Radiator Heat Transfer Analysis
The goal of this project was to analyze the change in fluid bulk temperature passing through a heat exchanger. Specifically, the heat exchanger of interest was modeled based on a dirt bike radiator. First, the radiator model was constructed in Solidworks using rectangular fins protruding from each fluid passage. Next, a mathematical model describing the temperature distribution along the fluid passage was derived using a combination of heat transfer and finite element analysis methods and verified by analyzing the effect that varying different parameters had on the results of the model. The next step was to set up two independent sets of simulation models using Solidworks Flow Simulation software. Once each model was set up, they were tested for grid independence, and sufficient mesh settings were selected to find a balance between computation time and accuracy. Parametric studies analyzing the effects of volume flow rate, ambient air temperature, and wind speed were conducted to verify the models individually, but also to validate the Solidworks and MATLAB models. The models were in good agreement with each other for each of the parametric studies, with errors between the math model and Solidworks simulations only presenting themselves for unreasonable volume flow rate or air speed values. Overall, the main purpose was achieved, along with each group member gaining valuable experience learning the CFD software and being able to validate the mathematical model that was derived by hand and transferred into MATLAB.
Simulation Snips |
MATLAB Script
Project Report
Presentation
| ||||||
Videos Showing External Flow Trajectories |
Videos Showing Internal Flow Trajectories |
Maximum Height of a Model Rocket Simulation
The purpose of this project was to build a model to determine the expected maximum height a model rocket would reach given geometry of the rocket and specifications of the engine utilized for thrust. The model was to account for both change in mass due to use of propellant as well as variable drag force as a function of velocity. The desired resolution of the model was to be accurate within 10% with many cases considered. The procedure to develop and ensure correctness of the model consisted of the following distinct steps: mathematical modeling, verification, validation, and execution of the model/simulation. The model accepts inputs pertaining to the geometry of the rocket, including diameter and mass, as well as engine specific-data. The mathematical modeling of the simulation exploited the computational solution method to be implemented by considering the acceleration to be constant during each small time increment considered. The validity of this assumption was investigated during the validation stage of analysis. Once a verified and validated model was created, over 30 different model rockets, each consisting of a unique combination of geometry and mass, were simulated. The results from these simulations were then compared to the manufacturer’s anticipated maximum height achievable. Upon verification, validation, and execution of the simulation for over 30 unique model rockets, the percent error was found to be less than 7% for both the ‘constant mass, constant drag’ case considered as well as the ‘variable mass, variable drag’ case considered. Neglecting major outliers, the percent error dropped to less than 5.3% for both considered cases. With these results, including or excluding outliers, the objective of the project was achieved.
Poster Summary
|
MATLAB Script
Project Report
Poster PDF
| ||||||
Senior Design Project: Extruder for Production of 3-D Printing Filament--Design Phase
My senior design project was heavily focused on sustainability. The Civil and Mechanical Engineering Department at Purdue Fort Wayne sponsored this project. The objective was to find a way to re-purpose/recycle 3-D prints generated from the 3-D printing lab that would otherwise be discarded. The solution was to create an extruder capable of accepting shredded-up 3-D printed components and produce usable 3-D printing filament for re-use.
This process began with constructing a problem statement, then brainstorming conceptual design ideas for each subsystem identified. Next, these conceptual design ideas were ranked and a final design was selected. There were many design decisions that had to be made along the way, including: sizing the band heaters required, sizing the drive motor required, and sizing the fans required for cooling the extruded filament. Extensive, complex simulations were created for each of these sizing requirements using Solidworks CFD. The results from the simulations were then validated by hand calculations when possible. Once all necessary sizing of critical components had been completed, the design process itself began. The final (WIP) result is shown below, as well as some other snips from throughout the design process.
This process began with constructing a problem statement, then brainstorming conceptual design ideas for each subsystem identified. Next, these conceptual design ideas were ranked and a final design was selected. There were many design decisions that had to be made along the way, including: sizing the band heaters required, sizing the drive motor required, and sizing the fans required for cooling the extruded filament. Extensive, complex simulations were created for each of these sizing requirements using Solidworks CFD. The results from the simulations were then validated by hand calculations when possible. Once all necessary sizing of critical components had been completed, the design process itself began. The final (WIP) result is shown below, as well as some other snips from throughout the design process.
Final Design and Misc. Snips |
Project Reports
| ||||||||
Video Showing Material Flow in Extruder (Motor Sizing Simulation)
Senior Design Project: Extruder for Production of 3-D Printing Filament--Build Phase
The build process for this project was quite extensive. In addition to all of the "mechanical" aspects of the project, there were also a great deal of "electrical" aspects--component sizing and selection, wiring, and coding Arduinos. Since there were no EE's working on this project and I had the most experience, I took on this role concurrently with the "mechanical" tasks. I learned a great deal from the EE side of this project, as this was my first time using an Arduino and the associated subset of C++ required. Section 1.9 of the final report details the majority of the electrical components and wiring required while sections 1.10-1.11 provides details about the code developed for both Arduinos implemented.
Overall, this project was a success. The only requirement not fully met was the ability to maintain a tolerance of ± 0.05 mm for the diameter of the filament produced. We believe we correctly identified the root cause of this issue and that it can be easily resolved with a slight modification to the hopper.
Overall, this project was a success. The only requirement not fully met was the ability to maintain a tolerance of ± 0.05 mm for the diameter of the filament produced. We believe we correctly identified the root cause of this issue and that it can be easily resolved with a slight modification to the hopper.
Chronological Build Process |
Project Reports
Arduino 1 Code: Heating Control
Arduino 2 Code: Motor Control
| ||||||||
Video Showing Filament Production
Advanced Stress Analysis: Thin Rectangular Section Subjected to Torsional, Unsymmetrical Bending, and Axial Loads
For this project, a cantilever beam with a thin rectangular section was subjected to multiple load types. Each of the loads were in terms of the same variable 'p', with varying magnitudes. The geometry of the rectangular section was all in terms of the same variable 'd'. The objective of this project was to determine the maximum allowable value for 'p' when 'd' ranges from 0.1 to 20 inches according to 5 major failure theories. This problem was first solved symbolically, which then allowed for an easy translation into computational logic in MATLAB.
Example Output of Model
|
MATLAB Script
Project Report
| ||||
Optimization of a C-Clamp Cross Section
The objective of this project was to determine the optimum cross-section for a C-clamp subjected to constraints regarding the maximum and minimum allowable stress and geometry. The optimization goal was to minimize both the maximum deflection of the clamp as well as the mass. This problem was solved using the Simulation package in SOLIDWORKS.
Solidworks Simulation Analysis |
Project Report
| ||
Cantilever Beam Profile Optimization
The purpose of this self-determined project was to optimize the profile of a solid rectangular cross-section cantilever beam subjected to a maximum beam weight constraint such that the deflection at the end is minimized. First, a simple case consisting of constant thickness with a single point load applied at the end was considered. Multiple solution types consisting of two unknown coefficients were considered and then optimized using the 'optimizing' MATLAB script. The ideal case was determined to be linear. This same problem was then solved in SOLIDWORKS Simulation by allowing the radius of an arc controlling the height of the beam as a function of its length vary. The optimized solution in SOLIDWORKS was with the radius tending towards infinity--a linear solution. The displacement given in SOLIDWORKS was also validated by creating a MATLAB script that utilizes the finite element method to determine the deflection at the free end, both of which were compared to the analytical solution determined using Castigliano's theorem.
Next, with the SOLIDWORKS solution method validated, the width of the beam was also allowed to vary as a function of its length. In addition, many different loads were added to the beam. The SOLIDWORKS solution method was then utilized in order to successfully determine the optimum profile for the beam as a function of its length.
Next, with the SOLIDWORKS solution method validated, the width of the beam was also allowed to vary as a function of its length. In addition, many different loads were added to the beam. The SOLIDWORKS solution method was then utilized in order to successfully determine the optimum profile for the beam as a function of its length.
Solidworks Simulation Analysis |
MATLAB Scripts
Project Reports
| ||||||||
Projectile Motion Project
The goal of this project was to determine the minimum initial velocity required to hit a 600ft home run in baseball with drag force considered. This project was coded in MATLAB and accepts the following input parameters:
|
|
|
Example Output of Model |
MATLAB Script |
|
Project Report
| ||||
Vibration Project
This project focused on determining how the position of a mill varies with time when it is subjected to a variable force due to a milling operation as well as a harmonic disturbance on the foundation to which it is mounted. The mass, effective spring constant, and effective damping coefficient were all given in the problem statement. This project was solved two different ways after developing the ordinary differential equation to describe the motion of the machine. Both an inverse Laplace transform solution method as well as a State Space solution method were utilized and the results for both solution methods were plotted on the same figure.
Example Output of Model |
MATLAB Script |
|
Project Report
| ||||
Pitch and Bounce of an Automobile
The objective of this project was to determine the pitch (angular displacement) and bounce (transverse translational displacement) of an automobile traveling across a "rough" road. The "rough" road was simulated with a sinusoidal function. The geometry and mass properties of the automobile as well as the effective spring rate and damping coefficient for the front and rear wheels were given. The system of ordinary differential equations governing the motion of the automobile were derived and translated into State Space form, allowing for an easy simultaneous computational solution in MATLAB.
Problem Statement Diagram |
MATLAB Script |
|
Project Report
| ||||
Animation of Particle-Like Wave Packet in Infinite Square Well
This project was completed for PHYS-442: Quantum Mechanics. The purpose of this project was to numerically solve an infinite square well problem. More specifically, an animation showing the probability density function (representative of the probability of a particle assuming any position inside of the square well) versus time was requested. An initial condition for the wave function, bounds of the square well, and spatial conditions for the potential energy inside and outside of the square well were given. This project was first solved analytically, which then allowed for an easy translation to a computational solution in MATLAB. The MATLAB script allows for the user to vary the initial wave function, the size of the square well, the number of terms to consider for the solution (the exact solution is an infinite linear combination), the resolution in both the spatial and time coordinates, and the maximum time to consider. All user inputs are shown in a text-box during the run-time of the animation.
Animation |
MATLAB Script
Project Report
| ||||
Various Other Projects
ThermodynamicsCombined Heat and Power (Coupled Brayton and Rankine Cycle)
Air Conditioning: Dehumidification and Reheat
|
Heat TransferHeat Sink Fin Optimization
Intermediate Electricity and MagnetismFlux Through a Cube With a Point Charge at Any Location Inside
|
Fluid MechanicsSolar Water Pump System for Irrigation
Computer ScienceJava Parking Garage Simulation
| ||||||||||||||