mechanical engineering design portfolio

Mechanical Engineering Design PortfolioJacob Warren (B.S. in Mechanical Engineering,

Minor in Aerospace Engineering)

Index

Mechanical Design Projects:

Can Crusher Analysis

Hoboken Linkage Design

Bottom Side Assembly of an Engine

Gear Train Design

Toy Car Manufacturing

Bridge Design

Airplane Design

Industrial Design Projects:

Medical Saw Blade

Thank you for taking the time to view my

portfolio. The goal of this portfolio is to give

you a more detailed summary of my pertinent

experience that I have gained throughout my

experience at Lehigh University.

I would be happy to discuss this portfolio

in greater detail. If you would like to do so,

please utilize the contact information provided

at the bottom of the page.

Jacob Warren – Cellphone: (717)-658-3115 – Email: [email protected]


Purpose:

Design can crusher links made of ABS

plastic that, under worst case loadings, can

operate at a factor of safety of 10.

Constraints:

• Must be done in SolidWorks

• Links must be designed as if they would

be injection molded (3mm wall

thickness)




Fixed Hinge

Simulated

Pushing Force

• Used static analysis to determine “simulated pushing force” for several scenarios

• Updated model accordingly and ran stress analysis to determine if standards were met


Purpose:

Create a Hoboken linkage that pushes two wooden

blocks into an open box. Use Solidworks MotionStudy to

analyze and plot various parameters.

Constraints:


• Blocks and box are cubes

• Blocks must be pushed at least two feet

• Box must be three feet from the edge of the “cliff”

• Realistic connections must be used




Key to connect

shaft to link

Motor to rotate linkage Realistic link connection

Pin with snap

ring

Bushing

Top view showing slot for linkage to pass through and pushing rod

Pushing Rod

Examples of parameters that I needed to vary in the study. Others

include:

• Coefficients of friction and restitution

• Contacts between bodies

• Toggling mates at specific times


Purpose:

Accurately model and assemble all components of the

bottom side of a simple four cylinder engine.

Constraints:

• Engine block does not have to be accurate

• Pistons must be in offset stages of the cycle like in a real car

engine

• Connections must be realistic




Engine Piston

Piston Pin

Piston Pin Bushing

Compression Ring

Oil Ring

Connecting Rod

Connecting Rod Bearing



Crankshaft

Crankshaft Bearing Cap

Crankshaft Bearing

Gear Train Design

Purpose:

Create an assembly for a two stage reverted compound gear train with a

12:1 ratio along with an appropriate and realistic standing housing for it.

Constraints:


• Gears must have a pressure angle of 20° and a diametral pitch of 6

• No gear ratio can exceed 10:1 and no gear in your train can be less than 24

teeth

• Any gear larger than 8” pitch diameter should have spokes. Any gear 8” or

less in pitch diameter should be solid


Gear Train Design


Began by sketching space between gear teeth. Used gear ratio

to determine number of teeth and pitch diameter for each gear.

Then cut extrude space between teeth and added spokes and shaft

as specified in the project description.

Keyway for

shaft

connection

Gear Train Design


Gear Train Main Housing

• Used ribs to reinforce thinner areas

• Feet have slots in them for adjustability

• Thick flange is so bolts can screw in when

securing cover

• Holes are for gear shafts

Gear Train Housing Cover

• Same design considerations as the main

housing

Gear Train Housing Gasket

• Inserted between the main housing and the

cover

• Purpose is to prevent leaking of any lubricant

put in the housing for the gears.

Gear Train Design


Sleeve

bearings for

shaft rotation


Purpose:

Work with middle school students to design and manufacture a car

to be raced against other teams.

Constraints:

• Car must be injection molded

• Car must fit in the track provided

• Must proceed with the design of the middle school students’ choosing

• Car must weigh less than 40 grams




Began by designing the car in SolidWorks, and then

modeling the sprue and runner system for injection molding. To

make the car hollow, it needed to be split in half.

Sprue and

runner system

Proceeded to use the previously

modeled parts to design the male and female

molds that will later be machined.



The molds were imported into NX 8.5 and virtual toolpaths were created to send to a CNC milling machine.

(G Code that the CNC machine can read is pictured at the far right)



The molds were machined out of aluminum, the car was injection molded, and then priming, painting and

putting wheels on were the last steps.

Bridge Design

Purpose:

Design and analyze a bridge that meets specified requirements

without failing.

Constraints:

• Must be done in AutoDesk Mechanical

• Bridge must be a superstructure

• Must attempt to minimize weight

• Must be a realistic size and include clearance for cars and trucks


Bridge Design


Chose to use a modified K truss. Weight

was reduced by reducing beam cross

sectional area where stress was small.

Airplane Design

Purpose:

Lehigh’s aerospace club is entering the national design,

build, fly (DBF) competition, and therefore is currently

working on designing and constructing a plane.

Constraints:

• Plane must be able to carry hockey pucks

• Wings must fold so the plane can fit in a tube

• Wings must lock in place automatically when removed

from tube


Airplane Design


Because we are still in the prototyping phase,

these are just examples of taking SolidWorks

models to AutoCAD drawings, and then using a

laser cutter to manufacture the pieces.

Medical Saw Blade

Purpose:

Design a tool to facilitate the revision knee surgery

process using Stryker Orthopedics’ knee implant

system.

Constraints:

• Tool must minimize damage to bone tissue

• Tool must create little to no debris

• Tool must reduce surgery time


Medical Saw Blade


Concept Generation

Initial Sketch SolidWorks FEA Dimensioned Drawing

Medical Saw Blade


Prototyping

Finished ProductQuenching to HardenHeat TreatingLaser Cutting

Medical Saw Blade


Testing

Test blades attached to consumer

oscillating saw.

Quantitative Testing Qualitative Testing

Miscellaneous

Handwheel made in SolidWorksBack scrubber made in SolidWorksCoke bottle made in SolidWorks

Spud gun made just for fun Fixture designed and created during

internship at GE Transportation

Lifting hook made in SolidWorks

mechanical engineering design portfolio

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