Mechanical Design Engineering Portfolio

Mechanical Engineering Design Portfolio

Nikhil Kulkarni - MS Mechanical Engineering

Arizona State University

[email protected]

+1 (480) 634 3323

mailto:[email protected]

CONTENTS

SL No TITLE PAGE NUMBER

1. Introduction and About me. 3

2. Jigs and fixture for ERU crutch fairing [Intern – HAL]. 4

3. Structural assessment and analysis of TVC hydraulic 8 system flight filter manifold.

4. Design for Autodesk. 15

5. Automatic basketball machine. 17

6. Automatic surveillance vehicle. 20

7. Orange picker. 23

8. Human powered paper bike. 25

9. Transfer wheelchair. 28

10. Miscellaneous. 31

Introduction:

Welcome, and thank you for taking the time to view my portfolio. My name is Nikhil Kulkarni. I am currently a final year graduate studentmajoring in Mechanical engineering with focus on product design and simulation at Arizona State University. The aim of this portfolio is to provideyou with a deeper insight into my design skills and experiences that I have acquired over a period of time. The Masters degree has helped medevelop sufficient foundation of knowledge so as to stamp my dominance in my field as a leading professional.

About me:

The word mechanical resembled a magical world to me in my childhood days, but an unseen force which made the world around me work, thepassivity of a circuit and yet achieving tasks that otherwise would have involved a lot of physical labor, resembled a land of Arabian nights for mea fairy tale in the making. Maybe the child in me still lives on but the curiosity of discovering this seemingly intangible world of mechanicalengineering remains. True I excelled in all my subjects during my school years and could have just been an equally successful financial analyst orjournalist but the prospects of those professions never stimulated my passion or imagination. And I believe without passion and a dream in onesfield of work, it stays just that, work. It was in my due interest of mechanisms of gadgets around me especially motor bikes, mechanicalcomponents of toys, mechanical devices with which I have grown up with that fueled me to pursue my bachelors and now masters in Mechanicalengineering. Having realized that the world is increasingly becoming a digital world today and even the simplest of advancements in this fieldaffects our day-to-day lives. More importantly any latest breakthroughs in the field of information technology or the telecommunication worldare a direct consequence of developments of the Design front. Thus my desire to be involved with technological advancements at the grassrootslevel or at a level that has far reaching impact, has made me keen to take my specialization in Product Design and simulation [CAE] at the Masterslevel. Besides my focus on academic excellence I made it a point to have a more thorough understanding of my subjects as compared to my peers.Whenever opportunities have come my way I have always made it a point to make the best use of them and involved in many implant trainingslike “Hindustan Aeronautics Limited- Research and Development Department” which is one off the top aerospace company in India during myundergraduate to get an insight into the practical nuances of the theory learnt in the classrooms. The project on “Design and Fabrication of DrillJig and Fixtures for a Fighter Jet Aircraft” was highly appreciated and was even selected to be sponsored by Hindustan Aeronautics Limited. Therichest of all the experiences has been working on the design projects during my graduate studies.

Now that I am about to graduate and will be soon awarded my masters degree, I am looking forward towards having a successful career in Mechanical design engineering. If given an opportunity I promise you that not only will I give my best, but strive to become an asset.

Introduction and About me

3

Jigs and fixture for ERU crutch fairing

Hindustan Aeronautics Limited

I worked as an Design engineering Intern in Tooling department atHindustan Aeronautics Limited, Bangalore, India. The project assigned tookabout 8 weeks to complete of which 4 weeks was spent at HAL.

Objective: To design and analysis jigs and fixture for ejector release unit[ERU] crutch fairing to improve the accuracy of machining, to decrease thecost and time consumed for manufacturing and to have interchangeability.

Assembly requirements:• The position of 4 holes to be drilled on top of the ERU crutch fairing

must have constant pitch maintained between them.• Riveting on the ERU crutch fairing must be done in proper positions at

16*4 places [as shown in the drawing].• The bulkheads must be positioned correctly inside the ERU crutch

fairing.• The 2 positions for the support arms must be maintained correctly using

locating pins.• Fairing skin must be properly and accurately trimmed so that when

attached with the pylon housing it fits perfectly.4


Setup1:

To drill 4 holes of 14mm dia. at different locations on the skin/fairingusing the drill template.

The drill templates are fastened onto the base plate of the fixture at thefirst location. Then the drilling operation is carried out, the center of thisdrilled hole are ensured to be in line with the axis of the hole present inthe bulk head. The bushes provided on the drill template acts as guide forthe movement of the drilling tool. The drill templates are removed fromtheir place only after completion of drilling in that location. Afterremoving the drill template it is fitted on the next consecutive location.This procedure is repeated till all the 4 holes of 14 mm dia. are drilled.

The drill template is removed from the fixture; then the fixture assemblyis cleaned ensuring that there is no waste chip present on the fixtureassembly.

5


Setup2:

To position and clamp the rivet hole templates and to carry out drillingpilot holes of 2mm dia. then enlarge this hole size to 3.2mm dia.

The rivet hole templates are fastened onto the base plate of the fixture atthe first location. The drilling of pilot holes are carried out one after theother, totally 16 holes are drilled at this location. Since the pitch distancebetween the holes are same the drilling operation is carried out using thesame template. The drill templates are removed from their place onlyafter completion of drilling in that location. After finishing at one placethe template is fastened onto another location. Hence a total of 64 holesare drilled using this template on the ERU fairing.

These pilot holes are then increased in diameter to 3.2 mm using separatedrilling tool other than the one chosen earlier.

6


Setup3:

Use the end contour blocks as reference to mark the trimming lines onthe fairing using height gauge and trim the unwanted part to finish alloperations.

The templates are removed from the fixture, the height gauge ismounted on the table. Taking the upper surface of the stopper block asreference a trimming line is drawn throughout the fairing using theheight gauge assembly. The trimming operation at this marked line andthe deburring operation is carried out to finish all the operations.

Results:

• A total cost of machining the ERU assembly for an aircraft was reducedby of 600$.

• Dimensional accuracy, repeatability and interchangeability ofassemble was achieved.

• Cycle time was improved by 40%

7

STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST

VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT

FILTER MANIFOLDThe project was a part of MAE 546: Advance CAE.

ObjectiveTo qualify the assembly as an aerospace component by performing pressure analysis for normaloperating, proof and burst pressure cases, acceleration and random vibrations analysis in X,Y and Zdirections so as to obtain the margin of safety and calculating fatigue damage ratio. Also, theprojects secondary objective was to optimize inner radius of the filter using parametric study,response surface and design of experiments so as to minimize the maximum stress inside the filterbowl.The analysis was performed in ANSYS 16.0 and for the filter model Design modeler was used.

Model Preparation

A fillet radius of 0.475 in is considered in the beginning to study if the assembly qualifies as anaerospace component. The fittings in the model were replaced with a solid with negligible density.To compensate for their masses point masses are applied at the CG of the fittings. This helps inminimizing the complexity of the geometry. Also, the point masses is an effective method to balancethe pressure loads that are being acted on the assemble. To account for tension in the bolts that fixthe filter assemble, fixed support boundary condition is applied to circular regions under themanifold surface. The fluid that applies on the inner surface of the filter is not modeled, but themass of the fluid is taken into account by adding 2/3rd of the mass to the mass of filter bowl and1/3rd of the mass to the mass of the manifold. Appropriate contact surfaces are also added. Fixed support

TVC filter manifold assembly

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FILTER MANIFOLDConvergence study

A convergence study is successfully carried out on the assembly to justify that the location of the maximum stress by locally refining the faces ofthe valve manifold and the filter bowl where the maximum stress is obtained when the assembly is meshed at 0.2 inches element size. Thefollowing data provides the convergence study wherein the maximum von-mises stress converges at a local mesh size 0.0125 inches with anerror present of less than 4% as per the specifications. The material is safe as the maximum stress induced is within the yield strength of thematerial properties. The images show the area where the mesh is locally refined.

0.025 in mesh size - Manifold

TVC Filter Manifold Assembly Finite Element Mesh

Convergence Study - Manifold

Mesh size Manifold Stress Combined Stress % Error

0.2 20600 20673

0.1 21944 27925 6.12%

0.05 24318 29918 9.70%

0.025 24615 31025 1.20%

Convergence Study - Filter

Mesh size Filter Stress Combined Stress % Error

0.2 20673 20673

0.1 29673 29673 5.77%

0.05 27960 27960 9.30%

0.025 30860 30860 0.30%

Convergence Study

0.025 in mesh size - Filter

Manifold Pressure

FilterPressure

9



FILTER MANIFOLDForce balancing

During the static cases, force reaction is checked by applying a reaction probe at the fixed support of the assemble. Force imbalance is observedin the Y – direction due to the gaps and anomalies in the geometry of the model assembly arising due to the model modification done initially tosimplify the simulation of the TVC filter assembly. Reaction probe applied at the fixed supports depicts the force imbalance in the assembly. Thetotal reaction force in along each component of the direction is required to be lesser than 5 lb. As per the specified requirements. Therefore,this imbalance in the force is balanced by applying 96 psi of additional pressure to the inner to surface of the filter bowl to obtain the netreaction force within the specified requirements. The maximum von-mises stress induced in the system in then recorded for the qualification ofthe assemble

Test SpecificationPressure cases Random Vibration• Normal operating pressure case: 3200 psi Longitudinal: X - direction• Proof pressure case (1.5 * NOP): 4800 psi Tangential: Y - direction• Burst Pressure case (2.5 * NOP): 8000 psi Radial: Z - direction

Acceleration cases+1g acceleration applied in X, Y, Z directions.

Scaling factor for MS and FDR calculations• 6.22 x Result for X – directional analysis• 2.00 x Result for Y and Z – directional analysis

NOTE: All tests require material to beCharacterized at maximum flightenvironment temperature: 135 deg C

Random Vibration requirements

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FILTER MANIFOLD

Margin of safety for flight acceleration – Longitudinal flight axis

Margin of safety for flight acceleration – Tangential flight axis

Margin of safety for flight acceleration – Radial flight axis

Margin of Safety for Assembly Components under Proof Pressure

Margin of Safety for Assembly Components under Normal operating pressure

Margin of Safety for Assembly Components under Burst Pressure

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FILTER MANIFOLD

Maximum Von- Mises Stress – Normal Operating Pressure

Maximum Von- Mises Stress – Proof Pressure

Maximum Von- Mises Stress – Burst Pressure

Maximum Von- Mises Stress – Axial (X) Acceleration

Maximum Von- Mises Stress – Lateral (Y) Acceleration

Maximum Von- Mises Stress – Lateral (Z) Acceleration12



FILTER MANIFOLDResults: Random Vibrations

3 sigma stress in Z direction

3 sigma stress in X direction

3 sigma stress in Y direction13



FILTER MANIFOLD

Clockwise from top right to left: Mode shapes 1 to 6 for Random Vibration analysis

Response Surface plots for fillet optimization Margin of safety and FDR ratio

calculations

Conclusion

The TVC filter manifold assembly achieved all the required margin of safety as positive values and all fatigue damageratios were less than the design limit of 1.Therefore, the TVC filter qualified as an aerospace component.

14

Design for Autodesk

Design for Autodesk is a program by Autodesk design academy which encourages students to learn and model in their latestCAD software Fusion 360.

Project requirements:

1. Project must be created exclusively using Autodesk Fusion 360.

2. Project must include 15+ individual unique parts (this does not include fasteners such as nuts, bolts, screws, etc.).

3. You must be the sole owner of the project and all materials submitted to Autodesk, and no third party (including yourschool) should have any rights of any materials you submit. Projects sponsored or funded by third parties may not beused.

4. All individual components of your mechanism must be modeled by you. You cannot import existing CAD data into yourdesign. (Standard parts may be accessed through the McMaster Carr library.)

5. You must combine the mechanism parts into an assembly.

6. The project requires the modeling of the externals and internals of the model/assembly.

7. Prismatic shaped models such as boxed furniture or architecture will not be accepted.

I have successfully submitted one of my CAD models and I am in the process of completing my second CAD model. The designprogram helped me gain a valuable opportunity to learn 3D modeling in one more new software.

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Design for Autodesk

6 Speed - BLENDER

16

Automatic Basket Ball Machine

This design challenge project was a part of MAE 540: Advance product design methods course.

Challenge

For amateur players most of the practice time is spent retrieving the basketball after it goes careening off the rim or backboard orafter it falls through the basket. As a result, there was a need to allow players to maximize shooting time by minimizing the timespent retrieving basketballs.

The design challenge was to design a system that returns a thrown basketball to the place of the shooter without manual rotation ofthe shooting return device. The targeted players were in 10-16 years of age.

The shooter could be as far away as 24 ft. The system designed must not block the shooter's access to the basket. It must be easilyset up on a hoop and court. It must fit any kind of hoop that a young player might have (e.g., hoops that are set up on home courts,garages or are free-standing). It should be easily transportable and storable in a small space. It should be affordable by the averagefamily.

Design

My design was rated the highest in the class and was regarded as an unique idea. I was successful in analyzing the problem anddesigning a device that met all the requirements . The design process implemented to solve the challenge was learnt in the MAE 540class. Also, during the design process I learnt and used 2 new software's, to formulate the problem statement and objective tree Iused ‘Problem formulator’ developed at Arizona State University and for idea generation I used ‘Ideation-space’.

The CAD models was created using Solidworks and Catia V5.

Design process

Problem formulation

Objective Tree, Requirements, User scenario,

Function decomposition

Brain storm,Morph chart,

Concept sketches

Modeling and Analysis

Documentation: CAD models, simulation,

BOM

17


Morph chart

Concept sketches

18


Final Design

Collection - The basketball thrown towards the basket hoop is collected using a net frame. The net frame was designed large enough so as to account even for air ball [ if the ball misses the basket board that is behind the hoop]. Once the ball is detected in the net frame a linear actuator stops the ball from entering into the return mechanism.

Sensing/Detection - The second stage makes use of 2 main sensors, an IR motion sensor that detects user position on the court and an ultrasonic sensor that detects the distance of the user from the return mechanism.

Return - Based on the inputs from the 2 sensors the return mechanism rotates and aligns itself to the user position. Now the linear actuator releases the basket ball into the return mechanism. The 2 rollers in the return mechanism rotate at a certain speed based on the distance data from ultrasonic sensor.

Figures showing basketball collection and return 19

Automatic surveillance vehicle

This was the second design challenge project which was a part of MAE 540: Advance product design methods course.

Objective: To design and build a functional device that is can automatically steer and surveys two buildings in ‘8’ pattern andthen stops at the midpoint in-between the two buildings.

Problem formulation

Objective Tree, Requirements, User scenario,

Function decomposition

Brain storm,Morph chart,

Concept sketches

Modeling and Analysis

Documentation: CAD models, simulation,

BOM

1 2

96”

48”

48”

Requirements• The vehicle must start at and stop at or near the reference indicated in the diagram.• The vehicle must fit within a 6x6xl2 inch box.• The vehicle must be powered by one or two Radio Shack DC motors (part number 273-223,

258 or 047) and compatible batteries. No other energy source shall be included within thevehicle.

• The vehicle must have an index mark which is to be used to position the vehicle in thestarting position and will be used to measure the distance between the index mark and thereference when the vehicle stops.

• Within one minute the vehicle must be placed in the starting position and motion initiatedby a "switch" on the vehicle. Once started, no communication of any kind shall betransmitted to the vehicle.

• The vehicle must travel around building 1, cross the reference point, and travel aroundbuilding 2, then come to a stop at or near the reference point.

• Micro-controllers or any type of CPU is NOT allowed; however non-programmable electronicor electrical components can be used.

• You are NOT allowed to place any guide chutes or tracks on the plywood outside the 6x6x12envelope.

Design process:

20


Final Design

The surveillance vehicle fabricated made use of two motors, one for steering and other for forward movement. Thedevice contained 2 clocks which was used as switches to open and close the circuits. The device was powered by 2 7 voltbatteries.

Pre calculations:• The time taken by the device to go around building 1.• Time taken by the device to complete the entire ‘8’ pattern.• The angle at which the front tires must be turned to go around the building 1 and building 2.

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Turning mechanism:The pre calculated time taken by the device to go around building 1 was around 10 sec, which was set on the first clock.After 10 seconds the second hand on the clock makes contact with a switch that closes a circuit. This triggers the firstmotor and turns the wheels which is set at an angle such that it makes a perfect circle around the building 2.

Stopping mechanism:The second clock is set for 18 seconds which was pre calculated time taken by the device to go around both thebuildings. After 18 seconds the second hand on the clock breaks the contact with a switch that opens the circuit.Thereby the power supply to the second motor that is used for forward movement is stopped. Since there is no breakingmechanism the power supply to the second motor is stopped 2 seconds before it approaches the center point in orderto account for inertia.

22

Orange Picking Device

This design assignment was a part of MAE 540: Advance product design methods course.

ObjectiveTo design a orange picking device that can be used in a backyard to harvest oranges from large, thick and mature trees.

Final designThe design made use of nested pipes to reach out to the oranges on the tree. A cup with an inflatable rubber tubeholds the orange in place. The cup then rotates to pluck the orange from the tree. Then rubber tube deflates and dropsthe orange in a net. All the oranges rolls down through the net and are collected at the bottom. The device is controlledby a joystick provided at the bottom.

Morph chart Conceptual Designs

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Orange Picking Device

Figures showing orange picking and collection 24

Human Powered Paper Bike

Arizona State University is all about finding new or innovated ways to accomplish a task. This design challenge

was a part of EGR 535: Engineering Innovation and entrepreneurship.

Satellite view of race path for the paper bike race.

Challenge

The challenge for the paper bike race is to build a human-powered vehicle out of paper products (e.g. cardboard, paperboard) to carry a rider and be pushed or pulled by another team member. The bike must be built in a two week time frame and the team will be racing against 5 additional teams. The race is played on a circular path with two sets of two laps each (Figure 1). The goal is to win the race.The race rules are as follows:• The paper bike must fully support one rider during the race.• The paper bike must be powered by a single puller or pusher.• Race consists of two heats of two laps each.• One or more team members can participate as the ‘power source’ or

‘passenger’ in one or more laps.

Functional Constraints• Bike must support the weight of one team member.• The bike must be powered by one team member.• The rider and the driver must wear head protection

while operating the bike.• Rider cannot operate the bike.

Physical Constraints• The bike must fit within a 5’ x 3’ x 3’ box when fully assembled.• The bike must be constructed with paper products and wood glue

only.• Vehicle has a budget of $0. Therefore materials must be provided

or recycled from elsewhere. 25


Functional Requirement Metric Rationale

The bike must hold one

team member and they

may not aid the

movement of the bike.

critical

The base of the bike will

have a back support and

foot support for the rider

so he can sit comfortably

and not interrupt the

motion of the bike.

Only one team member

may push or pull the bike

and a different team

member must remain

stationary on the bike.

The bike must be able to

move swiftly.

Cardboard wheels of

sufficient thickness

(layers of cardboard) will

be latched on an axle

attached to the base.

Additionally the wheels

will be smoothened to

avoid friction.

By providing tape over

the circumference of the

wheels, friction will be

greatly reduced.


easily make turns.

Turn right at 90 degrees

within a few seconds.

The course around

campus only has right

turns


finish 2 heats (4 laps)

around the course

successfully.

critical

The course is a

rectangular course of

‘insert dimensions here’.

This is a requirement to

win the race.

The pusher must be able

to easily support the bike

with the passenger while

operating it.

critical

A third wheel will be

added to the back

support to help carry the

load.

There will be two runs

and the pusher will be

switched between races.

Therefore each member

must be able to operate

the bike with the lightest

rider.

Physical Requirement Metric Rationale

The bike must remain

intact (avoid failure)

while the operator

pushes/pulls during

the race.

The base of the bike

will be made with

several layers of

cardboard to ensure

strength and

reinforced with very

sturdy cylindrical

cardboard pipes as

the back support.

The strength to

weight ratio must be

high to ensure easy

push/pull and

completion of the

race.

Bike must be

constructed entirely

with paper products.

critical

Paper products are

products consisting of

at least 50% paper by

mass.

This is a paper bike

race, so the bike must

be made of paper.

One side of the bike

must be longer than

the other two. Much

like a dolly.

The back support will

be the chosen longer

side as this can allow

the passenger to lean

comfortably while

being pushed/pulled.

Bike must be able to

fit within a 5’ x 3’ x 3’

box when fully

assembled.

Bike must be

lightweight.

Bike still must be

strong and meet

requirements of the

race.

Provide easier control

of the bike and

requiring lesser effort

by operator.

Easy to build and

disassemble

Fewer than 5

separate parts.

Bike should easy take

apart when finish

racing

Functional Requirement Physical Requirement Critical Component

One critical function for our paper bike is tobe able to continuously withstand a minimumpayload (the human rider) of roughly 130pounds. In order to accomplish this the bike’sframe must be structurally sound. Utilizingmaterial from previous paper projects webuilt the bike frame for our critical functionprototype (Figure). The bottom platform willsupport the rider and the ladder like backingwill aid the rider in remaining stationary onthe bike while the pusher is operating it.

26


Figures showing human powered paper bike 27

ObjectiveTo help disabled person to transfer onto the bed from the wheelchair without anyone assisting the user. To help the disabled person to become independent.

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Problem Statement:

In our current modern technological world there are very few transfer device that helps disabledpeople to transfer them from a wheelchair to any other seating surfaces like bed, a chair or atoilet etc. The major problems associated with these few devices are that they are heavy,expensive, complex, dependent, not user friendly, not ergonomic. Therefore there is an immenseneed for an innovative device that is simple and inexpensive and that gets the job done.

A lot of wheelchair users [disabled people] have the urge to do simple tasks like lying down onthe bed, using toilet or even as simple as sitting on any other surface to do it on their own,without anyone assisting them. Therefore the innovative transfer device must be designed thathelps make the disabled people independent and thereby helping them make their life better.

This is an innovation challenge which is my current project I am working on as a part of EGR 535: Engineering Innovation andEntrepreneurship.

Transfer Wheelchair

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Design thinking process Morph chart

Business Model Canvas

Transfer Wheelchair

Requirements

https://canvanizer.com/canvas/wm696qEoAkQ

https://canvanizer.com/canvas/wm696qEoAkQ

Transfer Wheelchair

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Design Concept

Miscellaneous

Mouse

Catia V5 surfacing design project

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Mechanical Design Engineering Portfolio

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