Vol. 3 No. 3 (2025)

Open Access

Article

Article ID: 2587

Optimization of mirror mount design based on opto-mechanical performance for space applications

by Fatouma Maamar

Mechanical Engineering Advances, Vol.3, No.3, 2025;

A new fixation type for mirror assembly was proposed in space telescope. The optomechanical design of a large aperture is necessary to maintain the stability of the optical structure regarding environmental disturbances, restrictions on the weight, size and shape of the mirror, which must be satisfied for space applications. This paper presents a study focusing on the optimal optomechanical design for mirror mounting using glue pad bonding. We have developed a new design specifically tailored for the BK-7 mirror with a diameter of 500 mm and a thickness of 45 mm. The primary aim of this research is to determine the optimal combination of glue pad number, size, and thickness to minimize both glue stress and errors in the mirror’s shape. To achieve this, we conduct simulations under various load cases, varying the size and thickness of the glue pads. The new design results demonstrate the effectiveness of the proposed optimization method, which greatly minimizes thermal stress in the mirror and ensures adequate supporting stiffness. This solution for the mirror and mount design can provide valuable support to decision-makers and optical engineers during the development phase of space optomechanical systems.

Open Access

Article

Article ID: 2529

Multi-objective Thermal Exchange Optimization algorithm applied to mechanical system design

by Fran S. Lobato, Fabian A. Lara-Molina

Mechanical Engineering Advances, Vol.3, No.3, 2025;

Engineering system design is a highly relevant and dynamic field, with numerous applications reported in the literature. This type of problem generally encompasses several objectives and constraints, including those arising from mass, energy, and momentum balances, material behavior equations, and a range of environmental, physical, and operational restrictions. To address such challenges, a range of evolutionary optimization strategies has been proposed and evaluated. This work presents a Multi-objective Thermal Exchange Optimization (MTEO) algorithm that integrates concepts of Pareto dominance along with crowding distance strategies. To assess its performance, the proposed algorithm is applied to three well-established mechanical design problems. The results demonstrate that the MTEO algorithm provides accurate approximations of the Pareto front in comparison with conventional evolutionary methods. Specifically, average reductions of approximately 36%, 32%, and 68% were observed for the respective design problems. Furthermore, the MTEO parameters were found to be easy to configure across all applications.

Open Access

Article

Article ID: 3077

Development of a stealth-enabled supersonic interceptor missile: Design, propulsion, and guidance

by Jacob Nagler

Mechanical Engineering Advances, Vol.3, No.3, 2025;

This research presents the Horned-Viper project—a technological demonstrator for a stealth-enabled, supersonic homing interceptor missile with multi-domain engagement capability (air-to-air, air-to-ground, and ground-to-ground). Distinguished by a dual-horn inlet blended into the fuselage, Horned-Viper achieves a 45% reduction in frontal RCS compared to canonical designs (e.g., AIM-120C-7, R-73). Its two-stage, dual-pulse solid-propellant architecture delivers a total impulse of 538.6 kN·s while sustaining 10 g maneuvers at Mach 1.5 and achieving a 60 km range from a 6000 m altitude launch—exceeding comparable systems by 20%–30% in agility and thrust management. A refined PNG-based guidance loop, augmented with PID (proportional-integral-derivative)-controlled canards, ensures a 10 Hz closed-loop bandwidth, yielding a 12% shorter time-to-kill relative to AIM-120C-7 under identical intercept conditions. The warhead employs directional spherical fragments, maximizing lethality within a 10 m lethal radius with an optimized fragment mass-to-explosive ratio, surpassing traditional fragmentation yields by 15 %. High-fidelity CFD (ANSYS Fluent) and 6-DOF trajectory simulations validate aerodynamic shaping and flight stability, demonstrating drag coefficient minimization in the Mach 1.8–2.2 regime and lift-to-drag improvements of 25% during terminal maneuvers. Collectively, these quantitative advances—coupled with modular servomotor and warhead innovations—establish Horned-Viper as a promising next-generation interceptor concept with critical performance advantages over X-90, R-73, Sidewinder, and Arrow systems.

Open Access

Article

Article ID: 3277

Sustainable mechanical design and manufacturing of pressure relief valves

by Suhaila E. Abidou, Ganna G. Ismail, Hesham A. Hegazi

Mechanical Engineering Advances, Vol.3, No.3, 2025;

This paper aims to provide an argument to take a closer look at the development and application of technology in relation to sustainability. Environmental awareness is driving industries across all sectors to re-evaluate their practices to reduce their impact on the environment. Therefore, integrating sustainability into the mechanical design and manufacturing of products and systems has become mandatory. An often-overlooked aspect of industrial processes is the role of valves; however, only a few studies have addressed their environmental sustainability. To address this research gap, this study aims to integrate mechanical engineering design with sustainable environmental engineering of industrial valves. The redesign concept has been applied to pressure relief valves and has been achieved by proposing the use of alternative materials other than metals, such as polytetrafluoroethylene (PTFE) and perfluoro alkoxy polymer (PFA). This study used some relevant tools to evaluate the suitability of such proposed materials, including energy consumption and CO₂ emissions. A modified design that met the properties and specifications of the proposed polymer type was implemented, resulting in a simpler valve design, fewer valve parts, easier assembly, less weight, and lower cost. The implications of the trade-offs between metallic and polymeric valves for sustainable manufacturing fall within the theoretical framework of 6R, where all its concepts play an important role in promoting sustainable and environmentally conscious manufacturing. All to reduce emissions, energy consumption, and waste.

Open Access

Article

Article ID: 1795

Further increase in the possible applications using AI with ROSES, our system for endovascular treatment

by Guido Danieli, Salvatore De Rosa, Olindo Di Benedetto, Pasquale F. Greco, Ciro Indolfi, Gabriele Larocca, Stefano Loizzo, Massimo Massetti, Emanuele Tinelli, Giovanni Tinelli, Umberto Sabatini, Yamume Tshomba

Mechanical Engineering Advances, Vol.3, No.3, 2025;

ROSES (Robotic System for Endovascular Surgery) continuously measures the resistance encountered by a catheter during advancement without requiring additional specialized components. The system consists of up to six robotic actuators arranged linearly on slides that move along an inclined rail toward the patient. The final slide accommodates the sixth actuator, which houses four stepper motors, allowing for adjustments in the relative positions of the actuators. The proximal actuator is affixed to the last slide using side bars. A force transducer, connected to the motorized slide by a wire, measures the gravitational component of any object on the rail, which remains constant as the actuators move. However, if an external obstruction hinders catheter or guidewire progression, the force changes, triggering an alert. The system also facilitates the introduction of the first catheter, even if pre-curved, enabling complete separation between the surgeon and the patient throughout the entire procedure. ROSES employs compact, purely mechanical, disposable components compatible with commercially available catheters and guidewires, making it suitable for a wide range of interventions, including cerebral arterial procedures, aneurysm treatment, ischemic interventions, angioplasty, Transcatheter Aortic Valve Implantation (TAVI), and various lower and upper limb surgeries. Future enhancements include AI-assisted brain endovascular treatments and the integration of animated catheters capable of shape adaptation via console control. By recording console inputs, resistance forces, device penetration lengths, and X-ray images, ROSES effectively functions as the “black box” of endovascular surgeries. The system is protected by multiple pending international patent applications.

Open Access

Article

Article ID: 3621

On supersonic projectile and its special versatile cannon-canister system

by Jacob Nagler

Mechanical Engineering Advances, Vol.3, No.3, 2025;

This manuscript presents the design, analysis, and validation roadmap for a compact 20 mm solid-propellant rocket projectile and an associated family of modular launchers optimized for mid-range interception and anti-armor engagement. The system addresses the capability gap between man-portable anti-armor weapons and high-volume point-defense nodes (CIWS). The propulsion architecture utilizes a high-efficiency AP/HTPB (ammonium perchlorate/hydroxyl-terminated polybutadiene) composite grain housed in a selectively laser-melted Inconel 718 pressure casing. Thermal protection is achieved via an integrated polyether ether ketone (PEEK) liner and graphite-phenolic nose, enabling sustained structural integrity against convective and radiative heat fluxes during the 2.5 s burn. Analytic internal-ballistic and nozzle isentropic calculations predict an exit velocity of approximately 1400 m/s (Mach 4) and an under-expanded supersonic jet profile. Terminal-effect models indicate rolled homogeneous armour (RHA)-equivalent penetration near 116 mm and approximately 140 mm into representative composite laminates, exceeding legacy autocannon performance. A compact, mechanically-armed setback primer ensures reliable, self-contained ignition within 6 ms of barrel exit. Three launcher classes are described: soldier-portable shoulder tube, building-mounted multi-tube interceptor, and adaptive variable-barrel arrays, enabling flexible engagement against modern threats such as unmanned aerial vehicle (UAV) swarms and light armor. Finally, the manuscript details a staged experimental validation plan and an environmental compatibility analysis to ensure operational feasibility, safety, and compliance with modern defense standards regarding emissions and handling.

Open Access

Review

Article ID: 1888

Advancement of ECAPed on the thermal stability of strain hardening behaviour and conductivity in an AA5083 under thermal effect

by Nagendra Singh, Manoj Kumar Agrawal

Mechanical Engineering Advances, Vol.3, No.3, 2025;

The plastic distortion of AA5083 after ECAP Process was founded under stress at thermal limit from 6.2 to 420 K. The EBSD method was used to investigated the microstructure changes during loading such as the kernel average misorientation mappings and orientation. The microstructure is distinguished by grains with many dislocations and small misorientation angles. When a piece is deformed at 130 K and density of deformation faults increases at 310 K than decreases. The yield strength mentioned thermal sensitivity shows that thermal energy starts the plastic deformation. A reduction in the removal of dislocations because of a reduction in atomic movement and increase in increased flexibility followed by a faster rate of strain hardening and durability of polycrystals as the temperature drops. The investigation of stress-strain graphs and the evolution of microstructure show that the thermally induced process of dominant less than 185 K. The activity of recovery processes has increased. The aim of this study is to examine the process of applying severe plastic deformation techniques, namely equal channel angular pressing, to achieve a nanoscale structure in AA5083. The effects of applying equal channel angular pressing on the microstructure and mechanical characteristics of AA5083 were investigated. Scanning electron microscopy was employed to analyze the changes in microstructure resulting from various thermal treatments applied to the material subjected to severe plastic deformation through this process. Furthermore, a more profound comprehension of the modifications in the mechanical characteristics of this aluminium alloy was obtained.

Open Access

Brief Report

Article ID: 3273

Design and construction of portable hand tilling device

by Rabiu Ahmad Abubakar

Mechanical Engineering Advances, Vol.3, No.3, 2025;

This study investigates the design, fabrication, and field evaluation of a portable, manually operated hand tilling device equipped with a fixed rake-like blade and a single guiding wheel. Targeted toward smallholder farmers in low-resource or rural settings, the device was engineered to offer an affordable and sustainable alternative to mechanized tilling tools. Constructed using mild steel for the tilling blade and aluminum alloy for the frame, the unit emphasizes simplicity, robustness, and ease of use. Field experiments were conducted on loamy, sandy, and clayey soil types to assess their performance based on tilling depth, area coverage per minute, and the manual force required for operation. Results showed that in loamy soil, the device achieved a tilling depth of 12 cm and covered 1.5 m²/min using a pushing force of 45 N. Sandy soil conditions allowed for 1.8 m²/min coverage at a slightly reduced depth of 10 cm with only 35 N of effort, indicating optimal performance in light soils. Conversely, clayey soil presented a more challenging environment, where tilling depth decreased to 8 cm and area coverage to 1.2 m²/min, with the highest force requirement of 50 N—still within ergonomic thresholds set by ISO 11228-1. The consistent structural integrity and ergonomic compliance across soil types validate the device’s utility in real-world farming scenarios. While particularly effective in loamy and sandy terrains, its limitations in high-resistance soils highlight potential areas for design refinement. Overall, the study underscores the device’s promise as a low-tech, high-impact agricultural solution for small-scale farming systems, contributing to sustainable agricultural development and local food security.