Applied Mechanics Commons^™

Combined Stressors In Reliability Failure Modes In Flip-Chip Electronic Packaging, Mahsa Montazeri

Graduate Theses and Dissertations

The trend toward miniaturization of electronic devices to fulfill Moore’s law introduces new reliability concerns to the electronic packaging process while worsening existing primary challenges. In solder interconnect specifically, temperature cycling is one of the prominent failure threats. However, with further downscaling of the flip-chip solder connections, electromigration also present a precarious failure mode in these interconnects. On the other hand, understanding the degradation mechanism in solders is crucial for the power electronic products' reliability considering the industrial tendency to replace wirebonds with solder attachment while improving the current carry capacity. This dissertation utilizes FEA simulation and an experimental approach …

Design And Development Of A Novel Soft Gripper Manipulated By A Robotic Arm, Derek Price

Symposium of Student Scholars

This study presents the design and development of a tendon-driven soft gripper manipulated by a 4 DOF robotic arm. The proposed robotic arm and the gripper explore the new areas focusing on increasing the grasping performance of the gripper as well as the workspace. The gripper is designed as a 3 finger and driven by tendons using two servo motors. The tension of the strings is adjusted using a pulley mechanism and a string. The opening and grasping of the soft gripper are accomplished by each motor. The wide opening allows the gripper to grasp wide objects. The parallel robotic …

A Manufacturing-To-Response Pathway For Formed Carbon Fiber Reinforced Polymer Composite Structures, Madhura Limaye

All Theses

Over the past decade, there has been an increased adoption of thermoplastic and thermoset based continuous carbon fiber reinforced polymer (CFRP) composites for structural applications in several industries. Among the different manufacturing methods, thermoforming process for thermoplastic based continuous CFRP’s offer a major advantage in reducing cycle times for large scale productions. Similarly, out-of-autoclave curing process for thermoset based continuous CFRP’s using heated tooling enables production of large composite structures. However, these manufacturing processes can have a significant impact on the structural performance of parts by inducing undesirable effects. These effects include inhomogeneous fiber orientations, thickness variations, and residual stresses …

Anisotropic Plasticity Modeling Of Thin Sheets And Its Application To Micro Channel Forming Of Steel Foils, Jie Sheng

Mechanical Engineering Research Theses and Dissertations

Thin sheet metals and ultrathin metal foils produced by industrial rolling processes are textured polycrystalline materials and their mechanical behaviors may depend strongly on the orientation of applied loading. Consideration of such plastic anisotropy in advanced modeling of these materials is of the paramount importance in designing optimal manufacturing processes for automotive and other applications using finite element methods. This research addresses several critical issues in anisotropic plasticity modeling and its applications in analyzing micro channel forming of ultrathin stainless-steel foils. An experimental study has first been carried out on the accuracy and sensitivity of measuring the plastic strain ratios …

Cnc Feed Drive Control, Ryan J. Funchess, Caleb P. O'Gorman, Nick J. Desimone, Juan M. Majano, Samuel K. Wong

Mechanical Engineering

This document serves as the Final Design Report (FDR) for a senior project developed by our team: four senior Mechanical Engineering students and one computer engineering student at California Polytechnic State University, San Luis Obispo (Cal Poly). While the project was completed for, and sponsored by, Professor Simon Xing of Cal Poly, the remainder of the university’s controls professors will be indirectly benefited from this project. Our goal was to design and implement a functional CNC Feed Drive to be used for educational demonstrations and data collection. This document discusses our early product research and benchmark goals, which established constraints …

F34 Beekeeper Assist, Kyle Ladtkow, Javier Guerra, Jose Velazquez, Ryan Heryford

Mechanical Engineering

Alejandro Jauregui is a veteran who now works as a commercial beekeeper. He lost both of his legs during his service. While his current prostheses allow him to fully complete his work, he has found that inspection of the bee boxes causes him severe hip and back pain. Bee box inspection is a critical task for beekeeping, especially since he maintains about 200 hives every day. Our senior project team was tasked with designing and building a device that would help him move the top bee box out of the way to allow for inspection. We performed preliminary research into …

Configurable Seat Track Latching Mechanism, Emily Sun, Kai Quizon, Rick Hall, Daniel Turn, Nicholas Holman, Alexander Kuznik, Jacob Winkler, Audrey Trejo, Phoebe Zeiss, Steven Kam

Mechanical Engineering

The reconfigurable seating system is a flexible seating solution for transit vehicles that allows operators to change the configuration of the floor plan in a timely manner in order to accommodate change in needs. This project consists of three senior project teams each working on a component of the design: system, track & latch, and articulation. Descriptions of the responsibilities of each team will be discussed below.

Composite Pegboard, Asa J. Cusick, Luis Corrales, Joelle Hylton, Wyatt Pauley

Mechanical Engineering

Many of those with mobility limitations who are told they will need a wheelchair for the rest of their lives can actually begin to stand and walk again given the proper tools and support. The current design for a wheelchair seeking to support this process is overly complex, heavy, and exhibits some features that could potentially pose a serious health hazard to those using it. The scope of this project is to aid in the design of an adaptable composite wheelchair frame that can be both lightweight and strong, while still allowing for physical diversity of potential users. Through research …

Adjustable Head Tube Angle Headset, Glenn Petersen, Ben Harper, Josh Martin, Dylan Prins

Mechanical Engineering

This final design review report describes the design, manufacture, and test process of a bicycle headset capable of quickly and easily adjusting the effective head tube angle. The evolution of mountain bike geometry has forced bike designers to compromise between climbing and descending performance when choosing a head tube angle. A headset capable of quickly adjusting the effective head tube angle would allow riders to optimize their bike’s geometry for different stages of riding. This report details the research, idea generation, concept development and selection, design, manufacturing, and testing of our adjustable head tube angle headset.

Tensile Testing Environmental Chamber – Structural, Michael Ingel, Erik Soldenwagner, Austin Marshall, Lauren Schirle

Mechanical Engineering

Environmental chambers for tensile testing machines are used to study how a multitude of materials behave in extreme temperatures. These chambers provide the necessary information to innovate cutting edge technology for materials in fields such as aerospace. These chambers are often heavy and expensive requiring a significant amount of time and money just in the installation process alone. This report will serve to outline and define the design and fabrication of an environmental chamber, conducted by a team of four senior mechanical engineering students at California Polytechnic State University, San Luis Obispo. The goals of the project include a low-weight …

Project Blipper, Peter Jacobs, Preston Delaware, Ryan Foster

Senior Design Project For Engineers

This project was sponsored by Clorox to design and create an automatic bottle-unscrambling system for possible implementation at their bottling plant in Chile. The objective was to use a robotic arm to unscramble bottles from an incoming conveyor belt and place them upright on an outbound conveyor belt. Throughout the research, design, and testing of solutions for this project, several design alternatives were found for each discipline, and will be presented to Clorox so that they can make an informed decision for how and if they want to move forward with implementation of this project.

The project was split into …

Half-Barrel Planter Mover, Mihir Shah, Natalie Lewis, Mason James Hughes

Mechanical Engineering

A device for transporting heavy barrel planters is needed. Barrel planters are wooden wine barrels that have been cut in half along the circumference. They are used to store and grow a variety of plants. As such, they can contain more than 300 pounds of soil. The products currently on the market are not designed for such heavy planters, are cost prohibitive, and do not take advantage of the tapered design of a wine barrel half. A solution is needed that is durable, easy to use, and low cost. This final design report will show the steps used to find …

Accelerated Controller Tuning For Wind Turbines Under Multiple Hazards, Aly Mousaad Aly, Milad Rezaee

Faculty Publications

During their lifecycle, wind turbines can be subjected to multiple hazard loads, such as high-intensity wind, earthquake, wave, and mechanical unbalance. Excessive vibrations, due to these loads, can have detrimental effects on energy production, structural lifecycle, and the initial cost of wind turbines. Vibration control by various means, such as passive, active, and semi-active control systems provide crucial solutions to these issues. We developed a novel control theory that enables semi-active controller tuning under the complex structural behavior and inherent system nonlinearity. The proposed theory enables the evaluation of semi-active controllers’ performance of multi-degrees-of-freedom systems, without the need for time-consuming …

Enduro Campers, Ryan J. Shomsky, Alexander W. Horst, Kevin S. Pickering, Jackson L. Aplanalp, Luke Arana, Will Firestone

Mechanical Engineering

The Enduro Campers senior project team (Formerly known as Lobo Campers senior project team) was recruited by Mr. Leif Stein to assist in the design, manufacturing, and testing of the materials and components of his company’s expedition box camper. The two main focuses of the project, divided into two sub-teams, were on the testing and manufacturing process of the materials used in the camper, and on the design and analysis of the camper’s access door, step box, and other subsystems.

The focus of the materials analysis and manufacturing team was based around the design parameter to use composite sandwich panels …

Jcati Base Plate, Jacob Atamian

All Undergraduate Projects

Students of the Mechanical Engineering Technology (MET) program at Central Washington University have contributed to an ongoing Carbon Fiber Recycler project funded by the Joint Center for Aerospace Technology Innovation (JCATI). The goal of this project was to modify the existing recycling system to produce a higher success rate of recycled carbon composite material. This report focuses on increasing the rigidity of the crushing gears so that the deflection occurring among the components during operation was below 0.005 inches to ensure proper operating conditions. The operating speed of the crushing gears was 2.5 rpm with a crushing load of 10,500 …

Balsa Wood Bridge, Andrew Harris

All Undergraduate Projects

Faculty at Central Washington University proposed a challenge to mechanical engineering students that could be accomplished in an in-home setting. The goal was to create a balsa wood bridge, weighing no more than 85 grams, that can support a load over an open span and raise above its resting position by means of a mechanical system. To produce a successful solution to the problem, a vertical lift bridge was created consisting of two lifting towers and a load bearing bridge. Using equations of static equilibrium and strength of materials, the required width for each member was determined. Project requirements were …

Mini Rc Baja Car, Jason Schindler

All Undergraduate Projects

Incorporating each aspect of engineering incorporated into a senior project is difficult. That is why an RC Baja car is a great senior project for Mechanical Engineering students. The approach that students must take to design, construct, and test the car is to set parameters, and to make overall goals that can be easily measured. These goals include, but not limited to things like a $700 budget and the ability to withstand a 1-foot drop to a flat surface on all four wheels simultaneously. First, the design must meet the specifications and rules that are set previously. This ensures that …

Hydraulic Balsa Wood Rising Bridge, Kaitlyn Greenfield

All Undergraduate Projects

What is the solution to allowing tall vessels to navigate past a vehicle bridge that is less than 10 [ft] above the water? To answer this question, a balsa wood bridge was designed, constructed, and tested. The bridge needed to articulate by mechanical means, allow for travel through the bridge, and be able to withstand ample force while the main structure only being constructed of balsa wood and glue. The project was analyzed in sections. These sections include: the bridge structure and its members, the hydraulic lift, and the pins needed for the bridge and hydraulic lift to operate. The …

Asme Rc Baja Car Drivetrain, Gizan G. Gando

All Undergraduate Projects

The purpose of the RC Baja Car is to compete in the American Society of Mechanical Engineers (ASME) competition, a series of events to prove the functionality of the vehicle. This series of events includes the Slalom, Drag, and Baja race. The Slalom is a test in the steering capability of the car. The Drag is a test in the acceleration of the car in a straight line. Lastly, the Baja puts all factors together in a race to test every component of the car. This project is about building an RC car that can function under these conditions and …

Thermomechanical Mechanisms That Cause Adhesion Of Aluminum High Pressure Die Castings To The Die, Alex Monroe

Dissertations, Master's Theses and Master's Reports

In high pressure die casting (HPDC) of aluminum, cast material adhering to die is a significant defect. Adhesion occurs in two primary ways. The casting may stick preventing its removal from the die. Aluminum can also adhere to the die and buildup in local areas on the die surface with additional casting cycles. This second form of adhesion is called soldering. Lubricant is the best technology to control all forms of adhesion, but it comes at the cost of casting porosity, blisters, reduced die life, and increased die casting machine wear. New strategies to prevent adhesion are desired to eliminate …

Dual Motor Drive System For Formula Sae Electric Race Car, Bryan D. Neill, Jackson T. Mcfaul, Cole T. Andrews, Isaiah D. Penzell

Mechanical Engineering

This paper serves as the Final Design Report (FDR) for the senior project developed by our team. This FDR builds on our CDR, in which the main deliverable was the detailed design of a planetary gearbox delivering a 5:1 reduction to be mated to an Emrax 188 motor. This planetary gearbox would allow for the possibility of implementing a dual-motor torque-vectoring rear-wheel-drive system in Cal Poly Racing’s electric FSAE car, which has demonstrated in simulation to yield significant performance gain over the current single motor/mechanical LSD system. As this project’s scope is purely mechanical, the intent is for the Cal …

Design For Additive Manufacturing (3d Printing), Michael O'Donnell, Michael J. Levy

Williams Honors College, Honors Research Projects

The goal of this project is to study the performance of a 3D printed mechanical part subjected to topology optimization. A part that is somewhat complex in its load bearing and geometry will be selected. That part will then be designed, finite element analysis will be performed on it to optimize its topology, and then it will be 3D printed and tested. The goal of topology optimization is to either save material cost and/or part weight due to the ability of 3D printing to manufacture parts with complex and obscure geometry.

Door Barricade, Alex Cerino

Williams Honors College, Honors Research Projects

My senior capstone project will be a door barricade. The main idea for the use of the door barricade is for schools in the case of an intruder. The barricade that I will be designing is a solution to the inefficient barricades that I saw at my high school. It could also be used at businesses and homes. My design would be easy to use and have a fail-safe option. The two areas of mechanical engineering technology that my capstone project will focus on are stress analysis and electronics. Every part for my door barricade is drawn in SolidWorks. All …

Additive Manufactured Formula Sae Brake Caliper, Auston Obringer, Robert Kucera, Steven Massarelli, Jared John, Michael Finer

Williams Honors College, Honors Research Projects

In a world where innovation has become the new norm, automobiles can often be found at the forefront of that movement. Each and every year there are new innovations and concepts that push modern day technology to the edge of what is physically possible. This can be seen from every aspect of these automobiles ranging from the conceptual stage all the way to production.

Most of these advancements have been made possible with the new technology that has become available on the manufacturing side of the designs. Instead of being constrained by what is possible on your average 3 to …

Hydraulic Vehicle Challenge, Jacob Steiner, David Kotovets, Evan Blitz, Luke Fetherston, Alex Colucy

Williams Honors College, Honors Research Projects

The target goal of this project is for a team of students to design a vehicle which is based on human power as the primary mover of the system and achieves vehicle propulsion through the required use of hydraulics and pneumatics. In summary, the rider will power a pump that will generate pressure in order to move the fluid that drives the motor. This will result in the powered rotation of the wheels. As there are many possible designs, naturally, this means that the final design for the vehicle will have specific limitations such as weight and the required use …

Design, Fabrication, And Reliability Effects Of Additively Manufactured First Level Compliant Interconnects For Microelectronics Application, Tumininu David Olatunji

Graduate Theses and Dissertations

Semiconductor packaging and development is greatly dependent on the magnitude of interconnect and on-chip stress that ultimately limits the reliability of electronic components. Thermomechanical related strains occur because of the coefficient of thermal expansion mismatch from different conjoined materials being assembled to manufacture a device. To curb the effect of thermal expansion mismatch between conjoined parts, studies have been done in integrating compliant structures between dies, solder balls, and substrates. Initial studies have enabled the design and manufacturing of these structures using a photolithography approach which involves a high number of fabrication steps depending on the complexity of the structures …

Data Analysis To Evaluate The Performance Of Breathing Masks Used For Filtering Nano-Level Particles At Manufacturing Sites, Gracia M. Dardano

Honors College Theses

The work performed in this research aims to evaluate the performance of commercially available breathing masks in filtering airborne nanoparticles at manufacturing sites. Nanoparticles are found virtually anywhere, from dust in a worksite to a simple sneeze. Therefore, they pose a substantial threat to human health as their velocity and volatility are high. This research analyzes if current efforts of breathing masks to hinder nanoparticles are effective, especially at manufacturing sites. Data has been collected in order to analyze the behavior of nanoparticles and to measure nanoparticle levels at manufacturing sites and its working environment. Data is statistical in nature …

Final Design Review Report: The Underdogs, Parker Johnson, Jack Montgomery, Katherine Thomas

Mechanical Engineering

Aspen is a three-legged dog with mobility issues from Berkeley, California. She was hit by a car and her rear left leg was amputated at the hip. Robin Swanson, Aspen's owner, and her friend, Audrey Beil, are the sponsors for this project. Jack Montgomery, Katherine Thomas, and Parker Johnson, “The Underdogs”, are tasked with helping Aspen regain some of her mobility and the ability to go on walks. Research was done into the problem by talking with the sponsors and looking into existing products, designs, and patents. This document, the Final Design Review Report, outlines the background information, problem specification, …

2 Degree Of Freedom Robotic Leg, Oded Tzori, Henry Terrell, Adan Martinez

Mechanical Engineering

Professor Xing, an assistant professor at Cal Poly, proposed the 2 DOF Robotic Leg project for this quarter’s senior project class. The project is to build a robotic leg attached at the hip to a stand, which will be used as a teaching tool and eventually help develop Cal Poly’s very own robotic quadruped. Since this project has multiple uses after its completion, there are multiple customers that it must perform well for: the Cal Poly Mechanical Engineering (ME) Department, the ME Lab instructors, and the students. The Scope of Work (Sections 2 & 3) is composed of 2 main …

Dynamic Analysis And Fabrication Of A Bi-Stable Structure Designed For Mems Energy Harvesting Applications., Masoud Derakhshani

Electronic Theses and Dissertations

Thanks to the rapid growth in demand for power in remote locations, scientists’ attention has been drawn to vibration energy harvesting as an alternative to batteries. Over the past ten years, the energy harvesting community has focused on bistable structures as a means of broadening the working frequency range and, by extension, the effective efficiency of vibration-based power scavenging systems. In the current study, a new method is implemented to statically and dynamically analyze a bistable buckled, multi-component coupled structure designed specifically for low-frequency vibration energy harvesting systems in both macro and MEMS-scale sizes. Furthermore, several micro-fabrication steps using advanced …