Manufacturing Commons^™

Rapid Decompression Containment System, Evan Domingue, Michelle Rudney, Daniel Trees

Mechanical Engineering

Cal Poly students; Evan Domingue, Michelle Rudney and Daniel Trees; are working with General Atomics Aeronautical Systems, Inc. (GA, ASI) and engineer John Wilcox to complete a senior project. The senior project is focused on finding a solution to meet the requirement set forth in MIL-HDBK 1791 4.2.5.2 for rapid decompression which requires cargo items to be designed with pressure relief devices or to be configured for air shipment as to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure. The goal of this project is to design a safe, cost-effective, and …

Titan 130 Engine Aft-Mount, Woody Newell, Michael Haworth, Dylan Perry

Mechanical Engineering

No abstract provided.

Exploration Station Kidshake Table, Jeremy Duhe, Philip Hopkins, Matt Ostiguy, Samantha Weiner

Mechanical Engineering

The KIDShake Table is an all mechanical earthquake shake table sponsored by the Exploration Station Children's Museum of Grover Beach. This interactive exhibit has two working mechanisms, a hand crank and pull rope, that provide two axis movement for knocking down block structures. This table was built and designed for a target age of 10 years.

Beach Wheelchair Project, Rory Aronson, Joshua Marcum, Samuel Coyne, Alex Hayes, Alexa Colburn, Max Hessel, Benedikt Strauss, Marvin Rimmele, Marco Pietsch

Mechanical Engineering

The Beach Wheelchair, Sandcrawler, is a machine intended to help give people with disabilities the full beach experience. The non-profit organization Bridge II Sports sponsored this project, and tasked us with developing the design and fabricating a prototype. This chair has several features including a linkage mechanism that raises and lowers a chair relative to an external frame, hand crank drive with Gates Carbondrive belt and sprockets, buoyant Wheeleez balloon tires, and much more.

Rebounder Fatigue Test Machine, Caroline Reeves, Will Robertson, Ethan Flory

Mechanical Engineering

JumpSport, a company that designs and sells trampolines and trampoline accessories, has sponsored this senior project team to design, build, and test a trampoline fatigue test machine. The machine must simulate a person jumping on the trampoline to test the life of JumpSport’s fitness trampolines and kids’ trampolines. Partway through the design process, the objectives were altered and this senior project team was tasked with merging with another Cal Poly senior project group to create an all-inclusive test machine to accommodate both full-trampoline testing and individual bungee cord testing.

The final design is centered on a slider crank linkage driven …

Human Powered Helicopter: Spars, Jason Addy, Sterling Fuentes, Graham Garvin, Kenneth Girardin, Lipski Timonthy, Daniel Logue

Industrial and Manufacturing Engineering

Abstract

Neal Saiki, a Cal Poly alumnus, donated a human powered helicopter to the Cal Poly Aircraft Design and Construction Club in Fall Quarter 2012. To achieve the requirements of the Igor Sikorsky Human Powered Helicopter Competition, this senior project was tasked with reducing the weight of the load-bearing spars without changing geometry.

The aluminum spars were replaced with carbon fiber. The spars were designed to maintain the bending and torsional stiffnesses. Twelve sections of carbon fiber tubes ranging from 8 to 12 ft in length and 2" to 3" in inner diameter were made using pre-preg carbon fiber wrapped …

S&G Metal Fab Battery Tray, Matthew Nartatez

Industrial and Manufacturing Engineering

This report was written for the design of a battery tray and manufacturing process for S&G Metal Fab. The manufacturing steps of how to process the sheet metal to create the product are defined and documented in this report. This project began with constraints given by S&G and were all accomplished using coursework knowledge obtained as a manufacturing engineer student at Cal Poly San Luis Obispo. This report mainly covers parameters regarding the cutting, bending and, deforming of sheet metal to acquire the desired shapes and sizes. It also analyzes the costs that are associated with these processes and material. …

Loaded Shift Tester Sram, Nick Cox, Sam Shaffer, Michael Polka

Mechanical Engineering

This report details the design, manufacturing, and testing of a loaded shift tester for the SRAM Bicycle Corporation. The machine is used to perform developmental and qualification tests on various bicycle drivetrain components. Using SolidWorks, the design team created a solid model of the machine on the computer, then ordered and manufactured the parts required to build it. The machine was tested to ensure that all the parts worked together, and was finally delivered to SRAM when it was deemed ready.

Bicycle Wheel Test Machine, Dylan Harper, Kevin Hom, Ross Williams

Mechanical Engineering

In recent years, the cycling industry has witnessed huge advancements in bicycle components and materials. The age old goals of speed and low weight are still present today, but the pursuit of these goals may be reducing the structural stability of various components integral to wheel performance, including the wheel hub bearings. These bearings are invaluable to bicycles but little is known about how the forces and loads applied to a bicycle affect the performance of these bearings. Broken axles and hubs are indicators of significant stresses within the hub, but little is known about how the resulting deformation affects …

Hoist To Transfer Athletes From Wheelchair Into A Kayak, Jennifer Batryn, Javier Mendez, Kyle Mooney

Mechanical Engineering

No abstract provided.

Ir Imaging Chip Fixturing System, Curtis Wagner, Scott Solomon

Mechanical Engineering

No abstract provided.

Human Powered Hydrofoil Bike Pontoon Floatation, Shelley Dangoor, Tyler Brennent

Mechanical Engineering

This report documents the brainstorming and design development of the hydrofoil bike floatation device. This project is in conjunction with senior project team MobyBike. MobyBike’s focus is in the development of the bike actuation system, as our team’s focus is on designing and developing the floatation device to be incorporated in the final hydrofoil bike design.

Guidance System, Kayaking For The Visually Impaired, D. Ryan Kirtland, Ryan Phife, William Gardner, Amy Johnson

Biomedical Engineering

Quality Life Plus is working with Team River Runner to develop an assistive guidance system for veterans who want to remain active by kayaking, after sustaining an injury that impairs vision. This system allows these veterans to complete a slalom speed race independent of a personal guide in the water. The system incorporates 3 stations that each contain a speaker connected to a microcontroller system covered by a Pelican Case on a custom made buoy. During the slalom race, a kayaker will travel from shore towards buoy #1 as it omits sound from the speaker. As the kayaker moves around …

Reliability Analysis Of Low-Silver Bga Spheres Comparing Failure Detection Criteria, Briana Fredericks

Industrial and Manufacturing Engineering

One of the challenges of solder joint reliability tests is estimating the time of failure of the solder joint. Failure criteria should be able to detect solder joint failure as early as possible, while minimizing the probability of false detection. The failure mechanism under study is cracks due to thermal fatigue. The most common method to estimate failure due to cracks is to monitor the resistance during testing, because solder imaging and cross-sectioning methods are destructive. Current industry failure criteria do not adequately demonstrate the relationship between the size of the crack and the resulting change in resistance. This project …

Starch Resin Moisture Level Effect On Injection Molding Processability And Molded Part Mechanical Properties With Pure Starch Resin And Polymer Blends, Jordan M. Ellingson

Theses and Dissertations

The current and forecasted global consumption of plastic packaging and products through the 21st century combined with the already reported and growing negative impact of plastics on the environment due to plastics being synthesized from nonrenewable resources that do not biodegrade is of serious concern. However, recent advances in starch technology including the development of thermoplastic starch (TPS) materials —polymers that are both renewable and biodegradable—have brought hope to reducing this impact. The mechanical properties of thermoplastic starch have often been improved by blending with synthetic polymers. One issue that arises with blending is volatilization of the melt from moisture …

Location-Allocation Optimization Of Supply Chain Distribution Networks: A Case Study, Mark Nicholas Helberg

Theses and Dissertations

The location of distribution centers is an important strategic decision in supply chain design, particularly as it relates to service quality, productivity, and profitability of the firm. There has been extensive research performed on distribution location models which require the use of complex algorithms and assumptions that make use of these models difficult in practice for small and medium enterprises (SMEs) that have limited capital and resources. Studies have also failed to capture and quantify potential business results of using more sophisticated methods. In this study, a deterministic and static location-allocation model is designed using a prototype software tool. The …

Application Of Assignment Problem Theory To Cal Poly's Week Of Welcome Program Presentation Schedule, Kevin T. Aban

Industrial and Manufacturing Engineering

The Week of Welcome (WOW) is a part of Cal Poly’s Orientation Programs. One of the main objectives of WOW is to provide content to new students on a variety of different topics in the form of Awareness Presentations. The problem being addressed in this paper is that of assigning the orientation groups of incoming students to these Awareness Presentations so that they have a schedule that meets all of the necessary criteria. The most important of those requirements is schedule balance and flexibility for future use. This scheduling problem is solved through the use of operations research and binary …

Gyroscope Assembly Process Improvement Analysis, Ian Douglass, Juan Ulises Saucedo

Industrial and Manufacturing Engineering

The gyro is a fundamental portion of many assemblies that Company S, a directional drilling company, manufactures. The gyro assembly is a highly sensitive and complex process, and it was paramount to establish efficiency and quality guidelines to base management decisions. The first guideline succeeded by increasing throughput by means of a simulation using ProModel. Next, non-value and value added activities were identified through a value stream map. Lastly, a database was developed in order to capture high integrity quality control data, or key performance indicators, such as, throughput, first-pass inspection yields at every test performed, and defects found. This …

Implementation Of A Sustainable Project Management Methodology For Cal Poly Sae Baja, Theo Graziadei

Industrial and Manufacturing Engineering

A lack of project organization manifested through unclear team goals, rush deliveries of materials, lost tools and materials, half days of effort due to improper planning, wasted design time, missed submission dates, lack of clear job positions at competition, and low competition scores. A process was created to properly manage the team and it was implemented through the use of various templates, examples, and calculation programs. Each deliverable received feedback from this project’s stakeholders and changes were reflected in the final process. The results were as follows:

Table 1: Summary of Results

Implement a sustainable project management methodology

Each step …

The Design, Testing, And Manufacturing Of A Pin Fin Extrusion Heat Sink, Arash Michael Mira

Industrial and Manufacturing Engineering

My senior project focuses on the design, testing, and manufacturing of pin fin extrusion heat sinks that are you used to cool simple electronic applications across a multitude of markets. Without the modern day heat sink, electronics that we have become familiar with throughout our everyday lives will cease to exist. I will design these heat sinks using Solid Works 3D CAD. I will then test the heat sinks using ICEPAK CFD software, where I will model the heat sink against a 5 watt application, inside of a cabinet that models the chassis of a computer. After receiving these results, …