Spacecraft testing includes acoustics, vibrations, and thermal vacuum. Cal Poly’s Space Environments Lab is equipped with multiple vacuum chambers, but no thermal vacuum chamber. The purpose of this thesis is to incorporate an ATS Chiller system with the HVEC vacuum chamber so students are able to experiment with a thermal vacuum chamber. The ATS Chiller had leaky pipes that needed to be refurbished and a shroud was implemented to improve thermal capabilities of the system. The full system was able to reach temperatures as low as -38ºC and as high as 58ºC at a pressure of 10-6 Torr. The ATS Chiller was able to absorb up to 500W of heat dissipation from a component mounted to the platen inside of the vacuum chamber. Thermal modeling of the apparatus was performed in Thermal Desktop. The model was incorporated with the test data to extract interface resistance information between connected surfaces. Another model is used to analyze a theoretical component inside the apparatus to evaluate mounting methods and determine theoretical temperatures of the component. The model adjusts for material properties, including thermal conductivity and emissivity to accurately simulate testing conditions within +/- 3ºC. Platen and shroud adjustments were able to accommodate a peak bake out temperature of 130±2.2℃ of any component without damage to the system. Three temperature cycles were performed by the thermal vacuum chamber to reach extreme temperatures of 58℃ and -38. A 300 Watt heater was used to simulate component heat dissipation for the duration of the test. Furthermore, this thesis lays out further possibilities for thermal testing using the HVEC Vacuum chamber and ATS chiller as a thermal vacuum chamber.

Creating a bicycle with a rideable geometry is more complicated than it may appear, with today’s mainstay designs having evolved through years of iteration. This slow evolution coupled with the bicycle’s intricate mechanical system has lead most builders to base their new geometries off of previous work rather than expand into new design spaces. This crutch can lead to slow bicycle iteration rates, often causing bicycles to all look about the same. To combat this, several bicycle design models have been created over the years, with each attempting to define a bicycle’s handling characteristics given its physical geometry. However, these models often analyze a single bicycle at a time, and as such, using them in an iterative design process can be cumbersome. This work seeks to improve an existing model used by the Cal Poly Mechanical Engineering department such that it can be used in a proactive, iterative fashion (as opposed to the reactive, single-design paradigm that it currently supports). This is accomplished by expanding the model’s inputs to include more bicycle components as well as differently sized riders. This augmented model is then incorporated into several search platforms ranging from a brute-force implementation to several variants using genetic algorithm concepts. These models allow the designer to specify a bicycle design search space as well as a set of riders upfront, from which the algorithms search out and find strong candidate designs to return to the user. This in turn reduces the overhead on the designer while also potentially discovering new bicycle designs which had not been considered previously viable. Finally, a front-end was created to make it easier for the user to access these algorithms and their results.

The Department of Energy (DOE) confirmed Team Solar Cal Poly from California Polytechnic State University, San Luis Obispo, as a competitor in the 2015 Solar Decathlon in February 2014. The Solar Decathlon is a biennial collegiate competition to construct a net-zero home and operate it for a week of “normal use”. Solar Cal Poly needed assistance with passive and active HVAC systems for the design, and thermal load models. The competition will take place in Irvine, CA [33.67⁰, 117.82⁰ W] from September 27 – October 3, 2015. After the completion, a potential final location for the house will be Santa Ynez, CA [34.61⁰ N, 120.09⁰ W]. Ms. Willis assisted with a climate study for both locations and research passive and active HVAC systems and design elements for Team Solar Cal Poly. She modeled the final summer design in DesignBuilder to calculate the heating and cooling loads. The heating load was calculated to be 26.7 kBTU/h. The cooling load was calculated to be 2-tons. A mini-split HVAC system was selected for the final summer design based off the calculated heating and cooling loads. For this design, the Fujitsu Hybrid Halcyon Flex met the minimum requirements, and was a multi-zone system that could condition all three major spaces of the design. This report provides a summary of information and the basic design process for future Solar Decathlon designs considerations.

The National Ignition Facility (NIF) is home to the world’s most energetic laser. The facility is one of the leading centers in inertial confinement fusion (ICF) experiments to research and understand sustainable fusion energy. To fully document and understand the physics occurring during experiments, precise diagnostics are used for a wide range of purposes. One diagnostic, the crystal backlighter imager (CBI), allows for X-ray imaging of the target at late stages of its implosion. The aim of this project was to increase the current capabilities of the CBI diagnostic with the addition of a second crystal. This thesis focuses on the design development of the 5 degrees of freedom precision stages used to align each of the crystals. The motivations for the addition of a second crystal are covered in the introduction. A ray tracing model was generated to explore the required range of travel for both crystals, as well as explore potential effects of transitioning to a two-crystal system. The requirements of the precision stage are outlined based on the flaws of the current stage and areas with desired improvements. A dynamic analysis was performed on modified supporting hardware for CBI, to determine areas of interest in redesigning components for the two-crystal system. Further research is performed on commercial and literature methods used to design precision optomechanical stages. Finally, the design development is documented outlining the considered options, modifications to the existing system, and the proposed design solution. A design is proposed that meets the project requirements set at the beginning of design development.

This thesis seeks to improve the workflow in the product development process when using the Product Lifecycle Management (PLM) system PLM2020, incorporated at Siemens Energy. Focus is on three problem cases that emerge when working with Computer Aided Engineering (CAE) data during the development process. Apart from solving these problems, a current situation analysis was conducted, and possible solutions of these problems were investigated on how they affect the lead time in the product development process. The problems consist of exploration of an unused function and solving of two problematic situations that can occur while using PLM2020 during development work. A case study was established to investigate the problems, using participatory observations and interviews. The interviews established the current situation of Siemens work methodology to handle these situations and how PLM2020 is used. During the observations, the problems were attempted to be solved using an arbitrary Computer Aided Design (CAD) model while exploring different functions in a sandbox environment. During the interviews, it was discovered that there exist different ways of working in PLM2020 and that some approaches nullifies the benefits of using a PLM system. The participatory observations revealed that that there exist functions in the PLM system that solves the problems encountered. A set of proposed solutions are presented to Siemens

3D printing is a revolutionary manufacturing method that allows the productions of engineering parts almost directly from modeling software on a computer. With 3D printing technology, future manufacturing could become vastly efficient. However, it is observed that the procedures used in 3D printing differ substantially among the printers and from those used in conventional manufacturing. In this thesis, the mechanical properties of engineering products fabricated by 3D printing were comprehensively evaluated and then compared with those made by conventional manufacturing. Three open-source 3D printers, i.e., the Flash Forge Dreamer, the Tevo Tornado, and the Prusa, were used to fabricate the identical parts out of the same material (acrylonitrile butadiene styrene). The parts were printed at various positions on the printer platforms and then tested in bending. Results indicate that there exist substantial differences in mechanical responses among the parts by different 3D printers. Specimens from the Prusa printer exhibit the best elastic properties while specimens from the Flash Forge printer exhibit the greatest post-yield responses. There further exist noticeable variations in mechanical properties among the parts that were fabricated by the same printer. Depending on the positions that the parts were placed on a printer platform, the properties of resultant parts can vary greatly. For comparison, identical parts were fabricated using a conventional manufacturing method, i.e., compression molding. Results show that compression molded parts exhibit more robust and more homogeneous properties than those from 3D printing. During 3D printing, the machine code (e.g., the Gcode) would provide the processing instructions (the x, y, and z coordinates and the linear movements) to the printer head to construct the physical parts. Often times the default processing instructions used by commercial 3D printers may not yield the optimal mechanical properties of the parts. In the second part of this thesis, the orientation-dependent properties of 3D printed parts were examined. The multi-layered composite theory was used to design the directions of printing so that the properties of 3D printed objects can be optimized. Such method can potentially be used to design and optimize the 3D printing of complex engineering products. In the last part of this thesis, the printing process of an actual automobile A-pillar structure was designed and optimized. The finite element software (ANSYS) was used to design and optimize the filament orientations of the A-pillar. Actual parts from the proposed designs were fabricated using 3D printer and then tested. Consistent results have been observed between computational designs and experimental testing. It is recommended that the filament orientations in 3D-printing be “designed” or “tailored” by using laminate composite theory. The method would allow 3D printers to produce parts with optimal microstructure and mechanical properties to better satisfy the specific needs.

One important aspect of our present age of monolithic high speed computers is the computer's capability to solve complex problems hitherto impossible to tackle due to their complexity. This paper explains how to use a. digital computer to solve a specific type of problem; specifically, to find the inverse solution of a in the elliptical equation V2U(x,y) = g(a,U,x,y), with appropriate boundary conditions. This equation is very useful in the electronics field. The knowns are the complete set of boundary values of U(x,y) and a set of observations taken on internal points of U(x,y). Given this information, plus the specific form of the governing equation, we can solve for the unknown a. Once the computer program has been written using the technique of quasilinearization, Newton’S convergence method, discrete invariant imbedding, and the use of sensitivity functions, then we take data from the computer results and analyse it for proper convergence. This data shows that there are definite limits to the usefulness and capability of the technique. One of the results of this study is the observation that it is important to the proper functioning of this problem solving technique that the observations taken on U(x,y) are placed in the most efficient locations with the most efficient geometry in the region of largest effectiveness. Another result deals with the number of observation points used: too few gives insufficient information for proper program functioning, and too many tends to saturate the effectiveness of the observations. Thus this paper has two objectives. first to develop the technique and secondly to analyse the results from the realization of the technique through the use of a computer.

The thesis focuses on investigating and optimizing a bushing script implemented as a tool in MSC ADAMS/Car. The study provides an insight on the representation of a rubber bushing and identify parameters which can be used to define the properties of a bushing in a simulation environment such as ADAMS/Car. The tool being studied here can be used to implement different kind of bushings such as a hydro bushing and a general rubber bushing, but optimization was implemented for the rubber bushing only. With an increasing reliance on Computer Aided Engineering (CAE) tools in the designing process, it is necessary that the vehicle behaviour can be predicted without relying on physical testing. CAE tools reduces the need of prototypes and provides a faster approach to designing vehicles. MSC ADAMS/Car is one such tool, which has been used here to predict the vehicle dynamic behaviour, which will influence the ride, handling and comfort characteristics of the vehicle. Rubber bushings, which have been studied here, have a significant contribution to the overall stiffness of the vehicle and as such, it is imperative that the tool being used here, is accurate and makes the designing process easy. The rubber bushing can be imagined to be a combination of a non-linear elastic spring, a frequency dependent Maxwell component and an amplitude dependent frictional element. In order to ease the design of the bushing properties, a reduced number of input properties are used to calculate the bushing properties internally. While trying to validate the force hysteresis loop obtained through the model with the measured data, it was seen that the accuracy was quite poor for the model when loading it with dynamic loads corresponding to amplitudes of0.2 mm and lower. The quasi-static loading and dynamic loading above 0.2 mm is shown to have a satisfactory accuracy when compared to the measured data.

The femur is the longest limb bone found in humans. Almost all the long limb bones found in terrestrial mammals, including the femur studied herein, have been observed to be loaded in bending and are curved longitudinally. The curvature in these long bones increases the bending stress developed in the bone, potentially reducing the bone’s load carrying capacity, i.e. its mechanical strength. Therefore, bone curvature poses a paradox in terms of the mechanical function of long limb bones. The aim of this study is to investigate and explain the role of longitudinal bone curvature in the design of long bones. In particular, it has been hypothesized that curvature of long bones results in a trade-off between the bone’s mechanical strength and its bending predictability. This thesis employs finite element analysis of human femora to address this issue. Simplified human femora with different curvatures were modeled and analyzed using ANSYS Workbench finite element analysis software. The results obtained are compared between different curvatures including a straight bone. We examined how the bone curvature affects the bending predictability and load carrying capacity of bones. Results were post processed to yield probability density functions (PDFs) for circumferential location of maximum equivalent stress for various bone curvatures to assess the bending predictability of bones. To validate our findings on the geometrically simplified ANSYS Workbench femur models, a digitally reconstructed femur model from a CT scan of a real human femur was employed. For this model we performed finite element analysis in the FEA tool, Strand7, executing multiple simulations for different load cases. The results from the CT scanned femur model and those from the CAD femur model were then compared. We found general agreement in trends but some quantitative differences most likely due to the geometric differences between the digitally reconstructed femur model and the simplified CAD models. As postulated by others, our results support the hypothesis that the bone curvature is a trade-off between the bone strength and its bending predictability. Bone curvature increases bending predictability at the expense of load carrying capacity.

A substantial amount of research has been done in the field of engineering knowledge management, where countless ontologies have been developed for various applications within the engineering community. However, despite the success shown in these research efforts, the techniques have not been adopted by industry. This research aims to uncover the reasons for the slow adoption of engineering knowledge frameworks, namely ontologies, in industry. There are two projects covered in this thesis. The first project is the development of a cross-domain ontology for the Biomesh Project, which spans the fields of mechanical engineering, biology, and anthropology. The biology community is known for its embrace of ontologies and has made their use quite popular with the creation of the Gene Ontology. This ontology spawned the establishment of the Open Biological and Biomedical Ontologies (OBO) Foundry, a consortium which approves and curates ontologies in the biology field. No such consortium exists in the field of engineering. This project demonstrates the usefulness of curated reference ontologies. Ontological knowledge bases in four different domains were imported and integrated together to connect previously disparate information. A case study with data from the Biomesh Project demonstrates cross-domain queries and inferences that were not possible before the creation of this ontology. In the second part of this thesis we investigate the usability of current ontology tools. Protégé, the most popular ontology editing tool, is compared to OntoWiki, a semantic wiki. This comparison is done using proven techniques from the field of Human-computer interaction to uncover usability problems and point out areas where each system excels. A field of 16 subjects completed a set of tasks in each system and gave feedback based on their experience. It is shown that while OntoWiki offers users a satisfying interface, it lacks in some areas that can be easily improved. Protégé provides users with adequate functionality, but it is not intended for a novice user.