DIMLab Stander Symposium Projects

2021

Transforming Topology Optimization Results into Manufacturable Frames

Braeden Jay Windham

View the poster in PDF View the poster in PowerPoint

Frames used in aircraft and automotive structures must be rigid and lightweight. With modern software, frame designs that are optimized for stiffness with respect to weight can be readily generated. Manufacturing these frames, however, can be costly and difficult. The purpose of this research is to accept the optimized frame results from the design software and pass them through an interpreter to create a frame that is akin the optimized result, but manufacturable with off-the-shelf components. Along with being more manufacturable, this process also eliminates variation in the final design associated with the frame being interpreted differently by different engineers. This optimization process, called topology optimization, begins with a specified design space, applied loads, and constraints. Within the design space, material is strategically removed in order to maintain the optimal stiffness with respect to weight. From there, the generalized shape is interpreted as an arrangement of members and nodes, which are places that two or more members meet. This information is then passed to a second optimization process that changes the size and geometry of the member and node locations to maintain an optimal shape. With the frame now optimized for stiffness as well as being manufacturable, an automated process generates a design model within SolidWorks with structural tubing and welds so that the physical frame can be created.

Design of a Performance Tricycle for Persons with Paraplegia Powered By Functional Electrical Stimulation of Leg Muscles

Nicholas Andrew Lanese

View the poster in PDF View the poster in PowerPoint Watch the brief video narration

The goal of this project is to design a performance tricycle for paraplegics whose leg muscles are stimulated to pedal via Functional Electrical Stimulation (FES). FES stimulates muscle contraction with small electrical currents and has proven useful in building muscle in patients while relieving soreness and promoting cardiovascular health. An FES-stimulated cyclist produces approximately 25 Watts of power, nearly 20 times less than a typical rider. At these reduced power levels, the challenges of pedaling are amplified. For example, as the pedal follows the traditional circular path, there are portions referred to as inactive zones, where neither FES-stimulated leg actively propels the cycle forward. One possibility for reducing or eliminating inactive zones is to redesign the circular path of the pedaling motion. Bicycles have recently been marketed that feature mechanisms that employ alternate pedaling motions. In addition to addressing inactive zones, these bikes also optimize the muscle capacity of the rider to deliver torque to the wheels. The alternative pedaling paths are achieved in our tricycle design optimization by developing quasi-static models to explore traditional, crank rocker, and coupler-driver mechanisms. These mechanisms allow for a comparison of torque generation which facilitates selecting the optimal design. Rider comfort and muscle capability are future steps taken for FES riders on the optimal design. Such a tricycle is seen to be beneficial for the health, mobility, and independence of the end user.

Designing Energy Efficient & High-Speed Mechanical Presses for Improved Ram Motion using Advanced Algebraic Techniques

Tianze Xu

View the poster in PDF View the poster in PowerPoint Watch the brief video narration

A mechanical press is a machine that shapes parts by driving a ram into metal and deforming the material into a desirable shape. As this is an incredibly common process for forming metal parts, from pop cans to car fenders, presses see significant use in industry on a global level. Two local companies, Aida Press and Nidec Minster, are serious contenders in this global market. The objective of the proposed research is to generate alternative drivetrain designs for mechanical presses that produce specialized ram motions, which is appealing to industry. The focus of this work is on mechanical presses due to their faster speeds, lower cost, greater accuracy, higher precision and energy efficient operation as compared to other pressing options. Due to their ubiquity, even small improvements yield huge savings in terms of processing time and energy consumed. The research work under this proposal is formulated to generate designs with practical dimensions and encountering forces in line with industry expectations. Moreover, these new designs will either improve dwell or improve the range of constant forming velocity, both strongly desired in industry.

Optimizing CubeSat Energy with Alternate Solar Array Positioning Devices

Mohamed Mohamed

View the poster in PDF View the poster in PowerPoint

CubeSats are standard and modularized satellites that have gained widespread implementation among the scientific research community due to their low cost of manufacture and launch. The only source of energy for CubeSat missions are from solar arrays, which are coupled to rechargeable batteries that provide power during the shaded portion of orbit. The goal of this research is to maximize the energy per weight ratio of solar array designs for a 3U CubeSat. The solar array configurations investigated include rigidly mounted to the CubeSat sides, and deployed with zero, one and two degree of freedom, active positioning actuation schemes. Numerical models are created for multiple variations of geo-synchronous and sun-synchronous orbits, which are common for CubeSat missions. The results for orbit parameters and energy acquisition for rigid-mounted solar arrays are validated with commercially available orbital mechanics software (SDK). The various solar cell designs are evaluated based on their energy acquisition potential and actuation complexity and weight of design.

Simulating Deflection of a Compliant Bistable Mechanism

Jared l Dunn

View the poster in PDF View the poster in PowerPoint Watch the brief video narration

This research involves the simulation and physical testing of a novel compliant bistable mechanism. Bistable mechanisms are commonly used in switches and other devices that operate in two distinct modes. The mechanism being developed is a single monolithic structure with simple geometry and does not require external components or post-manufacturing at large, or micro, scales. The goal of this research is to develop and refine a simulation process for this mechanism that accurately reflects the internal friction and large displacement caused by this compliant style of actuation. A prototype is presented to facilitate force and displacement measurements to compare against simulation results. The simulation and experimentation will be used to refine a set of scalable design equations for the compliant bistable mechanism.