With continuous improvements made to materials and computational fluid dynamics (CFD) over the last 60 years, the desire to fly farther and faster has never been more achievable. Less expensive and more accessible forms of conducting hypersonic flight research are needed. Western’s Parkview Scramjet Combustion Test Lab (PSCTL) will be a small-scale mobile and modular facility to conduct research on fuel combustion in supersonic flows ranging from Mach 1.5-3.0. Overall design calculations were done in MATLAB while an improved SolidWorks 3D model was developed. Fluid flow simulations using ANSYS Fluent CFD helped to provide material requirements and a plan of manufacturability for the facility, which will allow future students to execute supersonic combustion research.

Conducting a broad spectrum of tests on a wide range of water delivery and handling components requires a large amount of time, space, and equipment. A versatile test basin capable of accommodating multiple tests has been physically modeled using Autodesk® Revit® and Siemens Amesim software packages. The basin-automated configuration, through a LabVIEW user interface, enables users to select and conduct tests to evaluate component performance based on target specifications. Upon implementation, this test basin will provide an accurate, efficient, and ergonomic solution for testing water delivery and handling components.

The Center for Advanced Vehicle Design and Simulation (CAViDS) at WMU is developing an experimental platform dedicated to test vehicle components at the high speeds that modern electric vehicles require. This test stand will operate at speeds up to twenty thousand revolutions per minute (20,000 RPM). The rotating components require appropriate lubrication and cooling to ensure long-term reliable operation. The goal of this project is to design the lubrication and cooling systems for the CAViDS high-speed test stand. Several design concepts were developed and evaluated, using analytical techniques, against predetermined performance targets. Bench-top experiments were conducted to physically evaluate the cooling system performance. The final design concept was incorporated into a 3D computer aided design (CAD) model.

Each year the Western Michigan University Formula SAE team designs and manufactures a formula style vehicle to compete the SAE international FSAE competition. The suspension system and subcomponents of the vehicle wheels play a key component in the handling and driving performance of the vehicle. Using SolidWorks, a model was created considering carbon fiber composite layup processes and techniques. The design is simulated and validated using a composite FEA (Finite Element Analysis) in ANSYS ACP. The carbon fiber laminate layup helps reduce the weight of the wheel and increase the wheel stiffness improving upon vehicle weight reduction and reducing compliance within the suspension.

Current methods of ski and snowboard manufacturing require a unique mold for all different lengths, profiles, and shapes of skis and snowboards. A three-dimensional CAD model of a ski press was created in SolidWorks. This model was designed to eliminate the need for interchangeable molds. Numerical analyses were carried out utilizing ANSYS and MATLAB to establish strength and pressure conditions. The developed design was then built in order to produce skis and snowboards. This completed press allows for affordable and efficient profile changes without the need to create a new mold for every profile and length of ski and snowboard.

Wrist joints can be easily injured. People with injured wrists will feel discomfort as they move their hand in different ways. Although wrist injuries can be recovered by limiting wrist movement with a wrist brace or wrist guard, it is not easy to recover the strength of a once injured wrist. Moreover, doing certain wrist exercises inappropriately can further injure the wrist, thus making it harder to fully recover. A wrist-training exoskeleton equipped with resistance bands can be instrumental in helping wrist-injured individuals regain their wrist strength. Created with SolidWorks, a 3D Computer-Aided Design software, and tested in WMU’s Laboratory for Advances in Rehabilitation Sciences (LARS), this rehabilitation device is a low-cost alternative that can assist individuals with wrist problems and improve their hand functions.

This project resulted in the building of the Mobile Metal Sheet Loader (MMSL). The MMSL improved the safety and efficiency while using a sheet metal shear by 1) keeping the operator further from the moving metal sheet 2) saving the operator time and 3) allowing the operator to produce more parts per hour. Design of the device incorporated computer-aided design (Solid Works), analytical calculations, input from stakeholders, research and observation of the machine during use.  The model was tested through analytical calculations to compute the load durability, structural load handling, and safety of the model loader.

The white cane that has been in use by individuals with low vision, is of limited capacity. This has led to the development of a sensor vest to replace the white cane. The vest is equipped with sensors, an Arduino, a Bluetooth, and mobile phone. The sensors send out a signal that is returned back from obstacles and sent to an Arduino, which reads the signals and translates them into a message to the Bluetooth, and then to a phone with an application to relay an audio message. This allows low vision users to walk around with confidence.

FEMA operates three Nakamura CNC lathes with a single operator, resulting in the operator having difficulty keeping up with the required machining chip and coolant blow-off and part inspections. To reduce operator requirements, an automated outfeed system was designed to perform the blow-off. Machined parts exit the lathe and enter a chamber with pressurized air nozzles to carry out the blow-off. After the process is completed, parts exit into a collection system for inspection. Automation is implemented using electronic controls and mechanical actuators. The result is more time available to perform inspections for multiple machines, potentially increasing part quality.

The WMU Sunseeker solar car team currently lacks a vehicle model to simulate performance with respect to, for example, sun angle, road characteristics, and installed components. Initially, Sunseeker vehicle running data was collected on a dynamometer to support model development. These data were then used to develop physical parameters for a vehicle model that describes the power flow between the solar array, batteries, motor, and road wheels. Simulation of the model demonstrates its use for predicting energy efficiency and the effects of operational parameters on total performance under a wide range of conditions, which is essential for optimizing race strategy.

Ramjet missile creates propulsion by compressing incoming air using the ram effect and does not involve any moving parts. The technology used in this type of propulsion system is unique and only a few countries have developed it successfully. In this project, missile configurations are conceptualized using information from books, available technical papers, lecture notes, and engineering knowledge learned during the project period. Two-dimensional (2D) and three-dimensional (3D) geometries are created using ANSYS SpaceClaim software. Computational simulations of the complex compressible airflow are performed using computational fluid dynamics (CFD) software. A calculation of this magnitude is not possible on a standard personal computer. High-performance computing (HPC) clusters at Michigan State University were used to run 2D and 3D CFD simulations using ANSYS Fluent. Using the CFD predicted data, a supersonic intake, combustor, and converging-diverging nozzle were integrated into ramjet missile aerodynamic designs. The developed missile configurations constitute a conceptual framework and provide supporting insights for the development of a scramjet hypersonic missile.

Inadequate lint filter design in specific types of consumer clothes dryers can be a major pain point for users. The main problem comes from the filter facing downwards during removal, which results in collected material falling back onto clothes or the dryer top surface. To address this, a new lint filter design was developed through physical experimentation. Special care was taken to ensure the new filter design would maintain key operating parameters, while having minimal architectural changes to other dryer subsystems. The final design delivered offers a low-cost, simple, fire-safe, and easy to implement design change to increase customer satisfaction.