2024 - 2025

This project presents the design of a compound die and investigates the resulting burr heights of metal parts using theoretical and numerical approaches. The die was designed based on standard mathematical equations to perform blanking and piercing in a single press stroke, producing an exhaust gas recirculation (EGR) plate from four sheet materials (AISI 1006, AISI 1018, AISI 304, and AISI 202) with 2 mm thickness. The cutting process was simulated using the finite element method (ANSYS Explicit Dynamics) to evaluate directional deformations at the cutting edges, representing burr heights, under varying sheet thickness, clearance, cutting speed, and blank holder force. Results showed that a flat piercing punch produced the maximum burr heights for AISI 1006 and AISI 304, while for AISI 1018 and AISI 202, burr heights increased with smaller thickness and higher cutting speed, with the best cutting quality achieved at a low speed of 30 m/s. The study provides a validated compound die design procedure and shows how process parameters can be optimized to minimize burr heights and improve product quality for ferrous and stainless steel sheets.

Unmanned ground vehicles often struggle to navigate rough or unstructured terrain, making legged systems a superior alternative for complex environments. This project presents the end-to-end design and implementation of a four-legged (quadruped) robot engineered for stable locomotion across uneven surfaces. The mechanical frame was developed using CAD software and light-weight, high-strength materials to optimize payload efficiency and mobility. Each leg features 3 degrees of freedom (DOF), driven by high-torque servo motors to enable fluid, multi-directional motion.The embedded control architecture utilizes a central microcontroller paired with an Inertial Measurement Unit (IMU) to provide real-time attitude sensing and feedback. Inverse kinematics (IK) algorithms are implemented alongside rhythmic gait patterns—such as trot and walk gaits—to ensure dynamic balance and stability. Physical testing demonstrates that the system achieves smooth step execution, effective body stabilization against moderate disturbances, and reliable locomotion over obstacles. This design serves as a scalable foundation for applications in search-and-rescue, environmental monitoring, and hazardous area inspection.