Engineering Commons^™

Hydrogen Fuel Cell Catalyst Test Stand For Single Cell Evaluation, Tyler Johnson

Honors Theses

The main objective of this project was to develop at test stand and relevant testing procedures to aid in ongoing research being conducted by Dr. Ghantasala’s team on platinum-alternative catalyst materials used in proton exchange membrane fuel cells (PEMFCs). To do this, various software (Microsoft Excel, Python, and Simscape) were used to create fuel cell simulations of increasing complexity. These simulations served as baselines for PEMFC evaluation in experimental testing, and they were used to create polarization curves, a standard method for evaluating steady state fuel cell performance. A test stand was also created in order to effectively and efficiently …

Energy-Absorbing Helmet For Safer Football, Aidan Laudeman

Honors Theses

Football-related injuries are a common occurrence and are often detrimental to the player’s health. Force impacts frequently occur at the front, back, and sides of a player’s helmet, resulting in head injuries like concussions. The goal of this project is to reduce recurrent head injuries by designing a solution involving the use of energy-absorbing metallic materials that are inserted into a football helmet. These energy-absorbing materials are configured in target zones inside the helmet to reduce the acceleration of the head based on impact locations. The chosen materials are nitinol and spring steel, which display energy-absorbing properties. Various energy-absorbing material …

Development Of A Discrete Element Model For Artificial Turf, Justin Rittenhouse

Dissertations

NFL data exhibits a distinct correlation between an elevated lower extremity injury rate and synthetic surfaces. These ubiquitous injuries frequently relate to excessive foot traction (i.e., failure to release causing fracture or soft tissue damage). Consequently, a discrete element model was developed using open-source software to analyze stud traction. First, laboratory data was collected via bench level experiments covering seventeen different testing scenarios. A minimum of twenty-five samples were collected per scenario. Total work, average torque, and maximum torque were used as indicators of stud grip. And the latter two were statistically analyzed for outliers and significant differences. Next, an …

Obliquely Impinging Jet Heat Transfer Fields: Effects Of Mach Number On Nozzle-To-Plate Distance, Thinnesh Ragupathy

Masters Theses

This study investigates the consistent features of heat flux patterns on surfaces impacted by jets at various Mach numbers, ranging from 0.1 to 1.0. It utilizes temperature-sensitive paint (TSP) analysis to examine how these patterns change. The research also explores the presence of self-similarity in both the fluctuation of heat flux and skin friction patterns, which are derived from temperature and heat flux data. A semi-empirical model is proposed to explain this self-similarity, suggesting that Mach number primarily affects heat flux patterns through the recovery temperature at the impact site.

Understanding the self-similarity of heat flux patterns across different Mach …

Segregation And Heat Treatment Response Of Cast Quench And Partition Steels, Mujeeb Hussain Shaik

Masters Theses

Quench and partition (Q&P) steels have emerged as promising alternatives to traditional quenching and tempering methods, offering a superior balance of strength and ductility due to their unique microstructure of martensite, and retained austenite. This literature review examines the development and optimization of Q&P steels, focusing on their mechanical properties, heat treatment processes, and applications in various industries. This study explores the application and effectiveness of the Quench and Partition (Q&P) heat treatment process on cast steels and examines segregation phenomena in cast medium Mn steels. Medium Mn steels were employed for various Q&P cycles on cast specimens to investigate …

Design And Simulation Of Flow Channel Of Polymer Electrolyte Membrane Fuel Cell (Pemfc), Rishya Shringhan Ravichandran

Masters Theses

In Polymer Electrolyte Membrane Fuel Cell (PEMFC), flow channel plays an important role on the performance of the cell. This study mainly focuses on the simulation of flow channel under various conditions. A three-dimensional mode of PEMFC with 25cm² of active area was employed to simulate the flow channel of PEMFC which has various designs. The flow channel designs such as single serpentine, bi-serpentine and tri-serpentine channels were investigated using ANSYS FLUENT software. Initially, the flow channel width of 2mm was examined. The obtained results were compared to the experimental data to validate the model. Then, the dimension of …

Nonlinear Finite Element Model For Functionally Graded Porous Circular/Annular Micro-Plates Under Thermal And Mechanical Load, Enrique Nava Munoz

Masters Theses

A nonlinear finite element model for micro circular/annular plates under thermal and mechanical loading is developed using a third order shear deformation theory. In the kinematic assumptions, the change of plate thickness is allowed and no transverse shear strains are considered on the top and bottom surfaces. A power-law distribution is utilized to account for variations of two constituents through the thickness of the plate. Three different types of porosity distributions are considered. The strain gradient effect in micro scale structures is considered using the modified couple stress theory. The dynamic version of the principle of virtual displacements is used …

Enabling Energy Efficiency In Connected And Automated Vehicles Through Predictive Control Techniques, Farhang Motallebiaraghi

Dissertations

The transportation sector is a significant contributor to global energy consumption and emissions, necessitating the development of sustainable transportation systems. In this regard, connected and automated vehicles (CAVs) have emerged as a potential solution to transform the transportation industry. By harnessing advanced mapping and location technologies, Vehicle-to-Vehicle (V2V) and Vehicle-to-Infrastructure (V2I) communication, CAVs offer the promise of improving efficiency, reducing traffic congestion, and enhancing safety and comfort. However, the adoption of CAVs also brings about various challenges, including energy efficiency concerns that need to be addressed to fully realize their potential benefits. This dissertation investigates energy-efficient control techniques for transportation …

Improving Autonomous Vehicles Operational Performance Using Resilience Engineering, Johan Fanas Rojas

Dissertations

Autonomous vehicles are expected to revolutionize the transportation industry by providing a safer and more efficient means of transportation. However, as autonomous vehicles are deployed on public roads, they are exposed to significant risks, both in terms of safety and system performance. Recent studies have highlighted a range of errors and accidents associated with autonomous vehicles, underscoring the need for a systematic approach to improve their operational resilience. Resilience engineering, a discipline focused on designing and analyzing complex systems to better cope with unexpected events and disruptions, offers a promising framework for addressing these challenges. Despite the potential benefits of …

Design And Implementation Of Test Stand Upgrades For Investigating Gearset Churning Losses With Baffles, Matthew Martin

Honors Theses

The automotive industry is continually researching ways to decrease energy losses in drivetrain applications. Rotating gear sets in an oil bath suffer frictional losses due to oil churning. The Center for Advanced Vehicle Design and Simulation (CAViDS) consortium has proposed studies to understand and reduce these churning losses. The primary means to reduce these churning losses are to redirect the oil flow using baffles and/or alter the oil viscosity. To perform churning loss optimization under controlled conditions, an existing test stand was upgraded to improve safety, introduce oil temperature control, and allow for the interchange of baffle designs. For safety, …

Improving Future Vehicle Fuel Economy And Operational Design Domain Through Novel Data Pipelines, Kyle James Carow

Masters Theses

Modern automobiles have greatly advanced in recent years, with technological developments that enhance performance, safety, and comfort. However, there is still much room for improvement. Today’s vehicles are heavily reliant on the combustion of fossil fuels, proven to be harmful for the environment on both a local and global scale. In addition, the safety benefits of autonomous vehicles and advanced driver assistance systems are not yet fully realized due to the limited operational design domain of these technologies. In this research, these needs are addressed through the development of two novel data pipelines. In the first study, a novel methodology …

The Musical Water Fountain, Amy Nielsen

Honors Theses

An affordable musical water fountain was designed over the course of one year. The target consumers for this fountain are middle to upper class homeowners. Based on the design parameters and research found on the topic, the fountain presents an aesthetically pleasing light and water show for residential neighborhoods. The design was sought to be competitive on the market with preexisting fountains. Since it must play music and perform a water and light show all in synchronous, there was confidence in the unique features to sell with today’s consumers. SolidWorks was used extensively to design and model the fountain and …

Measurement Of Low-Speed Impinging Jet Structure Using Temperature Sensitive Paint, Arthur Dean Woodworth

Masters Theses

Temperature sensitive paint (TSP) is used to analyze surface flow structures driven by a jet impinging on a heated steel sheet. Temperature and Nusselt number images are calculated from CCD images of the TSP surface. TSP calibration is discussed. Skin friction data is obtained from the temperature images.

Data is collected for metal and 3D-printed plastic nozzles of varying shape and size at one or two jet airspeeds depending on the nozzle. For the circular nozzles, data is collected for four Reynolds numbers at impinging angles of 90, 70, and 50 degrees. For the elliptical nozzles and the star-shaped nozzle, …

Additive Metal Deposition Feedback Optimization For The 3d Hybrid Metal Printer, Andrew James Wyman

Dissertations

In the additive manufacturing realm, explicitly the direct energy deposition method, there continues to be numerous advancements along with advantages to control print quality of the component and the ability to apply the successful repetition of metallic layers consecutively. Metal additive printed components have the capacity to directly use the component for the desired application or intended purpose from which the three-dimensional model was created. In contrast, plastic printers that produce components that would not hold to the physical conditions required such as a metallic component could withstand.

Research exertions were focused on improving the present Western Michigan University patented …

Peridynamic Modeling Of Crack Propagation In Brittle Materials With Electromechanical Coupling, Semsi Coskun

Dissertations

The bond-based peridynamics (BB-PD) is a widely used peridynamic model in the literature. Despite Poisson's ratio restriction, it still serves as a powerful tool to solve challenging engineering problems with a relatively cheap computational cost. Consider the Poisson ratio of the material does not deviate from the ones that BB-PD can model. In that case, it becomes advantageous to use the BB-PD compared to other PD models in terms of computational cost and simplicity. However, the BB-PD suffers from the so-called surface or skin effect where the material response at boundaries becomes softer than the bulk material points. As a …

Model Predictive Controller Design For Internal Combustion Engines Based On The Second Law Of Thermodynamics, Muataz Abotabik

Dissertations

Energy resources depletion and worldwide strict emissions policies pose challenges that automotive manufacturers try to overcome through researching advanced powertrain technologies such as lean-burn gasoline, direct injection, homogeneous charge compression ignition engines, powertrain electrification, etc. Most of these developments have been focused on conventional internal combustion engines (ICE) emissions and performance enhancements. Most ICE control strategies are built based on the First Law of Thermodynamics (FLT) i.e., to deliver a specific load requirement, enhancing thermal efficiency, etc. The FLT doesn’t account for in-cylinder high temperature thermodynamics process irreversibilities that cause losses in the work potential; up to 25% of the …

Fsae Vehicle Instrumentation And Validation, Alexander Anthony

Honors Theses

Formula SAE is a student chapter of the Society of Automotive Engineers (SAE). Each year SAE hosts a collegiate competition for teams of university students to design, build, and compete with a formula-style vehicle. Students from all around the world collaborate to engineer and manufacture a competition worthy racecar. Each component of the vehicle is designed from scratch, using calculated load cases to optimize weight and strength. Once the car is built, students will test and validate their vehicle. Not every team has the opportunity to validate the critical load cases the vehicle is designed around. This senior design project …

Thermal & Efficiency Analysis For A High-Speed Gearbox, Austin Owen

Honors Theses

The aim of this project was to design and build a test stand to validate a thermal model of a high-speed gearbox developed by Western Michigan University’s (WMU) Center for Advanced Vehicle Design and Simulation (CAViDS) consortium. At the completion of this project, the experimental results measured from tests will be compared to those from a Siemens Amesim model of the same gearbox. For these tests, an electric inverter/motor/gearbox package was connected to an intermediate transmission for the purpose of output speed matching to an electric dynamometer. This dynamometer applied a load to the motor/gearbox to replicate its designed running …

Electromagnetically Propelled Garage Door, Connor Seifert

Honors Theses

Garage door systems are loud and energy inefficient given their many contact points and need for continual maintenance. Most garage door systems use a loud, bulky electric motor to pull the garage door up and down using a chain. To reduce noise and energy loss due to friction from the electric motor and chain, electromagnetic forces used in Electromagnetic Suspension (EMS) trains were researched and adapted to a garage door system. The electromagnetically propelled garage door (EPGD) system was designed and validated using SOLIDWORKS and ANSYS simulation with significantly less contact points due to non-contact electromagnetic propulsion (EMP). The design …

Standardized 1x6u Cubesat Structure Design, Maximilian H. Brummel

Masters Theses

A CubeSat is a small satellite composed of one or more 10cm x 10cm x ~10cm cubes. Sometimes referred to as a “U” as in unit, the cubes can be combined in configurations of 2U, 3U, 6U, and more. CubeSats provide many advantages that larger satellites cannot offer. They are relatively inexpensive and can be fabricated much faster. Small-scale projects that require a fast timeline from conception up to completion are perfect for CubeSats. Furthermore, educational programs use CubeSat projects to teach and prepare students for the satellite industry. Popular configurations for CubeSat are 1U, 3U and 6U where the …

Towards Real-Time Energy Efficiency Analysis Of A Hydraulic System, Montasir Mamun Mithu

Masters Theses

The study aims at developing a real-time data analysis system for the energy efficiency study of hydraulic systems. It also aims at implementing automation for hydraulic systems so that energy efficiency can be improved using the real-time approach. This research uses a system-level experimental methodology. A linear push system hydraulic prototype is developed for the study. The prototype contains hydraulic actuator, shock absorber, electronic flow control valve, and electronic sensor. This prototype is used to experiment with different operating conditions to characterize hydraulic system behavior. A real-time data analysis system is developed using LabVIEW and an Open Platform Communication (OPC) …

Advancing The Use Of Quality Control Tools For High-Density Data In Modern Manufacturing, Romina Dastoorian

Dissertations

In modern manufacturing, advanced metrology systems are continually being incorporated into quality control (QC) systems to provide high-density (HD) datasets. These datasets can contain millions of measurements that can be used to represent a part’s whole geometry. While integrating HD datasets into QC systems has brought several opportunities to enhance the performance of QC systems, it has resulted in new challenges in this area as well. While significant amounts of research have been performed in this area, the QC research community still strives to tackle these challenges. This study identifies key challenges regarding incorporating HD datasets into QC systems. Specifically, …

Charge Tracing For Determining Electrical Facility Effects On Electric Spacecraft Propulsion Systems., Joseph Backe

Honors Theses

Electric Propulsion Systems are the future of deep space travel. Since its design in 2016 Western Michigan University has been testing a Hall-Thruster from a previous Senior Design Group. One issue with Electric Propulsion Systems is tracing where the electrons go after being used to ionize propellant for spacecraft acceleration. Induced magnetic fields on Earth alter the electron paths found in the vacuum of space.

One solution is the EP TEMPEST. The EP TEMPEST is an electron tracer designed by the Air Force Research Laboratory. The goal of this project is to design an electron tracer like the EP TEMPEST …

Automated Form-Fill-Seal Loader, Amara Crosby

Honors Theses

Keystone Solutions Group requires a space, money, and time saving machine that can automatically load swabs and other similar sized devices into a new Multivac R245 form-fill-seal machine. Currently, Multivac “auto-loaders” are very costly and take up a great deal of space. A portable, easy-to-mount, automated swab loader was designed and initially prototyped. This design can be moved throughout the cleanroom with current material handling devices and contains enough storage to run continuously for upwards of a half an hour.

Hinging, Propping, And Latching Mechanisms For Sunseeker Solar Car, Zachary Ruppenthal

Honors Theses

In this project, designs for the hinging, propping, and latching mechanisms on the 2021 Sunseeker Solar Car were created. These designs allow for the car’s array of solar panels to be held at any desired angle to maximize collection of solar power and give the team access to the battery and driver compartment. Removable telescoping prop rods with pin attachments are used to set the array at a desired angle. The hinging mechanism allows for the array to be lifted vertically prior to rotation in order to avoid interference with the car’s roll cage. To accomplish this, two four-bar linkages …

Autonomous Vehicle Camera Mount Application, Yuan Sheng Sit

Honors Theses

Autonomous vehicles consist of many complex systems, an extensive set of hardware components, and various computing algorithms that constantly work in harmony to provide selfdriving capabilities to a vehicle. This project focuses on developing a universal mount for a ZED 2 stereo camera used in data collection for autonomous driving applications. The main purpose of the mount is to reduce dashboard, windshield, and lens glare that affect the quality of data collection for autonomous driving applications. Software such as Ansys and SOLIDWORKS are used to simulate stress, strain, and thermal distributions on the mount to better understand the strong and …

Software Tool For Analyzing The Bending Strength Of Gear Teeth, Tayla Hall

Honors Theses

Current finite element (FE) models for gear analysis are computationally expensive. We will develop a software tool in Excel to efficiently assess the effect of different root geometries on gear tooth bending strength. The tool will assess the change in root stress as the root fillet shape is changed, using a 2-D model of a representative gear tooth using an A to B comparison. This is assumed to correlate to equivalent stress reduction in an actual gear. The tool will be validated by comparing the root stress found using the software to a FE analysis of root stress using ANSYS. …

Synthesis And Characterization Of Non-Pgm Catalysts For Fuel Cell Applications, Sudharsan Sridhar

Masters Theses

Fuel Cells convert the chemical energy of a fuel and an oxidizing agent into electricity through a pair of redox reactions. Proton Exchange Membrane (PEM) fuel cells convert (efficiency-60%) hydrogen and air to power the electric motors with zero emissions, facilitating the development of environmentally friendly and sustainable automobile technologies. One of the major obstacles for larger commercial viability of Fuel Cells for automobile applications is their cost-effectiveness. Currently, fuel cells use platinum as a catalyst material, which is prohibitively expensive for commercial automobile applications. The development of non-Platinum Group Metal (non-PGM) catalyst materials with similar electrochemical performance to that …

Use Of Dimpling Techniques To Alter The Vibration And Acoustic Characteristics Of Beams And Plates, Mofareh Ghazwani

Dissertations

Structures such as beams and plates can produce potentially high levels of unwanted vibrations and noises in the environment. A method for improving the vibroacoustic characteristics of structures based on creating dimples on its surfaces is presented in this study. The goal of this technique is to keep the mass of the subject structure the same while changing its vibration and sound radiation characteristics. A boundary value model (BVM), derived using Hamilton’s Variational Principle, is used for modeling dimpled beams subjected to various boundary conditions. Using this method, the non-dimensional equations of motion, boundary conditions, and continuity conditions for a …

Experimental Study Of Collecting Running Water From Moderately Heated Water Vapors Using Turbulence-Induced Particles Collision (Tipc) Device, Hassan Ali Ghazwani

Dissertations

This dissertation describes the development of an alternative technique to collect water vapors or changing any vapor state to liquid state using a device called the turbulence-induced particles collision generator (TIPC). The experiment of collecting water vapors using the TIPC device is conducted at different values of temperature. The spatial patterns of droplets deposited on a wall due to the TIPC are measured at different values of pressure using luminescent oil technique, and the integrated intensity of deposited droplets is calculated. Also, the luminescent oil technique has been used to visualize the deposited particles on a pipe wall. ANSYS FLUENT …