Mechanical Engineering Commons^™

Formula Sae Turbocharger Engine Development, Eric Griess, Kevin Mccutcheon, Matthew Roberts, William Chan

Mechanical Engineering

This project, Formula SAE Turbocharger System Development, was sponsored by the Cal Poly, San Luis Obispo Formula SAE team. The team proposed this project in order to have a powerful yet lightweight engine so they can be extremely competitive at their competition. The baseline output of the single cylinder 450cc engine (2006 Yamaha WR450F) was 46 horsepower and 27 ft-lb of torque. The goal of this project was to increase the output of that engine to 60 horsepower and 35 ft-lb through the use of a turbocharger.

Selective Laser Sintering; A Design Of Experiments, Philip David Hopkins, Victor Castillo Phd

STAR Program Research Presentations

Additive Manufacturing (AM), also commonly known as 3D Printing or Rapid Prototyping, is a method of manufacturing that provides for the ability to make intricate internal features and easily customizable parts. The concept is to break a Computer Aided Design (CAD) file into a series of thin layers that are sent to the machine and laid down one layer at a time. Just like any other form of processing, material properties can alter by undergoing this process. Manipulating various parameters of the AM process can allow for different properties to be achieved. For this reason, an in depth study will …

Static Balancing Of The Cal Poly Wind Turbine Rotor, Derek Simon

Master's Theses

The balancing of a wind turbine rotor is a crucial step affecting the machine’s performance, reliability, and safety, as it directly impacts the dynamic loads on the entire structure.

A rotor can be balanced either statically or dynamically. A method of rotor balancing was developed that achieves both the simplicity of static balancing and the accuracy of dynamic balancing. This method is best suited, but not limited, to hollow composite blades of any size. The method starts by quantifying the mass and center of gravity of each blade. A dynamic calculation is performed to determine the theoretical shaking force on …

Thermocouple Calibration Device, Angelica M. Larios, Cameron D. Peck, Andrew J. Smith

Mechanical Engineering

The goal of this project is to develop a thermocouple calibration unit with a high degree of confidence and accuracy. This thermocouple calibration device will be designed and developed at Cal Poly San Luis Obispo and delivered to Tesla Motors Inc.

To best utilize thermocouples, they must be calibrated to a known accuracy. Non-commercially produced thermocouples have unknown accuracies. The final deliverable will be a semi-automated device that produces a calibration curve for each thermocouple with a known confidence and accuracy.

Biaxial & Twist Testing Of Composite Carbon-Fiber Sandwich Panels For Automotive Racing Vehicles, Erik Eckberg

Materials Engineering

Composite sandwich panels were constructed with 4-ply plain weave carbon-fiber/epoxy face sheets in the 0^o/45^o/0^o/45^o orientation and 1/8^th inch Nomex honeycomb core. The panels were cut into 5-inch square test plates for mechanical testing. All testing was done on a fixture designed and fabricated by Pratt & Miller Engineering and installed on an Instron testing system at Cal Poly. The twist test was performed by supporting diagonal corners of the plate while simultaneously loading the opposite two corners at a crosshead rate of .06 in/min (ASTM 3044-94R11). Out of 10 panels tested, …

Finite Element Modeling Of Ballistic Impact On A Glass Fiber Composite Armor, Dan M. Davis

Master's Theses

Finite Element Modeling of Ballistic Impact on a Glass Fiber Composite Armor

Dan Davis

Experiments measuring the ballistic performance of a commercially available fiberglass armor plate were used to guide the development of constitutive laws for a finite element model of the impact. The test samples are commercially available armor panels, made from E-glass fiber reinforced polyester rated to NIJ level III. Quasi-static tensile tests were used to establish material properties of the test panels. These properties were then used to create models in the explicit finite element code LSDYNA.

Ballistic impact testing of the panels was conducted using a …

Senior Project #7: Longboard Test Apparatus, Derek Chan, Colin Harris, Nico Lee

Mechanical Engineering

The aim of this project is to create a machine that will test longboards made by Method Sports and Freebord. Through analysis and many iterations, Board Busters has assembled a design to fulfill the requirements set forth by these companies, who also sponsor the project. Through use of a four-bar, frame, and two spinning disks, the machine will accurately simulate riding conditions seen by a board in use by customers, allowing the sponsoring companies to improve designs and verify warranties.

Supermileage Chassis Dynamometer, Jose Garcia, Steve Janning, Timothy Lui, Kyla Purvis

Mechanical Engineering

This report describes the final design and analysis of a hydraulic chassis dynamometer as a testing tool for California Polytechnic State University, San Luis Obispo Supermileage Vehicle Team (CPSMV). Literature review was conducted to understand the various types of chassis dynamometers on the market as of the year 2011. After rigorous research, it was determined that a hydraulic system was the best system for a chassis dynamometer in terms of functionality, performance, and cost. Critical study of hydraulics, dynamometers, and data acquisition systems (DAQ) was followed by a complete design of a hydraulic system. The chassis dynamometer proposed in this …

Lunalight Project: Solar-Rechargeable Led Lantern And Cell Phone Charger, Sean C. Dawson, Michael E. Deagen, Francisco N. Dye, Brian S. Mircheff, Ryan O. Ramelb

Materials Engineering

Today, 1.6 billion people in the world do not have access to grid electricity. Villagers living off the grid in developing nations resort to kerosene lanterns to light their homes. The fumes from burning kerosene are toxic and lead to respiratory illnesses over time. Our sponsor, OneMillionLights, plans to help people to escape poverty by providing them with a clean source of light at night. Children that must work in the fields during the day can use a solar-rechargeable lantern at night to read or study, and street vendors can use the lanterns at night to improve their businesses.

The …