Mechanical Engineering Commons^™

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Automated Mini-Tubular Ceramic Production, Hunter Brooks, Daniel Freeman, Leo Taranta-Slack

Mechanical Engineering

Researchers at Lawrence Livermore National Laboratory need a way to increase the rate of manufacturing of mini-tubular ceramics to be used in testing particulate air filters. This document outlines our process from researching and writing an initial scope of work all the way to fabricating and testing a final prototype. This journey takes us through the background research, ideation process and selection of a final design. We also detail the desired engineering specifications and our concept selection process. We dedicate a significant portion of this report to discussion of our final design. We delve into how it was manufactured as …

Investigation Of The Tribological Behavior Of Mineral Lubricant Using Copper Oxide Nano Additives, Ahmed A. Abdel-Rehim, Sayed Akl, Sherif Elsoudy

Mechanical Engineering

In this study, tribological properties of custom formulated and stabilized nano lubricant are investigated. Spherical CuO nanoparticles are suspended in 20W-50 mineral base lubricant using Oleic Acid (OA) as a surfactant. Three different nano lubricant concentrations with 0.2, 0.5, and 1 wt.% were analyzed through ASTM G-99 pin-on-disc tribometer standardized test under boundary/mixed lubrication regimes. The generated friction and wear analyses confirm a consolidation of tribological properties with a reduction in friction coefficient in the range of 14.59–42.92%, compared with the base lubricant. Analysis of worn surfaces (SEM/EDX) as well as (AFM) was conducted. Combined hypotheses were proposed from the …

Formula Sae Monocoque Chassis Development, Kc Egger, Brian Ford, Kyle Nagao, Neal Sharma, Donovan Zusalim

Mechanical Engineering

Formula SAE is a collegiate competition hosted by SAE International with the primary goal being to design, manufacture, and race an open wheel race car. The Cal Poly Racing Formula SAE team strives for improvement every race season and has remained competitive as a result. The 2019-2020 management team determined that further research and development towards the chassis would yield the greatest performance benefit for future seasons, as the previous chassis platform limited packaging and mounting options for vehicle subsystems which interfaced with the chassis.

A redesign of the Cal Poly Racing Formula SAE team’s carbon fiber reinforced polymer monocoque …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom

Mechanical Engineering

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …

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.

Composite Suspension For A Mass Market Vehicle, Sarah M. Chapiama, Brian Auyeung, Jose Guerrero, Ethan Lau

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.

Usa Boccia Ball Ramp For Athletes With Quadriplegia, Alissa A. Koukourikos, Matthew Lee, Nathan Bernards

Mechanical Engineering

In this report, the design process in creating an assistive device for Boccia Classification 3 (BC3) players is outlined. The initial research steps, including research into the rules of the game, capabilities of the players, and existing products is documented to show where ideas for the product stemmed from. This transitions into requirements that the sponsor requested, and preliminary designs and ideas for the product. Finally, this report explains the details of the final design, which has been analyzed for safety, ease of use, and ability to function under different conditions. The processes of manufacturing and testing will also be …

Reliability Test Fixture For Flexible Hybrid Electronics, Julia Akiko Roche, Maya Francesca Zumel Manzano, Paul Alfred Swartz

Mechanical Engineering

During the 2016-2017 school year, the Cal Poly NextFlex Group, in conjuncture with the Cal Poly Industrial and Manufacturing Engineering Department, was comprised of professors, undergraduate students, and graduate students all working towards the manufacturing of flexible hybrid electronics (FHEs). FHEs, which are comprised of a flexible plastic substrate (thermoplastic polyurethane), screen-printed silver ink, and a thin silicon wafer, have a wide range of potential applications. At the time of this project, FHEs and other flexible electronics did not have a set of test standards to characterize their mechanical and electrical properties. The Cal Poly NextFlex Group recruited three Cal …

Mini High Temperature Test Unit Final Design Report, Kevin Liu, Juan P. Castillo

Mechanical Engineering

Lawrence Livermore National Laboratory has invested considerable effort to develop new standard for nuclear grade HEPA filters that can withstand high temperatures along with methods to optimally test not only the experimental filter media, but also new frame seals and media binders. Therefore, LLNL in collaboration with Cal Poly has designed and built a Mini High Temperature Testing Unit (MHTTU) to recreate conditions observed during a fire and to test different materials in an effective, inexpensive, regulated and reliable method. The existing prototype was unable to achieve the ideal testing conditions of 1000°F air at the low flow rates of …

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 …

Low-Cost Prosthetic Transfemoral Socket, Emelie Deans, Joshua Ledgerwood, Leah Moore, Shaina Jung, Kristen Temnyk

Mechanical Engineering

The goal of this senior project was to design and fabricate a low-cost adjustable prosthetic socket for above the knee amputees. This low-cost consideration was incorporated with the original intent to be used in Fiji, however, this changed to the Dominican Republic. It became clear that the need for an adjustable socket was more as a transitional socket. This transitional socket would be used for the first 6 -12 months upon amputation because this when the most amount of volume fluctuation occurs. The project sponsor, LIM Innovations, has already designed the Infinite Socket which contains four main functioning parts: baseplate, …

Metals Additive Manufacturing Powder Aging Characterization, Thomas Russell Lovejoy, Nicholas Karl Muetterties, David Takeo Otsu

Mechanical Engineering

The metallic additive manufacturing process known as selective laser melting requires highly spherical, normally distributed powder with diameters in the range of 10 to 50 microns. Previous observations have shown a degradation in powder quality over time, resulting in unwanted characteristics in the final printed parts. 21-6-9 stainless steel powder was used to fabricate test parts, with leftover powder recycled back into the machine. Powder samples and test specimens were characterized to observe changes across build cycles. Few changes were observed in the physical and mechanical properties of the specimens, however, there were indications of chemical changes across cycles. Potential …

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

Mechanical Engineering

No abstract provided.

Forest Sign Maker, Victor Espinosa Iii, Kevin Ly, Lisa Yip

Mechanical Engineering

Executive Summary:

The Inyo National Forest is arguably one of the most beautiful locations in California, containing natural masterpieces such as Mount Whitney and the Ancient Bristlecone Pine Forest. Despite its magnificence, the Inyo National Forest can be a treacherous region. The Friends of the Inyo take pride in being able to facilitate the viewing experience for all outdoorsmen by maintaining the mountain trails, which includes providing adequate trail signage.

Unfortunately, there is a fundamental issue with the recent state of trail signage in the Inyo National Forest: the rate at which signs are being vandalized or naturally destroyed is …

Wolfpack Gear Inc. Composite Frame Firefighter Backpack, Gabriel Mountjoy, Blair Ridings, Carl Drummond Buchenroth

Mechanical Engineering

No abstract provided.