Mechanical Engineering Commons^™

Hydropower Collegiate Competition, Aiden D. Foster, Devon Bountry, Joanna Vo, Timothy Rinker, Amanda Rodriguez, Minh Nguyen, Eli Haushalter, Sophie Watkinson, Maiya Holton, Breanne Evans

Mechanical Engineering

The Cal Poly SLO HCC team presents a feasibility study and engineering design review package for retrofitting the non-powered Ritschard Dam in Colorado into a hydroelectric facility as part of the 2025 Hydropower Collegiate Competition. Through a rigorous and multi-staged assessment of plausible dam sites in the western US, the team has chosen the Ritschard Dam in Colorado to implement an electromechanical component designed to accommodate a large range of flowrates stemming from a large variance in upper reservoir capacity due to geographical and climate effects. The team evaluated non-powered dams based on technical feasibility, electric grid proximity, power generation …

Cryogenic Fuel Delivery System, Carter Josef, Reilly Humphreys, Joseph O'Connor, Nick Spreen

Mechanical Engineering

This project presents the design and validation of a cryogenic fuel delivery system aimed at enabling sustainable aviation through hydrogen fuel vaporization. Developed by a team of senior mechanical engineering students at Cal Poly and sponsored by Boeing, the system utilizes atmospheric air to vaporize liquid nitrogen, used as a stand-in for hydrogen, via forced convection heat exchangers, eliminating the need for engine-supplied heat and reducing parasitic loads. A feedback loop and turbine component are integrated to regulate pressure and recover energy, respectively. A benchtop prototype was built and tested to evaluate system performance, with results closely aligning with analytical …

Conversational Social Robot, Julianna M. Christopoulos, Mackenzie Goldman, Cece E. Hujanen, Jared Hunter

Mechanical Engineering

Background: Social robots are used in various settings to reduce burden on human workers and expand opportunities for people in need of assistance.

Challenge: Design a humanoid robot head and torso capable of holding conversations and interacting with a user using a LLM and motion. Conversations are limited to discussing Cal Poly resources and opportunities with visitors to the Bently Research Center on campus.

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 …

Evoque Delivery System Fixture Optimization, Jack Ellis, Florence Duff, Noah Dunsmore, Timothy Hunter, Rafael Castillo

Mechanical Engineering

No abstract provided.

3d Printed Fixed Wing Aircraft Competition, Sidney E. Long, Mitchell Heise, Jack Bride, Daniel Salinas

Mechanical Engineering

Cal State LA and Arlington University, Texas are hosting the same 3D printed, fixed wing aircraft competition for 2025. Cal Poly requires a competitive plane that can adhere to each rule and be piloted remotely to achieve the longest time in the air. The plane must utilize solely 3D printing technology for the wings, body, and all other structures. The only off-the-shelf components can be the motor and electronics, as well as mechanical devices such as hinges.

Combustion Liner Optimization, William Weeks, Daniel Reed, Isaac Trull

Mechanical Engineering

Solar Turbines provides gas power generation solutions, focusing on gas turbine engines and compressors. The Gas Turbine Products Engineering (GTPE) team at Solar Turbines needs a way to efficiently and cost-effectively maintain the combustion liner of the Taurus model gas turbine at or below the cold-side temperature target. The current system involves a manufacturing process with ergonomic concerns and uncertain cooling effectiveness.

To address this, our team proposed a new combustion liner system featuring impingement cooling. We provided Solar Turbines with heat transfer models of both the existing and proposed designs, demonstrating improved cooling performance. Additionally, a prototype of the …

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 …

Pendulum Wave Generator, Abigail Jocelyn Romero, Paul Staley, Wendy Dong, Kyle Schumacher

Mechanical Engineering

The Cal Poly Mechanical Vibrations Laboratory (Vibes Lab) serves to educate and excite students about mechanical vibrations through hands-on experiments. While the lab contains several relatively complicated technical experiments, it lacks simple demonstrations with immediate visual interest to appeal to audiences with less technical backgrounds. Because of this, faculty desired a fun and interactive demonstration project that could be operated with no prior training. The project chosen for this is a Pendulum Wave Generator which is a set of multiple pendulums with differing lengths that combine to create complex and observable patterns over time. This project was completed by a …

Adaptive Riding Mount Block, Lucas R. Reynolds, Lukas M. Moreau, Patrick J. Michael, Jandre D. Lafradez

Mechanical Engineering

Professor Sarah Stewart from the Animal Science Department at Cal Poly seeks to develop a solution to help people with disabilities mount horses. Users need a mounting block that can bring them closer to the horse’s back to ease mounting. The current system, consisting of two plastic two-step blocks, is inadequate—unstable, too small, and inaccessible for wheelchair users.

The required solution must meet several key specifications: it should accommodate at least three people standing side by side, be sturdy enough to support their combined weight, and remain stable on rugged terrain like gravel or sand without tilting or sinking. Additionally, …

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 …

Adjustable Dynamometer Motor Mount, Garrett Carson Ng, Elijah Siegel Reuven, Ethan Fong, Daniel Larimer

Mechanical Engineering

The Cal Poly Electrical Engineering Department and sponsor Dr. Dolan needs a manufacturable motor fixture that securely aligns motors of various sizes with dynamometers. Previous lab motor fixtures could not accommodate motors of different sizes, making precise alignment between motors and dynamometers time-consuming and unreliable. Our team developed a modular, manufacturable fixture capable of aligning various motor sizes quickly, accurately, and securely, enhancing lab consistency and usability.

Baja Sae Brakes, Carson Moore, Jaedyn Michael Imhoff, Will Duncan, Matthew Shaffer

Mechanical Engineering

Historically, the Cal Poly Racing Baja SAE has produced a braking system that has proven unreliable and barely passes competition rules and inspections, leading to ill performing and unsafe brakes. The goal of this project is to produce a system and documentation that meets the requirements provided by Cal Poly Racing Baja SAE. The final design includes a transient braking model of the vehicle to set system requirements, universal custom front and rear calipers modified from “Cal Poly BSAE Custom Brake Caliper Senior Project”, and a revamped hydraulic harness. Leaning on the team’s previous work and modifying the custom calipers …

Development Of 6d Electromagnetic Actuation For Micro/Nanorobots In High Viscosity Fluids For Drug Delivery, Mostafa Abdelaziz, Maki Habib

Mechanical Engineering

This research focuses on the development, design, implementation, and testing (with complete hardware and software integration) of a 6D Electromagnetic Actuation (EMA) system for the precise control and navigation of micro/nanorobots (MNRs) in high-viscosity fluids, addressing critical challenges in targeted drug delivery within complex biological environments, such as blood vessels. The primary objective is to overcome limitations in the actuation efficiency, trajectory stability, and accurate path-tracking of MNRs. The EMA system utilizes three controllable orthogonal pairs of Helmholtz coils to generate uniform magnetic fields, which magnetize and steer MNRs in 3D for orientation. Another three controllable orthogonal pairs of Helmholtz …

Investigation Of Surface Quality And Productivity In Precision Hard Turning Of Aisi 4340 Steel Using Integrated Approach Of Ml-Moora-Pso, Adel T. Abbas, Neeraj Sharma, Khalid Alqusaibi, Mohamed Abbas, Rakesh Sharma, Ahmed Elkaseer

Mechanical Engineering

AISI 4340 steel has applications in gun barrels, where the surface quality of the barrel is the prime factor. This study explores the application of a machine learning (ML) approach to optimize the precision turning of an AISI 4340 steel alloy using both conventional and wiper tool nose inserts under varying cutting parameters, such as cutting speed, depth of cut, and feed rate. The analytical framework integrates experimental machining data with computational algorithms to predict key output parameters: surface roughness (Ra) and material removal rate (MRR). A Multi-Objective Optimization based on Ratio Analysis (MOORA) method is used for data normalization. …

Helical Products Parts Display Stand, Binh Nguyen, Emily Yuan Mendyke, Zoe Porter

Mechanical Engineering

Helical Products needs a new product display stand that will demonstrate their custom springs, couplings, and u-joints. Their current display stand, a marble run contraption, is large, loud, and difficult to transport, so they would like the new stand to remedy these issues. The goal of this senior project is to create a display stand that captures the attention of their customers with dynamic product demonstrations while addressing the issues outlined above.

The new display stand is also a marble run contraption, but instead of being almost 4 feet tall and 3 feet long, it is 23” tall, 26.25” long, …

Emg-Based Intraoperative Neuromonitoring Using Advanced Machine Learning Approaches, Abdalla Nabil Elsharkawy, Nourhan Zayed

Mechanical Engineering

Intraoperative neuromonitoring (IONM) plays a critical role in minimizing nerve damage during surgeries by providing real-time feedback on neural integrity. This study evaluated models associated with deep learning and machine learning models for electromyography classification of signal during intraoperative neuromonitoring (IONM). The CNNLSTM model achieved the highest accuracy (85.2%), outperforming traditional models like KNN (53%), RF (62%), and CNN (76%). This demonstrates the degree to which the CNN-LSTM model can gain insight into temporal and spatial dependencies throughout the EMG signals, which makes it optimal for real-time classification in IONM applications. This implies that deep learning techniques can improve surgical …

Vanlife Desalination, Emily Rhee, Tomas Franco, Marco Jimenez

Mechanical Engineering

Van life can be defined as the unconventional lifestyle of living in a car, van, or motor vehicle. Living in a motor vehicle allows for you to effectively live in whatever location you deem fit, and with that comes certain standards that need to be met; one being fresh potable water used for drinking, hygiene, and basic living. The scope of this project is to design a system that can effectively remove salt from seawater (desalinate) and can be integrated into a van that can be used for off-grid living.

In this project we worked to create a design that …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …

Wind Turbine Rotor Test Stand, Ashlen Brooke Sperry, Cayley Mckee, Kristofer Lee Pascua, Francisco Medina

Mechanical Engineering

Dr. Lemieux and the mechanical engineering department at Cal Poly are renowned for the countless projects that allow students to be a part of hands-on learning and the “Learn by Doing” experience. One such experience is the wind energy class that requires students to design, build, and test wind turbine rotors; however, a test stand for these rotors is needed. Dr. Lemieux and the senior project team will design and build a test stand that will enable the simultaneous testing of two student-designed rotors at the existing wind turbine site. In addition to energy measurement, Lemieux emphasizes the importance of …

Effects Of Die Type On Mechanical Performance And Failure Behaviors Of Self-Piercing Riveting Joints In Aa5052, Lun Zhao, Amr Monier, Ao Zhang, Liya Li, Ahmed Elkaseer, Zeshan Abbas, Kai Ye

Mechanical Engineering

This study investigates the effects of self-piercing riveting (SPR) die type on the joint quality and failure modes of AA5052 SPR joints. Three die types: flat, pip, and ball-shaped were designed and processed for the SPR process, and 30 riveted specimens were prepared. A 2D axisymmetric finite element (FE) simulation model was established using LS-Dyna to evaluate the impact of each die type. The accuracy of the FE model was validated by comparing simulated joint cross-sections with experimental results. Subsequently, the quality and forming mechanisms of the SPR joints fabricated using each die type were analyzed. Mechanical properties were assessed …

Non-Invasive Glucose Monitoring Using Ppg, Ai, And Iot-Driven Mobile Integration For Real-Time Diabetes Management, Mostafa Abdelaziz, Amr Refaie

Mechanical Engineering

Diabetes mellitus patients must regularly monitor their blood glucose levels to manage glycaemia, typically requiring capillary tests at least three times daily and laboratory tests one to two times per month. These conventional methods involve finger pricking, causing significant discomfort and stress. This study introduces an innovative non-invasive glucose monitoring approach by integrating photoplethysmography (PPG) technology with an artificial intelligence (AI) algorithm, complemented by a mobile application using Flutter, IoT systems, and Firebase cloud for real-time data access. Among the AI models tested, polynomial regression demonstrated superior accuracy in glucose prediction, achieving a Mean Squared Error (MSE) of 14.76 and …

Ai-Driven Robotic System For Predictive Maintenance: Urban Road Defect Detection In Smart Cities, Mostafa Abdelaziz, Mahmoud Khedr

Mechanical Engineering

This paper presents the development and evaluation of an integrated AI & robotic solution for predictive maintenance in smart cities, focusing on urban road defect detection. The proposed system integrates a mobile robot equipped with a high-resolution camera and a GPS module to capture video footage and geolocation data of road surfaces. The collected data is processed using cloud-based AI models, with YOLOv9 and Roboflow 3.0 Object Detection (Fast) identified as the most effective for analyzing footage to detect cracks and potholes. Experimental results validate the system's ability to accurately identify defects and generate timely reports for maintenance teams. While …

Development Of A Compliant Soft Gripper With Embedded Force Sensors, Ayman Abbas, Abdelrahman Said, Tamer Kahlil, Mahmoud Magdy

Mechanical Engineering

Robotic manipulators have the capability to perform repetitive tasks with a level of efficiency and precision that exceeds the capabilities of human operators. Currently, they are commonly found and extensively utilized across various disciplines. However, robotic manipulators have gradually begun to make inroads into fields beyond manufacturing, such as medicine and agriculture. Due to the diverse range of industries utilizing robotic manipulators, the nature of tasks assigned to these devices can often be more intricate and multifaceted than conventional assignments. Hence, conventional mechanical grippers may not always be suitable, prompting a growing need for grippers capable of adapting to effectively …

Design Of Modular Soft Gripper For Harvesting, Mostafa Abdelaziz, Ahmed Reda, Abdulrhman Atef, Mahmoud Magdy

Mechanical Engineering

Soft robotics presents a transformative approach to agricultural automation, addressing the limitations of traditional mechanical systems in handling delicate crops. This paper introduces a modular soft robotic gripper designed for gentle harvesting applications, with a focus on adaptability, precision, and crop safety. The gripper's performance was evaluated through Finite Element Analysis (FEA) and experimental testing, targeting its ability to conform to objects of varying shapes, sizes, and fragility. The FEA confirmed the gripper's capability to apply a load based on the gripped crop of the range 0.6 – 0.75 N, sufficient for damage-free harvesting of sensitive produce like strawberries and …

Design And Implementation Of Smart Automation For Sustainable Plastic Recycling With Iot Integration, Mostafa Abdelaziz, Mahmoud Khedr, Amr Bakkar, Yossef Zidan, Abdelrahman Youssef, Mahmoud Magdy

Mechanical Engineering

Plastic pollution poses a critical environmental challenge, infiltrating ecosystems and impacting human health. One innovative solution involves repurposing recycled plastics into interlocking blocks as a sustainable alternative to concrete in construction. However, manual production methods hinder scalability, efficiency, and product consistency while generating material waste. This research addresses these limitations by automating the production process using PLC and IoT technologies. The findings demonstrate that automation significantly enhances production rates, ensures consistent quality, and minimizes waste, thereby improving operational efficiency and environmental sustainability. IoT is integrated to enhance the system's capabilities by providing real-time connectivity and data exchange. The IoT dashboard, …

Pre-Programmable Directional Stiffness In Continuum Robotic Arms: Effects Of Truss Configurations, Mostafa Abdelaziz, Zahy Elgendy, Mahmoud Magdy

Mechanical Engineering

This paper investigates the implementation of trussed designs in modular tendon-driven continuum arms (CAs) to address stiffness and stability limitations while maintaining adaptability. Various truss configurations— Single-Level, Combined-Level, and Alternated trusses—were analyzed using Finite Element Analysis (FEA) to evaluate their impact on flexural and axial stiffness under realistic loading conditions. Results demonstrate that truss placement significantly influences performance, with bottom-level trusses improving flexural stiffness by up to 33%, middle-level trusses enhancing axial stiffness by 43%. Further, Combined-Level configurations provide superior overall stiffness, with MiddleBottom trusses achieving a 66.5% improvement in flexural stiffness and a 70.9% increase in axial stiffness, while …

Multi-Objective Monitoring Of Cvd Diamond Micro-Grinding Tools Using Acoustic Emission And Force Signals With Neural Network Optimization, Ahmed Elkaseer, Jianfei Jia, Bianbian Meng, Bing Guo, Jun Qin, Guicheng Wu, Huan Zhao, Zhenfei Guo, Qingyu Meng, Qingliang Zhao, Honghui Yao, Amr Monier

Mechanical Engineering

Micro-grinding has been widely used in aerospace and other industry, and its application was mainly the asymmetric microstructure. Chemical Vapor Deposition (CVD) diamond has drawn attention for its good wear resistance. However, the small diameter and high spindle speed may cause difficulties on the monitoring of the micro-grinding processes. In order to solve the mentioned problem, a novel multi-objective monitoring method of structured CVD diamond micro-grinding tool based on acoustic emission (AE) and force signals is presented in this study to achieve the high efficiency of the tool condition and grinding quality. The relationship between the grinding quality, tool condition, …

Integrating Machine Learning And Symbolic Regression For Predicting Damage Initiation In Hybrid Frp Bolted Connections, Sherif Sorour

Mechanical Engineering

No abstract provided.

Nano-Second Pulsed Laser Ablation Of Inconel 718 And Mmpcd For Simultaneous Optimal Ablation Rate And Surface Quality, Ahmed Elkaseer, Islam Abdelgaliel, Jon Lambarri, Iban Quintana, Steffen Scholz, Mohamed Aly

Mechanical Engineering

This study investigates the ablation performance of Inconel 718, a nickel-based superalloy, and metalmatrix polycrystalline diamond (MMPCD), a super composite, using a nano-second (ns) pulsed laseracross a range of ablation conditions. Single trenches varying in energy fluence and scanning speedswere created, analyzing the experimental responses in terms of ablation rate and surface roughness.Using regression techniques, models were developed to understand these relationships. Four multi-objective optimization algorithms, weighted value grey wolf optimizer (WVGWO), multi-objectivePareto search (MOPS), multi-objective genetic algorithm (MOGA), and multi-objective sunfloweroptimization (MOSFO), were employed to optimize these models. Key findings include MMPCDachieving the highest ablation rates at maximum fluence …