This is an investigation of the buckling characteristics of short, thin-walled cylinders. This study was required as large storage tanks, which were converted from Boating roof to fixed roofed tanks, were found to buckle when severe atmospheric temperature drops and thus pressure differentials occurred. These severe ambient temperature changes are characteristic of the Highveld in South Africa where the tanks in question are situated. Since this modification is an uncommon procedure, codes of practice for storage vessels do not cover this type of cylinder. For the same reason, research performed in this field is limited. Buckling due to axial loading, lateral external pressure, hydrostatic pressure and a combination of axial loading and hydrostatic pressure are explored in this study. To compare with and verify theory, existing research for each case is examined, and the Finite Element Analysis package MSC Nastran used to determine trends. In some cases, to the best of the author's knowledge, no research exists and numerical analysis is performed to establish the relationships present in those cases. The study is extended to include the design of imperfect cylinders, as defined in the tank code AD Merkblatter where it is stated as being dependant on the major and minor diameters of the imperfect section . The study is also extended to the case of variable wall thickness cylinders, where the thickness variation is symmetrical about the axis of the cylinder. / Thesis (M.Sc.)-University of Natal, Durban, 2001.

This dissertation is undertaken under the auspices of both the CSIR, Division of Mining Technology and the University of Natal, School of Mechanical Engineering. The CSIR have outlined two fundamental objectives of the dissertation. Firstly, the need for competent design engineers has become increasingly evident. To this end, an evaluation and research into the science of design methodology has been conducted and regarded as a significant component of the thesis. The rationale behind this aim is that the subject of design has been practiced for thousands of years, but an understanding of the process is comparably in its infancy. The importance of the steps involved in the mechanical design process can in no uncertain terms be overemphasized as the adherence there to results in designs that are least likely prone to failure as well as the attainment of highly efficient product design time scales. This is vitally important more especially when the drive towards multifunctional multidisciplinary teams is rapidly developing in the global market place. Secondly, the CSIR, having done the appropriate market research, have defined the need for the design of a timber handling system to be implemented in a deep level mining environment. It is the authors expressed intent not to separate the theory from the design at hand but rather to allow this thesis to become, for the reader, forum where a holistic and integrated approach to design can be presented. / Thesis (M.Sc.)-University of Natal, Durban, 2000.

Rolling contact is experienced by a large number of components in mechanical designs. Examples include roller bearings and ink distribution rollers in the printing industry. Rolling contact results in surface wear. It is however possible to reduce rolling contact wear rates and surface fatigue by performing a surface modification such as powdered metal coating [35]. Powder coating methods such as Laser cladding and Plasma coating are two application processes that are completely different in method and therefore create different coating microstructures and bonding mechanisms between the coating and substrate. The aim of the research was to investigate the comparative rolling contact performance of two coating processes and two separate metal powder compositions. The coatings were applied to British standard En 9 steel test specimens. En 9 was selected due to its popular use in the manufacture of shafts, cylinders and rollers. Under rolling contact, material is removed from the surface as a result of wear and surface fatigue. Through testing and evaluation, the performance of the coating application processes were evaluated relative to one another and relative to the uncoated steel under rolling contact. The performance of the coating compositions were also evaluated against one another for a given coating application process. Results used to determine the performance of the coatings and coating processes were, the number of cycles to failure and the wear rates of the coated surface. Microstructure pictures of the coated surface were taken prior to testing and following testing. The pictures were used to qualitatively determine the effects of the rolling contact on the surfaces. Through the study of rolling contact, an explanation of the stresses induced in the contact area and the position of the maximum values were determined. The boundaries for the deformation regimes were identified through the understanding of the position of first yield and the shakedown limit under rolling contact. The theories of rolling contact fatigue are covered briefly as part of a better understanding of the failure mechanism however the experimentation is largely comparative based. / Thesis (M.Sc.)-University of KwaZulu-Natal, Durban, 2008.

In order to facilitate the materials handling requirements of production structures configured for Mass Customisation Manufacturing, the design of requisite materials handling and routing systems must encompass new conceptual properties. Materials handling and routing systems with the capacity to support higher-level management systems would allow for mediated task allocation and structured vertical integration of these systems into existing manufacturing execution and management systems. Thus, a global objective in designing a materials handling and routing system, for such production configurations. is to provide a flexible system mechanism with minimal policy on system usage. With the recent developments in mobile robot technologies, due to various advancements in embedded system, computational, and communication infrastructures, mobile robot platforms can be developed that are robust and reliable, with operating structures incorporating bounded autonomy. With the addition of materials handling hardware, autonomous agent architectures, structured communication protocols and robotic software systems, these mobile robot platforms can provide viable solution mechanisms in realising real-time flexible materials handling in production environments facilitating Mass Customisation Manufacturing. This dissertation covers the research and development of a materials handling and routing system implementation architecture, for production environments facilitating Mass Customisation Manufacturing. The materials handling and routing task environment in such production structures is characterised in order to provide a well defined problem space for research purposes. A physical instance of a functional subset of the architecture is constructed consisting of a semi-autonomous mobile robot platform equipped with the infrastructure for materials handling and routing task execution. The architecture orientates the mobile robot platform in such a way as to present a collection of functional units, integrated and configured for a range of applications, and prevents viewpoints in the sense of monolithic mobile robots less susceptible to reconfiguration and stochastic utilisation. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2008.

Automated Guided Vehicles (AGVs) depend on sensor systems to guide and navigate in manufacturing environments. The sensor system must ensure the correct path is followed and monitor the vehicle’s progress as it proceeds through the environment to complete assigned tasks. An AGV therefore needs an efficient guidance and navigation system, based on sensor technology that allows it to navigate safely and accurately. A variable sensor system will provide an AGV with the ability to interchange guidance and navigation techniques as the parameters in the environment change in order to complete tasks. This will maintain material handling operations and guarantee production rates. The standardization of sensor based guidance and navigation systems for AGVs and other autonomous robots will optimize performance. The project involved research, design, construction, assembly and testing of a variable sensor system for guidance and navigation of AGVs. Sensor technology facilitated AGV operation in changing environments and avoidance of other robots and automated machines in an Agile manufacturing environment. Routing algorithms and procedures enabled safe movement and AGV task completion. The project required mechanical, electronic and software integration for AGV navigation and guidance. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2008.

The high temperature fatigue crack growth behaviour of the newly developed, metastable titanium-based alloy, TIMETAL 21S, was investigated in an inert and an oxidizing environment. The investigation adopted a two pronged approached, namely, to initially establish the pure microstructural behaviour under oxidizing and inert environments at various elevated temperatures, and consequently, to establish the environmental effects on the fatigue crack growth behaviour in the various environments at high temperature. The effect of the oxidizing environment on the metastable alloy and on the mechanical and chemical events occurring at the fatigue crack were studied by using optical and scanning electron microscopy, including ED X analysis, x-ray diffraction, and Auger Electron Spectroscopy (AES) . For the microstructural investigation, the TIMETAL 21S samples were exposed for 5 hours to a pure argon and argon + 20% O2 environment at 300°C to 750°C in increments of 50°C. The results showed that in the oxidizing environment a more homogeneous nucleation of the alpha phase had occurred at higher temperatures and that the oxide Ti02, in addition to the alpha case, had predominantly formed on the exposed surfaces. AES analysis showed that dissolution of the oxygen into the alloy occurred even at low temperatures. An LEFM approach was used to investigate fatigue crack growth rate (FCGR) of C(T) specimens at 375°C, 450°C, 550°C and 620°C in the argon and argon + 20% oxygen environment. The crack growth rates were monitored using load-line compliance and the beachmarking method - a method by which beach marks were impressed on the fracture surface to track the progressing crack. The results showed that the crack growth rates were lower in the oxidizing environment and was influenced by a synergistic effect of the temperature, stress intensity at the crack tip and the environment. In addition to the phenomena of crack tip shielding (a process whereby the effective crack tip driving force experienced at the crack tip was locally reduced), other mechanisms such as slip character modification and secondary cracking ahead of the crack tip, leading to crack tip blunting and branching, had to be incorporated to fully explain the crack growth behaviour. The tests conducted in the inert environment effectively excluded the effect of oxygen on the crack growth behaviour and substantiated that various mechanisms ultimately determined the FCGR in TIMETAL 21S at elevated temperatures. / Thesis (M.Sc.Eng.)-University of Natal, Durban, 1995.

Shape memory alloys (SMA’s) are a family of metals that exhibit properties of pseudo-elasticity / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2009.

The following dissertation describes an investigation of the structural response behaviour of a composite solid rocket motor nozzle subjected to thermal and pressure loading during the motor ignition period, derived on the basis of a multidisciplinary numerical simulation approach. To provide quantitative and qualitative context to the results obtained, comparisons were made to the predicted aerothermostructural response of the nozzle over the entire motor burn period. The study considered two nozzle designs – an exploratory nozzle design used to establish the basic simulation methodology, and a prototype nozzle design that was employed as the primary subject for numerical experimentation work. Both designs were developed according to fundamental solid rocket motor nozzle design principles as non-vectoring nozzles for deployment in medium sized solid rocket booster motors. The designs feature extensive use of spatially reinforced carbon-carbon composites for thermostructural components, complemented by carbon-phenolic composites for thermal insulation and steel for the motor attachment substructures. All numerical simulations were conducted using the ADINA multiphysics finite element analysis code with respect to axisymmetric computational domains. Thermal and structural models were developed to simulate the structural response of the exploratory nozzle design in reference to the instantaneous application of pressure and thermal loading conditions derived from literature. Ignition and burn period response results were obtained for both quasi-static and dynamic analysis regimes. For the case of the prototype nozzle design, a flow model was specifically developed to simulate the flow of the exhaust gas stream within the nozzle, for the provision of transient and steady loading data to the associated thermal and structural models. This arrangement allowed for a more realistic representation of the interaction between the fluid, thermal and structural fields concerned. Results were once again obtained for short and long term scenarios with respect to quasi-static and dynamic interpretations. In addition, the aeroelastic interaction occurring between the nozzle and flow field during motor ignition was examined in detail. The results obtained in the present study provided significant indications with respect to a variety of response characteristics associated with the motor ignition period, including the magnitude and distribution of the displacement and stress responses, the importance of inertial effects in response computations, the stress response contributions made by thermal and pressure loading, the effect of loading condition quality, and the bearing of the rate of ignition on the calculated stress response. Through comparisons between the response behaviour predicted during the motor ignition and burn periods, the significance of considering the ignition period as a qualification and optimisation criterion in the design of characteristically similar solid rocket motor nozzles was established. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2009.

The purpose of the present study is to obtain insight into the formation, behaviour and magnitude of welding-induced residual stresses and distortions resulting from welding nozzles onto cylindrical pressure vessels. A hybrid methodology that comprises numerical analysis, experimental measurements and empirical calculations is used in the present study. The welding process induces a high thermal gradient on the material due to non-uniform temperature distribution; thereby causing the portion of the material that is exposed to high temperatures to expand. However, the relatively cooler material portion that is away from the weld pool resists such expansion, thereby subjecting the structure to stresses and distortions around the fusion zone (FZ) and the heat-affected zone (HAZ). Over the last two decades a number of studies have been done in an effort to predict the effect of welding-induced residual stresses on the integrity of welded structures. However, to this end, such studies have focussed on analysing residual stresses on bead-on-plate, plate-to-plate and [to a less extent] on pipe-to-pipe weld joints. Fewer studies have looked at nozzle-cylinder joints of pressure vessels as is the case in this study. The second chapter gives a detailed review of applicable literature. The constitutive model described in the third chapter includes a two-phase sequentially-coupled thermo-mechanical analysis, which incorporates metallurgical effects. The non-linear transient problem is solved using an axisymmetric 2D model with ‘element birth’ technique, developed on ABAQUS. The first phase comprises the thermal analysis based on Goldak’s moving heat source model that is used to determine temperature histories. The second phase is a sequel stress/strain analysis wherein the temperature fields are used as input loads. The results discussed in chapters three and four show that there is a high concentration of residual stresses close to the weld centre-line, and these die down as distance away from centre-line increases. It is also shown that the inside surface is under tensile stresses, while the outer surface is under compressive stress, whose magnitude approaches yield strength of the material. Axial deflections of up to 0.384mm and radial shrinkage of 0.0237mm are observed. Distortion decreases as distance away from weld centre-line increases. Minimum axial shrinkage, which is close to zero, is observed at the restrained end. The analytical results show adequate corroboration and agreement with the experimental measurements. A number of mitigation techniques are suggested in order to alleviate the impact of residual stress and distortions on fatigue performance of welded structures. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.

Controlling a system with chaotic nature provides the ability to control and maintain orbits of different periods which extends the functionality of the system to be flexible. A system with diverse dynamical behaviours can be achieved. Trajectory flows of chaotic systems can be periodically stabilised using only small perturbations from the controlled parameter. The method of chaos control is the Ott-Grebogi-Yorke method. In non-chaotic systems large system parameters changes are required for performance changes. A sagittal plane biped model which is capable of exhibiting periodic and chaotic locomotion was researched and investigated. The locomotion was either periodic or chaotic depending on the design parameters. Nonlinear dynamic tools such as the Bifurcation Diagram, Lyapunov Exponent and Poincaré Map were used to differentiate parameters which generated periodic motion apart from chaotic ones. Numerical analytical tools such as the Closed Return and Linearization of the Poincaré Map were used to detect unstable periodic orbit in chaotic attractors. Chaos control of the model was achieved in simulations. The system dynamic is of the non-smooth continuous type. Differing from other investigated chaotic systems, the biped model has varying phase space dimensions which can range from 3 to 6 dimensions depending on the phase of walking. The design of the biped was such that its features were anthropomorphic with respect to locomotion. The model, consisting of only the lower body (hip to feet), was capable of walking passively or actively and was manufactured with optimal anthropometric parameters based on ground clearance (to avoid foot scuffing) and basin of attraction simulations. During experimentation, the biped successfully walked down an inclined ramp with minimal aid. Real time data acquisitions were performed to capture the results, and the experimental data of the walking trajectories were analysed and verified against simulations. It was verified that the constructed biped exhibits the same walking trend as the derived theoretical model. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2012.