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Reverse Engineering and Redesign of a HUMMER RC Car

Reverse Engineering and Redesign of a HUMMER RC Car Moemen Taha 4034, Ranuk de Silva 4325 , Ahmed Riyad 2942, Omar Mohamed 2265 Mentors: Dr. Jamal Ahmad & Mr. Robert Craig Mechanical Engineering Program, The Petroleum Institute, P.O. Box: 2533, Abu Dhabi, UAE.

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Reverse Engineering and Redesign of a HUMMER RC Car

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  1. Reverse Engineering and Redesign of a HUMMER RC Car MoemenTaha4034, Ranuk de Silva 4325, Ahmed Riyad 2942, Omar Mohamed 2265 Mentors: Dr. Jamal Ahmad & Mr. Robert Craig Mechanical Engineering Program, The Petroleum Institute, P.O. Box: 2533, Abu Dhabi, UAE • Analysis Performed on the RC Car • SolidWorks Flow Simulation • Weight analysis and optimization • Stress and contact analysis • Sustainability test • Fuel consumption test Flow Simulation Comparison Design 02 was selected after comparing using an evaluation matrix. The SolidWorks Flow Simulation comparison of the initial and final product is shown below. Purpose The purpose of this project is to reverse engineer a remote controlled car by dissecting it, performing systemic analyses and improving the car based on the analyses conducted. • Objectives • Improve the performance and design of the RC car by: • Improving its aerodynamics • Decreasing its weight • Increasing its battery life • Making it cheaper to manufacture • Making it sustainable • Making the manufacture process environmentally friendly Weight Analysis and Optimization After the stress analysis, the weight of the main chassis was optimized while decreasing the maximum stress and reducing the thickness. SolidWorks Flow Simulation of the initial product Original mass = 55.739 g Original thickness = 16.33 mm Original stress = 1.9601 MPa Optimized mass = 45.3477 g Optimized thickness = 6 mm Optimized stress = 1.9566 MPa • Product Dissection • Study the RC car at the system, subsystem and component levels to understand how it works to meet its objectives. • Gain basic knowledge of the manufacturing processes, materials selection, assembly and disassembly. SolidWorks Flow Simulation of the redesigned product Main Chassis Sustainability and Life Cycle Assessment These tests are conducted to create more sustainable designs depending on material type, manufacturing process, material use and environmental impacts. Contact Analysis This analysis is done to observe the stresses and contact pressure between mating components. Tire and axel Design Alternatives Two designs were produced after the analysis. Both the designs are identical except the body shape. Final material: PE High Density Final mass: 54.55 g Initial material: PVC Rigid Initial mass: 74.49 g Environmental Impact Comparison Conclusion The final redesigned product fulfills all of the objectives stated earlier thus obtaining a relatively better product. Design 01 Design 02 Exploded assembly view of the RC car

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