Engineering Commons^™

Prove Primary Battery Structure, John D. Burkhart, Andy Mccormick, Ryan Yu, Soren Barclay

Mechanical Engineering

In conjunction with Prototype Vehicle (PROVE) Laboratory, our group designed, manufactured, and tested a prototype structure to house the battery boxes for PROVE’s endurance vehicle. Our structure was designed to support the batteries during normal use, and in the event of a front crash. Our design is comprised of a secondary composite box to house the battery boxes, a bottom plate to affix the secondary box to the chassis floor, a horizontal plate fastened to the chassis, and a brace structure welded to the chassis. From the outset, we chose to use a secondary box, the primary battery boxes must …

Enduro Campers, Ryan J. Shomsky, Alexander W. Horst, Kevin S. Pickering, Jackson L. Aplanalp, Luke Arana, Will Firestone

Mechanical Engineering

The Enduro Campers senior project team (Formerly known as Lobo Campers senior project team) was recruited by Mr. Leif Stein to assist in the design, manufacturing, and testing of the materials and components of his company’s expedition box camper. The two main focuses of the project, divided into two sub-teams, were on the testing and manufacturing process of the materials used in the camper, and on the design and analysis of the camper’s access door, step box, and other subsystems.

The focus of the materials analysis and manufacturing team was based around the design parameter to use composite sandwich panels …

A Single-Stage Passive Vibration Isolation System For Scanning Tunneling Microscopy, Toan T. Le

Master's Theses

Scanning Tunneling Microscopy (STM) uses quantum tunneling effect to study the surfaces of materials on an atomic scale. Since the probe of the microscope is on the order of nanometers away from the surface, the device is prone to noises due to vibrations from the surroundings. To minimize the random noises and floor vibrations, passive vibration isolation is a commonly used technique due to its low cost and simpler design compared to active vibration isolation, especially when the entire vibration isolation system (VIS) stays inside an Ultra High Vacuum (UHV) environment. This research aims to analyze and build a single-stage …

Design Of Structural Stand For High-Precision Optics Microscopy, Sara T. Novell

Master's Theses

Lawrence Livermore National Lab (LLNL) is home to the National Ignition Facility (NIF), the world’s largest and most energetic laser. Each of the 192 beamlines contains dozens of large optics, which require offline damage inspection using large, raster-scanning microscopes. The primary microscope used to measure and characterize the optical damage sites has a precision level of 1 µm. Mounted in a class 100 clean room with a raised tile floor, the microscope is supported by a steel stand that structurally connects the microscope to the concrete ground. Due to ambient vibrations experienced in the system, the microscope is only able …

Autonomous Guided Vehicle Frame For Outdoor Use, Thomas Mcgrath

Williams Honors College, Honors Research Projects

The overall goal for my project is to design a durable Autonomous Guided Vehicle (AGV) frame intended for carrying a heavy load over outdoor terrain. I will not be designing a complete vehicle, only the basic structure that can be used to build a complete AGV on. There will be complete 3D models of the design and its individual parts. I also would like to provide limited Finite Element Analysis of the design using ANSYS software to determine weaknesses and methods for improvement. The design I create is meant to be used as a framework for complete outdoor AGV designs. …

Crack Pattern Simulation Of Pressurized Borosilicate Glass Tube Under Pellet Impact Using Ale Method, Omkar Bhumkar

Dissertations, Master's Theses and Master's Reports

Transformer bushings are a common target for sniper attacks to cause power failure in large areas. Given the size, internal pressure and brittle nature of transformer bushing, pellet impact causes damage to surrounding components due to broken bushing pieces. To mitigate this, a project was initiated by United States Burau of Reclaimation to develop a safety mechanism. Finite Element Analysis is proposed to optimize and reduce cost of the design.

A simplified Finite Element model is created which consists of 0.22 caliber lead pellet impacting Pyrex 7740 borosilicate glass tube. Previous studies on the effect of the mesh pattern, size …

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

Universal Studios Hollywood Vip Trolley - Roller Frame, Jeffrey Ploss, Chase Montague, Lincoln Treanor

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Manufacture Of Complex Geometry Component For Advanced Material Stiffness, David Russell Bydalek

Master's Theses

The manufacture, laminate design, and modeling of a part with complex geometry are explored. The ultimate goal of the research is to produce a model that accurately predicts part stiffness. This is validated with experimental results of composite parts, which refine material properties for use in a final prototype part model. The secondary goal of this project is to explore manufacturing methods for improved manufacturability of the complex part. The manufacturing portion of the thesis and feedback into material model has incorporated a senior project team to perform research on manufacturing and create composite part to be used for experimental …

Thermal-Fatigue And Thermo-Mechanical Equivalence For Transverse Cracking Evolution In Laminated Composites, Javier Cabrera Barbero

Graduate Theses, Dissertations, and Problem Reports

Carbon fiber reinforced plastics (CFRP) are potential materials for many aerospace and aeronautical applications due to their high specif strength/weight and a low coeffcient of thermal expansion (CTE) resulting in a high long-term stability. Among candidate structures, the re-entry reusable launch vehicles (RLV), the fuel oxidant storage and transportation at cryogenic temperature, space satellites, and aircraft structure (frame, wings, etc...) can be highlighted. However, CFRP are prone to internal damage as a result of high residual stresses and thermal fatigue loading. In this study, micro-cracking damage evolution in laminated composites subjected to monotonic cooling and thermal cyclic loads is developed …

Design Optimization And High Cycle Fatigue Analysis And Of A Differential Case, Praveen Bulusu Surya Naga

Dissertations, Master's Theses and Master's Reports

Lightweight Innovations for Tomorrow (LIFT) is a consortium with several industries, universities and research institutes. It is operated by the American Lightweight Materials Manufacturing Innovation Institute (ALMMII). One of their projects, melt 5a, is to develop high silicon ductile iron (DI) alloys with improved mechanical properties and thin walled DI castings. These alloys have high strength to weight ratio compared to that of standard ductile iron (7003). Using these alloys, components can be re-designed that are much lighter which results in improved fuel efficiency, and reduced manufacturing costs and emissions. I

In this project, a differential case is being re-designed …

Fea Analysis And Optimization Of Differential Housing For Fatigue Stresses And Fatigue Test Design To Study Skin Effect In Ductile Iron, Swapnil A. Pandey

Dissertations, Master's Theses and Master's Reports

Automotive emission standards are getting more stringent day by day and governments worldwide are moving to reduce emissions from automobiles. In this scenario reducing the weight of automobile components becomes an important design objective to reduce emissions. A 10% reduction of weight in the complete automobile leads to 6-8 percent improvement in mileage (Mhapankar 2015). Also, powertrain components make up for approximately 27% of the total automobile weight and thus optimizing the design of components in the powertrain is an important task (Mhapankar 2015). Statistics show that 26% of component failures in automobiles are part of powertrain and 21% of …

Minimizing Run Time Of Finite Element Analyses: Applications In Conformable Cng Tank Modeling, Paul M. Roehm

Dissertations, Master's Theses and Master's Reports

REL Inc. has proposed a CNG tank that deviates from typical cylindrical storage methods. The goal of REL working with Michigan Tech is to minimize mass and meet NGV2 safety standards for pressure and drop testing for this tank.

The model has undulated outer surfaces and Schwarz P-surface internal geometry. To accurately mesh this, a small element size is necessary; this creates a model with millions of elements. In explicit analyses, this requires a large amount of computational resources to run.

This report focuses on methods to reduce model run time without reducing accuracy. Methods covered include creating symmetric building …

Design And Analysis Of The Impact Diffusion Helmet Through A Finite Element Analysis Approach, Steven Paul Warnert

Master's Theses

By applying the finite element approach to the design and analysis of the impact diffusion helmet, many helmet configurations were able to be analyzed. Initially it was important to determine what design variables had an influence on the impact reducing abilities of the helmet design. The helmet was run through a series of Abaqus simulations that determined that a design with two oval shaped channels running along the length of the helmet was best. Next, these options were optimized to generate the helmet that produced the greatest impact reduction. The optimization simulations determined that a helmet that pushed the channels …

Optimization Of Formula Sae Electric Vehicle Frame With Finite Element Analysis, Alexander Prorok

Williams Honors College, Honors Research Projects

Optimization of Formula SAE Electric Vehicle Frame with Finite Element Analysis

Analysis Of A Carbon Fiber Reinforced Polymer Impact Attenuator For A Formula Sae Vehicle Using Finite Element Analysis, John T. Rappolt

Master's Theses

The Hashin failure criteria and damage evolution model for laminated fiber reinforced polymers are explored. A series of tensile coupon finite element analyses are run to characterize the variables in the physical model as well as modeling techniques for using an explicit dynamic solver for a quasi-static problem. An attempt to validate the model on an axial tube crush is presented. It was found that fiber buckling was not occurring at the impactor-tube interface. Results and speculation as to why the failure initiation is incorrect are discussed. Lessons learned from the tube crush are applied successfully to the quasi-static Formula …

Development Of A Finite Element Model For Predicting The Impact Energy Absorbing Performance Of A Composite Structure, Matthew Lowell Roberts

Master's Theses

Because of their high strength-to-weight ratio, Fiber Reinforced Composite (FRC) materials are well suited for use in high performance racing applications where weight must be kept to a minimum. Formula SAE (FSAE) race cars are designed and built by college students, roughly following the model of a scaled down Formula One car. Strict regulations are placed on specific components of the car in the interest of equalizing competition and ensuring the safety of the drivers. Students are required to construct a survival cell (the chassis), which can resist large amounts of energy in the event of a crash, with an …

Computationally Efficient Finite Element Models Of The Lumbar Spine For The Evaluation Of Spine Mechanics And Device Performance, Sean D. Smith

Electronic Theses and Dissertations

Finite Element models of the lumbar spine are commonly used for the study of spine mechanics and device performance, but have limited usefulness in some applications such as clinical and design phase assessments due to long analysis times. In this study a computationally efficient L4-L5 FSU model and a L1-Sacrum multi-segment model were developed and validated. The FSU is a functional spine unit consisting of two adjacent vertebral bodies, in this case L4 and L5. The multi-segment model consists of all lumbar vertebrae and the sacrum. The models are able to accurately predict spine kinematics with significantly reduced analysis times, …

A Prediction Of The Acoustical Output Of A Golf Driver Head Using Finite Elements, Roger Sharpe

Master's Theses

A simulation was created using LS-DYNA® to determine the acoustical properties of a golf ball and golf driver head impact. LS-DYNA® has a coupled finite element analysis (FEA) and boundary element method (BEM) solver that uses the integral form of Helmholtz’s acoustic wave equation to deliver predicted sound pressure levels at predetermined acoustic points. Validation of the modeling was done on a simple plate donated by Titleist Golf. The plate was modeled and meshed using TrueGrid and impacted by a three layer golf ball model derived from “Tanka’s” paper on multilayered golf balls. The final converging model consisted of 10,900 …