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Mechanical Engineering Design Projects

Automated Solenoid Force Measurement Apparatus

Team Members: Eric Dornfeld, Leighton Lee, and Annika Hacker

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: William Brelig, Chief Engineer, Solenoid Group, The Lee Company

Sponsor: The Lee Company, designer and builder of state-of-the-art miniature fluid control products that exceed customer expectations for utility, performance, and quality

Goal: To design and build a highly automated apparatus that will measure the force that a solenoid coil can generate, and produce a force vs. displacement curve of the test results in one continuous operation. The project seeks to streamline the testing process such that a design engineer can set-up and conduct the test at the push of a button. The measurement process should be a fully automated sequence from start to finish, with a high data capture rate.

Automated Solenoid Force Measurement Apparatus

The Lee Company logo

 

Spherical Bearing Breakaway Torque Tester

Team Members: Anthony DeTullio, Andrew Hearn, and Mario Pierre

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: Jim Mitsch

Sponsor: RBC Bearings, provider of unique design solutions to complex problems and an unparalleled level of service, quality, and support to global industrial, aerospace, and defense customers.

Goal: To design a standalone automated tester that can be used to inspect/sort a quantity of bearings and also quantify the breakaway torque, which is the force needed to overcome the static friction of the bearing. The torque data will be recorded on each bearing and the data for the populations will be graphed automatically. After each bearing is tested, it will be placed into an appropriate chute based on the design criteria that it meets.

Spherical Bearing Breakaway Torque Tester

RBC Bearings logo

 

Fiber Brush Slip Ring Test Rig

Team Members: Adam Pietrycha, James Rhodes, and Alex Washburn 

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: Chris Sutton and Bill Welsh

Sponsor: Sikorsky Aircraft Corporation, designer and builder of the world’s most advanced helicopters for commercial, industrial, and military uses.

Goal: To design a professional, quality test rig that will test a new type of fiber brush which will be used in slip ring assemblies for helicopter rotors. The fiber brushes will be tested until failure at a scaled speed and vibration to determine if they will last longer and be more reliable than current slip ring brushes. If the new fiber brushes are a viable replacement for current slip ring brushes, helicopters will require less repair time, and will have higher reliability in harsh conditions.

Fiber Brush Slip Ring Test Rig

Sikorsky logo

 

Alternate Method for Incorporating Heat Transfer and Structural Support for use in an Amine Swing Bed

Team Members: Anthony Mastromarino, Coty Schappert, and Rachael Mandel

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: Miguel Torres, Senior Systems Engineer

Sponsor: United Technologies Aerospace System, provider of innovative aerospace technologies and integrated systems that advance the performance, safety and efficiency of commercial aviation, global defense and space exploration.

Goal: To develop an alternate component to the aluminum foam that is currently used in the amine bed that meets or exceeds today’s performance. A final recommendation will be provided for the aluminum foam replacement, the analytical models for the performance and structural prediction, and the actual test hardware.

Alternate Method for Incorporating Heat Transfer and Structural Support for use in an Amine Swing Bed

United Technologies Aerospace System logo

 

Fatigue Analysis of Cable

Team Members: Austin Matthews, Atilla Irmak, Raid Alhela, and Naif Salaghur

Faculty Advisor: Ismail Orabi, Ph.D.

Sponsor: Amphenol, a premier provider of advanced technology interconnect products to the world’s leading electronics companies.

Goal: To develop  a composite finite element analysis software model and determine which materials and construction factors impact  the fatigue life of the copper conductors in high speed copper bulk cables when subjected to an industry standard flex test.  The second goal is to develop a clamping block fixture for the single cable flex cycle testing machine that will allow the operator to rotate the cable exactly 90 degrees after the first set of 750 flex cycles.

Fatigue Analysis of Cable

 

 

Razor Blade Durability Tester

Team Members: Kasra Fatemi, Ricardo Gomez, Jonathan Spiegel, and Abdulhakeem Alrumaih

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: Tim Doyle

Sponsor: Edgewell Personal Care, a trailblazing personal care company leveraging colleagues' creativity and passion to challenge convention and drive growth.

Goal: To create a device that will mimic the loads and boundary conditions encountered in shaving application. The apparatus will replicate the damages that occur during consumer use and repeat the damage reliably for all other blades. The overall focus of the project is to have a final standalone device that will be able to work in parallel or replace the current testing method.

Razor Blade Durability Tester

 

 

Sikorsky Vibration Control Moment Gyroscope

Team Members: Chris Hill, Jeffrey Panko, and Matthew Gulotta

Faculty Advisor: Ismail Orabi, Ph.D.

Industry Advisor: Bill Welsh

Sponsor: Sikorsky Aircraft Corporation, designer and builder of the world’s most advanced helicopters for commercial, industrial, and military uses.

Goal: To improve the currently achieved primary gyroscope wheel rotational speeds. Current rotational speeds have not been able to exceed 7,500 RPM and have encountered motor issues leading up to this level. The aim is to analyze the shortcomings of previous iterations, quantify issues, and perform system upgrades in order to achieve the desired gyroscopic rotational speed of 13,000 RPM and precession speed of 1,032 RPM. The project is likely to become a production feature of future helicopter technology.

Sikorsky Vibration Control Moment Gyroscope

Sikorsky Aircraft Corporation logo

 

Wedge Speaker Redesign

Team Members: Christopher Zygmunt, Joseph Caruso, Peter Furnival, and  Roxanne Redwood

Faculty Advisor: Joseph A. Levert, Ph.D.

Industry Advisor: Mr. Adrian Winiarskyj

Sponsor: Strafe Acoustics

Goal: To design and implement a method of testing the structural capabilities of professional wedge speaker designs. The test should be able to accommodate any type or shape speaker to allow testing of different designs and models. In addition, this method will be applied to the current industry standard model and improve it in the areas of strength, weight, and cost. It is anticipated that this method will make the overall weight lighter while keeping the same strength or increasing the total amount of stress the speaker can sustain before the structure fails. This will greatly improve the logistics of the transportation and handling of wedge speakers for traveling artists and road crews.

Wedge Speaker Redesign

Strafe Acoustics logo

 

Airport Bridge Flexible Service Lines (Pantograph Replacement)

Team Members: Mohammed Alomair, James Hoey, Jeffrey Lieder, and George Murray

Faculty Advisor: Joseph A. Levert, Ph.D.

Industry Advisor: Patrick O’Brien, President/CEO

Sponsor: MCM Engineering Inc., providing customers with the highest quality engineering systems, products and service that the 400 Hz Ground Power industry has to offer.

Goal: To develop a new design that provide utilities such as cold air and power to stationary airplanes at terminal gates that is less obtrusive and more cost effective than the current pantographs. As airplanes sit stationary at the terminal gates, they require these utilities. The utility lines run across  the existing “jet way”  bridge, which connects the terminal to the airplane door. The bridge expands and retracts to adapt to different aircraft models and the existing pantograph enables the lines to adjust with the bridge. Current pantographs stand very high in the air and are obtrusive.  The team is developing less obtrusive designs which are equally cost effective.

Airport Bridge Flexible Service Lines (Pantograph Replacement)

MCM Engineering Inc., logo