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Worcester Polytechnic Institute

Mechanical Engineering

Department

2013 Project

Presentation Day

April 18, 2013

Schedule for Project Presentation Day Mechanical Engineering Department

April 18, 2013

8:00 AM Judges assemble Higgins Labs 102

8:00 AM to 8:30 AM Refreshments Judges Higgins Labs 102

Students Alden Hall

8:15 AM to 8:30 AM Judges Instructions Higgins Labs 102

8:30 AM to 12:00 PM Presentations Alden Hall

12:00 PM to 1:00 PM Lunch

Judges Higgins Labs 102 Students Alden Hall

1:15 PM to 1:30 PM Winners announced Alden Hall

Table of Contents

Biomechanical 4

Design 10

Manufacturing 30

Materials 32

Robotics 39

Thermofluids 43

Addendum — Design 51

Biomechanical

Load Absorption Device for Skate Blades

Karin Greene, Devon Rehm

Growth in technical and physiologic demands for skaters has led

to an increase in sport related injuries; studies have shown that

over 44% of figure skaters experience overuse injuries during their

career. Current skates are composed of stiff leather uppers, pad-

ding to ensure a tight fit and to help cushion landings, and a wood-

en and cork sole to which the blade attaches. Landing loads which

reach forces up to ten times a skater’s weight are repetitively ap-

plied to the skater’s joints without a means of cushioning. Repeti-

tion of exposure to these high landing loads leads to overuse inju-

ries that cannot be alleviated without rest. The objective of this

project is to develop a mechanical absorption system for figure

skates which will aid in the prevention of jump landing-related

injuries without obstructing the skaters’ motion or disregarding the

rules and regulations for competition. The design, which was real-

ized through the principles of axiomatic design, absorbs loads in

the vertical direction, preventing injurious loads from reaching the

foot and ankle. The design was created in SolidWorks and manu-

factured using ESPRIT and Haas CNC machines.

Advisor: C. Brown

Biomechanical

Development of Zero Leg Input Manual Transmission Driving

Interface

Gregory DiLullo, Stephen Kocienski, Daniel Zopatti

The goal of this MQP is to ameliorate the inability of paraplegics or dou-

ble-leg amputees to effectively control manual transmission automobiles

through the creation of a minimally invasive hand control interface. The

inspirations for this project include those who desire the ability to drive a

manual transmission vehicle because of their interest in recreational driv-

ing or because they own one-of-a-kind cars. While several unique and

effective products exist, such as the Kempf Digital Accelerator Ring

which allows people with disabilities to drive automatic cars, there are

few solutions for standard automobiles. The team evaluates the capabili-

ties of current assistive devices such as the Guidosimplex ‘Duck’ Semi-

Automatic Clutch and the Alfred Bekker Manual Hand Clutch. We es-

tablish that these products either require the use of one leg or reduce con-

trol of the vehicle. The team conducts testing and research in several

areas including the analysis of current assistive devices, exploration of

driving motions, maneuvers, and ergonomics, and calculation of the dy-

namics of pedal depression. This leads to the design and fabrication of

an ergonomic interface refining existing concepts to allow those without

the use of their legs to maintain full control of all of the inputs of a stand-

ard transmission vehicle.

Advisor: M. S. Fofana

Biomechanical

Design of a Powered Hand Orthosis

Elyssa Dorenfeld, Robert Wolf, Stephan Zeveska Current hand orthoses act as a brace or support for controlling

the posture of the hand and wrist. These types of orthoses often

prevent the use of the hand for various activities of daily living

(ADLs). The goal of this project was to design and manufacture

a fully functional powered hand orthosis, which could be con-

trolled and operated by the contralateral hand, and be used by

people with diminished hand functions. The design reduces the

twenty seven degrees of freedom in a healthy human hand to six

and replicates the motions needed to perform the most common

grips including the cylindrical, pinch, and key grips. Linear ac-

tuators are used to create the motion of the fingers. The actua-

tors drive the motion around two different finger joints through

a six-bar linkage. An additional degree of freedom results from

the circumduction of the thumb from the side of the palm to in

front of the palm. The device was designed to provide the user

with the average strength of a sixty to sixty five year old person,

and enable them to grasp and pick up common objects encoun-

tered when performing ADLs.

Advisors: A. Hoffman, H. Ault

Biomechanical

Motorsports Safety

Anthony Begins, Korapat Lamsam, Kerrie Maron

The prevalence of neck injuries and basilar skull fractures in mo-

torsports has caused many sanctioning bodies in top-tier auto-

racing divisions to mandate the use of a head and neck restraint.

Current commercially available head and neck restraints have

played an instrumental role in the racing world by reducing the

overall number of injuries in competition. However, the most

common restraint has inhibited drivers from exiting the car in

emergencies, such as a fire, as it can become entangled in the win-

dow nets, roll cages, or the ground depending on the orientation of

the car. Generally, this entanglement occurs due to the inability to

remove the device while wearing a standard racing helmet. As a

result, the Motorsports Safety group has designed and prototyped a

head and neck restraint device that can be removed easily while

wearing a helmet to facilitate exiting a car in an emergency.

Advisor: A. Hoffman

Biomechanical

Shoulder Mount for a Wearable Arm Orthosis

Richard Downey, Nikole Dunn, Adam Hoyt

Functionality of the upper limb is vital for performing

Activities of Daily Living (ADLs), such as bathing, dressing,

toileting, and eating. In some cases, motion can be restored with

the help of an orthosis. The goal of this project was to design,

analyze, manufacture, and test a shoulder mount to be used in

conjunction with a wearable powered upper-limb orthosis. The

device must enable adequate functionality for completion of

ADLs and fit multiple users within a range of body types

through adjustability.

Tests were performed to confirm functionality of the

design by measuring and comparing the joint angles that users

were able to achieve in shoulder flexion and shoulder abduction

with and without the device. The test subjects reported that per-

forming the ADLs was relatively easy while wearing the device,

and results showed that the orthosis enables the user to achieve

a range of motion necessary to complete all ADLs. On average,

the device limits the user’s shoulder flexion and abduction by

approximately 42% and 48%, respectively, and is reasonably

adjustable to both male and female users in the 25th to 75th per-

centile range. The final prototype weighed less than 4lbs, was

reportedly comfortable to wear, and did not significantly in-

crease the user’s body frame. The device could serve as a candi-

date for further design and development by adding powered ele-

ments, using alternate materials, and integrating the design with

that of an already patented wearable powered upper limb ortho-

sis.

Advisors: A. Hoffman, H. Ault

Biomechanical

The Effects of Changing Running Stride

Chelsea Cook, Heather Lewis, Alicia Turner

This study explores the effects of changing someone’s running

stride by analyzing the forces exerted on the knee and ankle joints.

Over a 5 week training period, 13 subjects were observed using

video and force-plate analysis in order to estimate the landing load

on the ankle and knee upon initial foot strike for two different

stride forms. Various kinematic variables, such as landing force,

joint moments, and landing angles were compared for two differ-

ent stride forms to determine if stride change is beneficial. Based

on the findings of this study, the benefits of stride change is de-

pendent on the individual.

Advisor: B. Savilonis

Design

Design of a Binding Plate to Reduce Anterior Cruciate

Ligament Injury During Alpine Skiing

Lauren Bisacky, Bryce Calvetti, Rinaldo Izzo, Elizabeth

Veracka

The objective of this project is to reduce the incidence of Ante-

rior Crucial Ligament (ACL) injury in skiing by designing, pro-

totyping, and testing a plate between the ski and binding to filter

out injurious loads that would otherwise be transmitted through

the ski to the skier. While ski technology in the past five dec-

ades has adapted to protect the skier’s foot, ankle, and tibia, the

knee and ACL are still susceptible to injury. There are two types

of ACL injuries; Boot-Induced Anterior Drawer (BIAD) and

phantom foot. Axiomatic Design was used to design a ski bind-

ing plate to minimize BIAD ACL injuries. After the design was

chosen, calculations, material selection, computer aided design

(CAD) drawings, and Finite Element Analysis (FEA) were con-

ducted. This project holds importance in both an economic and

societal context because ACL injuries cost Americans on aver-

age $250 million and the rest of their skiing season.

Advisor: C. Brown

Design

Manufacturing Bamboo Bicycle Frames with

Composite Joints Nathaniel Gee, Paolo Masakayan, Majd Sbat,

Mathew Skerritt, Robert Winthrop

Inexpensive bicycles can promote better development and improve

life in third world countries. One of the easiest ways to make a

cheaper bicycle is to use a cheaper material for the frame. Bamboo

can be comparable in strength to aluminum alloy tubes, yet has a

much lower cost. Bamboo bicycles are currently used as a mode of

cheap transportation in third world countries. Currently the pro-

cess used for manufacturing bamboo frames includes hand wrap-

ping a composite layup around each joint. This procedure is labor

intensive and results in a slow output of bamboo bicycles. The

objective of this project is to build a bamboo framed bicycle

cheaper and easier to produce than the ones that are currently

available. Axiomatic design was used. A new joint was designed

that should be easier to manufacture. The joint was modeled in

SolidWorks. Finite element analyses with normal static bike loads

were done in ANSYS. The tooling was CNC machined by a group

member on Haas machine tools using ESPRIT CAM software pro-

vided by DP Technology.

Advisor: C. Brown

Design

Measuring the Quality of Ski Edges

Frank Bruton, Jocelyn Close, Michael Dragonas, Jason Hopkins

The objective of this project is to design and manufacture an

instrument for measuring the quality of ski and snowboard edg-

es. Over the course of even one run, edges can start to dull, thus

decreasing their ability to perform. Although methods including

running your thumb or thumb nail against the edge of the ski are

current methods for checking the sharpness of a ski edge, no

products yet exist to qualitatively measure the sharpness of a ski

edge. The design functions were decomposed with the design

solution in a hierarchical manner consistent with axiomatic de-

sign. The resulting product appears to have satisfied the parame-

ters of a working ski tester prototype and was fully manufac-

tured in order to begin further testing.

Advisor: C. Brown

Design

3 in 1 Saw

Matthew Fredrick, Edward Galvin, Timothy Moreau

The objective of this project was to design and create a prototype

of a carpenter’s saw to perform the functions of three different

saws: slide-compound miter saw, table saw, and handheld circular

saw. Machine design analysis and testing was done.

Advisors: E. Cobb, J. Hall

Design

Hydraulic Braking System

Ryan Moseley, Mikhail Tan

The objective of this project was to create a physical model to

demonstrate the transfer of forces from the mechanical domain to

the hydraulic domain, and back to the mechanical domain. To do

this, a spinning wheel was designed to be stopped using a hand

brake connected hydraulically to a set of calipers and a brake ro-

tor. A wheel on a dead axle was spun up via a motor and once the

wheel was at speed, mechanical force was applied to the hand

brake to bring the wheel to a stop. Calculations for the model

were made to determine flexure, stress concentrations, natural fre-

quency and the mechanical advantage of the braking system. The

calculations showed that under normal operating conditions, the

whole assembly will not have any noticeable flexure, the stress

concentrations in the axle will not lead to catastrophic failure, the

natural frequency of the rotating wheel on a simply supported axle

is far above that of the operating frequency, and the hydraulic

brake has ample mechanical advantage to safely bring the wheel to

a stop. Once all these calculations ensured that the model would

not fail during operation, a physical model was constructed. Test-

ing and operation of the physical model showed that the calcula-

tions were accurate. The final model successfully shows the trans-

fer of mechanical force (the user squeezing the handle) to hydrau-

lic force (moving a piston) to mechanical force which generates

friction between the calipers and the brake rotor to stop a rotating

wheel.

Advisor: E. Cobb

Design

Pool Chair Lift Linjun Bu, Patrick Graham

January 31, 2013 marked the extended deadline of compliance set

forth by the federal government under the revised ADA (American

Disabilities Act) specifically for public accessible pools. When a

pool is “accessible,” under those standards, it has an entry and exit

that accommodates everyone specifically those with disabilities.

This act is not limited to public pools but also includes some private

businesses such as hotels, spas and wading pools. The pools lifts on

the market today can be expensive and also be expensive to install.

The goal is to safely move a person in a waterproof chair from the

deck of the pool, to over the water, into the pool, and when the user

is finished, safely remove them from the pool back to deck. Part of

this goal is keeping the chair as horizontal as possible. The design

has been developed using the 2010 ADA standards for accessible

design. The ADA standards indicate how far the center of the seat of

chair should be from the pool, how high the seat of chair should be

from pool deck, and how deep the seat of the chair should be sub-

merged below water. The design uses a parallel four-bar linkage

mechanism and is able to lift the chair with an average weight per-

son in and out of the pool.

Advisors: E. Cobb, A. Hoffman

Design

Redesign of a Medical Robot

Daniel Foley, Jonathan Gaffen, John Petitpas

Delivering supplies quickly and efficiently in hospitals is a

problem that can mean the difference in proper medical care. To

cut down on delivery times, redundant deliveries of supplies, and

create a streamlined process in hospitals, medical robots such as

the TUG® were implemented to help solve these problems by re-

moving a human courier. However, the TUG® and other existing

courier robots can get stuck in tight corners, and at bumps and in-

clines, for example, at elevator doors.

The primary goal of this project was to analyze the TUG®

and similar robotic couriers both in operation and design, and cre-

ate a drivetrain for a robot that is more robust and maneuverable to

help alleviate problems in daily operation, allowing robots such as

the TUG® to function to capacity. Existing drivetrain systems

were researched and analyzed through decision and design matri-

ces to choose a drivetrain which could most benefit this applica-

tion. A Mecanum drive was chosen, due to several factors includ-

ing mobility, reliability, and maintenance, among others.

Testing was conducted to evaluate how the robot com-

pared to existing applications. Static and dynamic stability, physi-

cal characteristics, and safety were all evaluated.

Advisors: E. Cobb, J. Sullivan

Design

Slider-Crank Demonstration

Eric Brigham, Christopher DeStefano, Zachary Killoy

The slider-crank mechanism is a particular four-bar linkage con-

figuration that exhibits both linear and rotational motion simulta-

neously. This mechanism is frequently utilized in undergraduate

engineering courses to investigate machine kinematics and result-

ing dynamic forces. The position, velocity, acceleration and shak-

ing forces generated by a slider-crank mechanism during operation

can be determined analytically. Certain factors are often neglected

from analytical calculations, causing results to differ from experi-

mental data. The study of these slight variances produces useful

insight. The following report details the successful design, fabrica-

tion and testing of a pneumatically powered slider-crank mecha-

nism for the purpose of classroom demonstration and experimenta-

tion. Transducers mounted to the mechanism record kinematic and

dynamic force data during operation, which can then be compared

to analytical values. The mechanism is capable of operating in bal-

anced and unbalanced configurations so that the magnitude of

shaking forces can be compared.

Advisors: E. Cobb

Design

All-in-one Hand Washing Station

Aaron Bianchi, David Markham, Joseph Pasquarelli, Jaimes Spring

Washing your hands is the most effective way to prevent the spread

of germs. Hand washing hygiene is an important aspect of disease

prevention and level of public safety measure. The goal of our Major

Qualifying Project is to design a more refined and clean way to wash

and dry hands. The proposed device needs to be easy to use and safe

according to the CDC guidelines for hand washing hygiene. Our solu-

tion approach is to design an all in one unit that encompasses a sink,

soap dispenser, and drying process technology. The unit is designed

to fit into the existing sink countertop, plumbing and draining pipes

and water intake lines. The touch free unit utilizes IR sensors and an

MCU to control the functions of the hand washing process. This pro-

cess begins once the sensors inside the unit recognize the user’s

hands. Upon recognition, the soap is sprayed from the wrist to the

fingers in 3 seconds. A short pause then allows the user to scrub their

hands if desired. Water will be sprayed from the wrist to the fingers in

another 3 seconds. Finally air is blown out of the top and bottom of

the main entrance to the device, thereby allowing the user to dry their

hands as they remove them from the device. The process is complete-

ly touch free and environmental performance conscious. The pro-

posed technology has greater opportunity to significantly improve the

hand-washing and drying process, and protection from germs and

contaminants. It accomplishes the hand washing and drying process

in less than 20 seconds. It reduces the wasting of soap, water, and

energy. Finally the cost for the proposed device is less than what is

currently available in the market. It is recognized that the proposed

device would be far more efficient and safer than any currently avail-

able technology. Our device will also allow people to wash and dry

their hands more often in an improved and sustained manner.

Advisors: M. S. Fofana, A. Emanuel (ECE)

Design

Analysis of Deep-Well Drilling Reliability Design

and Technology

Lukas Aschbacher, Conor Hennessey, Neil Innarelli

Offshore drilling encompasses enormous engineering challenges

and risks compared to land-based hydrocarbon production. The

depths of deepwater offshore drilling are over 500 feet, and thus

the drilling, cementing and casing of such wells are complex tasks.

To minimize the risk of well failure during well construction, en-

ergy companies install a BOP, or blowout preventer, which is a

large valve that is used to monitor, control, and in case of failure,

seal the well. The two largest accidental offshore oil spills resulted

from a failed BOP. In cent years, efforts to design safer, resilient

and adaptable BOPs have increased substantially. The goal of the

MQP project is to redesign a critical component of a BOP that will

improve well drilling and sealing at low, moderate and high pres-

sure flows of hydrocarbons. Current limitations and challenges

facing the use of BOPs in deepwater hydrocarbon extraction are

evaluated. The blind shear rams and shear blades of the BOP were

redesigned to improve well safety, reliability and stability. Finite

element method was employed to verify the safety, reliability and

stability of the developed components. The seals, shear rams and

blades were made from lightweight materials. Our proposed solu-

tions to improve the safety, reliability and stability of deepwater

hydrocarbon harvesting have greater superiority over current in-

dustry designs.

Advisors: M. S. Fofana, J. Plummer (CEE)

Sponsor: DOE – Diana Bauer, Kevin Easley

Design

Firepot Reliability and Engineering Design (F.R.E.D.)

Ryan Ismirlian, Joan Keyes, Daniel Mello, James Miller,

Ryan Rangle

A voluntarily recall of firepot gel fuels was initiated by the Consumer Prod-

uct Safety Commission (CPSC) due to large number of accidents resulting

from the spilling of gel fuel. The recall stimulated a joint effort by the firepot

gel fuel industry and CPSC to improve the safety and operation of current

firepot gel fuels in the market. The MQP project focuses on locating new

ways to improve the safety, reliability and stability of firepot gel fuels and

their storage containers. We describe how our effort would lead to renewable

standards, codes, regulatory and environmental performance for the safety

use of firepot gel fuels and storage containers of gel fuel. Background re-

search is conducted to understand the origin and purposes of the firepot gel

fuels and include the reasoning behind the removal of the gel fuels from the

consumer market. It was found that 76 incidents resulted in 84 injuries and 2

deaths, and they occurred with the use of the current firepots and storage

containers of the gel fuels. These incidents are evaluated by the team in

terms of the gel fuel and its viscosity, the storage container of gel fuels and

stability of the firepot. By utilizing a mechanical engineering thinking and

experimental means, a new safety oriented firepot gel fuels and storage con-

tainers are created and developed by the MQP team. A number of tests are

conducted to observe and verify the characteristics and viscosity of the gel

fuels and to provide a proof of concept for each storage container. The de-

rived solution is simply the incorporation of a metal meshing into the current

design of the gel fuel storage containers. The testing of various scenarios

involving the meshed gel fuel show a significant reduction in the amount of

fuel released from the container in comparison with the control tests without

meshing. Salient recommendations are made to improve the safety of firepots

and storage of gel fuel containers. The derived results have significant im-

provement over the current industry firepots and storage containers of gel

fuels.

Advisors: M. S. Fofana, N. Dembsey (FPE)

Sponsor: Consumer Product Safety Committee (CPSC)

Design

SLATE Ambulance Reliability Design: Designing a Sterile

Interior Storage System

Katrina Boynton, Jeffrey Perron, Victoria Spofford,

Daniel Topping

The purpose of this Major Qualifying Project (MQP) is to design and

implement a sanitary medical equipment vending mechanism that

protects pharmaceutical and consumables from contaminant, agent,

waste, organism and odor (CAWOO) in ambulance compartment. We

evaluate the storage and workspace environment of a selected number

of modern ambulances and identify the challenges to protect ambu-

lance occupants and accessories from CAWOO. A list containing the

quantity, weight and scale of all equipment, tools, instrumentation,

pharmaceutical, consumables and other accessories that must be in an

ambulance in accordance with State and Federal requirements is cre-

ated. Each piece of equipment or device is weighed and its dimen-

sions are measured. This information serves as a framework to deter-

mine how the ambulance collections and accessories should be cate-

gorized and stored in the new vending machine. A medical equipment

vending machine is created and developed to protect pharmaceutical

and consumables in the ambulance compartment design. Through the

use of program simulation, the proposed design follows the strict re-

quirements of the Star of Life Federal Regulation KKK-A-1822F,

NFPA, AMD and other recognizable national and international ambu-

lance standards. The vending machine provides greater opportunity

to protect pharmaceutical and consumables from CAWOO. This ma-

chine will be incorporated into the modern SLATE (Safe, Light-

weight, Affordable, Technology, Efficient) ambulance design of

MIRAD Laboratory. It is believed that the protection of pharmaceuti-

cal and consumables from CAWOO in ambulance compartment will

improve emergency pre-hospital care and reduce cost substantially.


Sponsor: Boston Emergency Medical Services

Design

SLATE Pediatric Ambulance Reliability Design

Michael LaRue, Gabriel Lyon, Yann-Frederic Schoenhagen Emergency Medical Services (EMS) are staffed with Basic, Interme-

diate and Advanced life support (BLS, ILS, ALS) or Emergency

Medical Technicians that provide prehospital care to the sick and in-

jured, and transport patients to hospital, clinics or rehabilitation cen-

ters for extended evaluation. Our project focuses on developing a new

prehospital medical services for pediatric and obstetrics and gynecol-

ogy (OB/GYN) care. This project creates and develops S.L.A.T.E.

(Safety, Lightweight, Affordability, Technology, and Efficiency) am-

bulance that can enhance the safety of pregnant women, newborns

and young children, and yet still function as a standard ambulance.

During the design process, background research is conducted to lo-

cate and validate performance specifications for an ambulance box

and chassis that can be used to provide pediatric, OBGYN and stand-

ard ambulance care. Special storage devices, improved and mobile

captain’s chairs, an incubation station and an improved workspace are

incorporated into the new pediatric and OBGYN ambulance. We use

lightweight materials and reinforce columns and arches to strengthen

the structure and stiffness of the ambulance box. Analysis of a num-

ber of current ambulance chassis is also conducted to select the most

suited one for the new SLATE Pediatric and OBGYN ambulance

care. Using indicators such as miles per gallon, gross vehicle weight,

engine type, safety, reliability and stability, the chassis for the pediat-

ric and OB/GYN ambulance is selected. The new pediatric and OB/

GYN ambulance with a resilient and adaptable chassis and box pre-

sent a greater opportunity to enrich the quality of pre-hospital care

across the country.


Sponsor UMASS Emergency Medical Services

Design

Fully Reversed Engineering

Ryan Muller, Christopher Thomas

The availability of rapid prototyping enhances a designer’s

creativity and speed, enabling quicker development of new prod-

ucts. However, because this process relies heavily on computer-

aided design (CAD) models it can often be time costly and ineffi-

cient when a component is needed urgently in the field. This paper

proposes a method to seamlessly integrate the digitization of exist-

ing objects with the rapid prototyping process. Our technique

makes use of multiple structured-light techniques in conjunction

with photogrammetry to build a more efficient means of product

development. This combination of methods allows our developed

application to rapidly scan an entire object using inexpensive hard-

ware. Single views obtained by projecting binary and sinusoidal

patterns are combined using photogrammetric feature tracking to

create a computer model of the subject.

We present also the results of the application of these con-

cepts, as applied to several familiar objects--these objects have

been scanned, modified, and sent to a rapid prototyping machine

to demonstrate the power of this tool. This technique is useful in a

wide range of engineering applications, both in the field and in the

lab. Future projects may improve the accuracy of the scans

through better calibration and meshing, and test the accuracy of

the digitized models more thoroughly.

Advisor: C. Furlong

Sponsor: Center for Holography Studies and Laser

micro-mechaTronics and PTI Industries, Inc.

Design

Dynamic Analysis of Bungee Jumping

Yanchen Li, Zhengyuan Lv

The recent accident occurred in bungee jumping off the bridge at

Victoria Falls, Zambia in the 2012 New Year’s Eve has brought

the safety issues of this popular extreme sport again to the public

concern. This project is to simulate the dynamic process when a

jumper dives off from a height and to determine some safety-

related quantities such as the maximum diving distance and the

maximum tension developed in the jumping cord. A single-degree

-freedom mass-spring-damper model is adopted where the mass

represents the jumper, the cord acts as a spring, and the damper

exhibits the air resistance. The motion of the jumper alternates

between free fall and vibration depending on if the cord reaches its

full length. Various spring and damping models were investigated

for a general discussion. Other health concerns induced by bungee

jumping were also studied and some precautions were provided to

improve the jumpers’ overall safety. The project may provide the

industry with fundamental understanding of the bungee jumping

process and a MATLAB based numerical tool to simulate the pro-

cess on site. Important physical quantities such as the maximum

tension in the cord can thus be determined to address some safety

related issues.

Advisor: Z. Hou

Design

Stress Concentration Analysis of an HPP Lever by the

Finite Element Method

Jacob Baril, Sowmit Barua, Nicholas Hayes

High pressure processing (HPP) is one of the most effective and

efficient ways of cooking food in the food industry due to its abil-

ity to prepare fresh, hygienic food. The goal of this project is to

reduce the stress concentration that arises in the contact area be-

tween the lever and lever guide in a particular HPP vessel. Vari-

ous finite element analyses were performed in order to devise an

effective solution that will reduce the stress concentration in this

area.

Advisor: Zhikun Hou

Design

Solar Tracker

Melanie Li Sing How, Myo Thaw, Dante Johnson-Hoyte,

Dante Rossi,

A Dual-Axis Solar Tracker with a 22.9m (75ft) by 8.23m (27ft)

panel was analyzed under critical weather conditions. Analytical

and simulated force and stress analyses were conducted for maxi-

mum wind loads of 89.4 m/s (200 mph) and maximum snow loads

of 220 kg/m2 (45lb/ft2). The results were verified by wind tunnel

experiments using a reduced scale prototype yielding an expected

full-scale drag and lift of 1.95 E6 N (0.439 E6 lbf) and 5.54 E6 N

(1.25 E6 lbf) respectively. For demonstration purposes, a small

scale functional model of the tracker was designed with a maxi-

mum polar and azimuth angles of 80 degrees and 360 degrees re-

spectively. Light, panel load and wind sensors were integrated into

the functional model to detect simulated weather conditions. Static

and dynamic mathematical models of the functional model were

developed for component selection and to control the tracking mo-

tion. The final tracking sensitivity is 2 degrees and 4 degrees for

the azimuth and polar rotations respectively.

Advisors: Alexander Emanuel (ECE), Stephen Nestinger

Sponsor: French Development Enterprises

Design

Formula SAE Vehicle Design and Manufacturing

David Alspaugh, Alessandro Aquadro, Dylan Barnhill,

Nicholas Beasley, Andrew Bennett, Timothy DeGreenia,

John Francis

This Major Qualifying Project (MQP) designed and manufactured

a vehicle for the Formula SAE Michigan collegiate competition.

The Formula SAE (FSAE) competition is an annual collegiate de-

sign series that challenges teams all over the world to conceive,

design, fabricate and develop formula style vehicles, which are

validated through competition. The team built upon a vehicle in-

tended for the 2012 FSAE collegiate competition. Through base-

line testing and component evaluations, systems of the car were

identified as areas that reduced performance and prohibited pre-

dictable vehicle dynamics. These systems were the car’s rear sus-

pension, component packaging/ergonomics, continuously variable

transmission (CVT), air intake, and exhaust. By reducing vehicle

weight in numerous areas and through modifying components and

sub-systems, the team was able to design and construct a more

intuitively controlled vehicle. As a result, the vehicle’s perfor-

mance in static and dynamic competition events was improved

while reducing cost. An innovative approach was achieved utiliz-

ing an exoskeleton wrap for the vehicle body. All components and

sub-systems were designed and validated using computer-aided

modeling and simulation techniques.

Advisor: D. Planchard

Design

SAE Baja front suspension and steering 2012-2013

Christopher Boyle, Raymond Casola, James Tauby, Jesse Taylor

The Baja Society of Automotive Engineers (SAE) competition is

held annually in order to provide engineering students an opportunity to

design and build a competitive off-road vehicle. This Major Qualifying

Project (MQP) focused primarily on a major redesign of a previous WPI

Baja SAE car (2008-2009 Design and Fabrication of a SAE Baja Race

Vehicle), by determining it strengths and weaknesses through design re-

views and field-testing. The MQP improved the following subsystems,

identified as the weakest components of the car: drivetrain, steering,

brakes, and front suspension.

The team removed the existing hybrid-hydraulic drivetrain and

designed, fabricated and tested a new mechanical drivetrain. The steering

geometry was designed according to the Ackerman principle and to bal-

ance the effects of caster and camber. The required braking force for the

car was calculated, and a new front and rear braking system was installed

with the ability to lock all four wheels at speed, as stated in the SAE rule-

book.

The front suspension was addressed to provide proper ground

clearance in accordance with the SAE guidelines and to maximize sus-

pension travel. New components and sub-systems were designed using

SolidWorks. SolidWorks Simulation was used to perform finite element

analysis to optimize each component and subsystem to determine the

necessary strength while minimizing weight. Material selection was

based on design factors including weight, cost, and performance.

All work was performed in accordance with the SAE Baja

guidelines to maintain the car’s eligibility for competition.

Advisor: D. Planchard

Design

Irish Flute Design Optimization

Ying Bao, Kiara Gravel, Ian Jutras, David Knight

The goal of the project was to improve the intonation and ergo-

nomics of an Irish flute as well as assess the feasibility of rapid

prototyping a flute. SolidWorks was used to model existing Del-

rin and PVC flutes. A rapid prototyping machine was used to cre-

ate an identical model of the six holed Pratten-Style Delrin poly-

mer flute. Using the rapid-prototyped Irish flute and PVC flute,

the group collected frequency-based data. Frequencies were col-

lected in the first and second octaves and compared to the A440

Hz standard of tuning musical instruments. Through studying

acoustic principles of an open tube, the group developed equations

to predict the distance from each of the tone holes to the embou-

chure hole based on standard frequencies as well as various di-

mensions within an Irish flute. Parameters of the flute such as the

bore diameter, tone hole diameter, cork position, chimney heights,

and length of the flute were isolated and analyzed. These equa-

tions were then linked through a design table in SolidWorks to the

3D model and used to design and create a new optimized rapid

prototype. The design table facilitates the process of making di-

mensional modifications to the flute without having to manually

calculate the values and input them into a model. The final result

was an optimized Irish flute that required minimal tuning. The

group gained a deep understanding of the relationships that exist

between parameters of the Irish flute and the acoustics through the

instrument. Recommendations for further studies on the Irish flute

are included.

Advisors: J. Sullivan, D. Planchard

Manufacturing Engineering

Manufacturing Automation Reliability Design and Technology

Sayok Chattopadhyay, Adam Donovan Kaczmarek, Alberto Mateo

The principal objective of this project is to evaluate the need for

and implementation of a new lean Manufacturing Automation Sys-

tems Engineering (MASE) at Spence Engineering Company, in

Walden, New York. The proposed methods for MASE evaluation

and validation include a reconfiguration of the current state plant

layout, creating a new value-added System Manufacturing State

space, integrative CAD/CAM and augmented data assimilation

and interactive dialcom checklists. We will show how the new

MASE model can eliminate waste, delays, vulnerability and uncer-

tainty and yield greater opportunity for maximization of return on

investment at CICOR Spence Engineering. The outcome will also

provide a detailed explanation of the steps taken to implement the

changes in the Company. The essentials of lean manufacturing

automation design and technology are fully integrated into the new

MASE model system. The risk of machining down time, making

defects, long setup times and unintentional accidents is minimized

in the new MASE model System at Spence Engineering Company.

Advisors: M. Mustapha, E. Hallenbeck

Sponsor: CICOR Spence Engineering

Manufacturing Engineering

High Efficiency Moped

Tim Ellsworth

The objective of this MQP was to design, build and test a high

efficiency moped. This moped would be an alternative solution to

current mopeds available. The purpose of this moped project was

not only to achieve high fuel efficiency, but also to fully utilize the

bicycle components, use an alternative fuel, and keep the design

simple enough to be easily made from a standard bicycle as a kit.

A propane engine, the use of the existing bicycle drive train, and a

dog clutch were the main parameters made at the beginning of the

project. All three of those parameters were met along with the fuel

efficiency specification at a mile per gallon rating of over 200.

Advisors: K. Stafford, C. Furlong

Materials Engineering

Intelligent Preprocessing of Electronic Waste During

Recycling; a Source for Critical Materials

Patrick Ford, Amy Loomis

A study of the end of life treatment of mobile phones identified a major

challenge to the optimization of the preprocessing stage of recycling. The

lack of supply chain transparency in the mobile phone life cycle limits

recyclers’ knowledge of the chemical composition of incoming waste,

reducing the effectiveness of this critical stage of resource recovery. X-

Ray Fluorescence Spectroscopy (XRF) was employed to identify the

chemical composition of shredded electronic waste, and the results sup-

port XRF implementation to enable intelligent sorting during prepro-

cessing. By identifying profitable precious metals and hazardous materi-

als in these waste streams with XRF, recyclers can make more informed

decisions regarding electronic waste handling during preprocessing.

Advisors: D. Apelian, J. Plummer (CE)

Sponsor: Center for Resource Recovery & Recycling, Umicore

Corporation


Evaluation of Fiber Reinforced Polymer Bench Scale Specimen

Sizes and Prediction of Full Scale Flame Spread Testing for

Building Applications

Christian Acosta, Shawn Mahoney, Nicholas Nava,

William Wright

Fiber Reinforced Polymers (FRPs) are quickly becoming an im-

portant building material due to their aesthetic and environmentally

"green" characteristics. As with many building materials FRPs can

potentially be a fire hazard in regards to flame spread. The Interna-

tional Building Code (IBC) limits flame spread for materials which

are to be used as interior finish based on large scale ASTM E84

(Tunnel) testing. Unfortunately for FRP and other manufacturers,

Tunnel testing is not a particularly cost effective way for developing

new materials. To make development more affordable, use of the

bench scale ASTM E1354 Cone Calorimeter (Cone) test is desirable.

FRP Cone standard samples (100mm by 100mm) often exhibit non

1D behavior in terms of edge burning. Cone sample burning behavior

was analyzed by comparing standard samples to enlarged samples

(175mm by 175mm). Testing larger samples is thought to more

clearly identify the onset of edge burning. Statistical methods helped

analyze and compare the two sample sizes in terms of typical Cone

data. Additional analysis involved the use of finite difference meth-

ods to compare sample temperature profiles.

A flame length model for material burning in the Tunnel test based on

1D Cone test results for material behavior was created to simulate the

limited burning behavior of materials with a flame spread index 25 or

less. This model can be used as a screening tool for material develop-

ment. Additionally, the model can be used to establish compliance

criteria for interior finish materials consistent with IBC requirements.

Advisor: N. Dembsey (FPE)

Sponsor: Kreysler & Associates


FRP Thermal Properties and Fire Performance for

Building Exteriors

Jacob Czarnowski, Kristen Nich, Kristina Zichelli Fiber reinforced polymers (FRPs) are becoming more prevalent as a

building material due to their versatility and ease of installation. For

building exterior envelope applications, FRPs provide potential bene-

fits relative to limited heat transmission but are also a potential hazard

due to fire spread. In order to be used in exterior envelopes, sheathing

materials are required by the International Building Code (IBC) to

meet a range of criteria to ensure that fire cannot spread from floor to

floor over the envelope. One criterion is based on the costly full-scale

NFPA 285 test which measures flame height of the sheathing material

when subjected to an open flame over time.

This project studied heat transfer and flame spread characteristics of

five FRPs using Cone Calorimeter testing (ASTM E1354). Using data

collected from the Cone and additional data gathered from thermo-

couples placed throughout the specimens during testing, a procedure

was developed to estimate thermal properties of the FRPs during the

early stages of heating when the materials have nominal inert behav-

ior.

Using existing 2D spill plume and flame height theories, and data

collected from an NFPA 285 test involving one of the five FRPs, a

screening tool was created that will allow manufacturers to predict the

outcome of a full-scale NFPA 285 test. The screening tool uses FRP

Cone data to predict sheathing material flame height. Given the low

cost of Cone testing the screening tool will allow FRP manufacturers

to reduce the cost of material development.

Advisor: N. Dembsey (FPE)

Sponsor: Kreysler & Associates


Effects of Graphene Coating on Lithium-Ion Battery Cathodes

Kevin Keane, Livia Motz, Hayley Sandgren, Peter Tuma

As electronics and portable technologies progress in a society of in-

creasing environmental awareness, there is a growing need for batter-

ies with improved capacity and larger energy density. Lithium-ion

batteries offer a possible solution to this problem by offering the ad-

vantages of high voltage and energy density, low self-discharge rate,

and extremely good cycling capability. Lithium silicates have been

proposed as candidates for future batteries with a high theoretical ca-

pacity because they contain two lithium atoms in each molecule. Suc-

cessful prototypes have incorporated active materials such as

(where M=Mn, Fe). It was found that cath-

ode materials with mixed M offer superior performance to the pure

phases. Because lithium silicates are not very conductive, the cathode

must be coated with a more conductive material, such as carbon. In

this project, we studied the effect that carbon coating with graphene

has on the performance of Li2Fe0.5Mn0.5SiO4 cathode materials. Gra-

phene is a form of carbon with a layered anisotropic crystalline struc-

ture, which allows the conductive coating to be distributed evenly

among the cathode particles. This allows the batteries to achieve a

high current efficiency without inhibiting the existing high capacity

of the lithium silicates. We synthesized the Li2Fe0.5Mn0.5SiO4 cathode

materials and tested their performance. The composites were then

characterized through several tests, including XRD, SEM, and coin-

cell battery testing. We found that the graphene greatly improved the

discharge capacity of the batteries while maintaining exceptional cur-

rent efficiency, making graphene coated Li2Fe0.5Mn0.5SiO4 cathode

materials a significant advance in energy storage.

Advisors: J. Liang, D. DiBiasio (CM)


Environmental Effects on the Properties of Commercial

Biopolymer Products Kelly Buffum, Hannah Pacheco

The current trend towards sustainability has created new interest in

biodegradable plastics. While many investigations have examined

the behavior of biodegradable plastics, the changes in properties

that may occur during use have not been fully developed. The me-

chanical properties of seven types of biodegradable plastics were

analyzed. In addition, the properties of polystyrene (PS) used in

similar applications were examined. The effects of UV exposure,

humidity, and accelerated aging on the mechanical properties were

studied. In general, the strength of several biopolymers was less

than that of PS. Polylactic acid and wheatstraw had a higher

strength than PS. The properties of biodegradable plastics general-

ly deteriorated significantly upon exposure to UV radiation and

humidity, with polylactic acid, wheatstraw, potato starch, and the

bamboo bulrush wheatstraw blend being affected the most. Accel-

erated aging data indicate that after 6 months under ambient condi-

tions, the potato starch, wheatstraw, and bamboo bulrush

wheatstraw blend have a reduction in strength and modulus. Ther-

mal analysis displayed a general weight loss curve for all samples

tested, with the exception of potato starch. The major weight loss

region occurred over a temperature range of 250-400 degrees Cel-

sius with weight loss values of approximately 69-97%. Additional

improvements may be necessary to resist environmental effects so

that biopolymers can be effective replacements for traditional plas-

tics.

Advisor: S. Shivkumar


Mechanical Characteristics of Elastomeric Hockey Pucks

under Practice and Game Conditions

Steven Deane-Shinbrot, Jonathan Rapp

Ice hockey is an ever growing sport throughout the world with the

pucks used to play being produced by multiple manufacturers. Al-

so, there are few standards in place for preparing for these pucks

for game play. The goal of the project was to examine and test the

mechanical and material properties of the puck in order to assist in

finding meaningful data for optimizing puck use and consistency.

The mechanical and material properties of pucks of the three dif-

ferent manufacturers were found through different tests. In order

to determine the cause in performance variation, an analysis of

surface temperature variations, surface roughness, the coefficient

of restitution, impact toughness and pressure distributions were

performed. The data demonstrated the quality of pucks to differ

from each manufacturer. The effect of surface temperature on the

pucks appeared to be the biggest single factor influencing game

play. By standardizing puck storage prior to game play, factors

such as bounce and surface roughness, may become more predict-

able, causing more consistent game play. Eventually as consisten-

cy improves, so too will the quality of game play.

Advisor: S. Shivkumar


Economic Feasibility of a Novel Alkaline Battery

Recycling Process

Ricardo Bonhomme, Paul Gasper, Joshua Hines,

Jean Paul Miralda

Spent primary alkaline batteries present an unused source of sec-

ondary metals in Europe and the US, with at least 300,000 metric

tons of batteries being landfilled each year. While battery recy-

cling programs exist, current hydrometallurgical and pyrometallur-

gical processes are not profitable when used for dedicated alkaline

battery recycling, so industry growth is difficult. A novel mechani-

cal separation process consisting of shredding, baking, magnetic

separation, and specific gravity separation was developed to recy-

cle alkaline batteries at a lower cost than current methods. Finan-

cial analysis was conducted using a Process Based Cost Model to

specifically address the challenges of modeling a recycling pro-

cess. The cost to recycling alkaline batteries via the developed

process is $529 per metric ton, with revenue of $383 per metric

ton. This cost is lower than that of other reported processes, but is

still not economically feasible. The inherently low value of alka-

line battery recovery material is identified as the most significant

economic barrier for their recycling.

Advisors: Y. Wang, D. Apelian, J. Schaufeld (BUS)

Robotics

Engineering Virtual Skin Simulation

Gregory Andujar, Duje Jelaska, Jonathan Ng, Cullen O’Brien,

Chris Rimchala

The objective of this MQP project is to demonstrate the fea-

sibility of engineering virtual anatomical consciousness

(EVACU) patients that mimic world-class realistic patient

simulation for a broad spectrum of diagnosis, care, treatment

and patient situational responses with respect to stimulus or

perturbations. An adaptable system for the skin, that is capa-

ble of displaying physiological changes in the skin caused by

controlled and uncontrolled perturbations is created and de-

veloped. The system encompasses organic light emitting di-

ode (OLED) displays that are implanted underneath the skin

of the mannequin. After performing fatigue analysis and con-

structing a proof of concept, it is shown that the use of strate-

gically placed OLED displays could realistically simulate

physiological skin changes under controlled and uncontrolled

perturbations. The proposed design will serve as a frame-

work to medically simulate a range of reversible physiologi-

cal changes of conscious and unconscious patients under

controlled and uncontrolled perturbations.


Sponsor: STRATUS Medical Simulation Center

Robotics

ROVEN Sealion: Designing an Underwater Remotely

Operated Vehicle for Deep Sea Energy Wells

Bradford Bailey, Gregory Bailey, Gimo Barrera, Aren Johansen,

Shannon Ketcham, Kevin Malehorn

Extracting energy from offshore oil wells presents enormous

engineering challenges in ensuring that the energy is harvested safely

and efficiently. Recent events have shown that the failure to monitor

and control the various systems used during production can lead to

environmental disasters. Blowout preventers are large stacks of hy-

draulically operated rams located on the sea floor and are the last line

of defense against oil spills. It is nearly impossible for humans to

work on such structures without special equipment. Remotely operat-

ed vehicles (ROVs) are a common method of maintaining the systems

on the blowout preventers and allow humans to safely monitor the

structure from the oil platform or a nearby boat. Without adequate

visual and environmental feedback, operators of these machines can-

not perform their task safely. The purpose of this project was to de-

sign and build an ROV capable of monitoring the condition of under-

water structures. After studying current industry standards for deep

sea observational ROVs, the team designed a prototype which can

perform similar tasks in shallow waters. This prototype ROV is able

to provide feedback from several sensors, including a video camera, a

temperature sensor, pressure sensors, and a compass. With regard to

future work, the ROV was designed as an open frame with adjustable

thruster and battery locations. The lightweight design of the ROV

also allows for the addition of a payload, which could include robotic

manipulators and additional sensors and thrusters.

Advisors: M. S. Fofana, F.J. Looft (ECE)

Robotics

Toward Biologically Inspired Human-Carrying Ornithopter

Robot Capable of Hover Woo Chan Jo, Bo Rim Seo, Nicholas Deisadze

Since dawn of time humans have aspired to fly like birds. However,

human carrying ornithopter that can hover by flapping wings doesn’t

exist despite many attempts to build one. This motivated

our MQP team to address feasibility of heavy weight biologically

inspired hovering robot. To this end, aerodynamics of flapping wing

flight was analyzed by means of an analytical model and numerical

simulation, and validated through physical experiments. Two orni-

thoper prototypes were designed, constructed and evaluated under

repeatable lab conditions. A small ornithopter, weighing 2.0 kg with a

1.2 m wingspan flapping at 2.5 Hz flapping frequency, was designed

with a crank-rocker drive mechanism having wings with integrated

flaps for reduced upstroke induced drag. This model was activated on

a force plate to measure the lift forces. Due to a low signal-to-noise

ratio, this experiment was unable to validate our theoretical model. A

large ornithopter, weighing 22 kg with a wing span of 3.2 m flapping

at 4 Hz flapping frequency, used a spring-based drive mechanism to

enhance power output during downstroke. The large ornithopter was

tethered to a spring and activated while data were gathered with high-

speed video camera. Results from these experiments agreed with our

theoretical prediction. Interestingly, our power requirement study

show that ornithopters can be more advantageous compared to fixed

wing and rotary blade aircraft. With high maneuverability, a large

range of possible speeds, and reduced power require-

ments, ornithopters may be a viable and attractive mode of transporta-

tion that deserves more dedicated research and practical realizations.

Advisors: M. Popovic (PHY), S. Nestinger

Robotics

Design of a Rotary “One-To-Many” Actuator

Christopher Berthelette, Matthew DiPinto, James Sereault

There is currently a need for new actuator technologies that emulate

muscle dexterity for the purpose of advancing research in soft-

robotics, prosthetic devices, and multiple degree-of-freedom robotic

systems. The goals of this project were to explore existing technolo-

gies and develop a light-weight, cost-effective, energy-efficient, and

portable novel actuator to manipulate a soft-robotic exomusculature

for use in post-stroke rehabilitation. This project is built off the “One-

to-Many” (OTM) concept, a research effort that aims to allow a sin-

gle artificial actuator to output multiple independently actuated and

controlled degrees of freedom. To accomplish this, the team designed

a modular device that could be linked together in a network that al-

lows individual modules to share inputted energy from a single elec-

tric motor. Each module utilizes a clutch assembly to transfer energy

from the system to a rotating elastic element where the energy is

stored. Charged modules can then release the stored energy by con-

verting the elastic potential energy to kinetic energy through the use

of Bowden cables to produce a linear actuation. The team iterated

through several designs to improve upon device efficiency and reduce

system cost. Several devices have been manufactured and construct-

ed. Tests have been conducted to show that multiple actuated degrees

of freedom can be successfully and efficiently operated off of one

initial actuator. Additional tests have shown that the stored energy in

the elastic element is augmented to produce higher initial output forc-

es and can be controlled and distributed over variable periods of time.

The device can be easily miniaturized for more advanced applica-

tions. The initial prototypes functioned successfully but present

opportunities for refinement in the design.

Advisors: M. Popovic (PHY), E. Cobb, F. Hoy (BUS)

Thermofluids

Computational Modeling of Fire Sprinkler Spray

Characteristics Using the Fire Dynamics Simulator

Matthew Bourque, Thomas Svirsky

Large-scale testing is necessary to verify a specific sprinkler’s per-

formance in order for the sprinkler to become listed and approved.

An example of a sprinkler certification test is an actual density

delivered (ADD) test. An ADD test requires the use of a large lab

space, lab assistants, and expensive lab equipment. By using com-

putational fluid dynamics, the cost and time of this certification

process could be reduced. The goal of this project is to determine

how accurately the Fire Dynamics Simulator (FDS) 6 can predict

the distribution of water of an automatic fire sprinkler by inputting

the manufacturer’s specifications and measured characteristics:

spray angle, spray offset, initial velocity and droplet size. A sensi-

tivity analysis was completed to document the relative importance

of each model input in the FDS 6 simulation. These model inputs

were measured through use of Particle Image Velocimetry, digital

images of spray, and historical data. The FDS 6 output of water

flux distribution was compared to experimental results of a bucket

test. Future testing should include more accurate and simpler

methods for obtaining the model inputs as well as a larger sample

size of different fire sprinklers.

Advisor: K. Notarianni (FPE)

Sponsor: Underwriters Laboratories

Thermofluids

Vertical Axis Wind Turbine Evaluation and Design Lucas Deisadze, Drew Digeser, Christopher Dunn, Dillon Sarkar

This project studied roof-mounted vertical axis wind turbine

(VAWT), systems on house roofs. The project analyzed and de-

signed several types of VAWT blades in order to maximize the

efficiency of a shrouded turbine. The project also used a wind

simulation software program, WASP, to analyze existing wind

data measured on the roofs of various WPI buildings. Scale-model

tests were performed in the WPI closed-circuit wind tunnel. An

RPM meter and a 12 volt step generator were used to measure tur-

bine rotation speeds and power output at different wind speeds.

The project also studied roof mounting systems for turbines that

are meant to dissipate vibrations to the roof structure. Turbine

vibrations were measured during the wind tunnel tests and in im-

pact tests on a scale-model house. Recommendations were made

for future designs of roof-mounted VAWTs.

Advisors: D. Olinger, P. Mathisen (CE), J. O’Shaughnessy (CE)

Thermofluids

Thermomechanical Reliability

Roberto Alvarado, Michael Bartlett, Richard Beski,

Santiago Isaza, Congji Li

Microsystems, microelectronics, and MEMS are all new technologies

that are being increasingly integrated into society and everyday life.

These technologies are constantly changing as both hardware and

software are integrated to push the limits of imagination to meet the

ever-growing needs of the consumer. Some of the main concerns in

the reliability of micro-electronics are the solders, leads and packages

within the systems. Our project involved the observation, testing, and

analysis of the different types of electrical, thermal, and mechanical

failures that occur in surface mount technology (SMT). We have con-

ducted extensive literary research on the history of the technology and

how it has advanced in the past, what failures and issues commonly

occur, how failures and issues are being addressed, and what research

has already been conducted on the subject. We have contacted manu-

facturers and industry leaders that utilize SMT to understand the cur-

rent state of these issues, in order to gain a perspective of how preva-

lent the failures of SMT systems are and how they are being mitigat-

ed. Lastly, we used finite element analysis (FEA) software to test fail-

ures due to but not limited to vibrations, thermal expansion mismatch,

and material properties. We correlated the results of our modeling

with laboratory testing and supportive detailed uncertainty analysis.

Keywords: SMT, thermo-mechanical, deformation, reliability, FEA,

solder, joint, attachment, stress, strain, fatigue, vibration, thermal ex-

pansion mismatch, uncertainty analysis

Advisors: R. Pryputniewicz, G. Iannacchione (PHY)

Sponsor: WPI-ME/CHSLT-NEST

Thermofluids

Enclosed Wind Turbine

Christopher Brandmaier, James Everett, Anthony Hassan,

Andrea Kates

Vertical axis wind turbines (VAWTS) are mounted on residential

and public buildings, providing sustainable, green energy. The

project focused on designing and testing enclosures that surround

the turbine, allowing faster air flow in order to improve the overall

efficiency. Utilizing SolidWorks, the team designed different en-

closures with the goal of maximizing the wind speed inside the

enclosure, where the turbine blades would be located. By altering

the location and size of the enclosure’s inlet and outlet, the team

identified three promising enclosure designs. These were then

manufactured using acrylic tubing and tested in the WPI closed

circuit wind tunnel. The rotational velocity, allows for the power

to be calculated. The results show the power generated by the tur-

bine is significantly increased with the installation of an enclosure.

These designs and results demonstrate the potential of enclosed

vertical axis wind turbines for harnessing wind energy.

Advisors: B. Savilonis, J. O’Shaughnessy (CE)

Thermofluids

Thermal Analysis of the deCordova Snow House Exhibit

Nicholas Broulidakis, Shuimiao Ge, Jenny Marquez,

Maria Paredes

The deCordova Snow House exhibit consists of an underground

granite structure which preserves an enormous snowball from win-

ter to summer solstice. The team was tasked with the thermal anal-

ysis of the exhibit to recommend viable options for insulation and

storage.

By performing a heat balance on the proposed design, a finite dif-

ference model was created to calculate the temperature change

through the top layer of soil and the energy change throughout the

structure during a four month period, which results in the final

diameter of the snowball in summer. Also, to justify the model, the

team utilizes ANSYS, a finite element analysis software package,

to simulate a 3D analysis of the structure, resulting in a tempera-

ture change throughout to be compared with the results from the

first approach.

The results show that, to ensure that the snowball is of an accepta-

ble diameter at the end of the four month period, it will be neces-

sary to utilize industrial insulation methods such as expanded pol-

ystyrene and polyurethane blocks, and preindustrial ice house de-

signs.

Advisor: B. Savilonis

Sponsor: deCordova Sculpture Park and Museum

Thermofluids

Wind Energy Device Design

Gregory Ford, Victoria Hewey, Nicholas Lima

The aim of this project was to design and construct a wind pump

that is able to provide water to a rural third world village. This was

achieved by using a Savonius-Darrieus turbine connected to a rope

pump in order to create a system that was robust and easy to con-

struct in a low-technology area. The pump proved to be a cost-

effective source of clean water which could easily be reproduced

in this area.

Advisor: Brian Savilonis

Thermofluids

Wheelchair Cooling Pad via Heatpipes

Yusuf Rashid, Cing Lun Thang, Bin Zou

People restricted to wheelchairs for extended periods of time are at

a high risk for developing bedsores or pressure ulcers. Pressure

ulcers result in approximately 60,000 deaths each year. The fre-

quency of pressure ulcers is correlated with stagnant activity, ele-

vated body temperatures and humidity. Wheelchair bound people

frequently exhibit these conditions. Along with the pressure ap-

plied to the skin due to prolonged immobility, heat and moisture

significantly accelerate tissue deterioration by enhancing the ef-

fects of friction. To address the thermally related problems in-

volved with pressure ulcers, we designed and fabricated a self-

regulating cooling pad that utilizes heat-pipe technology to cool

wheelchair-confined patients. Heat pipes are inexpensive sealed

pipes that frequently make use of the evaporation and condensa-

tion of a fluid known as the working fluid to transfer heat from

one location to the other. Our design uses a pad filled with an am-

monia mixture, which will change phase from liquid to vapor at

approximately 28 ˚ C (82˚F). The energy required to vaporize the

ammonia comes from the seated person. The vapor rises naturally

to the back of the wheelchair where it releases its energy to the

ambient temperature environment, circa 22˚C (71˚F) and then con-

denses back to the pad. Our cooling device requires no external

energy and can potentially reduce the frequency of pressure ulcers

by reducing the effects of heat and moisture accumulation.

Advisor: John Sullivan

Design

Updating Selected Laboratories for Engineering

Experimentation Course at Worcester Polytechnic Institute

Mengjie Liu

This project aimed at updating two existing laboratories in

Engineering Experiment course at Worcester Polytechnic

Institute: Strain and Pressure Measurement Laboratory and

Vibration Measurement Laboratory. Without major alterna-

tion to the experiment designs, the author examined laborato-

ry equipment, software and instruction materials for both la-

boratories.

Two alternative signal conditioners are recommended as re-

placements to the current system; software is updated to im-

prove usability; and comprehensive laboratory instructions

are developed based on existing materials. The updated ma-

terials are suitable for future use at WPI and other universi-

ties.

Advisor: C. Furlong

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