Research & Projects

Overview

This project focused on selecting a new material for the lever of an ABC dry chemical fire extinguisher. The goal was to reduce the mass of the lever while maintaining or improving its performance, thereby minimizing environmental impact and promoting sustainability. The lever is a crucial component, responsible for actuating the extinguisher and controlling the discharge of extinguishing agents.

Objectives

• Minimize the mass of the fire extinguisher lever.

• Ensure the lever withstands at least 75 pounds of force during actuation.

• Maintain a Young’s modulus of at least 65 GPa for effective actuation.

• Ensure the lever operates within a temperature range of –65°F to 120°F.

• Select materials that are non-corrosive and ergonomic.

Results

The project evaluated several materials, including Titanium Alloys, Silicon Nitride, and Carbon Fiber Reinforced Polymers (CFRP). Despite the promising properties of these materials, the final analysis concluded that 409 Stainless Steel remains the best choice due to its balance of strength, manufacturing efficiency, and sustainability. While not the lightest option, its advantages in cost-effectiveness, energy consumption, and recyclability make it the most suitable material for the fire extinguisher lever. Further research is recommended to explore materials that may better align with the project’s objectives.

Overview

This study investigates advanced techniques to reduce surface roughness in electrodeposition. It reviews critical deposition parameters and their effects on surface roughness. A COMSOL Multiphysics model will simulate surface defects and height differences. Taguchi analysis will identify significant variables. An objective function will optimize parameters for minimizing roughness in nickel electrodeposition, recommending maximal forward/reverse currents, high solution conductivity, and a forward time proportion over 0.5. This research aims to improve micromanufacturing in electronics, automotive, and biomedical industries.

Objectives

• Minimize surface roughness in electrodeposition using advanced optimization techniques.

• Reduce the gap between maximum and minimum deposition heights.

• Investigate the effects of forward/reverse currents, forward time proportion, and solution conductivity.

• Develop a COMSOL Multiphysics model to identify optimal parameters.

• Enhance micromanufacturing processes in various industries.

Results

The study optimized electroplating to minimize surface roughness. Using an objective function and simulated annealing, optimal parameters for current densities, forward time, and solution conductivity were identified. These parameters significantly reduced surface roughness (Δy = 0.258). Graphical analysis showed improved surface quality and reduced defect height. Comparison with non-optimal conditions confirmed the benefits, contributing to advancements in micromanufacturing for electronics, automotive, and biomedical applications.

Overview

The automotive industry is evolving, leveraging innovative methods to enhance vehicle performance and safety. 3D printing, or additive manufacturing (AM), is transforming automotive design and manufacturing. One essential application is producing brake pedals crucial for vehicle deceleration. Optimizing 3D-printed brake pedals requires understanding the interplay between material properties, printing parameters, and mechanical performance.

Objectives

This project investigates the performance of a 3D-printed brake pedal using Design of Experiments (DOE) and ASTM standard testing. Specific objectives include:

1. Analyze mechanical characteristics: tensile, flexural, and impact strength.

2. Study the influence of:

   • Infill pattern: Evaluate the effects of grid, triangular, and cubic patterns on strength and durability.

   • Raster angle: Investigate how varying angles affect mechanical performance.

   • Layer thickness: Analyze the influence of strength and resilience.

   • Material: Compare ABS, PLA, and nylon for suitability.

   • Infill density: Study effects of varying density on mechanical properties.

Results

The study successfully met its goals using DOE and ASTM standard tests. Key findings:

• Infill density is crucial for performance and strength.

• Material selection significantly impacts mechanical properties.

• Optimal printing orientations are vital, as raster angle variations affect performance.

• Using generative design and reverse engineering, a superior brake pedal design was achieved, showcasing the potential of advanced technologies.

The enhanced brake pedal demonstrates improved qualities and robust construction, promising improvements for braking systems across industries. Future research can explore new variables and production techniques to improve 3D-printed brake pedals, unlocking the full potential of additive manufacturing for mechanical engineering and braking technology innovation.

Overview

Enhanced the endurance of USB cords by mitigating bending, fraying, and damage caused by improper handling during transportation. Conducted a comprehensive comparative study between the new 3D printed protector and existing market models to assess performance and cost-efficiency.

Objectives

1. Design a new, innovative cable protector using 3D printing technology and ABS material to enhance durability and efficiency.

2. Conduct a detailed comparative study between the newly designed protector and existing market solutions to highlight performance improvements.

3. To ensure robustness, perform a thorough analysis of the stress and strain on the new protector under various load conditions.

4. Evaluate the new protector’s load-bearing capacity to ensure it meets or exceeds the demands of typical USB cable use.

Results

The comparative study revealed significant improvements in the performance of the newly designed 3D-printed ABS cable protector over the existing models. The new protector exhibited a maximum deformation of 0.21003 mm, nearly 83% less than the 1.2458 mm deformation observed in the existing protector. This reduction indicates a substantial increase in structural stability. Additionally, the equivalent strain in the new protector was measured at 0.0020328 mm/mm, approximately 92% lower than the 0.026348 mm/mm strain in the existing model, reflecting a significant enhancement in material resilience. The equivalent stress in the new protector was found to be 122.4467 MPa, a reduction of about 88% compared to the 1055.4663 MPa stress in the existing protector, indicating a notable decrease in stress concentration. Moreover, the new protector successfully withstood loads up to 100 N, ensuring its applicability in everyday scenarios. These findings demonstrate that the new 3D-printed cable protector is more durable and cost-effective and significantly improves the lifespan and reliability of USB cables.