Engineering Science and Materials Commons^™

Theoretical And Experimental Study Of Active Magnetic Bearing Control Integrated On Bently's Rotor Kit, Arturo Mario Flores

Master's Theses

This thesis focuses on the comprehensive study of controlling a customized Active Magnetic Bearing (AMB) installed on Bently Nevada’s RK4 rotor kit in Cal Poly’s Vibrations and Rotordynamics Lab. The AMB was uniquely designed and manufactured by a Cal Poly senior project team to fit Bently’s rotor kit and the results of this research are distinctive to the custom system. To achieve practical functionality of the AMB system, we designed a controller a Virtual Instrument (VI) using the National Instrument software, LabVIEW. From the experimental study, we calibrated the programming to find unknown parameters of the AMB system and validated …

The Center For Centering Dome, Olek Piechaczek, Ryan M. Scharf

Architectural Engineering

The Center for Centering seeks to create a large-scale healing center, conducive to individual centering of the mind and body. This mobile installation provides a relaxing, enclosed space while still maintaining a connection to the outdoors. The clients liked the idea of having a pop-up installation that could be easily set up as a touring display. With a deadline for installation looming in June 2022, a team of students had five months to design and manufacture the structure.

In winter 2022, the students developed custom geometry to minimize the number of individual parts and built a ¼ scale model of …

Precious Plastics - Plastic Brick Machine Fabrication, Timothy Ukaobasi Kanu, Evi Paraskevi Troulis

Architectural Engineering

The goal of this research is to determine the structural parameters of the recycled plastic polypropylene when molded into bricks resembling CMU blocks. To accomplish this, three mechanisms had to be assembled: the shredder, the injector, and the 1x1 mold. A tensile and compression test were to be performed on the plastic brick, and the values would be used to compare the tensile and compressive strength of PP plastic bricks, as well as their modulus of elasticity and stress vs. Strain performance. These values would be analyzed to determine whether it would be feasible to build an entire plastic wall. …

Evaluating The Effects Of Granulated Rubber And Glass Fibers In Polymer Concrete As A Structural Material For Wafer Grinding Machines, Kevin Gabriel Kuehn, Philip Randall Streeter

Materials Engineering

Polymer concrete is a composite material used to replace cast iron and steel in wafer grinding machines for vibration damping. During the grinding and lapping processes of manufacturing silicon wafers, excessive vibrations may cause subsurface damage which requires additional polishing and reduces yield. Nine compositions containing various levels of granulated rubber and glass fibers were manufactured. CRM WRF-10 granulated rubber was examined at 0%, 5%, and 10% and Corning Cem-Fil glass fibers were added at 0%, 0.5%, and 1% by weight. Smooth-On EpoxAcast 690 epoxy resin was held constant at 16% for each composition. Crushed granite aggregate from Martin Marietta, …

Dynamic Response Of Elastic Two-Story Steel Moment Frame Scaled Structure Equipped With Viscous Dampers, Garrett L. Barker, Alexander L. Poirier

Architectural Engineering

The authors of this report are Architectural Engineering undergraduate students at California Polytechnic State University, San Luis Obispo. Damping is a complex, experimentally derived value that is affected by many structural properties and has a profound effect on the dynamic response of structures. Deducing the inherent damping of a steel moment frame and affecting the damping ratio with viscous dampers are two topics explored in this paper. Dampers are commonly implemented in resilient structures that perform better in a design basis earthquake, reducing the seismic cost and downtime. Undergraduate coursework does not delve into the factors that affect damping and …

In-Situ Defect Detection Using Acoustic Vibration Monitoring For Additive Manufacturing Processes, Ali Harake

Master's Theses

The world of additive manufacturing revolves around speed and repeatability. Inherently, the process of 3D printing is plagued with variability that fluctuates with every material and parameter modification. Without proper qualification standards, processes can never become stable enough to produce parts that may be used in aerospace, medical, and construction industries. These industries rely on high quality metrics in order to protect the lives of those who may benefit from them. To establish trust in a process, all points of variation must be controlled and accounted for every part produced. In instances where even the best process controls are enacted, …

Insole Fall Prevention Device, Nick M. Hughes, Andrew M. Slaboda

Biomedical Engineering

Falls among the aging population occur every single day, with 1 in every 5 resulting in some injury and 300,000 hospitalized every year with a hip fracture [1]. The most popular and effective way to mitigate these falls is through physical therapist intervention. However, with the increased popularity in telerehab, many patients at risk for falls cannot accurately convey their gait tendencies to their physical therapists from the comfort of their home or while not in direct contact with the PT. A device like an insole, implanted with force sensors, which measures different parts of a patient’s foot, could convey …

Development Of A Marine Biodegradable Target Balloon, Blake Samuel Robinson, Arash Sam Akhavi, David Leonardo Albarran-Martinez

Materials Engineering

The US Navy utilizes PVC target balloons, known as Killer Tomatoes, that are inflated onboard a naval vessel then deployed into the ocean to calibrate a variety of weaponry. The Navy has requested the investigation of biodegradable polymers to replace the PVC in attempts to reduce ocean waste that is generated from the leftover PVC material. After communicating with American Pacific Plastic Fabricators (APPF), the current manufacturer of the Killer Tomatoes, we gained an understanding of the manufacturing process and the material requirements that would allow a new material to be integrated into their current process. Two proprietary, trial polymers …

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 …

The Use And Explanation Of The Phase Angle In Forced Vibration Testing, Nicholas R. Slavin, Ryan D. Thornton

Architectural Engineering

Forced vibration testing is a tool used to characterize a structure’s dynamic properties. When subjecting a structure to a forced harmonic load, the results help define the structure’s fundamental frequencies and dominant mode shapes. However, when conducting testing, it is difficult to determine the contributions of each mode to the response at a given location in the structure. The recorded response from a forced vibration test is a combination of unknown modal constituents. Excitation may not result in the pure, single mode response that the experimenter desires, but may instead result in a combination of modal responses that obscure the …

Mechani-Kits Senior Design Project, Jake Utley, Sophie Carson, Vincent Seguin

Mechanical Engineering

Studies suggest that when designed and executed well, hands-on activities can enhance student understanding of key mechanics concepts. Current products are expensive and typically not designed to meet a variety of learning objectives. Through the Mechanics of Inclusion and Inclusivity in Mechanics grant, the Cal Poly Physics and Engineering Departments are seeking to incorporate new hands-on activities into their courses. Our team has designed three inexpensive ”MechaniKits” to be used in physics, statics and dynamics courses [1]. This Final Design Review outlines our findings, objectives, and final designs for this project. It also explains our manufacturing and design verification plans. …

Design, Modeling And Control Of A Two-Wheel Balancing Robot Driven By Bldc Motors, Charles T. Refvem

Master's Theses

The focus of this document is on the design, modeling, and control of a self-balancing two wheel robot, hereafter referred to as the balance bot, driven by independent brushless DC (BLDC) motors. The balance bot frame is composed of stacked layers allowing a lightweight, modular, and rigid mechanical design. The robot is actuated by a pair of brushless DC motors equipped with Hall effect sensors and encoders allowing determination of the angle and angular velocity of each wheel. Absolute orientation measurement is accomplished using a full 9-axis IMU consisting of a 3-axis gyroscope, a 3-axis accelerometer, and a 3-axis magnetometer. …

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.

Pnnl Dark Matter Bubble Chamber, Ryan Robinson

STAR Program Research Presentations

The Pacific Northwest National Laboratory (PNNL) prototype bubble chamber is intended to address issues encountered with the current PICO dark matter search detectors and improve the functionality of future experimental designs. The PNNL bubble chamber accomplishes this with a simplified interface between the hydraulic pressure controls and the target vessel and altering the standard chamber design such that it can be easily exchanged and replaced with vessels of various sizes and materials for testing purposes. The chamber itself is a glass vessel which houses perfluorobutane and holds the target fluid above room temperature and atmospheric pressure. The target fluid becomes …

Analysis Of The Low-Cycle Fatigue Behavior Of Silicone Rubber For Biomedical Balloons, Chase Cooper

Materials Engineering

The development of a medical drug delivery device that allows for the deployment drugs into the adventitial tissue of blood vessels requires the inflation of a silicone elastomer. The inflated silicone must be able to consistently endure multiple loading cycles without failing so that the device can operate reliably. There are multiple methods of processing the silicone for the device and the goal of this study is to examine the effect of the various processing methods on the characteristics of the silicone. The Dynamic Mechanical Analysis Machine (DMA) is used to model the conditions of the device’s application by performing …

Beauchemin Residence, Hannah E. Rogers

Architectural Engineering

The following report details the structural engineering completed on the Beauchemin Residence, as well as the associated drawings, details, and special considerations. The Beauchemin Residence is an existing single story wood frame building on raised wood floor, located in the city of San Clemente. The scope of work includes calculations for a new roof, new walls (gravity & lateral), retrofit of the existing foundation, new foundation, and providing calculations. The process and progression of the structural design is documented, and correlated to the final product in the Appendix A & B.

The Role Of Soil Stiffness In Reverse Fault Rupture Propagation, Moises I. Buelna

Master's Theses

A nonlinear Mohr-Coulomb constitutive model with a strain dependent yield surface and non-associated flow was employed to study the plastic soil properties which affect the rate of surface fault rupture propagation in reverse events. These numerical simulations show a trend for soils with higher stiffness to have a higher rate of rupture propagation. Additionally the study shows the effects of strain softening and hardening on the rate of rupture propagation. Soils which strain harden exhibiting ductile behavior typically require more basal offset to rupture to the surface than soils which strain soften exhibiting brittle behavior. These results agree with our …

A Comparison Study Of Composite Laminated Plates With Holes Under Tension, Joun S. Kim

Master's Theses

A Comparison Study of Composite Laminated Plates with Holes under Tension

A study was conducted to quantify the accuracy of numerical approximations to deem sufficiency in validating structural composite design, thus minimizing, or even eliminating the need for experimental test. Error values for stress and strain were compared between Finite Element Analysis (FEA) and analytical (Classical Laminated Plate Theory), and FEA and experimental tensile test for two composite plate designs under tension: a cross-ply composite plate design of [(0/90)4]s, and a quasi-isotropic layup design of [02/+45/-45/902]s, each with a single, centered hole of 1/8” diameter, and 1/4" diameter (four sets …

Mechanical Testing Protocol For Characterizing Composite Lamina Pre-Pregs, Kenneth Blain Ainslie, Joshua Gustav Brinkmann

Materials Engineering

Zodiac Aerospace currently employs finite element analysis (FEA) computer models to predict the material behavior of its composite products. The objective of this project was to develop a testing protocol for obtaining detailed material property data to use in these FEA models. With accurate material data, FEA models can reduce the need for expensive physical testing and achieve timely troubleshooting when testing complex components. The specific material characterized in this project was an 8-satin weave fiberglass phenolic pre-preg used as the facesheet material in many of Zodiac’s sandwich panel composites. The developed testing protocol involved mechanical testing of lamina and …

Inkjet Printing Of Nano-Silver Conductive Ink On Pet Substrate, Skyler Jiang

Materials Engineering

Printing of conductive ink traditionally uses copper-based ink and was used on high temperature metal substrates due to the high curing and sintering temperature of copper. In this experiment, however, Metalon JS-B25P nano-silver conductive ink was printed using an Epson Stylus C88+ inkjet printer on polyethylene terephthalate (PET) based Novele printing media made for low temperature applications. With silver’s lower sintering temperature, the nano-silver particles in this ink are desired to be able to sinter at a low enough temperature to be used on the PET substrate. The printed ink traces were cured with a temperature-controlled hotplate at 100℃, 120℃, …

Development Of 3d Compression Molded Composite Primary Structure, Sean D. Tischler, Jacob H. Goldstein, Alea A. Perez

Mechanical Engineering

The work accomplished by the Black Gold team improved upon the carbon fiber compression molding research and information available on the Cal Poly San Luis Obispo campus. The team used the rear suspension rocker arm off a Ventana Alpino mountain bike as a design goal for this project. This research and body of work includes the methods used to design a compression molded part for complex part loading and shape. This extends to the process of choosing an appropriate layup process, in addition to benefits and drawbacks of the use of chopped fibers in compression molding. The research includes the …

Bear Minimum: Ultralight Composite Bear Canister, Rama B. Adajian, Adam C. Eisenbarth

Mechanical Engineering

The ultralight backpacking community needs a strong, easy to use, safe bear canister that is lighter than current market products for trekking in the backcountry. A full design of the lid for the bear canister is to be completed. This includes the locking mechanism to ensure it is bear proof, the interface between the lid and the canister, and the structure of the lid so it passes the strength and weight specifications. The lid, along with the already designed canister body, is to be manufactured with formal documentation. The lid will initially be tested separately and then with the canister …

Deployable Antenna For Cubesat, Mackenzie Thomas Lennon, Caleb Andrew Barber, David Matthew Galves

Mechanical Engineering

This project is a proof-of-concept ground model of a large deployable antenna designed for the small space requirements of CubeSats. This small deployment module is designed to fit a 2 m by 1 m reflective antenna inside a storage volume of with the dimensions 20 cm by 20 cm x 40 cm. The reflector will be deployed to a parabolic shape with the goal of modeling the reflector necessary for high frequency communication. Because this module is designed as a proof-of-concept for the deployable parabolic reflector specifically, no electrical components will be incorporated and will just focus on the deployment …

Biomimetic Seal Flipper Test Rig, Gordon D. Belyea, Laura Kawashiri, Dylan Rinker, Kurt Beske

Mechanical Engineering

No abstract provided.

Experimental Building Demonstration Model With Viscous Fluid Dampers, Blake Thomas Reeve, Brianna Jean Kufa, Aden Malek Stepanians, Sophie Carmion Ratkovich

Architectural Engineering

The Architectural Engineering major places a heavy emphasis on structural dynamics and the role of wind and seismic loading in building analysis and design. Buildings of high importance that are critical to community function, such as hospitals, often utilize supplemental damping devices like supplemental viscous fluid dampers or base isolators to reduce the overall demands on the structural system. The design and analysis of these dampers are typically not taught at the undergraduate level, and is frequently performed by mechanical engineers, in lieu of structural engineers.

To better understand and research building behavior with supplemental damping devices, our multi-disciplinary team …

Carbon Fiber Reinforced Polymer Roofing At Ac2 Auditorium: A Case Study, Jacob R. Hague

Construction Management

Carbon Fiber Reinforced Polymer (CFRP) has been used in several capacities in the manufacturing of products such as high performance cars and airplanes, as well as many other smaller products. In construction, it has primarily been used as a way to strengthen or repair existing structures, and in some more recent applications, in tension cables. This paper will examine a new way to use CFRP- as a roofing material, and will specifically focus on the design and installation of a CFRP roof installed at Apple’s new AC2 Auditorium, forming the roof for the main entrance lobby. Installed in February of …

Design Of A Folding V-Scraper With Roller For Orchard Applications, Chase Ulrich

BioResource and Agricultural Engineering

This senior project discusses the design of a folding 15 ft. wide leveler for orchard use. This design utilized a category 2 three-point hitch to connect the implement to a tractor. The folding mechanism uses the tractors hydraulic system to actuate the folding movement using hydraulic cylinders. The blades, when wings in operational position, are rigid with one another after some assembly. When the implement is folded the width is reduced to nine feet.

Process Development For Compression Molding Of Hybrid Continuous And Chopped Carbon Fiber Prepreg For Production Of Functionally Graded Composite Structures, Corinne Marie Warnock

Master's Theses

Composite materials offer a high strength-to-weight ratio and directional load bearing capabilities. Compression molding of composite materials yields a superior surface finish and good dimensional stability between component lots with faster processing compared to traditional manufacturing methods. This experimental compression molding capability was developed for the ME composites lab using unidirectional carbon fiber prepreg composites. A direct comparison was drawn between autoclave and compression molding methods to validate compression molding as an alternative manufacturing method in that lab. A method of manufacturing chopped fiber from existing unidirectional prepreg materials was developed and evaluated using destructive testing methods. The results from …

Effect Of Surface Omniphobicity On Drying By Forced Convection, Madani A. Khan, Jeffrey Alston, Andrew Guenthner

STAR Program Research Presentations

Low energy surfaces can strongly repel both oil and water. Recently these surfaces have been fabricated on various substrates including fabric, aluminum, stainless steel and many other materials. In this experiment we explore the use of low energy surface deposition on aluminum alloy, stainless steel and silicon substrates, to enhance the drying rate of liquids removed from the surface by forced convection. We control surface roughness by substrate abrasion and by the growth of Al₂O₃ nanograss to enhance liquid repellence by use of a hierarchical texture. Liquid repellence of the substrates is measured by contact angles of …

Molecular Dynamics Investigation Of The Arabinan-Cellulose Interface For Cellulose Nanocomposite Applications, Luke Thornley

Materials Engineering

Atom level computer simulations of the arabinan and cellulose interface were performed to better understand the mechanisms that give arabinan-cellulose composites (ArCCs) their strength with the goal to improve man-made ArCCs. The molecular dynamics (MD) software LAMMPS was used in conjunction with the ReaxFF/c force field to model the bond between cellulose and arabinan. A cellulose nanocrystal with dimensions 51 x 32 x 8 Å was minimized with various weight percent of water, 0%, 3%, 5%, 8%, 10%, and 12%. After the system was equilibrated for at least 100,000 femtoseconds, an arabinan molecule composed of 8 arabinose rings was added …