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Novel Tool Steel Alloy P179-X17 made with Rapid Alloy Development for Additively Manufactured Die Inserts to be used in Aluminum Injection Molding
Get PDFThe purpose of this project is to find an alloy that can be additively manufactured into die inserts for aluminum injection molding. Current die inserts are manufactured through casting, but additive manufacturing would allow for more intricacy in shape design and better design of cooling passages. A successful alloy must have a minimum hardness of 40 HRC and retain 50% of its strength after a thermal exposure of 600°C for 50-hours. The alloys under consideration are H13 tool steel, Dievar, and P179-X17 – a novel steel alloy developed by Oerlikon Surface Solutions. Cast and printed samples were received for each alloy. Microhardness and bend testing were conducted to determine the hardness and strength of each alloy before and after a thermal test. Of the cast samples, P179-X17 was the only alloy to meet the desired property goals with an average hardness of 46 HRC and 41 HRC before and after the thermal test, respectively, and a 27% and 9% decrease in yield and tensile strength, respectively. When printed, P179-X17 did not meet the minimum hardness of 40 HRC which is likely due to it being manufactured with elemental powder blends rather than atomized powder
SeaSpine Force Limiting Handle With Replaceable Components
Get PDFThis document outlines details of the Cal Poly-SeaSpine senior project collaboration for the force limiting handle with replaceable components. This document will cover a brief introduction of the project itself, background information about the problem, customer requirements and engineering specifications, ideation and concept selection, detailed design, description of testing and manufacturing plans, design verification and validation results, conclusions, and future work.
The design process included background research and scope identification, ideation, concept selection based on quality functions and customer requirements, detailed design, manufacturing, testing and iteration, and design verification and validation. Key specifications for the device included a force to break the device greater than the force to insert the spinal cage during spinal fusion surgery, 378.3 N, and less than the lower limit of the force to break the spinal cage, 923 N. The force to break the device was found to be 776 N, with upper and lower tolerance limits of 793 N and 759 N, which were well within the specified allowable range. Further details of data analysis and testing are included in Section XIII
University Rover Challenge
Get PDFOur team has designed, created, and tested a base rover for the University Rover Challenge (URC), conducted by the Mars Society. The rover\u27s design focuses on modularity and robustness, incorporating a chassis constructed from aluminum extrusions, a robust rocker-bogie suspension system, a six-wheel drive train, and basic controls. The choice of aluminum extrusions ensures modularity for future enhancements, while the rocker-bogie suspension system, commonly used in other competitive and actual Mars rovers, provides improved stability and maneuverability. Rover operations are governed by a server-client architecture, with an Xbox controller input providing an intuitive user interface for movement control. Comprehensive testing confirmed the rover\u27s capability for remote operations and maneuverability, and it meets URC design specifications with a weight of 35 kg and dimensions of 1.168 x 0.991 x 0.457 m. Future teams will need to incorporate a robotic arm, in-situ testing capability, and autonomous navigation, enabling full competition readiness for the URC
Adjustable Portable Makeup Chair
Get PDFThis Final Design Report (FDR) presents the development and evaluation of our adjustable portable makeup chair that is designed to meet the specific needs of makeup artists. To remedy the lack of height adjusting and compact makeup chairs in the market currently, our senior design project planned on creating a height adjusting and portable makeup chair that will be suitable for makeup artists of different heights and is easily transported from one location to another, ideally in the makeup artists car backseat. After finalizing our design, through CAD (SolidWorks), dimensions, equipment and materials which were needed to create our chair, we ordered our materials through different vendors and started building in the machine shops available to us. We used various manufacturing processes such as metal saw cutting, welding, hydraulic tube bending, and 3D printing. The main gas spring we were planning on using to be the main mechanism to activate the height adjusting feature of the chair as well as make it compact was unavailable due to time and manufacturing constraints, so a 3D printed telescoping cylinder was used. Some tolerancing issues also arose when it came time to build the chair. These issues while creating obstacles led us to refine our design and learn from them in order to improve the manufacturing and building of the chair for future production. There was also some instability in the chair that might cause it to tip over and this observation was important to us to make some recommendations or let our sponsor know this might be an aspect that needs refining as well to make a more stable chair. After manufacturing we finished our prototype that showed the functionality of the chair and that it would be compact. Again, without the spring we could not lock the chair at various heights, but our prototype showed it could be compact and ideally it would be suitable to be height adjusted if a proper mechanism could be locked at a certain height
Advanced Wildfire Hose Clamp
Get PDFWe, Team AHC, have designed, manufactured, and tested an advanced firehose clamp for wildland firefighters to use during extended hose lays. The clamp is designed to stop high-pressure water flow in a firehose so that a new length of hose can be added. The current industry standard, the Timberline hose clamp, is expensive and wears down over time effecting the speed and success of hose lays. Our goal was to improve firefighter\u27s tools and therefore improve fire fighting effectiveness
Optimizing the Induction Coil Heat Treatment Parameters for Golf Club Iron Hosels to Facilitate Room Temperature Bending
No full textTo personalize loft and lie angles for avid golfers, TaylorMade Golf bends clubs to fit their needs. Our project goal is to find the best heat treatment parameters in order to prevent golf club hosels from breaking in manufacturing, which will save TaylorMade time and money. We did microhardness and microstructural analysis on 20 golf club heads. These include two different types of steel, 8620 and C450. For each steel, we received a non-heat-treated sample, 3 samples heated to their nominal temperature, 3 samples heated 100℃ below the nominal temperature, and 3 samples heated 100℃ above the nominal temperature. 20 cylindrical tensile specimens were also tested with the same heat treatments. Through microstructural analysis we confirmed that the +100℃ sample’s heat affected zone showed signs of recrystallization indicating a full phase transformation into the austenite region during heat treatment. Microhardness testing showed no significant differences in hardness between the different heat treatments. Tensile data showed a significant increase in percent ductility with hotter heat treatments. Although the nominal heat treatment should reach full austenitization, we believe the samples are not being held at this temperature long enough, due to the rapid rate of induction coil heating, for diffusion to occur. Thus, the reason why we are seeing 3-4% less ductility in the nominal heat treatment compared to the +100℃ heat treatment
Bruxism Biofeedback Device
Get PDFThis paper aims to summarize the design process for a biofeedback bruxism device, covering the necessary background research, engineering requirements, design process, prototyping, manufacturing, and testing for the device. The purpose of this project was to design an engineering solution for the treatment of bruxism. This entails both measuring and significantly reducing clenching and grinding during sleep, as many current solutions may reduce symptoms of the disorder, but do not treat bruxism itself. Engineering requirements included biocompatibility, size and weight, electrical safety, and easy of use and comfort. Many design options were proposed, and a Pugh Matrix was used to help choose the best design, given customer and engineering requirements. The selected conceptual design includes a pressure sensor embedded in a custom mouthguard that communicates using radiofrequency (RF) to a haptic feedback module in a headset to alert the user when they are clenching. This feedback device activates above a bite force threshold–effectively treating bruxism with classical conditioning, pairing a haptic response with the action of unclenching. The design went through several rounds of prototyping to make circuit alterations and manufacturing changes, while attempting to verify the device efficacy. A final proof-of-concept product was presented to the sponsor, including two functional circuits that are able to 1) sense pressure using a pressure sensor embedded in silicone, 2) send a signal using an RF transmitter to a receiver connected to the haptic circuit, and 3) trigger the haptic response module to vibrate, with a minimal response lag time between force being applied and response triggering. The result of this project produced a proof of concept circuit for both the sensing and responding circuits. A final conceptual design is proposed for the ideal circuits and mouthguard design, including manufacturing and testing plans. Next steps are outlined to aid in the continuation of this project in future years
Valve Efficiency Testing Device
Get PDFThis document serves as the official Final Design Review (FDR) for the mechanical engineering team on the Valve Efficiency Testing Device project for the Phillips 66 Rodeo Refinery. The team attends California Polytechnic State University, San Luis Obispo. The project involved designing and building a valve efficiency testing device. The goal was to create a finished test device that can be used in the Phillips 66 Rodeo Refinery machine shop to test reciprocating compressor valves before they are installed. The purpose of this document is to describe the manufacturing and design verification activities that have been completed since Critical Design Review in February and evaluate how well the design achieves the project’s goals. The key findings of this report include a description of the final design, as well as how the final prototype was manufactured and tested. It also summarizes lessons learned throughout the project, along with recommendations for Phillips 66 concerning the optimal utilization of the test stand. During testing, the test stand successfully measured the leakage of 8-inch suction and discharge poppet valves and reported leakages much less than the maximum allowable leakage of the given valves. The final design meets the objectives because it is fast to test one valve and can test valves up to 16 inches in diameter. By following the recommendations, Phillips 66 can safely and successfully utilize the test stand in determining valve efficiency and adopt the test stand for a wider range of valve sizes
Northrop Grumman Collaboration Project
Get PDFThe Northrop Grumman Collaboration Project (NGCP) is a collaborative club project sponsored by Northrop Grumman for the students of Cal Poly San Luis Obispo (CPSLO) and Cal Poly Pomona (CPP) to create a fleet of vehicles to aid in the simulated rescue of stranded hiker. The CPSLO club is responsible for delivering an autonomous flight vehicle that can suppress a fire and retrieve a payload. Mechanical Design Team of the CPSLO team was responsible for the design of the frame, electronics housing, and payload and fire suppression systems
Supper: the social food app
Get PDFThis social app aims to increase a user’s social network through dining experiences. It creates a framework for how their users are to take their connection from the digital realm to the physical one. The app cultivates friendships through individual and group connection, while providing users with suggestions on nearby restaurants to connect in person. This application aims to reach users that may be new to an area and thus may not know anyone and are largely unfamiliar with local restaurants, or even those that simply want to expand their social circle. Because meals are commonly a social or communal event, this app aids in expanding a user’s social network through dining experiences. Social apps such as Tinder, Hinge, and Bumble are designed for connection, though they largely revolve around cultivating romantic relationships while ignoring platonic ones. Along with this, there is a lack of framework for how their users are bridge physical & digital realms. Therefore I see an opportunity to create a social app that aids in expanding a user’s platonic social network with a framework for how and where to meet. This project aims to create a fully designed interface of a mobile application. 1. Improve UX design skills 2. Improve project management abilities (time, accountability, and planning