Mechanical and Aerospace Engineering Presentations Session A - Spring 2021
CARBON FOOTPRINT REDUCTION FOR ALLEGAN COUNTY
The current carbon dioxide level is at a maximum for the last 650,000 years leading to a rise of more than 1 °C for global temperature, and over 3 mm increase in sea level per year. This rise in the global temperature will have negative long-term effects on the environment. A comprehensive strategic action plan for Allegan County was developed with various methods that can be undertaken to reduce the overall carbon footprint in the sectors of Transportation, Electricity Generation and Consumption, and Residential and Industrial Heating.
SCRAMJET COMBUSTION LAB DEVELOPMENT
Scramjet engines are an area in need of further research, particularly their combustion chambers. A three-dimensional CAD model of a scramjet combustor lab was created in SolidWorks. This model was used to conduct heat transfer and stress analysis and simulations. Numerical analyses were done in MATLAB to establish fluid flow conditions and requirements. The developed design provided a concept and supporting analytics to build the scramjet combustion lab at the College of Engineering and Applied Science, WMU.
DECREASING THE AERO-ACOUSTIC NOISE GENERATED BY WIND TURBINE BLADES
One of the most prevalent restrictions on wind energy development is the noise pollution caused by turbine blades. To address this issue, three-dimensional airfoil models were developed, incorporating several design methods for reducing the aero-acoustic noise generated at the trailing edge. These models were 3D printed at a scale level and evaluated in a WMU acoustic wind tunnel. Simulations were performed in ANSYS to visualize the pressure fluctuations of the air flow over the airfoils. The experimental data affirm the effects of the noise-reducing features that were implemented. Reducing the low-frequency noise produced by wind turbine blades will enable larger expansion of wind energy applications.
AUTOMATED FORM-FILL-SEAL LOADER
Automated loading systems for form-fill-seal machines are large, costly, and fully integrated with the form-fill-seal machine itself. A portable, non-robotic automated loading system prototype was developed within SolidWorks and built to operate with a form-fill-seal loading area model. Simple material loading and controls help to limit the required amount of human interaction during operation. All service life and initial dynamic motion calculations were completed using analytical methods. Various subsystem prototypes were created throughout the design process to validate the conceptual and 3D model designs. The designed automated loading system reduces operation cost, and saves material and time.
ROTARY JOINT SEALING SURFACE MANUFACTURING IMPROVEMENTS
SX rotary joints are designed to link rotating machinery to stationary piping, but if the sealing surfaces of the joint are not spherical enough to provide a perfect seal, leaks will occur. The manufacturing process of the 3300SXB rotary joint body was analyzed to isolate variables that introduced inconsistencies in the spherical sealing surface. Through testing, these variables were evaluated, and manufacturing solutions were proposed to minimize manufacturing inconsistencies. These solutions decreased variability of the sealing surface and improved sealing performance.
PNEUMATIC CYLINDER AUTOMATED TESTING FIXTURE
Pneumatic cylinders must currently undergo a series of manual, time consuming tests before being shipped to a customer. To reduce testing time and effort, a test fixture is presented that will quickly measure the characteristics of each cylinder with little manual work. The fixture supplies regulated air flow and verifies the orientation of cylinder components, tests rod extension and retraction, and checks changes in air pressure. A Programmable Logic Controller that relies on a variety of position and pressure sensors is used to automate the testing process. Automating the test process decreases the cycle time and lowers labor costs associated with the production of a pneumatic cylinder.
FSAE ELECTRIC FORCED INDUCTION SYSTEM
This project outlines the design and development process of an electric-based, forced- induction system for the Western Michigan University Formula SAE vehicle. It is a rethink of forced-induction that eliminates the limitations imposed by mechanical coupling. A DC motor is fitted to the centrifugal compressor in place of an exhaust turbine or pulley-belt setup to supply boost independently of engine speed. Activation of turbo boost is programmable per application and driver. GT-POWER and MATLAB are utilized to test and validate an engine performance model and lap time simulation. By increasing the torque and power outputs through selected moderation, this system will decrease the FSAE vehicle's lap times, increasing WMU's competitive edge.
OPTIMIZATION OF CYLINDER DEACTIVATION LATCH DESIGN IN A DIESEL ENGINE
Cylinder Deactivation (CDA) is utilized often within Passenger Vehicles for fuel economy benefits. Studies show that CDA reduces emissions (NOx) and improves fuel economy in Commercial Vehicle (CV) applications. CV engines operate with lower oil pressure than passenger vehicles. The goal of this project was to enable a Latch Pin System on a diesel CV application to reliably operate at pressures as low as 1.0 bar. The feasibility of optimizing the existing design or redesigning the system were explored. The tools used in this project include: GT-SUITE to design key features, Minitab for Design of Experiments (DOE), and CAD software to create the model for Testing and Packaging.
AIRCRAFT ENGINE MOUNT REDESIGN
The aviation sector is a demanding and ever improving market to design and build the optimum products to surpass customers’ expectations. Our team created a three-dimensional engine mount that was designed in SolidWorks, a solid modeling computer-aided design and engineering program. The model can be used to study the stresses and deformations that come from inflight conditions using Finite Element Analysis. The completed model assists in the future modifications which can then be utilized and implemented in the design of aircrafts.
CHARGE TRACING FOR DETERMINING ELECTRICAL FACILITY EFFECTS ON ELECTRIC SPACECRAFT PROPULSION SYSTEMS
Electric Propulsion Systems are the future of deep space travel; however, analysis of how testing facilities affect system performance, especially with respect to the flow of charged particles, at universities lacks proper equipment. Using COMSOL, a physics simulation and modeling software, and SolidWorks, a 3D CAD software, a small-scale instrument for tracking charge in electric propulsion testing facilities was designed based on a larger version in use by the Air Force Research Laboratory. This design will allow universities to analyze the flow of charged particles in the propellant stream of electric propulsion systems, providing universities with a vital instrument to continue research into electric propulsion systems.
LONG-DURATION VENUS EXPLORER
Due to the high temperatures and pressures on Venus, no scientific landers have been able to survive on the surface for more than two hours, which significantly limits the amount of science that can be collected. To address this, a lander was designed to withstand the extreme conditions of the Venusian surface for an extended period. Passive pressure management and thermal control systems were designed as an improvement upon prior landers, and a thermoelectric generator was selected to provide power to the lander by utilizing the difference between the lander’s interior and exterior temperature. The design was rendered and validated using software packages such as Inventor, MATLAB, and Simscape. A long duration Venus lander can help determine whether Earth could evolve to be as inhospitable as Venus in the future and answer questions about the evolution of the solar system.
PASSIVE THERMAL CONTROL SYSTEM DESIGN AND ANALYSIS FOR OPS-CUBE 6X1 CUBESAT
The team will be designing and analyzing a passive thermal control system for the Optical Plasma Spectroscopy Cube-Satellite. The full success criteria for this project will be proving the thermal control system has effectively reduced the heat flux within the satellite via thermal modeling in a specialized software, as well as product selection for the thermal control components. This is fully realized by ensuring that component temperature is maintained within given standards for consumer off-the-shelf materials. This is determined and adhered to for application-built hardware.
CHAINLESS CHALLENGE HYDRAULIC BIKE
A vehicle that utilizes hydraulics with human power serving as the prime mover needed to be designed and built to compete in a competition against 16 other universities. First, a conceptual design needed to be created to place necessary components needed for the vehicle to function using hydraulics as the propulsion system. Calculations were then made to drive the choice of components needed for the vehicle. Next, ordering and receiving of components took place until a working prototype was assembled. Finally, evaluation of the prototype commenced with testing and final adjustments until the vehicle met desired performance and efficiency parameters.