Engineering Commons^™

Design And Analysis Of A Materials Management System For Boeing Commercial Airplanes' (The Boeing Company) Metallic Raw Material Supply Chain With A Focus On Lead Time Manipulation And Corresponding Effects On Inventory And Cost, Henry Lu

Industrial and Manufacturing Engineering

The purpose of this project is to identify the costs associated with an aggregation strategy run by Boeing Commercial Airplanes. In order to identify these costs, a rudimentary replenishment system must be designed for the supply chain due to the fact that there is currently no such system in place. This replenishment system will be used to create a model (created in Excel) to calculate the total annual costs of the system. The model must allow changes to some of the important inputs such as mill performance measures and lead times and report the resulting changes in the total annual …

Companion Pass Program, Andrew Toney

Industrial and Manufacturing Engineering

At the end of each quarter the students of Cal Poly prepare to sign up for their classes for next quarter. This process is more difficult for seniors who must meet very specific requirements in order to graduate on time. Students can spend hours trying to find the “perfect schedule”, that one schedule that fits their personal schedule and their graduation requirements, while not over taxing themselves during that quarter by having too much class work. This Cal Poly explores the creation and implementation of an extra scheduling tool to address the weaknesses of the current scheduling system, PASS, and …

Bicycle Mounted Iphone 5 Case With Charging System, Patrick Goebel

Industrial and Manufacturing Engineering

This purpose of this project is to design and manufacture a bicycle handlebar mounted case that will house Apple’s iPhone 5 and a charging system that utilizes a charge from a generator hub in the front wheel of a bicycle. The charging system and software for this project will be developed by an Electrical Engineering Graduate student. The case and charging system must be a self-contained unit that is weather-proof and aesthetically pleasing. It must allow the user to use all of the features of the iPhone 5 under a wide range of speeds. It must be adjustable between portrait …

Analyzing The Costs Of Different Energy Storage Systems For California Polytechnic State University, Christian Royer

Industrial and Manufacturing Engineering

The goal of this project was to analyze the different ways to release energy from an energy storage device into the grid to save money. This project was worked in conjunction with a Master’s of Science student. An entire year of Cal Poly’s energy usage was examined and multiple trends were observed about when the maximum amount of energy was used. These trends looked at the time of day, the day of the week, and season to see what would be the best way to release energy into the grid to save money. There were two different batteries sizes examined …

The Decision Process Of Transitioning From A 3-Axis To A 4-Axis Or 5-Axis Mill Machine, Andrew Van Cleve, David Sherman

Industrial and Manufacturing Engineering

Companies are always looking for new ways to increase productivity and help the company save money. The way this is done is by researching new and more efficient ways to produce whatever it is the company is selling. Since there are always new technologies coming forward it can be difficult to distinguish which ones are viable and which ones are not. This paper looks at the decision of moving a company from a traditional 3-axis milling set-up to a 4-axis or 5-axis milling set-up. Through research and analysis this report will guide a company through the decision making process and …

Reducing Customer Wait Time And Improving Processes At Abc’S Atv Rentals, Thomas Allen Merrill Jr.

Industrial and Manufacturing Engineering

This project serves to explore the system bottlenecks of a small, family owned ATV rental company. The main objective is to reduce the average time a customer spends in the system, focusing on customer wait time as well as other areas that can be improved. This was done by collecting time studies and inputting the values into simulation software, which was run to represent the current system as well as various other possible scenarios encountered by rental companies. While creating the simulation, adaptive techniques were incorporated into the simulation. These techniques aim to increase the durability and reusability of the …

Evaluation And Redesign Of Potting Shed For The Non-Profit Organization, Growing Grounds Farms, Adya Sinha, Julianna Levy

Industrial and Manufacturing Engineering

Growing Grounds, a local nonprofit organization, operates as a fully functioning nursery in San Luis Obispo. Their planting facility is outdated and the process is inefficient. They have new funding available and need to determine if they should automate certain processes or improve existing methods. This report details the current process and presents two possible ergonomic solutions and the accompanying layouts and improvements. An analysis is conducted to determine which new layout is recommended for Growing Grounds based on their current production and revenue, and future recommendations are given.

Fire Protection Analysis Of Campus Building, Mackenzie Hill

Fire Protection Engineering: Culminating Experience Project Reports

A prescriptive and performance based analysis has been conducted on a College Campus Building in Southern California. This building is still in the approvals process and has been designed to meet the design standards in the 2010 California Building Code (CBC) and relevant NFPA codes. The building is proposed to be the center of operations as well as having administration facilities for the College. It will house an administrative office, production and support facilities. The project is three stories and includes a balcony that does not qualify as a story. The top floor is greater than 30 feet from grade …

Fire And Life Safety Analysis- Center For Science And Mathematics Building #52, Laura Radle

Fire Protection Engineering: Culminating Experience Project Reports

The purpose of this fire and life safety analysis is to determine whether Cal Poly’s Center for Science and Mathematics (CSM) meets fire safety goals. The primary fire safety goal is to provide building occupants with an environment that is reasonably safe from fire. This goal can be achieved by protecting the occupants not intimate with the initial fire development and improving survivability of those occupants intimate with the initial fire development, (NFPA 101, 2006). A prescriptive-based design approach and a performance-based design approach are used to evaluate building safety. The prescriptive-based approach is used to evaluate the building’s structural …

Bruno The Robotic Bear, Aaron Brauner, Ian Panzer

Computer Engineering

Creating homemade robots are becoming a popular hobby among engineers. With the dramatic reduction in costs over the past few decades, it is finally possible to build a personal automated mailbox. Microcontrollers needed to function as the brains of the robot are also becoming powerful enough that relatively complicated instructions could be programmed into the robot to handle a plethora of sensors and peripherals. In order to demonstrate how the Computer Engineering department models the synthesis of computer science and electrical engineering, the topic chosen was robotics, specifically, a stuffed bear robot.

The microcontroller chosen was the Arduino Mega 2560 …

Mixed‐Use Commercial And Residential Podium Building, Gene Voloshenko

Fire Protection Engineering: Culminating Experience Project Reports

This report provides a summary of the principal fire protection and life safety features for a mixed use commercial and residential Podium Building for compliance with the 2000 International Building Code (IBC) and the 2003 NFPA 101 “Life Safety Code”. IBC permits compliance with the prescriptive Code requirements using Alternative Solutions that will achieve at least the minimum level of performance required by the IBC as defined by the objectives and functional statements and as described in the NFPA 101 Chapter 5. Alternative solutions for this project were modeled using the Fire Dynamics Simulator (FDS). One of the primary recommendations …

Fire Protection Analysis Of The Bonderson Engineering Projects Center, John Cote

Fire Protection Engineering: Culminating Experience Project Reports

A Fire and Life Safety Analysis of the Bonderson Engineering Projects Center (BEPC) located on the Cal Poly campus is performed. Prescriptive and Performance Based approaches are used to evaluate the BEPC for compliance with the current fire and building code requirements. The fire protection systems and features of the BEPC analyzed include the following: Egress Systems, Fire Detection, Alarm, and Communications Systems, Fire Suppression Systems, and Structural Fire Protection Systems. Prescriptive analyses are performed to determine if the as-built design meets the requirements of the code. Performance-Based analyses are performed to provide insight to the prescriptive design utilized in …

Telecommunications Network Switching Facility, Eric Kumar

Fire Protection Engineering: Culminating Experience Project Reports

This report is on a mission critical telecommunications network switching facility located in Southern Mississippi. The life safety and property preservation measures are summarized in this report. The prescriptive design approaches for various fire and life safety systems in telecommunications facilities were evaluated against the performance based approaches studied in the Cal Poly Fire Protection Engineering curriculum. Majority of the prescriptive approaches are in accordance with the performance based solutions, however the smoke management system’s performance and prescriptive design yields a significant discrepancy. For the smoke management system, a difference in the flow rates is observed between the exhaust and …

Fire And Life Safety Evaluation Of The Providence Pavilion, Oscar J. Zuniga

Fire Protection Engineering: Culminating Experience Project Reports

The fire and life safety systems of the Providence Pavilion, a four-story addition to the Providence Medford Medical Center in Medford, Oregon, are examined for compliance with applicable design and construction codes and standards and are found to comply with codes and conform to standards. The prescriptive requirements for occupancy classification, construction type, structural fire protection, egress systems, fire alarms, and fire protection are reviewed. Three different fire scenarios are developed and are then employed to study the fire and life safety systems’ performance using fire and egress modeling tools and simulations. Using this performance-based approach, the fire and life …

Culminating Project- U.S. Federal Courthouse, Joshua W. Elvove

Fire Protection Engineering: Culminating Experience Project Reports

The purpose of this report is to select and evaluate a building for compliance with prescriptive and performance based requirements, that apply the concepts learned from previous courses taken as part of the master’s fire protection engineering degree curriculum at Cal Poly, San Luis Obisbo. The report discusses applicable code requirements for building construction, egress, fire alarm initiation and notification, and fire suppression and evaluates the building’s performance, including occupant movement, when subjected to two assumed fires. Fire Dynamics Simulator (FDS) was used to generate data used during the performance analysis. The performance analysis reveals that meeting prescriptive requirements doesn’t …

Fire Protection Analysis Of A Fresno Elementary School, Garen Lencioni

Fire Protection Engineering: Culminating Experience Project Reports

This report details the fire and life safety analysis of a Fresno Elementary School. Both prescriptive and performance based analysis were used to determine compliance with the building codes and fire codes which the building was constructed under. The prescriptive analyses included evaluation of the egress system, structural fire protection requirements, fire detection and alarm system and fire suppression systems. The prescriptive analyses were done to show the code requirements and how the building complies with them. The performance analyses were done to analyze the performance of the building in the event of a fire scenario. Three fire scenarios were …

The Effects Of Heat Treatment On The Grain Growth, Phase Evolution, And Hardness Of Newly Developed Steel-Based Hardfacing Alloys For Industrial Applications, Renee Kuzniar

Materials Engineering

Steel-based hardfacing alloys are welded onto the outside diameter of tool joints in three beads with a slight overlap between welds for underground drilling to prolong the tool joints’ life. Current hardfacing alloys have a shortened life due to cracks occurring in neighboring weld beads. To decrease cracking, the effects of composition and heat treatment on the microstructure was investigated on five alloys. Five small arc-melt circular ingots roughly 1.4 x 0.3 inches were produced. Each sample had varying amounts of C, B, Cr, Mn, Mo, Nb, Si, Ti, V, and W. The carbon levels in the alloys were .91wt%, …

Grain Size Control In Post-Forged C263 Seamless Rolled Rings, Christopher Smith

Materials Engineering

Seamless rolled rings of C263 superalloy were forged by Carlton Forge Works in Paramount, CA and sectioned for mechanical testing. The as-forged ring sections were then machined into tensile samples. To simulate cold working done after Carlton’s forging process, the C263 tensile samples were strained using an Instron tensile tester to 1, 3, 5, 7, and 9% plastic strain. These tensile samples were then solution treated at 2100°F for 30 minutes and water quenched before being aged at 1470°F for 8 hours and air cooled, following Carlton Forge Works’ heat treatment process. The gauge length sections were metallographically prepared and …

Simplifying The Testing And Calculation Of Fracture Toughness Of Thermoplastic And Thermoset Matrix Composite Materials, James Shedden

Materials Engineering

Fracture toughness, or the ability of a material to resist fast fracture by crack propagation is an important property in the use of composite materials for structural designs. Other mechanical tests such as tensile, flexure, and compression are more established and practical than testing fracture toughness. Fracture toughness testing is less commonly used because it requires specific specimens and non-conventional test methods. In composite materials specifically, delamination of the plies of materials is tested for G_IC and G_IIC values to find the critical strain energy release rate of the two types of fracture modes. The common two tests …

Development Of A Production Line Appropriate Test For Teflon Adhesion On 304 Stainless Steel 0.01-0.03" Diameter Coronary Guide Wires, Danielle Dunham

Materials Engineering

A test was developed to determine relative adhesion of Teflon-coated 304 stainless steel guide wires. Two sets of wires were provided by Abbott Vascular for testing: one set was known to have poor Teflon adhesion, the other had acceptable adhesion. A prototype device was designed and manufactured that produced a shear force on the coating by dragging the wire under a ½ inch-diameter 440C hardened stainless steel cylinder. Testing consisted of increasing the force on the wire during each consecutive pass with the cylinder until the Teflon coating failed. The force on the wire during the failure producing pass was …

Residual Stress Measurement Of 7050 Aluminum Alloy Open Die Forgings Using The Hole-Drilling Method, Alexandra Viksne

Materials Engineering

Open die forged 7050 aluminum alloy has residual stresses that can be measured by the hole-drilling method following standard ASTM E837-01. Weber Metals (Paramount, CA) assumes that the stress is uniform throughout the thickness of an open die forged plate. Four different stress relieved 7050 aluminum samples were tested to confirm if the measurements by the hole-drilling method at the surface of a plate is indicative of the stress throughout. The different stress relief methods included: two water quenched samples at temperature ranges of 60°-90°F and 120°-130°F and two samples plastically deformed by forging at room temperature 1% and 3%. …

Analyzing The Flexural Properties Of Self-Constructed Bamboo Laminates, Brett Dorren

Materials Engineering

Bamboo plies of 1/8" and 1/32" thicknesses were glued together to form multiple unidirectional and cross-ply laminates that measured 12" by 12". The thickness of each laminate was between 0.25" and 0.375". All laminates were pressed together with a Tetrahedron MTP-10 bench top precision press at 75°F and 1000 lb_f for 40 minutes. Laminates were then cut with a band-saw into four 3" by 12" test specimens, 24 hours after pressing. Each test specimen was three-point bend tested to identify the modulus of rupture (MOR) and apparent bending stiffness. Three-point bend testing was also performed on laminates that were …

Evaluation Of High Phosphorus Electroless Nickel Platings To Protect Carbon Steel Heat Exchangers In Seawater Service, Nathan Brink

Materials Engineering

The purpose of this project was to determine the suitability of using a high phosphorus electroless nickel (HPEN) coating to prevent corrosion in carbon steel heat exchangers in seawater service. 1 in. x 4 in. samples were cut from ¼ in. SA-516-70 pressure vessel plate, pickled to remove mill scale, dressed with 300 grit sand paper and sent out for plating with 2 mils of HPEN. Due to a clerical error during plating, samples were plated to a significantly lesser extent than requested. Samples were plated with approximately 0.6 mils of HPEN versus the 2 mils requested, however this was …

Measuring The Mechanical Properties Of A Newly Developed Discontinuous Carbon Fiber And Epoxy Composite, Morgan Adams

Materials Engineering

Engineering firm Pratt & Miller have developed a new and previously untested carbon fiber/epoxy composite using a spray lay-up process similar to a process commonly used in fiberglass production. This new composite is made by using a pneumatic chop gun that simultaneously cuts the carbon fibers to a specific length and deposits the chopped fibers and resin onto surface of an exposed mold surface. The composite is then rolled down to flatten and better wet the fibers and then the whole mold is vacuum bagged at room temperature to cure. The flexural stiffness and flexural strength of the composite with …

Tensile Properties Of Adhesive Joints Between Alclad 2024-T3 Aluminum Sheets And Extruded 6061-T6511 Aluminum For Use In Ultralight Personal Aircraft, Kevin Jones

Materials Engineering

Cold cure two-part epoxy adhesives were tested in aluminum joints to investigate their viability for use in an ultralight aircraft. The joints consisted of Alclad 2024-T3 aluminum sheets adhesively bonded to extruded 6061-T6511 aluminum, and are part of low-load-bearing members required to carry a minimum load of 175 lbs./ft. or 14.58 lbs./in. The Alclad 2024-T3 and 6061-T6511 aluminum were prepared by sanding with 80 grit abrasive paper, the surface was cleaned with acetone to remove surface contaminants, rinsed with distilled water, and dried using paper towels. Once the surface was prepared, the test coupons were assembled using one of the …

Design Of A Children’S Earth Science Exhibit For The Exploration Station In Grover Beach, California With An Emphasis On Fog Collection, Kathryn Thomas

Materials Engineering

An outdoor earth science museum exhibit was designed for the Exploration Station in Grover Beach, California, and will use the harvesting methods of fog as a clean water resource to educate children. The design of the exhibit has two parts: a 1 m x 1 m static Standard Fog collector for long term fog collection which rises 2 m off the ground, and a mobile six-panel display consisting of six different materials and structures of meshes, all of which could potentially be used in a large scale fog collection setting. The six-panel portion will present the children with a hands-on …

Thermally Insulating Coating For Steel Drill Pipe, Matthew Mccaffrey

Materials Engineering

A 5/16 in thick, 6 in x 6 in steel plate was used as a simple analog to 4 inch grade “S” steel drill pipe. Ethylene tetraflouroethylene (ETFE) applied as a powder coating was selected as the desired thermally insulating coating because of its excellent chemical resistance, maximum service temperature of 300°C, its thermal conductivity of 0.238 W/m-K, and for its ability to be applied in thicknesses of up to 80 mils. A powder primer coat of approximately 2 mils was applied using a conventional corona electrostatic powder sprayer, and then the high build topcoat was applied directly over the …

Design And Construction Of A Simulated Evaporative Heat Exchanger For Testing The Mitigation Effects Of Pipe Coatings On Mineral Scale Deposition, Taylor J. Anderson

Materials Engineering

The thermal efficiency of evaporative heat exchangers is diminishing due to mineral scale buildup on heat exchanger surfaces. A simulated evaporative heat exchanger was designed and constructed for testing the mitigation effects of polymer coatings on mineral scale deposition rates. The heat exchanger was designed to cool hot mud at 200°F using a cooling water supply with a calcium concentration of 1000 ppm. The system was constructed using 1.5-inch diameter polypropylene piping, a DIG Corporation drip irrigation system, a TotalPond 530 GPH pond pump, an Omega CSI32K miniature benchtop controller, Omega FWH321-020 high temperature heater tape, and fifteen copper pipe …

Analyzing The Acoustical Properties Of Alternative Materials In Guitar Soundboards To Reduce Deforestation, Chris Dunn

Materials Engineering

To mitigate the effects of deforestation, man-made alternative materials were analyzed and tested for potential use in the soundboards of acoustic guitars. The materials evaluated included 0.06 in. foamed polycarbonate, 0.12 in. single-ply honeycomb fiberglass, and 0.04 in. epoxy fiberglass. The properties of Sitka spruce, the most common tonewood, were used as a benchmark. The Young’s modulus to density ratio found in Sitka spruce is relatively high, making its properties ideal for soundboard applications. Both Young’s modulus and density were necessary to calculate the acoustic constant of each material that was tested. The samples were subject to the impact of …

Interactive Museum Exhibit To Introduce K-6 Grade Students To Circuits And The Electric Conductivity Of Various Materials, Thien Vu-Nguyen

Materials Engineering

The SciTechatorium (SciTech) is a museum filled with interactive exhibits for visitors to learn science informally. A new exhibit was developed to explore electric conductivity and circuits. The design was made based on the size of the material sample the students will use and to allow interactions with multiple users. The materials the students will use were selected using Cambridge Engineering Selector (CES) to sort the materials by resistivity, the inverse of conductivity. After sorting the materials by resistivity, five different materials (balsa wood, polystyrene, polyester, stainless steel, and copper) were chosen for the exhibit. The target size of the …