Mechanical Engineering Commons^™

Finite Element Analysis Of The Bearing Component Of Total Ankle Replacement Implants During The Stance Phase Of Gait, Timothy S. Jain

Master's Theses

Total ankle replacement (TAR) implants are an effective option to restore the range of motion of the ankle joint for arthritic patients. An effective tool for analyzing these implants’ mechanical performance and longevity in-silico is finite element analysis (FEA). ABAQUS FEA was used to statically analyze the von Mises stress and contact pressure on the articulating surface of the bearing component in two newly installed fixed-bearing total ankle replacement implants (the Wright Medical INBONE II and the Exactech Vantage). This bearing component rotates on the talar component to induce primary ankle joint motion of plantarflexion and dorsiflexion. The stress response …

Deep Ocean Vehicle Applications And Modifications, Nichole "Nikki" T. Arm

Master's Theses

This project had two primary goals: (1) to explore opportunities to further a deep-ocean vehicle’s reach using alternative pressure spheres, and (2) to implement an existing deep-ocean vehicle (lander) in active scientific research.

I gained a greater understanding of the limitations and design choices made for existing pressure spheres using Finite Element Analysis (FEA). My simplified FEA model predicted sphere failure for the existing 30% Fiber Glass 70% Nylon injection molded spheres at an external pressure of 3,954psi or 2,690m ocean-depth (only a 7.38% error compared to the tested minimum failure depth), so I determined it a valid model. I …

Discourse Analysis In Engineering: Investigating Patterns In Brainstorming Conversations, Aimee Chiem

Master's Theses

Brainstorming is a critical part of the engineering design process and can have a significant impact on the outcomes of the overall project. While research has studied the outcomes of brainstorming and the ideas that teams generate, the role that language and conversation play in these activities is still relatively underexplored. Observing the different ways people use specific types of discourse can reveal how conversations can affect brainstorming itself. To that end, this research aims to answer the following questions:

1) What are the different kinds of discursive moves that students make during engineering brainstorming activities?

2) What patterns or …

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 …

Implementation Of Topology Optimization Into The Mechanical Design Process, Nolan Clapp

Master's Theses

Topology Optimization is a lightweighting method based on finite element analysis that produces a part with optimum material distribution in the design space. Results from topology optimization often have organic shapes and curves that are difficult if not impossible to machine with traditional subtractive manufacturing methods. This paper analyzes the implementation of the Solidworks® Topology Optimization add-in into the mechanical design process and discusses required postprocessing to ensure manufacturability of the optimized part though a case study on two example parts. Results of traditional optimization, topology optimization and “selective” optimization (optimization using the results from topology optimization to selectively remove …

Design Of A System To Investigate The Relationship Between Feedback And Delivery Medium For A Novel Motor Task, Ashley Humpal

Master's Theses

Stroke is a chronic, lifelong illness, and full recovery requires continuous physical and cognitive rehabilitation. Such long-term rehabilitation is cost-prohibitive; however an approach to providing long-term therapy that has recently gained traction is the use of socially assistive agent (SAA) systems. These systems make use of non-contact communication devices and can be used to guide people through a variety of rehabilitative tasks. They have the potential supplement current rehabilitation practices by providing motivation during intense exercises, and can extend the reach of the therapist into remote and home settings.

Though SAA systems have been used in a variety of rehabilitative …

Pressure Disturbance Upstream Of The Boundary Layer Data System, Michelle S. Leclere

Master's Theses

The primary objective for this work was to evaluate the reliability of computational fluid dynamics (CFD) tools in the prediction of upstream surface pressure disturbance and pressure drag of various instrument excrescence shapes for a small aircraft flight test device called the Boundary Layer Data System (BLDS). Insights on pressure disturbance will serve as a guide for the placement of BLDS probes/sensors, and pressure drag can be used to ensure sufficient adhesive is used to install BLDS instrumentation. The Mach number for all CFD cases was 0.12 and the Reynolds number based on excrescence height varied from 4 x 10 …

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 …

Understanding The Effects Of Long-Duration Spaceflight On Fracture Risk In The Human Femur Using Finite Element Analysis, Keyanna Brielle Henderson

Master's Theses

Long-duration spaceflight has been shown to have significant, lasting effects on the bone strength of astronauts and to contribute to age-related complications later in life. The microgravity environment of space causes a decrease in daily mechanical loading, which signals a state of disuse to bone cells. This affects the bone remodeling process, which is responsible for maintaining bone mass, causing an increase in damage and a decrease in density. This leads to bone fragility and decreases overall strength, posing a risk for fracture. However, there is little information pertaining to the timeline of bone loss and subsequent fracture risk.

This …

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 …

Simulating Particle Packing During Powder Spreading For Selective Laser Melted Additive Manufacturing Using The Discrete Element Method In Abaqus, Priscilla Ng

Master's Theses

Metal additive manufacturing allows for the rapid production of complex parts that are otherwise impractical using conventional subtractive manufacturing techniques. Applications for additive manufacturing span across a broad array of industries including aerospace, automotive, and medical, among many others. One metric of printing success is material properties, including part density. While there has been extensive research completed for the density of printed parts, there is little published work concerning powder packing density on the build plate associated with powder spreading.

In this thesis, a Discrete Element Method (DEM) model was created in Abaqus to simulate the spreading behavior of particles …

Design Of A 5 Degree Of Freedom Kinematic Stage For The Dual Crystal Backlighter Imager Diagnostic, Nicholas Nguyen

Master's Theses

The National Ignition Facility (NIF) is home to the world’s most energetic laser. The facility is one of the leading centers in inertial confinement fusion (ICF) experiments to research and understand sustainable fusion energy. To fully document and understand the physics occurring during experiments, precise diagnostics are used for a wide range of purposes. One diagnostic, the crystal backlighter imager (CBI), allows for X-ray imaging of the target at late stages of its implosion.

The aim of this project was to increase the current capabilities of the CBI diagnostic with the addition of a second crystal. This thesis focuses on …

Hybrid Iii 95th Percentile Large Male Finite Element Model Neck Alteration, Eric Riley Day

Master's Theses

The motivation behind the project was to update the Livermore Software Technology Corporation (LSTC) Hybrid III 95th percentile finite element model, such that the neck assembly response under varying simulated loading conditions equals that of the federally regulated Hybrid III 95th percentile anthropomorphic testing device (ATD).

The family of Hybrid III crash test dummies approximate the physical properties and response of the human body in a frontal automotive crash. The Hybrid III is used to assess the effectiveness of vehicle restraint systems. LSTC offers Hybrid III finite element models for use in their Multiphysics simulation software package, LS-DYNA. The Hybrid …

A Methodology For Verification Of Structural Standards For A Seating System By Finite Element Analysis, Zachary Kelly Dworaczyk Wiltshire

Master's Theses

Currently California Polytechnic State University has a patent pending on a new type of seating system designed to increase the functionality of public transportation vehicles. The patent is based on the work completed by a senior project group in 2016, whose design showcased the feasibility of the idea. Further development was completed by a second senior project group, the Adjustable Seating Systems, in 2019. The intent of the Adjustable Seating Systems group was to develop a seating system with the intent of commercialization and implementation in paratransit vehicles with future development into large buses and trains.

Seating systems used in …

Fracture Control Modeling With The Finite Element Method, Jorge A. Pluma Reyes

Master's Theses

This thesis investigates the feasibility and usability of the finite element method approach in the design of crack arresting devices. Current design and manufacturing practices are improving structures' susceptibility to fracture, in particular brittle fracture; however, cracks in structures are still observed within their lifespans due to severe unexpected service conditions, poor designs, or faulty manufacturing. Crack arrester systems can be added during service to prolong the longevity of structures with sub-critical or critical flaws. Fracture properties of different specific structures under specific services can be obtained experimentally, however, experiments are expensive and of high complexity. Alternatively, the finite element …

Mechanical Characterization Of Selectively Laser Melted 316l Stainless Steel Body Centered Cubic Unit Cells And Lattice Of Varying Node Radii And Strut Angle, Christopher James Hornbeak

Master's Theses

An experimental study of several variants of radius and strut angle of the body centered cubic unit cell was performed to determine the mechanical properties and failure mechanisms of the mesostructure. Quasi static compression tests were performed on an Instron® universal testing machine with a 50kN load cell at 0.2mm/min. The test samples were built using a SLM Solutions 125 selective laser melting machine with 316L stainless steel. Test specimens were based on 5mm cubic unit cells, with a strut diameter 10% of the unit cell size, with skins on top and bottom to provide a cantilever boundary constraint. Specimens …

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 …

Refurbished And 3d Modeled Thermal Vacuum Chamber, Lauren M. Glenn

Master's Theses

Spacecraft testing includes acoustics, vibrations, and thermal vacuum. Cal Poly’s Space Environments Lab is equipped with multiple vacuum chambers, but no thermal vacuum chamber. The purpose of this thesis is to incorporate an ATS Chiller system with the HVEC vacuum chamber so students are able to experiment with a thermal vacuum chamber. The ATS Chiller had leaky pipes that needed to be refurbished and a shroud was implemented to improve thermal capabilities of the system. The full system was able to reach temperatures as low as -38ºC and as high as 58ºC at a pressure of 10-6 Torr. The ATS …

Corgi: Compute Oriented Recumbent Generation Infrastructure, Christopher Allen Hunt

Master's Theses

Creating a bicycle with a rideable geometry is more complicated than it may appear, with today’s mainstay designs having evolved through years of iteration. This slow evolution coupled with the bicycle’s intricate mechanical system has lead most builders to base their new geometries off of previous work rather than expand into new design spaces. This crutch can lead to slow bicycle iteration rates, often causing bicycles to all look about the same. To combat this, several bicycle design models have been created over the years, with each attempting to define a bicycle’s handling characteristics given its physical geometry. However, these …

The Effect Of Biocomposite Material In A Composite Structure Under Compression Loading, Benjamin Andrew Sweeney

Master's Theses

While composite structures exhibit exceptional strength and weight saving possibilities for engineering applications, sometimes their overall cost and/or material performance can limit their usage when compared to conventional structural materials. Meanwhile ‘biocomposites’, composite structures consisting of natural fibers (i.e. bamboo fibers), display higher cost efficiency and unique structural benefits such as ‘sustainability’. This analysis will determine if the integration of these two different types of composites are beneficial to the overall structure. Specifically, the structure will consist of a one internal bamboo veneer biocomposite ply; and two external carbon fiber weave composite plies surrounding the bamboo biocomposite. To acquire results …

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 …

Physical Testing Of Potential Football Helmet Design Enhancements, Michael Jeremy Schuster

Master's Theses

Football is a much loved sport in the United States. Unfortunately, it is also hard on the players and puts them at very high risk of concussion. To combat this an inventor in Santa Barbara brought a new design to Cal Poly to be tested.

The design was tested in small scale first in order to make some preliminary conclusions about the design. In order to fully test the helmet design; however, full scale testing was required. In order to carry out this testing a drop tower was built based on National Operating Committee on Standards for Athletic Equipment, NOCSAE, …

Design And Testing Of A Top Mask Projection Ceramic Stereolithography System For Ceramic Part Manufacturing, Dylan Robert De Caussin

Master's Theses

Ceramic manufacturing is an expensive process with long lead times between

the initial design and final manufactured part. This limits the use of ceramic as a viable material unless there is a large project budget or high production volume associated with the part. Ceramic stereolithography is an alternative to producing low cost parts through the mixing of a photo curable resin and ceramic particles. This is an additive manufacturing process in which each layer is built upon the previous to produce a green body that can be sintered for a fully dense ceramic part.

This thesis introduces a new approach …

Finite Element Modeling Of Delamination Damage In Carbon Fiber Laminates Subject To Low-Velocity Impact And Comparison With Experimental Impact Tests Using Nondestructive Vibrothermography Evaluation, George Rodriguez Iv

Master's Theses

Carbon fiber reinforced composites are utilized in many design applications where high strength, low weight, and/or high stiffness are required. While composite materials can provide high strength and stiffness-to-weight ratios, they are also more complicated to analyze due to their inhomogeneous nature. One important failure mode of composite structures is delamination. This failure mode is common when composite laminates are subject to impact loading.

Various finite element methods for analyzing delamination exist. In this research, a modeling strategy based on contact tiebreak definitions in LS-DYNA^®was used. A finite element model of a low-velocity impact event was created to …

Design And Analysis Of A Lift Assist Walker, Deep P. Shah

Master's Theses

Walkers provided stability to the elderly but cannot assist a person from sitting to standing. The objective of this project is to present the design and analysis of a lift assist walker. This report discusses the design and analysis of a collapsible lift assist walker capable of lifting a patient up to 250 lbs. from seated to standing in under 10 seconds. The designed walker utilized a two stage scissor mechanism with a gas spring assisted embedded linear actuator.

Development And Validation Of A Tibiofemoral Joint Finite Element Model And Subsequent Gait Analysis Of Intact Acl And Acl Deficient Individuals, Nicholas Czapla

Master's Theses

Osteoarthritis (OA) is a degenerative condition of articular cartilage that affects more than 25 million people in the US. Joint injuries, like anterior cruciate ligament (ACL) tears, can lead to OA due to a change in articular cartilage loading. Gait analysis combined with knee joint finite element modeling (FEM) has been used to predict the articular cartilage loading. To predict the change of articular cartilage loading during gait due to various ACL injuries, a tibiofemoral FEM was developed from magnetic resonance images (MRIs) of a 33 year male, with no prior history of knee injuries. The FEM was validated for …

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 …

Net Zero Residential Design For Solar Calpoly, Bryce Reiko Willis

Master's Theses

The Department of Energy (DOE) confirmed Team Solar Cal Poly from California Polytechnic State University, San Luis Obispo, as a competitor in the 2015 Solar Decathlon in February 2014. The Solar Decathlon is a biennial collegiate competition to construct a net-zero home and operate it for a week of “normal use”. Solar Cal Poly needed assistance with passive and active HVAC systems for the design, and thermal load models. The competition will take place in Irvine, CA [33.67⁰, 117.82⁰ W] from September 27 – October 3, 2015. After the completion, a potential final location for the house will be Santa …

Benchmarking, Characterization And Tuning Of Shell Ecomarathon Prototype Powertrain, Eric J. Griess

Master's Theses

With the automotive industry ever striving to push the limits of fuel efficiency, the Shell EcoMarathon offers a glimpse into this energy conserving mindset by challenging engineering students around the world to design and build ultra-efficient vehicles to compete regionally. This requires synchronization of engineering fields to ensure that the vehicle and powertrain system work in parallel to achieve similar goals.

The goal for Cal Poly – San Luis Obispo’s EcoMarathon vehicle for the 2015 competition is to analyze the unique operating mode that the powertrain undergoes during competition and improve their current package to increase fuel efficiency. In this …

Experiment And Simulation Of The Acoustic Signature Of Fatigued-Cracked Gears In A Two-Stage Gearbox, Matthew James Ostiguy

Master's Theses

This thesis focuses on the development of a health monitoring system for gearbox transmissions. This was accomplished by developing and understanding a two-stage gearbox computer model that emulates an actual gearbox test rig. The computer model contains actual gearbox geometry, flexible shafts, bearings, gear contact forces, input motor torque, output brake torque, and realistic gearbox imbalance. The gear contact force of each gear stage and the input bearing translational acceleration were the main outputs compared between a healthy gearbox and damaged gearbox computer model. The damage of focus was a fatigue crack on the input pinion gear. A sideband energy …