Other Mechanical Engineering Commons^™

Utilization Of Recycled Filament For 3d Printing For Consumer Goods, Alexa Peterson

Apparel Merchandising and Product Development Undergraduate Honors Theses

The 3D printing market has been used in a wide variety of manufacturing industries including textile and apparel. Many consumers can now own a personal 3D printer at home for recreational printing. There are even websites dedicated to 3D printing patterns made by consumers. However, the materials used in the 3D printing process pose a problem for the environment due to their plastic-based nature. 3D printing is a layered process with each layer being printed depending on the layer below it for strength and stability. During the 3D printing process, great amounts of waste are produced as a result of …

Impact Of Magnetocaloric Material Properties On Performance Of A Magnetocaloric Heat Pump., Michael G. Schroeder

Electronic Theses and Dissertations

In the field of magnetocaloric heat pumps much research has been performed around machine design and theoretical machines, but little has been researched around practical problems such as variability in material properties. The present work defines a simulation tool that has been proven with experimental data. Magnetocaloric material cascades were statistically analyzed and parameterized, such that they could be recreated parametrically using a split Lorentz function with normally distributed parameters. Correlated curve-defining values with standard deviations were used as input into the simulation tool to determine the effect of variation on cooling heat pump performance for a household refrigerator application. …

Service Dog Ramp, Matthew Lundgren, Ariel Tolentino, Dallas Rocha, Adam Mayeda

Mechanical Engineering

This project involves designing a device to help a service dog easily get into and out of a truck. It details the design and manufacturing process. The project was interrupted due to the COVID-19 pandemic, so detailed instructions are provided for whoever takes on the project in the future.

Impact Of Part Thickness And Drying Conditions On Saturation Limits In Binder Jet Additive Manufacturing, Nathan B. Crane

Faculty Publications

Binder jetting (BJ) is a high build-rate additive manufacturing process with growing commercial interest. Growth in BJ applications is driven by the use of finer powders and improved post-processing methods that can produce dense, homogenous final parts. However, understanding of the basic droplet/powder interaction is relatively limited. This paper considers the impact of in-process drying, part geometry, and droplet size on a key printing parameter: binder saturation. Parts of varying thicknesses are printed with a range of saturation levels under various heating conditions. The ratio of the printed part mass to the theoretical part mass is used to detect bleeding. …

Composite Guitar, Ryn Rollins

All Undergraduate Projects

Traditional wood-bodied products such as boats, hockey sticks, and guitars can be easily chipped or cracked if not properly taken care of. The wood can absorb moisture and deteriorate over time. If that wood is replaced with composite materials, those products can become stronger, more lightweight, and resistant to temperature and corrosion. Two of the most popular composite materials are carbon fiber and fiberglass. Because these composite materials have such a high strength, the core of a guitar body can also be replaced with a lighter material such as Styrofoam which makes for a lighter and more durable guitar. The …

R/C Mini Baja Car: Drive Train And Steering, Carlton R. Mcdonald

All Undergraduate Projects

The purpose of the Baja R/C Car is to compete in the ASME eFX competition in 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 vehicle, the Drag is a test in the acceleration of the vehicle in a straight line, and the Baja puts all factors together in a race to test every component of the vehicle. This project is about building an R/C car that not only functions, but also has maximum performance capabilities …

Automated Runout Measurement Tool, Ethan Tisch

Williams Honors College, Honors Research Projects

A new measurement process and tool is to be developed to improve the existing method for measuring runout on the commutators of brushed DC product.

After an armature is manufactured, the commutator is inspected by placing the completed rotor assembly in one of several non-standard measurement fixtures. An indicator is then positioned on the commutator. A trained operator proceeds to rotate the armature while taking runout and bar-to-bar measurement at various positions along the length of the commutator.

This existing process is slow, costly, and unreliable. For these reasons, there is substantial economic pressure to develop a superior method for …

Influence Of Droplet Velocity, Spacing, And Inter-Arrival Time On Line Formation And Saturation In Binder Jet Additive Manufacturing, Trenton Colton, Nathan B. Crane

Faculty Publications

Binder Jetting (BJ) is a low-cost Additive Manufacturing (AM) process that uses inkjet technology to selectively bind particles in a powder bed. BJ relies on the ability to control, not only the placement of binder on the surface but also its imbibition into the powder bed. This is a complex process in which picoliter-sized droplets impact powder beds at velocities of 1-10 m/s. However, the effects of printing parameters such as droplet velocity, size, spacing, and inter-arrival time on saturation level (fraction of pore space filled with binder) and line formation (merging of droplets to form a line) are unknown. …

A Numerical And Experimental Study On Effect Of Composition Of Ar-N2 Shielding Gas On The Weld Bead Profile And Its Prediction For Hot Wire Arc Additive Manufacturing, Niraj Pudasaini

College of Graduate Studies: Theses & Dissertations

Wire arc additive manufacturing is a process of making three-dimensional metal parts in a layer-by-layer approach using a feed wire and electric arc as a heat source. Wire arc additive manufacturing (WAAM) is becoming more popular due to its ability to create complex 3D parts, less build time, high deposition rate, and significant cost savings. Out of the many parameters used in WAAM, one of the important parameters is shielding gas which plays a significant role in material quality, properties, and defects. In this study, a controlled amount of Argon (Ar) and Nitrogen (N₂) shielding gases are used …

Adhesion Testing Of Printed Inks While Varying The Surface Treatment Of Polymer Substrates, Clayton Neff, Edwin Elston, Amanda Schrand, Nathan B. Crane

Faculty Publications

Additive manufacturing with conductive materials enables new approaches to printed electronics that are unachievable by standard electronics manufacturing processes. In particular, electronics can be embedded directly into structural components in nearly arbitrary 3D space. While these methods incorporate many of the same materials, the new processing methods require standard test methods to compare materials, processing conditions, and determine design limits. This work demonstrates a test method to quantitatively measure the adhesion failure of printed inks deposited on a substrate without changing the ink printing conditions. The proposed method is an adaption of single lap shear testing in which the lap …

Mechanical And Temperature Resilience Of Multi-Material Systems For Printed Electronics Packaging, Clayton Neff, Justin Nussbaum, Chris Gardiner, Nathan B. Crane, James L. Zunino, Mike Newton

Faculty Publications

In this work, two AM technologies were utilized to compare the effectiveness of fabricating a simple electronic device with a conductive trace and hollow cylinder representative of ‘printed packaging’ that would survive harsh environmental conditions. The printed packaging cylinder delineates printed potting for electronics packaging. An nScrypt direct write (DW) system was the primary manufacturing system but a developing technology—coined large area projection sintering (LAPS)—manufactured a subset of samples for comparison. The tests follow Military Standard (MIL STD) 883K and include resiliency evaluation for die shear strength, temperature cycling, thermal shock, and high G loading by mechanical shock. Results indicate …

Wetting Metamorphosis Of Hydrophobic Fluoropolymer Coatings Submerged In Water And Ultrasonically Vibrated, Matthew Trapuzzano, Nathan B. Crane, Rasim Guldiken, Andrés Tejada-Martínez

Faculty Publications

Many important processes, from manufacture of integrated circuit boards, to an insect’s ability to walk on water, depend on the wetting of liquids on surfaces. Wetting is commonly controlled through material selection, coatings, and/or surface texture. However, wetting is sensitive to environmental conditions. In particular, some hydrophobic fluoropolymer coatings are sensitive to extended water exposure as evidenced by a declining contact angle and increasing contact angle hysteresis. Understanding “degradation” of these coatings is critical to applications that employ them. The durability of a series of fluoropolymer coatings were tested by measuring the contact angle before, during, and after extended submersion …

Binder Jetting: A Review Of Process, Materials, And Methods, Mohsen Ziaee, Nathan B. Crane

Faculty Publications

Binder Jet printing is an additive manufacturing technique that dispenses liquid binding agent on powder. Layers are formed repeatedly to build up a physical article. Binder jetting (BJ) can be adapted to almost any powder with high production rates. The BJ process utilizes a broad range of technologies including printing methods, powder deposition, dynamic binder/powder interaction, and post-processing methods. A wide variety of materials have been demonstrated including polymers, metals, and ceramics, but a common challenge is developing printing and post-processing methods that maximize part performance. This article presents a broad review of technologies and approaches that have been applied …

System Integration Of C-Arm Robotic Prototype Using Motion Capture Guidance For Accurate Repositioning, Alireza Yazdanshenas

Mechanical Engineering Theses

One of the important surgical tools in spinal surgery is the C-Arm X-ray System. The C-Arm is a large “C” shaped and manually maneuvered arm that provides surgeons and X-ray technicians the ability to take quick quality X-rays during surgery. Because of its five degrees of freedom, the C-Arm can be manually maneuvered around the patient to provide many angles and perspectives, ensuring surgical success.

This system works fine for most surgical procedures but falls short when the C-Arm must be moved out of the way for complicated surgical procedures.

The aim of this thesis is to develop an accurate …

Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz

Mechanical Engineering

This report provides a comprehensive description of the research, analysis and design work that The Incompressibles have completed thus far in the senior project process. This document includes all the work that The Incompressibles have completed for the team’s Preliminary Design Review (PDR), Critical Design Review (CDR), the work leading up to the 2019 FPVC competiton and the competition results. This report includes the initial research that the team completed for the fluid power competition, first iterations of designs, final iterations of designs, manufacturing results and processes, and finally testing and results from competition. With a new design for the …

Nano Fab Lab 63, Brian K. Deemer, Josh Clemons, Nick Brodine, Delaney Fitzsimmons

Mechanical Engineering

Lawrence Livermore National Laboratories (LLNL) has several steps in the production process for ceramic nanofiber tubes that they would like to improve - electrospinning, cutting, rolling, sealing and heat treating. We undertook the challenge to deliver LLNL with a semi-automated process that efficiently integrates the steps of cutting, rolling, and sealing to save time and improve control over end dimensions. In this document, we discuss the technical background of the manufacturing steps currently followed to create nanofiber tubes, identify which steps are incorporated in our prototype and explain how they will interface with one another, define the design requirements, present …

Human Powered Vehicle Trainer, Nicholas Hung Nguyen, Gregory Reece Bridges, Jacinta Garcia, Mitchell Sidney Smith

Mechanical Engineering

This Final Design Review (FDR) document describes the final design and completed prototype of a Mechanical Engineering senior project team at California Polytechnic State University, San Luis Obispo. The project goal is to create an adjustable human powered vehicle training bike for George Leone that allows a rider to gain confidence with the unique reclined bike geometry ahead of the World Human Powered Speed Challenge at Battle Mountain, Nevada. This document outlines the customer’s needs and technical research performed which together determine the project’s scope and engineering specifications. Next, we present the initial idea generation process and its results, along …

Problem Based Learning: A Case Study From Mechanical Engineering, Kevin Delaney, Ger Nagle

Conference papers

Engineering graduates today must be capable of much more than solving technical problems taught in engineering school. Despite learning to quantify the performance of certain engineering objects, undergraduate students find it challenging to integrate these elements into basic design concepts through a coherent and systematic design process. To help students develop real-world engineering skills as part of their engineering education, the Mechanical Engineering Discipline in Technological University Dublin (TU Dublin) introduced Problem Based Learning (PBL) for Third Year Mechanical Engineering students in 2005.

A recent review of this teaching approach highlighted deficiencies not envisaged when the initial PBL module was …

Framed Human Powered Vehicle Frame, Keyanna Brielle Henderson, Brendon Howard Morey, Kyra Noelle Schmidt, Austin Patrick Henry

Mechanical Engineering

The following is the Final Design Review (FDR) Report for Framed, a team tasked with designing and fabricating the frame of the 2018-2019 Cal Poly Human Powered Vehicle (HPV) Club bike. The bike is to be raced at the 2019 World Human Powered Speed Challenge in Battle Mountain, Nevada with the goal of breaking the American collegiate speed record. The purpose of the FDR Report is to introduce the project’s background and objectives, discuss the final design, and present the results of manufacturing and testing. Prior to beginning work on the design of the frame, the group conducted extensive research …

Vaccine Cooler For The Global Poor, Benjamin J. Larson, Cooper E. Gibson, Eilbron Younan, Cody R. Volk

Mechanical Engineering

Cal Poly physics professors Peter Schwartz and Nathan Heston approached the Solar Freeze team with the problem that remote communities in Africa have limited access to modern-day medicine or vaccines. They suggested that we try and design a cooling device that can keep vaccines cold for multiple days at a time while the medicine is transported to remote villages. Currently, there are vaccine cooler products on the market, but most of them are very expensive or lack portability. Peter and Nate have tasked the Solar Freeze team to come up with a less expensive solution that is also portable and …

Danny’S Recumbent Bike Accessibility Device Final Design Report, Joseph J. Lee, Huy Nguyen, Jack Mcatee, John Kulick

Mechanical Engineering

The purpose of this document is to fully define our design solution and explain our manufacturing and testing results. Our project’s goal is to find a way to allow Danny Knutson, a retired Navy pilot and incomplete quadriplegic with limited use of his arms and an impaired sense of balance, to enter and exit his recumbent tricycle without any discomfort for him or his aide. We completed multiple interviews with Danny, patent research, existing product research, and other technical literature research in order to fully understand the problem. We synthesized this information to create a concrete list of customer wants …

Universal Bike Suspension Design, Ernesto Huerta, Gregory Ryan Ritter, Chris Michael Fedor, Michael Wu

Mechanical Engineering

Cal Poly Bike Builders (CPBB) is a student club at Cal Poly helping students design and fabricate their own bicycles. Currently, club members build rigid frames and mountain bikes with only front-suspension–commonly referred to as a “hardtail”. As more students join the club, interest grows in building full-suspension mountain bikes (FSMTB). Designing and manufacturing a mountain bike rear-suspension system requires a diverse skillset and a substantial time commitment. As a result, individual efforts building FSMTB have proven unsuccessful. The scope of this project is to develop a defined method and necessary tools such that all CPBB members can efficiently build …

Restore-L Satellite Servicing Internship Final Report, Giovanni Campos

Publications and Research

This paper reviews the Restore-L mission purpose and the necessary research and simulations to meet mission specification for the Propellant Transfer Subsystem (PTS). It is essential the PTS undergoes functionality testing, environmental testing, and calculations to understand the capabilities of the system. For the testing of components from PTS, a proper test setup is required. It is vital for test hardware, such as hoses and valves, to stay in place while the test is being performed. For the test hardware to operate correctly, positioning, orientation, and alignment are critical as well. In addition to the testing, calculations for pressure drop …

Investigation Of Design, Manufacture, Analysis, And Test Of A Composite Connecting Rod Under Compression, Thomas Juhl Rohrbach

Master's Theses

Composite materials hold great potential for the replacement of traditional materials in machines utilized on a daily basis. One such example is within an engine block assembly where massive components inherently reduce the efficiency of the system they constitute. By replacing metal elements such as connecting rods, cylinder caps, or a crank shaft with composite alternatives, a significant increase in performance may be achieved with respect to mechanical strength, thermal stability, and durability, while also reducing mass. Exploration of this technology applied to a connecting rod geometry was investigated through a combination of process development, manufacturing, numerical analysis and testing. …

Torsional Stiffness Of A Race Car, Reiley A. Schraeger, Cameron Kao, Raymond Deng, Omar Roman

Mechanical Engineering

Torsional stiffness plays a major role in any road vehicle. To understand torsional stiffness of a vehicle and make future iterations and improvements, a proper torsional stiffness jig is required to prove accurate and useful data. This report encompasses the new and improved testing jig and potential improvement ideas for more accurate results. With real data result relating to FEA calculations, designers can be confident in the FEA changes to torsional stiffness is accurate and will yield the probably results they desired. This report shows the methodology, manufacturing process and testing procedure to use on any Baja or SAE vehicle …

Stair Climbing Hand Truck, James Mcpherson

All Undergraduate Projects

Abstract

Getting a heavy object up a flight of stairs usually requires a team of two or more people. Even with a team of people, the task is often still difficult, dangerous, and possibly insurmountable by one person. This problem is especially prevalent in for those who are moving into apartment complexes. Most apartment complexes have many buildings with two or more floors of living quarters, and elevators are often missing. This project sought to offer a solution to this problem. The solution in question; a motorized hand-truck with 2, trigonal planar pinwheels in place of the stock wheels. The …

Composite Recycler: Delamination, Nathan Sauer

All Undergraduate Projects

A great deal of composite waste is generated in the construction of wings for the Boeing 777. These carbon fiber “wing trimmings” are currently being disposed of in a landfill. These carbon fiber boards are made of several layers laminated together, making them very rigid and hard to recycle. This report proposes a method to delaminate the layers of these composite wing trimmings using a hydraulic press and a V-shaped steel die so that they may be more easily shredded and thus recycled. A top, “male” die with two points is pressed into a bottom, “female” die with three points …

Autojack - Hydraulic Powertrain System, Tyce Vu

All Undergraduate Projects

A primary problem for mechanics and automotive enthusiasts is the risk associated with lifting and securing a vehicle with conventional jack stands. Often times, improper jack-stand installation results in the vehicle collapsing unexpectedly, causing injury and/or death. This problem can be minimized through the application of a newly re-designed vehicle lifting system. The conventional method for lifting cars is time consuming and can be unsafe in many circumstances. A better, safer, and more efficient lift design was needed; the AutoJack. The approach of the AutoJack design was entirely focused on the safety of lifting a vehicle. Safety was improved by …

Custom Foot Prosthetic: Diabetic Care, Chandler Streuli

All Undergraduate Projects

Across the United States there are people every day who lose their toes to diabetes or to loss of circulation within their legs. The problem becomes building a more cost effective and efficient prosthetic for these individuals. The prosthetics that are used for medical purposes are often costly, especially without the help of insurance. The new prosthetic was designed to be taken in and out of shoes so that it is fast and easy for the user to move the device from shoe to shoe. The manufacturing method for this project was using a 3D printer to build the initial …

Ares Cleaning System, Andy Sagers, John Cunningham, Peter Greig, Jack Glynn

Mechanical Engineering

In this Final Design Review, the team outlines the general scope of the ARES Cleaning System project and the final design direction chosen and built. This team consists of a group of four mechanical engineering students who have been tasked with designing and manufacturing an autonomous ARES cleaning system to help their sponsor, Fracsun, better track soiling losses measured at large solar arrays. They designed, conceptualized, manufactured, and tested throughout the project as they looked to create a final, functioning product. In creating this Final Design Review, they have identified how the product will perform the desired functions and what …