Mechanical and Aerospace Engineering Presentations - Fall 2020

Retrofitting a Low-Cost Hall Effect Thruster to Achieve Long-Life

This Hall Effect Thruster (HET) is a redesign of a previous Senior Design project that experienced a significant amount of erosion to the inner channel walls which limited operational life. Manipulation of magnetic field lines reduced that issue and created a longer-lasting HET. The use of engineering software such as COMSOL Multiphysics® and SolidWorks, along with the ordering and machining of the necessary materials for the HET, allowed for the testing of the magnetic field topology. This HET provides future students the ability to utilize and expand their understanding of electric propulsion.

CLOSED PRESENTATION

Aerodynamic and Validation Package for Formula SAE Vehicle

Aerodynamics have played a progressive role in the development of Formula SAE’s top-ranking teams for the last 5 years. However, the empirical data acquisition for validation is still the limiting factor in terms of performance analysis. This project aims to provide a viable solution to this engineering challenge by creating an aerodynamic package with an integrated validation package using a data acquisition board and strain and pressure transducers.

Frame and Body Design of an Electrical Scooter

Walking on campus from building to another may cause a late arrival due to long distance. Therefore, an electrical scooter was created using Pro/Engineer and SolidWorks modeling software. An aluminum tubing cross section frame was 3D printed. The framework consists of carbon fiber panels and handlebar, rubber grips, and rubber wheels. The light vehicle with a descent speeds up to 15 mile per hour makes long distance shorter.

Software Tool for Analyzing the Bending Strength of Gear Teeth

Current finite element (FE) models for gear analysis are computationally expensive. A software tool was developed in Excel to efficiently assess the effect of different root geometries on gear tooth bending strength. The tool assesses the change in root stress as the root fillet shape is changed, using a 2-D model of a representative gear tooth. The tool was validated by comparing the root stress found using the software to a FE analysis of root stress using ANSYS. A physical test fixture was created for experimental validation. The software tool provides a resource for quick optimization of root fillet geometry in gear design.

Poppet Redesign of a Pneumatic Regulator

A current regulator design uses a brass poppet valve to adjust air pressure in a pneumatic system. An attempt to consolidate this part had been halted due to reduced air flow seen with an injection molded poppet. Benchmark testing was performed on the current design to monitor the maximum flow rate, which dictated the desired flow in prototype designs. Autodesk Inventor and ANSYS Fluent were used to conduct FEA and CFD, respectively, to validate prototypes before fabrication. The new injection molded design standardizes parts and takes advantage of economies of scale across product lines with equal or improved functional parameters.

Preliminary Design and Functional Mockup of a NASA Lunar Rover

One goal of the Revolutionary Aerospace Systems Concepts Academic Linkage (RASC-AL) project for 2020 was to design and create a rover that could support scientific missions on the moon, provide reconnaissance for future human landing sites, deploy infrastructure for human missions, and perform other risk reduction activities before another manned mission to the moon. A senior design group from Western Michigan University proposed a design for a modular based system that could be configured for various missions. The proposed design was used to develop a small-scale working prototype. Modifications to the proposed design were made as needed for manufacturing purposes. The functional prototype can be used for testing and troubleshooting without requiring large amounts of resources.

Development of a Formula SAE Hub and Wheel Assembly

Western Michigan University’s Formula SAE team designs and manufactures a formula-style racecar each year to compete with schools from around the world. To maintain competitiveness; innovative design, materials, and manufacturing process must be used.  Redevelopments to the current front and rear wheel assemblies were made to reduce mass and increase reliability using methods including static and dynamic simulation, as well as SolidWorks topology optimization. The components that were redesigned to achieve these goals included the uprights, hubs, and wheel centers with optimization checks on the bearings, wheels, and tires. The designs were constrained to comply with the current suspension geometry of the 2020 and 2021 WMU FSAE car while the redeveloped components are to be implemented into the 2022 vehicle.

Part Optimization: Longboard Truck

Current limitations on the manufacturing of highly stressed components result in parts with relatively simple geometries or assemblies. Additive manufacturing methods present an opportunity to produce more complex, efficient, and cost-effective parts. In this project, the topology optimization technique using Fusion 360 was applied to a CAD model of a reverse kingpin truck hangar. The output model is lighter weight while maintaining its structural integrity. The newly designed trucks can be manufactured using  the 3D metal printing technique.  Topology optimization was used to conduct a finite element simulation and to obtain an optimum shape of longboard truck. The project constitutes a series of ‘trial and error’ simulations of optimized the output model using different boundary conditions per simulation.

Multiple Applications Table

Exercise and physical activity can have a positive effect against multitude of health-related problems for individuals affected with mobility issues.  Physical therapy facilities require multiple pieces of equipment for specific therapeutic manipulations and exercises.  The MAT table is a multiple application therapy table to assist physical therapists and patients maneuver and exercise efficiently.  This engineered model was developed using SolidWorks software as a design and numerical analysis tool.  Fundamental analytical analysis was also performed to assist in the design process as well as to validate the numerical analysis.  This engineered design will serve as a model for the continuation to manufacture a commercial product certified for medical applications.

CLOSED PRESENTATION