Mechanical Engineering Commons^™

Formula Sae Interchangeable Independent Rear Suspension Design, Mike Mccune, Daniel Nunes, Mike Patton, Courtney Richardson, Evan Sparer

Mechanical Engineering

The Suspension Solutions design team has completely designed built and tested an independent rear suspension system for the 2008 FSAE car. The car currently features a solid rear axle, and the task of converting it to incorporate an interchangeable rear suspension has been undertaken in order to quantify the advantages and disadvantages of each design philosophy. The car has been properly tested with both the solid axle and independent rear suspension side-by-side, however more testing is suggested. After pushing both setups to their limits on a 50ft diameter skid pad, the test results were quantified, and a final comparison between …

Broccoli Floret Cutter: Gold Coast Packaging, Inc., Sean Stamm, Walter Salguero, Felipe Gomez Jr, Ruben Duenas

Mechanical Engineering

No abstract provided.

Callaway Golf: Variable Curved Impulse Sealer, Justin Cook, Ben Jones, Sean Reynolds

Mechanical Engineering

No abstract provided.

Boundary Layer Data System (Blds) Heating System, John Hauge, Drew Hutcheson, Paul Scott

Mechanical Engineering

The boundary layer data system (BLDS) is the result of a collaborative effort between Dr. Westphal, a researcher and instructor at Cal Poly, and Northrop Grumman. The BLDS is capable of measuring the boundary layer profile and characteristics of flow over aerodynamic surfaces and is intended for high altitude, high speed use. The instruments inside the BLDS malfunction at the low temperatures present when operating in flight at altitudes above 30,000 ft. To solve this problem, analysis was done on the existing BLDS which determined the heating requirements, around 50 watts, needed to keep the internal temperature within the rated …

Two-Material Cylinder Stress Response Software, Katherine Gage, Matt Highstreet, Liz Del Cid

Mechanical Engineering

No abstract provided.

Module Cover Conductivity Enhancement, Niles Dhanens, James Fortner

Mechanical Engineering

A clam shell module cover for printed circuit boards (PCB) has been designed for use in Boeing’s AECM cabinet. The cover utilizes materials with high thermal conductivity and cools the PCB by conducting the heat to a cold plate interface. Materials were compared and aluminum 6061-T6, aluminum 3003, and annealed pyrolytic graphite (APG) were chosen. A prototype was built and tested using aluminum 6061-T6 which was able to dissipate 57.7% of the projected wattage. Issues may include unforeseen complications in assembly along with components performing at lower levels than specified by manufacturers. The APG prototype was unable to be tested …

Pump Sequencing Optimization, John S. Allan, Kyle J. Nekimken, Spencer B. Weills

Mechanical Engineering

The purpose of this document is to demonstrate the design, production, and testing of optimum pump sequencing logic for variable frequency drive (VFD) pumps in commercial heating ventilating and air conditioning (HVAC) systems. The product will be developed by Pump Efficiency Solutions (PES), which is a group of Cal Poly students working on their senior project. The product is being developed for Trane, an industry leader in large scale HVAC systems. MATLAB™, Microsoft Excel, Pump System Improvement Modeling Tool™ (PSIM), and fluid mechanics hand calculations were used during software development. Next, we converted the program into Trane’s graphical programming language …

Hydraulic Hand Press Final Project Report, Nathaniel Marc Brown, Matthew Thomas Knorr

Mechanical Engineering

This report provides a thorough description of the design of a hydraulic hand-operated press by mechanical engineering students at California Polytechnic State University, San Luis Obispo, California, for the Estrella Warbirds Museum in Paso Robles, California. It begins with research into hydraulic operations, a brief study of fluid power and incompressible fluids, and a look into existing products. Specified customer requirements stipulate the loading and general size constraints. As part of the project, a schedule is laid out following industry techniques. Brainstorming and decision matrices are utilized as well, conveying our design process. A basic structure is developed using strength …

Indirect Pipe Pressure Measurement, Clayde Barkley, Mikel Betts, Anthony Olay

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.

Chip Removal Tool Project, Brett Mori, John Cote, Kyle Rowland, Micah Wells

Mechanical Engineering

The Cal Poly senior project team worked with Helical Products Inc. to develop an automated method for removing swarf and chip buildup from the drill bits of their CNC milling machines. The removal methods in this report were designed for and tested using a Fanuc Robodrill while keeping the potential in mind for their use in other CNC milling machines. After extensive background research, preliminary and prototype design and testing the final chosen design is shown below. The cleaning device is made from flexible sheet metal and placed on a fixture that occupies one of the two pallet locations inside …

Air Cooling For Aecm Module, Final Project Report, Kevin Whipp, Abraham Bruno Caulk

Mechanical Engineering

Advancements in electronics have created the need for improved cooling standards. The AECM standard, created to replace the antiquated ARINC 600 specification for aircraft, draws inspiration from a cooling specification known as VITA 48.2. The ARINC standard is in early stages of development and this project researches the feasibility of using air as a convective fluid instead of a liquid, the fluid used in the VITA specification.

A performance factor calculated from the ratio of the heat dissipated by convective heat exchanger plates over the power used to cause forced convective flow over said plates helps to quantify the effectiveness …

Best-In-Class Global Bumper Reinforcement Beam, Garret Anthony Bautista, Chad Anthony Hardin, Benjamin Ray Taylor

Mechanical Engineering

Modern bumper systems are governed by laws and regulations imposed separately by various countries. Today, the regulations in China, North America, and Europe are becoming more similar, but there is not a widely accepted bumper reinforcement that meets the requirements of all markets around the globe.

A universal bumper reinforcement beam incorporating Plug-n-Play techniques was developed to meet and exceed all testing requirements and performance standards of each country. These Plug-n-Play techniques consist of adding energy absorbing attachments to the front of a base bumper beam. Simple beam analysis and FEA were the primary analysis tools in the development of …

Supermileage Team - Urban Concept Competition Vehicle Chassis Design Report, Andrew Allport, Kevin Braico, Kevin Charles, George Kyi, William Lai

Mechanical Engineering

This research and design project was proposed by the Cal Poly Supermileage team. They have requested for our team to design an Urban Concept car, a new category of vehicles to compete for fuel efficiency in the Shell Eco-marathon in 2010. The primary focus of our team is in the design and construction of a chassis the Supermileage team can use for the 2010 competition in Fontana, CA. This design must meet dimensional and functional requirements set by Shell while being designed to maximize efficiency in the competition.

There were various chassis concepts under consideration that would possibly work for …

Enhanced Vehicle Identification Utilizing Sensor Fusion And Statistical Algorithms, Stephane Roussel, Hemanth Porumamilla, Charles Birdsong, Peter Schuster, Christopher Clark

Mechanical Engineering

Several studies in the area of vehicle detection and identification involve the use of probabilistic analysis and sensor fusion. While several sensors utilized for identifying vehicle presence and proximity have been researched, their effectiveness in identifying vehicle types has remained inadequate. This study presents the utilization of an ultrasonic sensor coupled with a magnetic sensor and the development of statistical algorithms to overcome this limitation. Mathematical models of both the ultrasonic and magnetic sensors were constructed to first understand the intrinsic characteristics of the individual sensors and also to provide a means of simulating the performance of the combined sensor …

Work In Progress - Role Of Faculty In Promoting Lifelong Learning, Jonathon Stolk, Susan M. Lord, Candice Stefanou, John Chen, Katharyn E. K. Nottis, Michael J. Prince

Mechanical Engineering

Students’ development of self-directed and lifelong learning capacities is vital for their success in today’s engineering environment. Instructors play a critical role in influencing outcomes related to self-directed learning (SDL) through their design of courses that support students’ transitions from controlled to autonomous learning behaviors. Yet there is a critical lack of research examining how instructor choices promote self-directed (and eventually lifelong) learning development in undergraduate engineering students. In this work in progress, we introduce a project that explores how instructor choices affect a range of student outcomes related to their development as self-directed and lifelong learners. Drawing on existing …

A Nonlinear Constituent Based Viscoelastic Model For Articular Cartilage And Analysis Of Tissue Remodeling Due To Altered Glycosaminoglycan-Collagen Interactions, Gregory C. Thomas, Anna Asanbaeva, Pasquale Vena, Robert L. Sah, Stephen M. Klisch

Mechanical Engineering

A constituent based nonlinear viscoelastic (VE) model was modified from a previous study (Vena, et al., 2006, “A Constituent-Based Model for the Nonlinear Viscoelastic Behavior of Ligaments,” J. Biomech. Eng., 128, pp. 449–457) to incorporate a glycosaminoglycan (GAG)-collagen (COL) stress balance using compressible elastic stress constitutive equations specific to articular cartilage (AC). For uniaxial loading of a mixture of quasilinear VE constituents, time constant and relaxation ratio equations are derived to highlight how a mixture of constituents with distinct quasilinear VE properties is one mechanism that produces a nonlinear VE tissue. Uniaxial tension experiments were performed with newborn bovine AC …

Development Of A Reusable Aerospike Nozzle For Hybrid Rocket Motors, Patrick Lemieux

Mechanical Engineering

The Department of Mechanical Engineering at the California Polytechnic State University, San Luis Obispo, has developed an innovative program of experimental research and development on hybrid rocket motors (where the fuel and the oxidizer are in different phases prior to combustion). One project currently underway involves the development of aerospike nozzles for such motors. These nozzles, however, are even more susceptible to throat ablation than regular converging-diverging nozzles, due the nature of their flow expansion mechanism. This paper presents the result of a recent development project focused on reducing throat ablation in hybrid rocket motor nozzles. Although the method is …

Electro Mechanical Actuator Test Stand For In-Flight Experiments, Michael Koopmans, Catlin Mattheis, Austin Lawrence

Mechanical Engineering

The Prognostic Center of Excellence at NASA Ames is currently researching actuator prognostics, specifically in the application of electro mechanical actuators (EMA’s). Cal Poly ME students Michael Koopmans and Catlin Mattheis and EE student Austin Lawrence have chosen to undertake the task of building a test stand that will be flown in flight while testing EMA’s specific faults. A stand was designed to fit inside a standard 19” rack, take power from the aircraft 3 EMA’s, a computer, data acquisition, and electric magnets switches are powered. A MIL STD 1553 interface is present to allow fault injection. Vibration and temperature …

The Magic Atm, Amber Iraeta, Jason Sy, August Brower

Mechanical Engineering

No abstract provided.

Dynamics Simulation And Malfunction Diagnosis Of Heavy Machinery Using Msc Adams, Dewen Kong, Jim M. Meagher, Xi Wu

Mechanical Engineering

No abstract provided.

Integrating Adams Software Into An Upper Division Mechanical Design And Analysis Course, Xi Wu, Dewen Kong, Jim Meagher

Mechanical Engineering

No abstract provided.

Simulating The Growth Of Articular Cartilage Explants In A Permeation Bioreactor To Aid In Experimental Protocol Design, Timothy P. Ficklin, Andrew Davol, Stephen M. Klisch

Mechanical Engineering

Recently a cartilage growth finite element model (CGFEM) was developed to solve nonhomogeneous and time-dependent growth boundary-value problems (Davol et al., 2008, “A Nonlinear Finite Element Model of Cartilage Growth,” Biomech. Model. Mechanobiol., 7, pp. 295–307). The CGFEM allows distinct stress constitutive equations and growth laws for the major components of the solid matrix, collagens and proteoglycans. The objective of the current work was to simulate in vitro growth of articular cartilage explants in a steady-state permeation bioreactor in order to obtain results that aid experimental design. The steady-state permeation protocol induces different types of mechanical stimuli. When the specimen …

Use Of Ultrasonic Sensors In The Development Of An Electronic Travel Aid, Chris Gearhart, Alex Herold, Brian Self, Charles Birdsong, Lynne Slivovsky

Mechanical Engineering

Ultrasonic sensors present one of the most cost-effective digital distance measurement systems available for mobile applications. Their effectiveness is limited, however, in applications involving complex environments and when information on sensor position is unavailable. This paper focuses on the implementation and limitations of ultrasonic sensors and system design considerations during development of an Electronic Travel Aid [ETA] for the visually impaired utilizing ultrasonic sensors and vibrotactile feedback. Our work with sensors included signal filtering and triangulation to improve performance characteristics of ultrasonic-based measurements. Additionally, we describe the use of computer modeling to aid in the design of ultrasonic sensor systems.

Undergraduate Engineers Develop Hydraulic Servo Control Systems Using Model-Based Design With Simulink, Charles Birdsong

Mechanical Engineering

In the past, control engineering was the exclusive province of computer and electrical engineers with advanced degrees and years of experience in low-level programming languages. Today, engineers and students alike can use Model-Based Design to rapidly design and implement real-time control systems without having to learn low-level programming. Used throughout the automotive and aerospace industries, Model-Based Design places a high-level system model at the center of development. This approach helps engineering students understand not only the basic physics of system components, but also the interaction between components and the behavior of the overall system.

The Effectiveness Of Asynchronous Podcasting Of Classes, John Chen

Mechanical Engineering

In this study we examine in some detail the effectiveness of enhanced podcasting compared with traditional face-to-face class meeting. Enhanced podcasting goes beyond simply recording the audio portion of a lecture. It may include the video footage from the class meeting or, as in our case, the presented material (including each written pen stroke) exactly as seen by students sitting in the classroom with the instructor. The course we studied is Applied Thermodynamics, a junior-level course for mechanical engineering students. For this study we had access to three sections of the course, all taught by the same faculty member. For …

Transient Refrigerant Migration And Oil Distribution Of An R134a Automotive A/C System, Steffen Peuker, P. S. Hrnjak

Mechanical Engineering

Automotive fixed orifice tube (FOT) systems are especially prone to cycling losses due to their clutch cycling operation. Therefore, it is important to better understand the dynamics of the refrigerant and oil migration during transient events such as cycling and start-up. To measure the refrigerant mass and oil distribution of an automotive R134a FOT breadboard system, two ball valves around each component are added. By simultaneously closing the valves, the refrigerant and oil is trapped in different sections of the system and can be measured. The transient refrigerant migration during a stop-start transient as well as the refrigerant mass distribution …

Harvesting Human Exercise Power At The Cal Poly Rec Center: Exercise Bike Power Generator Ii, Jared Rounsevell, Claire M. Shubert, Matthew Snitowsky, Andrew Wong

Mechanical Engineering

The overall goal of this project is to create a workable system to harvest the power generated on exercise bikes at the Cal Poly Rec Center so that the electricity produced can eventually be sent to the power grid. Our part of the project will focus on the mechanical harvesting of this power with the goal of using the product to run the Morningstar ProStar 12V 30 amp charge controller available from the 2007 project. Eventually, the power produced could be fed to the grid in the appropriate form. The finished result of this project should be marketable to exercise …