confirmed the consistency of results, supporting repeatability. The study concluded that higher infill densities generally led to greater resistance to deformation, and infill type had a significant effect on mechanical behavior.Tétel Korlátozottan hozzáférhető HARNESSING BIG DATA FOR ENHANCED OPERATION AND MAINTENANCE IN MECHANICAL ENGINEERINGZaid Al-Kilani, Tariq Mahmoud Shareef; Deák, Krisztián; DE--Műszaki KarCubing (Meisterbock) events are vital for quality assurance in the automotive industry, using a CNC machined aluminum body to test parts fitment before production, thus preventing costly delays. However, planning these events has traditionally been labor-intensive and error-prone due to manual CAD data extraction. This thesis introduces an automated macro tool that standardizes and digitizes the planning process, aligning with Industry 4.0 practices. The macro converts CAD data into structured Excel tables, creating an error-free dataset for efficient scheduling. A key innovation is the Change Index system, which flags design changes early, allowing teams to address potential issues before they arise during cubing events. This proactive approach enhances communication among engineers and supply chain teams, transforming the cubing schedule into an early warning system for quality control. Overall, the thesis demonstrates how this macro not only streamlines planning but also embodies the principles of Industry 4.0, paving the way for a more integrated and intelligent automotive manufacturing process.Tétel Korlátozottan hozzáférhető GEOMETRIC MEASUREMENT AND COMPUTER AIDED MANUFACTURING DESIGN OF A BEVEL GEARShafqat, Rana Salman; Bodzás, Sándor; DE--Műszaki KarThis thesis encompasses the use of 3D optical profilometry technique to make a CAD model of straight bevel gear using KEYENCE VR6000 optical profilometer. It also recommends the criteria for the selection of machine, tools, manufacturing and repair technologies for bevel gear.Tétel Korlátozottan hozzáférhető Design and Optimization of a wireless power syste, between Household and Electric vehicle Using Solar EnergyAkhter, A N M Fariha; Menyhárt, József; DE--Műszaki KarWireless power transfer (WPT) is one of the most promising technologies for electric vehicle (EV) charging. This research is focused on developing a wireless power transfer system that utilizes solar energy as a source of energy. The main objective of this research is to develop and optimize a solar-powered electric vehicle wireless power transmission system while considering critical issues related to material selection, coil design, thermal management, system performance, safety, and efficiency. A detailed methodology for designing and optimizing the solar power transmission system will be developed based on insights from the reviewed literature. The following key aspects are considered in developing efficient solarpowered WPT electric vehicles. First, material selection for electromagnetic coils should focus on high magnetic permeability and low coercivity to enhance energy transfer efficiency. The design of these coils must consider their ideal characteristics, including dimensions, shape, and material composition, to optimize energy delivery. In addition, it has brought into view the thermal management practices applicable in air and liquid cooling systems as crucial to maintaining operating temperatures at ideal levels that prevent overheating. This research study, aimed at optimizing system performance, safety, and efficiency, was conducted to ensure that the solar-powered WPT system operates efficiently for scalable EV charging. The research results are documented in the smallest detail to the maximum extent, capturing not only the achievements but also the challenges encountered during the research process. The results are discussed in great detail, taking into consideration the successes and, at the same time, the future challenges when gaining the research methodological result. Specifically, the aforementioned future challenges, along with those related to material selection, system efficiency, and thermal regulation, will be discussed. Additionally, different strategies were proposed to address these issues, with significant contributions made to how these challenges could be overcome in future versions of the system. Discussion on the problems and proposed remedies that follow will present a more concrete picture of the challenges native to the design of the solar-powered wireless power transfer system and the extra steps that could be given towards the improvement process.Tétel Korlátozottan hozzáférhető CFD Analysis of Aerodynamics Drag Reduction and Improving Fuel EconomyFarooq, Umar; Hajdu, Sándor; DE--Műszaki KarThe main objective of this thesis is to examine and analyze the effects of several aerodynamic modifications on truck model drag reduction and fuel consumption using Computational Fluid Dynamics (CFD) simulations. The study began by Ahmed body standard for guaranteeing the precision and reliability of simulations to validate the CFD model. After the successful validation process, a created a CAD model of truck and modified by different aerodynamics attachments and achieved results by CFD analysis, aimed to decrease drag and improve fuel efficiency. At first the coefficient of drag (Cd) value for the base truck model was 1.209. By implementing the initial set of modifications which included gap filling and front fairing drag coefficient was lowered to 1.065 and resulted in an 11.91% reduction in drag. Further aerodynamic modifications included the teardrop shape, resulted in further coefficient drag was lowered 1.075 and the percentage of drag reduction slightly decreased at 11.08%. In the addition of tail fairing in together with the previous modification the result was more significant in drag reduction with Cd falling 0.861 and 28.78% reduction. Ultimately the whole truck design including the front fairing, gap filling, teardrop, tail fairing, and side skirts, resulted in the lowest drag coefficient of 0.840, the overall drag reduction of 30.52%. The drag equation, which considers the truck's density, velocity, and reference area, was then used to obtain the drag force values: FD = 0.5×ρAV2CD. The drag forces were used to calculate the fuel consumption per 100 km using L/100km=0.008051×𝐹𝐷. With each attachment modification the result demonstrated reduction in fuel consumption. The basic model showed no fuel savings. However, with modification of the front fairing and gap filling fuel saving of 2.840 L/100km was achieved. Further teardrop modification fuel consumption was reduced with 2.636 litters savings per 100 km. By combining the front fairing, gap filling, tail fairing, and teardrop modification resulted were achieved fuel saving 6.857 L/100km. Finally, the completely modified truck model demonstrated the highest potential for fuel saving 7.272 liter per 100 km.Tétel Korlátozottan hozzáférhető Enhancing Motorcycle Maintenance: a Study on Centre Lift DesignMaphosa, Sandiswa Thandokuhle; Deák, Krisztián; DE--Műszaki KarThe reason for my study was to find a way I could enhance motorcycle maintenance and the solution for this was to design a center lift stand that is capable to improving maintenance. The stand is able to elevate a motorcycle and makes it much easier to move the bike around, especially for users with confined spaces. The stand will allow full access to the wheels as well as the suspension. When a motorcycle is on the ground it is hard to do any maintence especially on the wheels or suspension in a safe manner meanwhile this stand gives easy access since the motorcycle will be elevated. The casters allow for easy mobility since they allow full 360 degree turning in small spaces and this will also allow for easy cleaning and overall maintence due to the less effort being used. There is less risk off the bike tipping over during maintenance due to the wide base of the stand and there’s stability. Due to the lever operated mechanism, the bike can be lifted very quickly with less effort meaning less physical strain to the user. Lastly the stand allows for easy storage when the motorcycle is not in use and this can help improve tire life as well as less wear on the suspension if the bike is stored for long periods of time.Tétel Korlátozottan hozzáférhető Optimization of Manufacturing Processes using AutomationFernandes, Dylan Noel; Matko, Andrea Emese; DE--Műszaki KarThis thesis explores the optimization of manufacturing processes through the application of automation. The study highlights the importance of automation in manufacturing as well as Shop floor management. An optimization plan will be developed, targeting specific areas for automation to enhance efficiency and productivity. Key Performance Indicators (KPIs) will be defined to assess the potential impact and effectiveness of the proposed changes. Data provided by Rollexco Zrt supports the research. Moreover, this theoretical investigation will examine how automation can address key problems identified within the production process. The study will also explore the implications of automation, including its impact on operational costs and overall equipment effectiveness.Tétel Korlátozottan hozzáférhető Manufacturing and FEM analyses of spiral bevel gears of a vehicleXingyu, Liu; Bodzás, Sándor; DE--Műszaki KarThis work successfully integrated CAD modelling, simulation, and FEM analysis to optimize the design and manufacturing of spiral bevel gears, providing a practical framework for industrial applications. The results demonstrated the viability of using five-axis CNC machines as an alternative to specialized gear generators, particularly for prototyping and low-volume production.Tétel Korlátozottan hozzáférhető Optimization of the Wiper Motor Gear System for Enhanced Load Bearing CapacityMlonja, Hussein Abdulrahman; Bodzás, Sándor; DE--Műszaki KarWiper motor is among of the essential components in the vehicle manufacturing. Due to the necessity of such component especially in increasing the automobiles and vehicle safety on driving, it is very important to considet the problems arising in them including high stresses resulting in their incompetence in load bearing and durability. This study aims in investigating the optimal approach and design of the wiper motor gear systems to increase their capabilities in handling high loads and increasing their durability. The study also suggests the manufacturing technology for the suggested approach. The methodology and the results of this study are replicable and applicable in the optimization process of other gear train systems.Tétel Korlátozottan hozzáférhető DESIGN AND FINITE ELEMENT ANALYSIS OF BIODEGRADABLE ORTHOPAEDIC SCREWS WITH BULK AND GYROID MATRIX COREGaima, Emmanuel Andrew Reuben; Huri, Dávid; DE--Műszaki KarThis thesis research aims to design a standard HB 6.5 biodegradable orthopaedic screw and modify its mechanical behaviour by integrating a triply periodic cellular gyroid core. The methodology involves modelling a gyroid lattice with 0.5mm channels and integrating it into the core of the screw. The concept being explored is to investigate the reduction in screw stiffness within a measurable ratio, which could alleviate stress shielding and promote biological integration of growing bone into the exposed gyroid core. A finite element analysis methodology was used to assess and compare the mechanical performance of a gyroid-core HB 6.5 cancellous orthopaedic screw with an identical bulk-core screw. The chosen material for the screw is biodegradable magnesium alloy (WE43), known for its biocompatibility and favourable in vivo characteristics. The decision to use gyroid lattice as the core structure stems from a publication by researchers at the University of Debrecen, which demonstrated that triply minimal surfaces can enhance osteointegration properties. A prototype was developed using a 3D resin-based printer, allowing for further experiments and visualisation for future researchers.Tétel Korlátozottan hozzáférhető Manufacturing and Optimization of a Specialized Axial VentilatorAl-Saifi, Sultan Mohamed Jaffar Said; Bodzás, Sándor; DE--Műszaki KarThis paper explores the manufacturing of a unique, patented type of axial ventilator designed by the University of Debrecen. The approach to solving the problem starts from measuring and transforming the physical model into a digital one. Followed by creating a manufacturing process and subsequent toolpaths. The machining time and cost are determined, and an optimized solution is investigated in those same two parameters. Finally, the original and optimized methods are compared to determine the best approach to manufacture the unique axial ventilator.Tétel Korlátozottan hozzáférhető Optimization of Supply in context of Industry4.0 by integrating Six Sigma, FMEA and Preventive Maintenance.Mashele, Nkosingiphile Boys; Deák, Krisztián; DE--Műszaki KarThis thesis focuses on optimizing supply chains within Industry 4.0 by integrating Six Sigma, FMEA, and predictive maintenance. It explores how these methodologies can enhance efficiency, reduce risks, and drive continuous improvement in modern supply chain operations. Advanced analytics and data-driven strategies are utilized to streamline processes and ensure timely decision-making. Real-time communication platforms play a critical role in monitoring and improving key performance indicators (KPIs). Six Sigma is applied to minimize process variation and maintain high-quality standards, while FMEA identifies and mitigates potential risks in the supply chain. Predictive maintenance is incorporated to enhance equipment reliability and prevent unexpected downtime. The combination of these approaches fosters a resilient and adaptive supply chain framework suited for the challenges of Industry 4.0. Results are analyzed through graphical data, showing measurable improvements in supply chain performance from 2020 to 2024. This research highlights the importance of integrating quality, risk, and maintenance strategies for achieving long-term supply chain optimization.Tétel Korlátozottan hozzáférhető Uneven wear of Volvo caliper break padsAubakirov, Daniyar; Menyhárt, József; DE--Műszaki KarUneven brake pad wear is a significant concern in the operation and maintenance of large truck braking systems, particularly in commercial vehicles like Volvo trucks. This study examines the primary origins, effects, and possible remedies to this issue, emphasizing materials science and design optimization. A mixture of theoretical investigations, finite element analysis (FEA), and three-dimensional simulation modeling was employed to assess the frictional interactions between brake pads and discs under diverse operating situations. The study commences with a comprehensive examination of the physical qualities and composition of the brake pads and discs, emphasizing attributes such as compressive strength, thermal conductivity, and wear resistance. Multi-circuit pneumatic systems working pattern as well as the principal work of pneumatic braking system starting from the relatively old models of trucks was analyzed. Furthermore, the effect of friction forces resulting in the change of internal energy was showed. The primary findings of the 3D modeling indicated that temperature variations on the contact surfaces substantially enhance wear in specific regions of the pads. This was validated by FEA experiments, which detected hot patches and stress concentrations under severe friction. Furthermore, the modeling demonstrated how braking dynamics, including uneven drive force and disc surface irregularities, intensify the wear pattern. This paper proposes solutions that involve altering pad shape for improved pressure distribution, employing modern materials with enhanced thermal resistance, and optimizing cooling methods. Suggestions for future endeavors encompass the incorporation of machine learning algorithms for predictive maintenance and the examination of novel self-regulating brake systems. This study's conclusions seek to augment the reliability of brake systems, increase safety, and diminish maintenance expenses for Volvo trucks and comparable heavy-duty vehicles, thereby contributing to the overarching advancement of sustainable and efficient transportation technology.Tétel Korlátozottan hozzáférhető Performance Analysis of a Drone Propeller by Analytical and Numerical MethodsKaspapettai Kuppusamy, Naveen; Szodrai, Ferenc; DE--Műszaki KarThis study focuses on calculation the aerodynamic forces of a small quadcopter propeller under hovering conditions, which is vital for drones used in Industry 4.0 applications like photogrammetry and facility inspection in automotive production. The research analyzes a straight tri-blade propeller with a NACA 0012 airfoil using analytical methods (momentum and blade element theories) and numerical simulations (ANSYS CFX with RANS method). The analytical model predicts a thrust of 1.2519 N, which is validated by simulation results showing a thrust of 1.3604 N, with an 8.67% difference, confirming the model's accuracy. These findings shows the particality of optimizing small drone propellers using combined analytical and numerical approaches. The study contributes to advancing drone designs for real-time, flexible production processes and digital twin creation in the automotive industry.