Mechanical Engineering Commons^™

Experiential Learning And The Revitalization Of Manufacturing Education At The University Of Dayton, Sean Cahill

Research and Reflection on Learning and Teaching in Higher Education

This perspective paper explores the role of experiential learning in preparing future-ready manufacturing engineers at the University of Dayton, set against the backdrop of Dayton’s legacy as an industrial innovator and the broader national movement to revitalize domestic manufacturing. As automation, cyber-physical systems, and Industry 4.0 technologies reshape the manufacturing landscape, there is a growing need for engineers who possess both technical fluency and systems-thinking capabilities. To meet this need, the manufacturing engineering technology department implemented hands-on, integrated lab-and-lecture modules through support from the Experiential Learning Innovation Fund for Faculty (ELIFF). Grounded in Kolb’s Experiential Learning Theory and constructivist learning …

Design Of Ballistic Armor Using Multi-Composite Sandwich Structures With Nanomaterial Additives, Carmen Alaichamy

College of Engineering Summer Undergraduate Research Program

This study explores the bulletproof capabilities of Kevlar composites fabricated using advanced additive manufacturing techniques. Continuous fiber reinforced 3D printing (CFRP) is employed to produce Kevlar-reinforced polymer matrix composites (PMCs) with optimized structural configurations for ballistic protection. The primary objective is to evaluate the impact resistance of these composites against 9mm projectiles through systematic experimental testing. A series of ballistics tests are conducted using a high-velocity gas-gun system to fire 9mm projectiles at varying speeds angles. The tests will be conducted at the San Luis Obispo Range, with projectiles fired at various angles. The effects of fiber volume fraction, reinforcement …

Leveraging Smartphones For Balance Assessment, Kelly Graham

College of Engineering Summer Undergraduate Research Program

Assessment of human balance provides valuable metrics to track the health, development, and fall risk of individuals. The prominent method for objective balance assessments has used force plates to track the center of pressure (COP) position as a participant attempts to balance during varying tasks. However, the use of force plates is limited by the cost of equipment and expertise required, leading to recent interest in using embedded inertial measurement units (IMUs) in mobile devices instead. Many researchers have explored placing mobile devices close to the subject’s center of mass (COM) to approximate the subject’s COM acceleration and using the …

Comparison Of Anti-Fouling Performance Of Textured Glass Surface Fabricated By Ductile-Mode Peening And Precision Grinding, Hayato Tagaya, Yutaka Kameyama, Shuhei Kodama, Hideaki Sato, Kento Shinagawa, Ayumu Sekiguchi, Seiji Hirai, Hitoshi Ohmori

15th International Conference on Shot Peening

Recently, there has been a growing demand for precision processing glass. In addition to dimensional accuracy, surface texturing to impart functional properties has attracted increasing attention. For example, anti-fouling performance against powder adhesion is required for cover glasses of solar cells. Powder adhesion is governed by van der Waals forces, which depend on the surface texture of the substrate, suggesting that surface structures influence adhesion behavior. Our previous study demonstrated that angled fine particle peening (FPP) could fabricate a nanoscale fine texture on glass surfaces through ductile-mode peening—glass processing without brittle fracture. In this study, the effect of surface texturing …

Roughness Parameters For Evaluating Blasted Or Shot Peened Surfaces, Stefanie Stoeckel, Sophie Groeger

15th International Conference on Shot Peening

A review of the papers presented at the last three International Conferences on Shot Peening revealed that the most used parameters are Ra and Rz. There has been comparatively little exploration of other parameters, particularly the S-parameters. Furthermore, the ISO 4287 standard for profile parameters was replaced by the new ISO 21920-2 standard in 2021. This is accompanied by the introduction of new parameters as well as alterations to existing ones. This paper demonstrates the limitations of Ra and Rz, as well as Sa and Sz, and explores additional areal and profile parameters that are useful for the description of …

The Effects Of Shot Peening Highly Loaded Compression Springs, David J. Breuer

15th International Conference on Shot Peening

The compression spring in this test study is typical of one used in a demanding off-road vehicle suspension. The cyclic loads applied during fatigue tests were severe enough to cause failure in approximately 11,000 cycles without shot peening.

The objectives of this study were the following: (1) Design a compression spring similar to those used in the off-road recreational industry. (2) Design & manufacture a fatigue test stand that could withstand high loads for months of testing. (3) Generate a matrix of shot peening treatments to produce different amounts of residual compressive stress. (4) Measure the shot peening residual compressive …

Computational Fluid Dynamics (Cfd) Modeling For Bio-Inspired Aerodynamic Optimization In Autonomous Drones, Hyginus C.O. Unegbu, Danjuma Saleh Yawas

Makara Journal of Technology

This study explores the aerodynamic benefits of bio-inspired design modifications for autonomous drones using advanced Computational Fluid Dynamics (CFD) simulations. Four bio-inspired configurations—leading-edge serrations, winglets, riblet surfaces, and curved wings—were assessed and compared against a baseline drone model to evaluate their impact on aerodynamic performance. The results indicated that all bio-inspired designs significantly enhanced lift, reduced drag, and improved overall aerodynamic efficiency. The leading-edge serration configuration achieved the highest performance gains, with a 33.6% increase in maximum lift coefficient (CL) and a 29.5% improvement in lift-to-drag ratio (CL/CD), primarily due to delayed flow separation and reduced turbulence. Winglets minimized wingtip …

Implementation Of Reliability Centered Maintenance On Crude Booster Pump, Dzulfikar Ali Hafizh, Maya Agustianingrum Putri St., Ph.D., D. Rizal, Adzra Qanita

Journal of Materials Exploration and Findings

Crude oil booster pump is one of the critical equipment in oil refinery operations. In aging plants that have been operating for more than 25 years, where reliability and maintenance issues on equipment often cause operational disruptions and even unplanned shutdowns. This study aims to develop a structured reliability-centered maintenance (RCM) strategy for crsude oil booster pump systems that is also in line with the principles of asset integrity management system (AIMS). This methodology follows the RCM II approach, starting with system function analysis, failure mode identification, and criticality assessment through Failure Mode, Effect, and Criticality Analysis (FMECA) to determine …

Integration And Testing Of A Quadruped Robot With Ros2, Jeremy S. West

Master's Theses

The Cal Poly Legged Robotics Group has been developing research and teaching platforms for agile legged robotics since 2020. These platforms are expected to provide students with opportunities to develop complete legged-robot systems from low-level control to advanced robotics tasks such as motion planning and decision making. However, the current prototyped quadruped robot lacked the software and sensing capabilities for high-level quadrupedal gaits and advanced robotic research.

To address these challenges, this project developed Switch, a robotic platform that builds upon the previous BRUCE platform with significant hardware and software upgrades. Switch features a modular design that allows individual software …

Synergistic Enhancement Of Tribological Behavior And Colloidal Stability In Cuo Nanolubricants Via Ligand Tuning, Sherif Elsoudy, Sayed Akl Akl Dr, Sayed Akl A. Akl Dr, Esm Lane, Abas Hadawey, Philip D. Howes

Mechanical Engineering

Nanoparticle-based lubricants, or nanolubricants, can exhibit superior tribological properties compared to unmodified base oils. However, these performance gains are highly dependent on the nanoparticle surface chemistry, particularly in maintaining stable colloidal dispersions. This study explores the influence of oleic acid (OA) and oleylamine (OAm) functionalization on the tribological and colloidal properties of CuO nanoparticles dispersed in an SAE 20W50 base oil. We present a hybrid optimization framework combining Response Surface Methodology (RSM) with Bayesian Optimization (BO) to identify the optimal OA to OAm ratio (OA–OAm) for CuO nanolubricants. Unlike prior studies that employed either RSM alone or trial-and-error approaches, this …

Advancing Real-World Implementation Of The Well Optimized Linear Finder (Wolf) High-Speed Atmospheric Turbulence Compensation Method, Timothy Evan Coon

Theses and Dissertations

This dissertation advances the real-world implementation of the Well Optimized Linear Finder (WOLF) method for high-speed Atmospheric Turbulence Compensation (ATC). Atmospheric turbulence introduces phase aberrations into optical wavefronts and degrades image quality in terrestrial imaging systems. Traditional phase diversity methods are computationally intensive and poorly suited to real-time operation. The WOLF method addresses these limitations through a novel, point-wise formulation of the optical transfer function (OTF) as a structured autocorrelation of the generalized pupil function (GPF). This formulation enables the estimation of phase aberrations at individual spatial coordinates with distributed computational complexity.

The research begins by developing a MATLAB-based simulation …

Soft Hexapod Robot With Tendon-Driven Continuum Legs For Internal Infrastructure Inspection, Setayesh Yavari

LSU Master's Theses

The need for robotic systems capable of operating in confined, hazardous, or complex environments has driven interest in soft and legged platforms for industrial inspection and structural integrity assessment. This thesis presents the design and fabrication of a tentacle-like, soft-legged hexapod robot, which uses six cable-stiffened, pre-curved, tendon-driven continuum robot (TDCR) legs. These biologically inspired legs are designed to offer a balance between compliance and control, enabling the robot to navigate unstructured terrains and potentially grasp cylindrical structures such as pipes. The design phase involved the development and comparison of multiple leg geometries using CAD modeling and finite element analysis …

An Engineering Solution For Fan Aeroacoustics Measurements Correction In A Non-Anechoic Testing Environment, Saad-Eldin Taha, Mohamed Y.Zakaria, Mohamed Abdelgaied, M.M. Bassuoni Prof. Dr.

Journal of Engineering Research

Abstract- Nowadays, acoustic signatures of daily used applications are to be minimized. The study of noise generated through aerodynamic interaction with moving bodies has passed through different phases since the early 50s, and this leads to the evolvement of many analytical, empirical and computational techniques in order to be able to estimate the emitted noise. Concerning fan blades, until now the researches are still going for a reliable method for noise estimation during the early phases of design which help in the development of blades with a lower aeroacoustic signature, the Brooks, Pope and Marcolini (BPM) model was chosen to …

An Eulerian-Pfem Approach To Model Transient Capillary Forces On Moving Contact Lines Of Spreading Liquid Drops: Applications In Hydraulic And Fluid Dynamics, Elaf N. Mahrous, Syed Yousufuddin, Muhammad Saleem Professor, Mohammed N. Iqbal, Muhammad T. Bin-Saleem

Journal of Engineering Research

This study addresses the complexities of simulating multiphase flows, particularly the dynamics of droplet behaviour on solid substrates, which are influenced by intricate capillary interactions. Despite advancements in fixed-grid and moving-grid methodologies, there remains a critical gap in accurately modelling transient phenomena and dissipative forces at the solid-liquid interface. We introduce a novel Eulerian-particle finite element method (PFEM) framework that captures the transient capillary forces associated with the movement of contact lines in liquid droplet spreading scenarios. Through a numerical assessment of three established dissipative force models—Jiang’s, Bracke’s, and Seeberg’s we identify Jiang's model as the most effective and stable …

Efficient Thermal Design Of Data Centers, Keats M. Baggett, Andrew Ergood, Colin Brace, Jack Zilligen

Mechanical Engineering

Our sponsor needs a way to categorize and quantify the top 3 colocation center sites based on a series of criteria for given power specs. The sponsor also needs a single innovative cooling method to meet thermal and power requirements while also being manufacturable at scale. This device must also be able to interact with the given Colocation Heating Ventilation and Air Conditioning (HVAC) system. This design will be tested to provide insight and data that will be applicable to further the development of colocation center cooling. This project will be executed by the Cal Poly senior project team and …

Design, Fabrication, And Testing Of A Dual-Rate Spring System For Mountain Bike Frames, Lucas P. Grizzle

Master's Theses

The design of full-suspension mountain bikes is a careful balance of suspension kinematics, structural dynamics, and manufacturing optimization for the expected use case. A bike designed to excel in one area will likely exhibit reduced performance in others. This optimization problem is addressed by designing, integrating, and testing a dual-rate spring system within a fully custom frame. The dual-rate spring is fully decoupled from the rest of the suspension kinematics, providing designers with an additional parameter to achieve ideal suspension behavior. This is accomplished by placing a thermoplastic polyurethane (TPU) bushing in series with the rear shock. The influence of …

Scitechatorium, Olivia Lafferty, Yvonne Brien Miller, Colton Swinth, Savannah Pinheiro, Gage Heinze

Mechanical Engineering

Bellevue Santa-Fe Charter School (Bellevue) is a K6th grade public charter elementary school in Avila Beach, California. The primary focus at Bellevue is fostering unique learning experiences, empowering students through project-based learning, and engaging students in creative endeavors. Following these themes, the school has allocated space and funding for an on-campus science and technology museum known as the SciTechatorium. The museum is currently open during students’ lunch period, providing interactive displays on concepts in human biology, nature and wildlife, physics, and electronics. Bellevue’s K-6th grade science teacher, Christian Strauli, and Bellevue parent volunteers are primarily responsible for the museum’s upkeep …

License To Drill, Gabrielle Noemi Orlando, Alexcias Olga Meeks, Dayana Guadalupe Gonzalez, Mark Dahmen

Mechanical Engineering

The goal of this project is to provide the student machine shops with an updated License to Drill (LTD) certification training, formally known as the Red Tag. The current training has two key components: a preliminary Canvas course and an in-person training with a safety tour, safety quiz, and a hands-on project. Currently, the hands-on project is outdated and unengaging. Thus, the primary focus is to replace it with an inspiring and memorable project, which includes written and visual instructional content on how to make it. The Canvas will thus be updated, a new instructional video will be created, and …

Lidss Raft Battery Pack Integration, Jack Maxwell, Vincent Stevens, Matthew Hoodmaker, Colin Flanders

Mechanical Engineering

Lawrence Livermore National Laboratory is a critical member of the United States Department of Defense. Their Independent Diagnostics Scoring System (LIDSS) uses rafts that operate in the ocean to collect missile test data. Several times a year, the United States will test their Inter-Continental Ballistic Missiles by launching them into the ocean near the Marshall Islands. This is where the LIDSS rafts collect their test data. Our project was centered around re-designing the battery pack used by the rafts. The current battery pack design experiences water ingress problems and is difficult to access. Our re-designed battery pack is waterproof to …

Van Accessibility, Ann Larson, Camelia Anne Noureddine, Stephanie Rose Ruzicka, Kayla Joanne Gowey

Mechanical Engineering

The SLO Achievement House provides resources and activities for their clients, including daily trips to different parts of the community, to keep their clients connected to society. These trips require the clients, many of whom struggle with general mobility and strength, to step up to the high entrance of a van or company car. This daily activity poses a challenge both physically and emotionally for the clients. The current solution utilizes commercially available step stools, which lack handrails, overall stability, and adequate step depth. The Achievement House needs a stool or ramp tailored to their client’s needs and their specific …

Uv Vessel Hoist Scope Of Work, Quinn J. Horak, Harvey Perkins, Andrew A. Osborn, Mikayla H. Nieman

Mechanical Engineering

The San Luis Obispo Wastewater Treatment Plant uses ultraviolet (UV) tubes to purify water. These tubes are cleaned by an internal wiping mechanism that must be removed for servicing and replacing damaged tubes. Currently, this is accomplished by using an engine hoist, but this method requires a large amount of effort and is not safe. Technicians have requested a new method of lifting wiper mechanisms that is safer, faster, and easier to use than their current method.

To solve this problem, we have developed a design that consists of a custom gantry crane with a hoist on a trolley. The …

Brush Seal Cycling Test Rig, Angelo J. Reis, Neil M. Bedagkar, Max A. Soury, Eoin K. Lenham

Mechanical Engineering

To prevent backflow from the high pressure compressor stages of their gas turbines to lower pressure regions, Solar Turbines utilizes brush seals along their driveshafts. Due to manufacturing limitations, no shaft is perfectly symmetric about its rotating axis, leading to orbiting that creates asymmetric friction on the shaft through rubbing. With this biased application of friction comes a hotspot on one side of the shaft, causing bowing of the shaft and cascading into an amplified vibrational response. Our goal is to gather data on this phenomenon and offer a potential solution.

2024-2025 Cal Poly Fluid Power Vehicle Competition Team, Jaskaran Singh Hothi, Justin Menzie Lesko, Tristan Kai Crawford, Lucas Rupert Erickson, Diego Velazquez

Mechanical Engineering

The Fluid Power Vehicle Challenge (FPVC) provides an avenue for the exploration of fluid-powered transportation, adhering to regulations set by the National Fluid Power Association (NFPA). This document serves as a roadmap for our team’s research, design, and manufacturing of a vehicle for participation in the FPVC. The team’s journey began with extensive background research, encompassing stakeholder engagement, analysis of existing solutions, and education on fluid power fundamentals. From this information, we decided to focus on enhancing mechatronics systems, improving the transmission, optimizing the mounting, adding a pneumatic element, and improving the efficiency of the hydraulic system of the vehicle …

Hi-Trac Camera Jig, Gabriel Frank Junge, Josh Sherreitt, Jake Weiser, Luke Silver

Mechanical Engineering

Uranium fuel assemblies are stored upright in an underwater container inside the spent nuclear energy fuel pool at Diablo Canyon. The engineers and in-service-inspection team all work together to safely locate this container inside the pool on pins so it is guaranteed safe before they begin loading it with spent uranium fuel rods. The Operators currently employ the use of a zip-tied camera jig that is lowered into the pool along with the tank (called a HI-TRAC) to ensure it is oriented correctly in the pool. This camera jig is in desperate need of re-vamping and re-designing to optimize efficiency …

Floating Wind Turbine Foundation, Clayton Lahodny, Dillon Nelson, Trevor Ortega, Andrew Cervantes

Mechanical Engineering

The 2024 Collegiate Wind Competition (CWC) has introduced a new element to their Turbine Design Competition: a floating foundation. In previous years, foundations have been fixed-bottom in a box of sand and water. The Cal Poly Wind Power Club, who competes in the CWC every year, requires a floating foundation to be designed, manufactured, and tested to assist in winning the competition. The foundation is a large, hollow, cylindrical barge with a hanging spar (heavy mass). The barge will provide a restoring moment using buoyancy, and the heavy spar provides additional restoring moment. Four cables will be attached at the …

Design Principles For Robotic-Controlled 3d Printing Of Soft Tissue-Mimicking Materials, Karina Mealey

Master's Theses

Geometrically and physically accurate 3D models are emerging as essential tools for surgeons in pre-operative planning and training, but current methods of producing these models are not sufficient. Existing solutions have downsides such as high costs, long and tedious production times, high complexity resulting in a lack of scalability, or an inability to meet material requirements for accurately simulating human tissue.

The objective of this work is to develop principles for a low-cost, easy-to-use 3D printing system capable of prototyping with soft tissue-mimicking materials. To pursue this goal, a MyCobot280 robot arm was used as the mechanism to explore the …

Thermal Modeling Techniques For Additively Manufactured Porous Metals, Lucas D. Rambo

Master's Theses

Advances in additive manufacturing have enabled the creation of metallic components with tailored porosity, offering design flexibility for thermal, structural, and fluid transport applications. This thesis investigates the effective thermal conductivity (ETC) of porous Inconel 625 (IN625) and Inconel-ceramic composites (IN625-RAM2) fabricated by Laser Powder Bed Fusion (LPBF) using Elementum 3D’s PermiAM technology. Experimental measurements of thermal conductivity using the laser flash method are compared to numerical models built from micro-computed tomography data. Simulations were performed using both finite element (FE) and finite volume (FV) methods to evaluate thermal transport in real microstructures. The study investigates the effects of micro- …

Hands-Free Balance Protocol And Development Of An Iphone App For Self-Assessment, Jacob Matties

Master's Theses

For many clinical populations, the measurement of balance is a critical task. Previous studies have agreed that smartphone IMUs provide a valid measure of balance that can be significantly correlated with force plate measurements and is sensitive enough to distinguish between various balance poses, but many balance assessment protocols require uncommon equipment or the use of hands during assessment. These limit accessibility of balance assessment. To eliminate the need for hands or any additional equipment, this study assessed the use of a smartphone recording the root mean square of 3D acceleration magnitude. The goal of the study was to determine …

Molecular Dynamics Study Of Phase Change And Interfacial Behavior In Nanoconfined Argon, Ying-Chu Chen

Mechanical Engineering Research Theses and Dissertations

As electronic devices continue to reduce in size, effective thermal management becomes increasingly critical. Thin-film evaporation offers a promising solution due to its high heat flux capacity and passive nature. However, the applicability of continuum theory to thin-film evaporation becomes uncertain at the nanoscale. This work presents a two-phase Molecular Dynamics(MD) study of liquid argon confined within two parallel platinum walls, focusing on both equilibrium and non-equilibrium phase change behavior under nanoscale confinement.

In the first phase, Equilibrium Molecular Dynamics (EMD) simulations investigate the influence of channel height (4, 8, and 16 nm) and wall-fluid interaction strength on bulk and …

Mechanical Engineering Senior Design Capstone Modine Engineering: Collapsible Hvac Coil Expansion Table, Austin M. Hipskind

Honors Theses

For the Mechanical Engineering Senior Design class, teams of seniors were asked to find a sponsor company willing to provide a problem they were experiencing at a local plant. Using the skills gained throughout college, they were asked to go through a standardized problem-solving method to develop a solution for the sponsor company. I was teamed with Fernando Arellano and Henry Lindsey to work with Modine Engineering on creating a modular and collapsible table for use with large, custom-designed coils. This table would have to hold large, heavy coils during the expansion process. Modine requested a 3D design, the cost …