• Conceptualised and designed a 2.5 m Tunnel Boring Machine head to test microwave-assisted mining.

• The head was designed to be thrusted with a raised bore machine with a maximum load of 2700 kN.

• The location of the 16x17in cutters was optimised to minimise the moment on the drive shaft while also considering the interferences of the cutters.

• As part of the cutter spacing, I designed a custom linear cutting machine to verify if the spacing is sufficient to break-out a granite sample block.

• From the LCM tests, the cutter spacing had to change.

• A custom centre cutter was also required to ensure the 17in cutters would not interfere with each other at the centre.

• Enginuity Labs updated the design with the findings of the LCM results after I moved to the Netherlands.

• Redesigned wet drill-head to a dry drill-head with a custom bevel gearset.

• Bevel gearset allowed hydraulic motor to mount offset from drill axis for improved airflow.

• Developed hollow shaft design enabling dust and air extraction directly through drill tip and gearset center.

• Designed sealing system to prevent vacuum suction of lubrication from gear housing.

• Delivered complete 3D SolidWorks CAD assembly to client.

• Design Parameters:

  • • Max Drill Speed: 350 RPM

    • Max Drill Torque: 250 Nm

    • Max Thrust Load: 100 kN

• Reused existing bearing selection from wet drill-head design for cost and reliability.

• Bevel gearset design governed by pinion gear stress limitations for durability and longevity.

• Selected minimum pinion gear size to balance strength and compactness.

• Minor geometry changes to drill-head body.

• 1:1 bevel gear ratio with 23 teeth, module 5, pressure angle 20°.

• Gearset material: Carbon steel, Brinell hardness ≥ 223 HB.

• Estimated service life: 9 years (max 30°C operating temperature).

• Achieved minimum safety factor of 1.15 on gearset design.

• Analyzed equivalent von Mises stress levels in HDDR-CAT vehicle chassis during twisting maneuver over 300 mm obstacle at 3.9 km/h max speed using linear static Finite Element Analysis (FEA).

• Employed 3D solid finite element model with mesh refinement in critical areas for accurate stress results.

• Simplified client-supplied CAD model for FEA.

• Results evaluated following Sound Engineering Practice.

• Assessed equivalent von Mises stress levels in Drill Pivot Boom Mounting under maximum allowable drill load and dead loads, using a 3D solid finite element model with mesh refinement.

• Evaluated results according to Sound Engineering Practice and the Mine Health and Safety Act (1996).

• Determined maximum drill load the boom’s main pin can safely support, evaluating the pin per BS EN 13001-3-1, Part 5 (crane design and proof of competence for hooks).

The Finite Element Analysis confirms that the HDDR-CAT vehicle's chassis maintains all local primary stresses below the allowable limit of SY = 335.0 MPa, with general primary von Mises stresses below 2/3*SY = 233.3 MPa. Secondary stresses remain under SUTS = 470.0 MPa, and combined stresses in welded regions do not exceed S = 382.2 MPa. Therefore, the chassis meets the requirements for traversing a 300 mm obstacle at 3.9 km/h with a dynamic load factor of 2.1. For the boom, maximum drill loads are 25 kN when positioned to the side and 31 kN in front. All stress levels are compliant, and the bifurcation buckling load factor exceeds 4, indicating buckling is unlikely. The main pin limits the maximum drill load to 10 kN, as per BS EN 13001-3-1 calculations. The Drill Pivot Boom Mounting meets the standards outlined in this report and complies with Sound Engineering Practice and the Mine Health and Safety Act (1996). It is safe to operate under the specified conditions, but the client must ensure the drill load does not exceed 10 kN to avoid pin failure.

• Verified structural integrity of Toyota 5-ton Forklift Canopy against falling objects after modifications to the legs.

• Design calculations based on impact test specified in ANSI/ITSDF B56.1-2020.

• Used Dynamic Elastic-Plastic Finite Element Analysis to assess roof support shortening.

• Assessed canopy for protection against large, heavy falling objects, ensuring roof displacement remains within allowable limits with shorter supports.

• Excluded cube test from ANSI/ITSDF B56.1-2020 (local deformations) as no changes were made to the canopy roof design.

• Canopy must withstand 32640 J energy from a softwood pile, ensuring the distance between canopy and Seat Index Point (SIP) remains at least 765 mm after deformation.

The Finite Element Analysis confirms that the Toyota 5-ton Forklift Canopy can absorb the impact energy of 32640 J from a falling object, as specified by ANSI/ITSDF B56.1-2020. The maximum deflection is within allowable limits, and the canopy can be shortened by up to 148 mm. The canopy met the ANSI/ITSDF B56.1-2020 requirements for impact loading. However, inspections of the welds are necessary to check for any cracks after a heavy object impacts the canopy. 

• Conducted mechanical design review for Rope Shovel Front Jack Extension Arm to ensure safety for use in South Africa (imported from China).

• Performed linear static and bifurcation buckling Finite Element Analysis (FEA) to evaluate equivalent von Mises stress levels under maximum working and hydraulic cylinder loads.

• Used solid finite element model for a single extension arm and a rigid body for the excavator.

• Applied mesh refinement in critical areas for accurate stress results.

• Evaluation followed Sound Engineering Practice and the Mine Health and Safety Act (1996).

The pin calculations confirmed that the pin material is adequate for working load conditions, but the pins will fail in bending under maximum hydraulic load. Buckling calculations show that the lateral support tube between the extension arms will not fail in worst-case scenarios, and the hydraulic stem and cylinder are safe at a rated 70 MPa working pressure. However, the Finite Element Analysis results for the maximum hydraulic load indicate that the stresses exceeded allowable limits for general, local, and secondary stress regions, particularly in some welded areas. In contrast, the maximum working load analysis showed all general stress regions were below SY/4, with local and secondary stresses within acceptable limits. The bifurcation buckling load factor was above the minimum requirement of 4, indicating no buckling risk under maximum hydraulic load. Thus, the Rope Shovel Front Jack Extension Arm meets the minimum requirements per Sound Engineering Practice and the Mine Health and Safety Act (1996) for the maximum working load only. It is essential for the client to ensure that hydraulic loads do not exceed 100 tons. Operating without this limit would not meet the specified standards.

• Evaluated structural integrity of dish hinge for CSP system using linear static Finite Element Analysis (FEA).

• Assessed von Mises stress levels in hinge components under maximum wind loads and the dish's weight during operation and stow conditions.

• Used solid finite element model of hinge assembly with rigid body representing dish hub.

• Applied mesh refinement to critical areas for accurate stress results.

• Results evaluated according to Sound Engineering Practice.

The pin calculations confirm that the pin material used in the design is adequate for worst-case wind conditions, as per SANS 10162-1. The Vesconite bushing calculations also indicate sufficiency according to the manufacturer's design manual. The M20 bolted connections showed no signs of joint separation and are expected to perform safely under the loads outlined in this report, in compliance with SANS 10162-1. The Finite Element Analysis results reveal that all general stress regions are below SY/4 across the plate thickness, while local and secondary stress regions are below Sy and SUTS, respectively. The combined shear and normal stresses at all welded areas did not exceed allowable limits. Overall, the New Dish Hinge Design meets the minimum requirements established in this report and is safe to operate under the specified conditions, adhering to Sound Engineering Practice.