a showcase of enterprise and senior design student · pdf fileenterprise and senior design ......

IMAGINATION COLLABORATION INNOVATION SOLUTIONS

A SHOWCASE OF ENTERPRISE AND

SENIOR DESIGN STUDENT PROJECTS

2 • Michigan Tech Design Expo 2017www.itc-holdings.com

Jon E. Jipping, PEExecutive Vice President and Chief Operating Officer ITC Holdings Corp.

MTU class of 1991 – MS, Electrical Engineering

Welcome to Michigan Tech’s Design Expo. If this is your first visit, you’ll be astounded

at the creativity and sophistication of the demonstrations and displays. These Enterprise

and Senior Design Student Projects reflect everything that goes into an engineer’s

education and preparation at MTU – a dedicated and involved faculty and staff, a laser-

focused administration and tremendously supportive alumni, donors and corporate

benefactors. It all adds up to an environment that produces top-tier engineers who are

fully prepared to take on and master the most difficult real-world challenges.

ITC is proud to sponsor Michigan Tech’s 2017 Design Expo

Michigan Tech Design Expo 2017 • 3

More Special ThanksTo the distinguished judges who give their time and talents to help make Design Expo a success, and to the faculty advisors who generously and richly support Enterprise and Senior Design—thank you for your dedication to our students.

Table of ContentsWelcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Leonard Bohmann, Associate Dean, College of Engineering Rick Berkey, Director, Enterprise Program

Student Projects Enterprise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Senior Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

ScopeDesign Expo highlights hands-on, discovery-based learning at Michigan Tech. More than 1,000 students on Enterprise and Senior Design teams showcase their work and compete for awards. A panel of judges—made up of distinguished corporate representatives and Michigan Tech staff and faculty members—critique the projects. Many team projects are sponsored by industry, which allows students to gain valuable experience through competition, as well as direct exposure to real industrial problems. Design Expo is hosted by the College of Engineering and Pavlis Honors College.

Student Awards

Black & Veatch Building a World of Difference® Student Design Awards

Senior Design AwardsBased on poster

• First place—$150 • Second place—$100 • Third place—$75 • Honorable mention—$50 (three to be awarded)

Enterprise AwardsBased on poster and presentation

• First place—$300 • Second place—$150 • Third place—$100

Ann Arbor SPARK Design Expo Image Contest

Design Expo Image ContestPhoto or non-photo graphics

• First place—$100 • Second place—$50

Design Expo Innovation AwardsBased on application

• First place—$250 • Second place—$150 • Third place—$100

On the cover

Aerospace Enterprise team member Mariah McLeod tests the power controller board of the Oculus-ASR Satellite. Electronics on the board convert power received through the spacecraft’s solar panels into a form that charges the spacecraft’s battery and power components.


On behalf of our faculty, staff, and students, welcome to Design Expo 2017!

We’re pleased to have you with us to enjoy one of the most rewarding and inspiring events of the year: Design Expo! Today, we showcase the talents of the more than 1,000 bright, highly motivated students enrolled in our Enterprise and Senior Design programs. Their skills and accomplishments are the result of many hours spent creating plans, communicating with clients, thinking creatively, solving open-ended problems, and meeting deadlines. Perhaps just as important are the hours spent changing those plans, managing team conflicts, critiquing ideas, troubleshooting unforeseen problems, and getting behind schedule. As Henry Ford once said, “The only real mistake is the one from which we learn nothing.” For our students, Enterprise and Senior Design are a huge investment with an even greater return; today we celebrate the successes of our Huskies, knowing they are well-prepared to create the future!

For the sixth consecutive year, we are pleased to acknowledge ITC Holdings as our Directing Partner sponsor. Supporting Partner sponsors include Black & Veatch and Ann Arbor SPARK. Collaborating Partner sponsors include American Transmission Company, Code Blue, Kimberly-Clark, Michigan Tech’s Office of Innovation and Industry Engagement, and Pavlis Honors College—Innovation Center for Entrepreneurship. Our Innovating Partner sponsor this year is Miller Electric. We thank all our partners for their support and commitment to Design Expo.

Our Senior Design program challenges teams of highly dedicated, senior-level students to explore and address practical design challenges—a capstone experience where teams must integrate prior coursework and new learning. Our program connects students and industry through open-ended projects where teams follow the complete design process from ideation to realization. We often say it’s more like a first job than a last class. Our seniors will show you their readiness to lead and contribute on day one, as they make the final transition into their early careers.

Michigan Tech’s signature Enterprise program is open to all majors and facilitates interdisciplinary learning, leadership development, and team-based project work. Diverse teams of first-year through graduate-level students develop products, processes, and services within their market space. Multi-year participation in a business-like environment provides a unique opportunity for students to maximize personal and professional growth. Faculty advisors coach and guide, while industry sponsors serve both as clients and mentors. Enterprise has been recognized as a national best practice and is revolutionizing our approach to undergraduate education at Michigan Tech. Experience the revolution as you meet with many of the 800 students who have chosen the Enterprise pathway.

We would like to thank the more than 120 partners and sponsors who generously support our educational mission by providing meaningful project experiences, financial support, and mentorship for our students. The benefits of industry and academia working together as partners are clearly evident at Michigan Tech’s Design Expo.

Enjoy your Design Expo experience, and Go Huskies!

Rick BerkeyDirector, Enterprise Program

Leonard Bohmann, Associate Dean, College of Engineering

6 • Enterprise Teams 2017

Team LeadersSeth Rottschafer, Engineering Management, and Matthew Luebke, Mechanical Engineering Technology

AdvisorKevin Johnson, Mechanical Engineering-Engineering Mechanics

SponsorsAramco, DENSO, Ford Motor Company, General Motors, Fiat Chrysler Automobiles, ArcelorMittal, Cummins, John Deere, Magna, Meritor, Milwaukee Tool, Nexteer Automotive, Mitsubishi Electric, Great Lakes Sound and Vibration, the Enterprise Manufacturing Initiative funded by the GM Foundation, KA Wood, Solidworks

BackgroundMichigan Tech’s Blizzard Baja Enterprise builds a single-seat, off-road competition vehicle to compete in the SAE Collegiate Design Series Baja SAE events held in various locations across the US. The team prepares and presents a written design report, cost analysis, and sales presentation for a panel of SAE judges. After passing a rigorous safety and technical inspection, we compete with other collegiate teams on acceleration, hill climb, maneuverability, suspension, and endurance. The Blizzard Baja Enterprise also organizes and hosts the Winter Baja Invitational event, a longstanding university tradition dating back to 1981.

OverviewMultiple Blizzard Baja Enterprise subteams have focused on improvements for this year’s competition vehicle. The hybrid reduction gearbox subteam has integrated high strength, lightweight materials like titanium in order to reduce rotational mass. The suspension subteam collected suspension load data by instrumenting a past competition vehicle. This real-world information aided in improved suspension-component design and optimized suspension points on the frame for better vehicle dynamics in a more space-efficient vehicle envelope. Another team is investigating composite j-arms using a 3-D printed core with a carbon fiber filament for improved strength without a foam core.

New internals for gearbox

101Blizzard Baja


Enterprise

Team LeadersMark Brouwer and Nicholas Brodowski, Mechanical Engineering

AdvisorJason Blough, Mechanical Engineering-Engineering Mechanics

SponsorsAramco, DENSO, Ford Motor Company, General Motors, Fiat Chrysler Automobiles, ArcelorMittal, Yamaha Motor Company, Polaris, Bosch, John Deere, Meritor, Magna, Milwaukee Tool, Nexteer Automotive, PCB Piezotronics, TE Connectivity, FEV Inc., Mitsubishi Electric, Great Lakes Sound and Vibration, the Enterprise Manufacturing Initiative funded by the GM Foundation, KA Wood, Advanced Sleeve

BackgroundMichigan Tech’s Clean Snowmobile Challenge Enterprise builds snowmobiles to compete in the SAE Collegiate Design Series Clean Snowmobile Challenge held at the Keweenaw Research Center in Houghton, Michigan. As part of the competition, the team submits an engineering design paper, determines a justified MSRP (Manufacturer’s Suggested Retail Price), and presents an oral design presentation that outlines its approach to the clean snowmobile conversion. Following a comprehensive technical inspection, the vehicles undergo dynamic testing that includes acceleration, handling, cold start, noise, and emissions. Michigan Tech’s Clean Snowmobile Challenge Enterprise typically competes in both the Internal Combustion (IC) and Zero Emissions (ZE) classes.

OverviewThe Clean Snowmobile Challenge 2016-17 projects included a variety of improvements to each of the team’s two snowmobiles. To decrease engine noise and emissions, the IC team created a custom muffler and implemented a catalytic converter and lean stoichiometric combustion environment. They worked to maintain near-stock power and performance characteristics throughout the process. The ZE team adopted a 2014 Polaris Indy 600 Chassis, and began the conversion process to an all-electric drivetrain from a Brammo Empulse motorcycle. The team designed and built many electrical safety circuits that ensured performance and adhered to safe electrical practices.

Austin Dohse entering the snowmobile sound trap for noise level evaluation

102Clean Snowmobile Challenge


Team LeadersIsabella Kesler and Brett Michaud, Mechanical Engineering

AdvisorJames DeClerck, Mechanical Engineering-Engineering Mechanics

SponsorsAltair, Aramco, DENSO, Ford Motor Company, General Motors, Fiat Chrysler Automobiles, ArcelorMittal, Cummins, John Deere, Magna, Meritor, Milwaukee Tool, Nexteer Automotive, PCB Piezotronics, FEV Inc., Mitsubishi Electric, Great Lakes Sound and Vibration, the Enterprise Manufacturing Initiative funded by the GM Foundation

BackgroundMichigan Tech’s Formula SAE Enterprise builds a competition vehicle based on the concept of an affordable race car geared toward the weekend autocrosser. The team competes in SAE Collegiate Design Series Formula SAE events held in various locations across the country. The team prepares a written design report, a cost analysis, and a business case to present to a panel of judges. After passing a technical inspection, the vehicle competes in a series of dynamic events, including acceleration, skid pad, autocross, endurance, and efficiency. Michigan Tech Formula SAE has a long history of top-performing cars and has gained a reputation for developing cutting-edge designs that help shape the future of racing.

OverviewThe Formula team pursued new technologies in 2016-17, developing a continuously variable transmission (CVT), dynamometer cell improvements, a CVT dynamometer stand, an electronic CVT, and a dynamic fuel control system. These engineering projects were made possible by improving design, testing, and knowledge transfer processes.

Welding the Formula car chassis together.

103Formula SAE


Enterprise

Team LeadersPierce Jensen, Mechanical and Electrical Engineering, and Connor Olson, Electrical and Computer Engineering

AdvisorRick Berkey, Pavlis Honors College

SponsorsDENSO, Ford Motor Company, General Motors, Fiat Chrysler Automobiles, ArcelorMittal, Cummins, John Deere, Magna, Meritor, Milwaukee Tool, Nexteer Automotive, PCB Piezotronics, Mitsubishi Electric, Advanced Sleeve

BackgroundThe Supermileage Systems Enterprise builds a single-seat, high-efficiency vehicle that competes in either the SAE Collegiate Design Series or the Shell Eco-marathon. The powertrain utilized by the vehicle is determined by the competition and is either a small displacement internal combustion engine or a battery electric design. Regardless of the event, the team must engineer a competitive vehicle and submit a written report detailing the vehicle design. The team must also deliver an oral presentation that demonstrates understanding of the engineering principles that support the design. Following a technical inspection, the vehicle must complete a dynamic performance event that measures miles per gallon (MPG) or mile per gallon equivalent (MPGe).

OverviewThis year, the Supermileage Systems Enterprise will compete in both the Shell Eco-marathon competition and the Society of Automotive Engineers Collegiate Design Series. The team is building an Eddy-current brake dynamometer that will be able to effectively and efficiently switch between testing either the internal combustion engine or the electric motor. The team also installed a HUD in the car to display important information about the car’s performance.

Supermileage team’s redesigned dynamometer showing the new eddy current absorber, load cell, and Briggs & Stratton Junior 206 engine

103Formula SAE

104Supermileage Systems Enterprise


Team LeadersEster Buhl and Johnathan Presti, Electrical Engineering

AdvisorGlen Archer, Electrical and Computer Engineering

SponsorsGeorgia-Pacific, Halla Mechatronics, ArcelorMittal, Caterpillar

BackgroundBlue Marble Security (BMS) Enterprise is a student-led enterprise that focuses on securing the future through the thoughtful use of technology. The team specializes in engineering design and product development. Blue Marble has developed a culture that fosters high professional standards, creativity, and productivity. BMS defines “national security” through the provision of technological support to the defense, the corporate economy, and the personal well-being of the country and all its people.

OverviewThe ArcelorMittal team developed a vision system for dimensional verification of steel slabs. The Caterpillar/Society of Women Engineers (CAT/SWE) joint venture team (BMS/Consumer Product Manufacturing) took first place in the Boeing SWE Team Tech Competition at the SWE 2016 Conference. The Georgia-Pacific team is developing an alternative energy source for automatic towel and soap dispensers. The Halla Mechatronics team finalized a working prototype for a braking system in electric vehicles and also created a test bed to allow for brake system testing. The Outreach team hosted events to foster an interest in STEM among youth in the community and to spark an interest in electrical engineering. Finally, the Website team created and improved upon the Blue Marble Security website.

105Blue Marble Security

Robot "Charlie" used and built by the BMS autobot team.


Enterprise

Team LeadersHarley Colburn, Civil Engineering, and Michael Norman, Mechanical Engineering

AdvisorsTony Rogers and Sean Clancy, Chemical Engineering

SponsorsNanoMag, Kimberly-Clark, Britten Studios, Yanfeng Automotive Interiors, Transportation Services, Caterpillar, Society of Women Engineers

BackgroundConsumer Product Manufacturing (CPM) Enterprise aspires to empower students with the entrepreneurial, technical, and professional skills to conceive, develop, and market successful products in a company-like setting. Students on the team come from many disciplines and use hands-on experiences to identify and solve real-world engineering problems. CPM aims to exceed the expectations of company sponsors, improve the lives of consumers through innovation, and develop our team members into highly marketable professionals.

OverviewThis has been an exciting year for CPM. The Caterpillar/Society of Women Engineers (CAT/SWE) joint venture team (CPM/Blue Marble Security) won the Boeing SWE Team Tech Competition in Philadelphia with the Bowl Optimization project. The NanoMag team continues to work on their ski and hockey blade projects. The Biogas team is making great progress in creating their small scale anaerobic digester. CPM also has multiple new projects this year, including Kimberly-Clark-sponsored research on sustainable packaging. Another project, sponsored by Michigan Tech Transportation Services, has civil and environmental students designing a potential parking structure for the Michigan Tech campus. Another team is developing models for Britten Studios that demonstrate for potential customers how the BannerSaver product works under certain wind loads.

Bryant Rowe of the nanoMAG subteam prepares to create a hockey stick blade using Resin Transfer Molding.

106Consumer Product Manufacturing


Team LeadersRon Hasenbusch and Matt Wray, Construction Management

AdvisorLynn Artman, School of Technology

SponsorPavlis Honors College

BackgroundETEC’s mission is to work with communities to implement energy-efficient designs into new and existing construction projects. ETEC is a multi-disciplinary team of highly motivated students focused on developing, solving, and redefining today’s engineering problems. The team is dedicated to the principles of efficient design, social impact, environmental stewardship, and value to sponsors.

OverviewEfficiency Through Engineering and Construction (ETEC) Enterprise has prepared a water treatment and distribution system renovation proposal for Michigan Technological University School of Forestry Resources and Environmental Science’s Ford Center and the Village of Alberta, Michigan. The purpose of this project is to design the water supply, treatment, and distribution systems to provide a long-term water supply for the Ford Center and the Village of Alberta. The current treatment system has significantly deteriorated since its installation in the 1970s and is ineffective in removing manganese. It is also expensive to operate. ETEC’s proposed plan includes changing the primary water source, centralizing the treatment process in compliance with EPA guidelines, and replacing the underground pipe distribution network.

Project layout

107Efficiency Through Engineering and Construction


Enterprise

Team LeadersAnthony Bacon and Ryan Walton, Mechanical Engineering

AdvisorSteve Lehmann, Mechanical Engineering-Engineering Mechanics

SponsorsChurning Rapids Snow Bike Trails Club, ArcelorMittal, Boss Snowplow, Rhythm Bike & Board, Department of Kinesiology and Integrated Physiology, Pavlis Honors College

BackgroundVelovations is a bicycle design enterprise dedicated to collaborating with the bicycle industry to develop new products and processes. The goal is to educate team members in the fundamentals of product development—from customer need through product and process design and testing, manufacturing, supply chain management, marketing, and distribution. Velovations leverages multiple majors, including mechanical engineering, electrical engineering, business, and technical communications, to deliver product and process innovations to the bicycle industry.

OverviewThis year, Velovations worked on two projects. For the first project, students worked with the Churning Rapids Snow Bike Trails club to develop a multi-implement groomer for maintaining their fat-tired snow biking trails. Abundant snowfall in the Copper Country makes it a challenge to offer a quality groomed surface for snow biking, a relatively new sport. The multiple implements allow the trail groomer to easily swap in the proper grooming tool for the amount or type of snow. Velovations’ second project is an arm ergometer developed specifically for the Department of Kinesiology and Integrative Physiology to use in testing of their RENEW-U exercise concept.

Testing the groomer in the V-plow configuration

108Velovations


Team LeadersJulie Karl, Biomedical Engineering, and Mario Calabria, Mechanical Engineering

AdvisorsRadheshyam Tewari, Mechanical Engineering-Engineering Mechanics, and Nathan Manser, Engineering Fundamentals

SponsorStryker, Pavlis Honors College

BackgroundInnovative Global Solutions (IGS) pursues solutions for the needs of developing countries, making contributions towards solving Grand Challenges. Team members improve technical skills and gain hands-on experience with an international engineering project. Typical project areas focus on energy, water, health, education, entrepreneurship, transportation, infrastructure, and more.

OverviewIGS is redesigning its low-cost ventilator for mass production and deployment in developing countries. The Enterprise is currently collaborating with a team of engineers at KNUST University in Ghana to improve their existing Model 1.0, which was deployed in summer 2015. IGS intends to ship an updated model, Model 2.0, at the end of spring 2017. Stryker has sponsored a project with IGS to develop a system that, via discrete or continuous sampling and analysis of patient vital signs, predicts the possibility of future degradation of a patient’s clinical status. The goal of the project is to assist clinical staff in the identification of at-risk patients and prioritize their care.

Internal components of low-cost ventilator for developing countries

109Innovative Global Solutions (IGS)


Enterprise

Team LeadersMatt Byrne, Environmental Engineering, and Evan Tumey, Mechanical Engineering

AdvisorBrett Hamlin, Engineering Fundamentals


BackgroundThe focus of the General and Expedition Adventure Research (GEAR) Enterprise is to design, model, test, prototype, and manufacture a wide variety of goods and equipment used in recreational outdoor and commercial expedition endeavors. Team members analyze and develop innovative solutions on both internal and industry-sponsored projects. GEAR worked on soft and hard goods related to backpacking, camping, climbing, snowshoeing, kayaking, canoeing, mountaineering, and military applications.

OverviewGEAR Enterprise is currently working on three projects: the Base Camp Water Filter, the Avalanche Beacon, and the 4-Season Hammock. The water filter utilizes gravity-fed membrane filtration, coupled with a UV LED disinfection system. The system was designed for group camping or extended backcountry camping trips. The Avalanche Beacon team is designing an affordable avalanche beacon, intended for practice rescue scenarios. The team is designing a fully functional backcountry beacon with innovations to aid in the search and rescue process. The 4-Season Hammock seeks to bring winter camping to hammock lovers. This semester, the team concentrated on component design and concept modeling of insulation and heat generation techniques using ThermoAnalytics heat modeling software.

Water filter design rendering

110General and Expedition Adventure Research (GEAR)


Team LeaderElliot Vickers, Mechanical Engineering

AdvisorsJay Meldrum, Keweenaw Research CenterDavid Shonnard, Chemical Engineering

SponsorsOshkosh Corp, Village of L’Anse, WPPI Energy, andRichard and Bonnie Robbins Endowed Fund

BackgroundAlternative Energy Enterprise (AEE) provides opportunities for students in multiple academic disciplines to research and develop alternative energy sources. Projects, research, and development are done in conjunction with industry sponsors to produce viable solutions to real-world energy problems. Each team is interdisciplinary and receives a rewarding hands-on experience while working on challenging problems and seeking innovative solutions.

OverviewThe Community Solar project in conjunction with WPPI Energy will design a large-scale solar array for the Village of L’Anse, with the opportunity for the community to lower their utility costs by investing in the system. The REMM project includes the redesign of the REMM Power Module, designed by Oshkosh, to provide necessary power to the system during unexpected extended outage periods. The Sustainability Demonstration House project retrofits an existing home into a sustainable, high-efficiency home that will serve as a resource to the community to learn about low-carbon living. The Biofuels project optimizes a pilot-scale fast pyrolysis plant in order to increase the yield of bio-oil from the reaction.

Redesign of the Oshkosh REMM Expeditionary Power Module project

111Alternative Energy Enterprise


Enterprise

Team LeaderMitchell Anderson, Computer Engineering

AdvisorGlen Archer, Electrical and Computer Engineering

SponsorsGreat Lakes Research Center, Ford Motor Company

BackgroundThe Robotic Systems Enterprise focuses on seamlessly integrating exceptional knowledge in electronics, robotics, and programming to solve real-world engineering problems. All majors are welcome—the team depends on more than just the skills and talents of engineering and science majors. The Robotic Systems Enterprise produces solutions that contribute to industry, recreation, and medical research.

OverviewThe Robotic Systems Enterprise worked on four projects this academic year: a buoy power management system, outreach, submersible development, and Clearpath modular robot platforms. The buoy project is sponsored by the Great Lakes Research Center to develop and implement a power management system that prolongs the data collection period of their buoys. The team’s new outreach project is working to promote robotics and STEM fields through a wide variety of events targeting K-12 and Michigan Tech students. The submersible team is making progress with software and testing efforts by developing a graphical user interface. Lastly, the new Clearpath project involves the operation and modification of the modular Husky and Jackal robot platforms, with the goal of autonomous data collection in hazardous weather conditions.

Clearpath Husky

112Robotic Systems

111Alternative Energy Enterprise


Team LeadersBernard Kluskens and Zach Metiva, Computer Network and System Administration

AdvisorRussell Louks, School of Business and Economics

SponsorsHARMAN International, Central Michigan University, UP Health System–Marquette, Little Brothers—Friends of the Elderly Upper Peninsula Michigan Chapter, Office of Alumni Engagement, School of Business and Economics

BackgroundITOxygen is a cross-disciplinary, student-run enterprise that specializes in information technology (IT) for student organizations and businesses, with a focus on developing information system and IT solutions. Team members work on real-world projects that foster skill development and business savvy. Areas of interest include systems and information analysis, software development, database design, and web-based application development.

OverviewCurrently, ITOxygen is working with HARMAN International, Little Brothers—Friends of the Elderly, UP Health, and Central Michigan University, as well as on projects within Michigan Technological University. The team worked on a variety of projects this academic year, from iOS and Android development to designing software to test and read diagnostic messages from a head unit over a CAN bus.

Hardware setup for the automated Harley test tool

113ITOxygen


Enterprise

Team LeaderSamantha Stein, Communication, Culture, and Media

AdvisorErin Smith, Humanities

SponsorsPavlis Honors College, William G. Jackson Center for Teaching and Learning

BackgroundThe Cin/Optic Communication and Media Enterprise enables students to develop skills in video design and production. By balancing the creative and technical aspects of video, the primary goal is to focus on client needs and expectations, while developing artistically engineered products. Capitalizing on team member creativity and technical strengths, Cin/Optic provides an opportunity for those involved to broaden their education in the media industry through real-world business experiences.

OverviewThe project goal is to create a promotional video for an addition to NASA’s wildfire response online map platform, RECOVER, that would help wildfire responders plan for potential debris flows. Researchers at Michigan Tech, University of Arkansas, and Idaho State University have developed an addition to the RECOVER platform that will function as a map layer. This map layer indicates potential debris flow areas based on new modeling developed in the geological engineering department. The video will help the team communicate the new debris flow map layer’s usefulness to wildfire response groups so that they may request a debris flow analysis and map layer after future wildfire events.

Example of a debris flow model showing predictability

114Cin/Optic Communication and Media


Team LeaderAaron Richard, Mechanical Engineering

AdvisorsRobert Page, Mechanical Engineering-Engineering Mechanics, and John Lukowski, Electrical and Computer Engineering

SponsorsGeneral Motors, Milwaukee Tool

BackgroundMembers of Hybrid Electric Vehicle (HEV) Enterprise research, design, build, and test state-of-the-art hybrid electric vehicles. The current project vehicle is based on a 1949 Chevrolet truck. The team learns about the performance trade-offs of different types of hybrid powertrain architectures while fabricating and assembling various vehicle components and subsystems. Team members develop and use skills in leadership, project management, and vehicle calibration.

OverviewThe hybrid electric truck project, based on a 1949 Chevrolet, is mostly functional. HEV completed the installation and integration of the engine, electric motor, transmission, clutch, and driveshaft earlier this year. Current projects on the hybrid electric truck include developing a control system for gear shifting and developing a supervisory vehicle control system. Other project teams within HEV Enterprise are finishing the cooling system for the vehicle and optimizing individual components to integrate all of the components together.

1949 Chevy HEV Truck

115Hybrid Electric Vehicle


Enterprise

Team LeadersTino Moore and Libbey Held, Computer Engineering

AdvisorChristopher Cischke, Electrical and Computer Engineering

SponsorsFord, Real Food Ranch, Little Brothers–Friends of the Elderly

BackgroundThe Wireless Communication Enterprise (WCE) focuses on wireless, optical, renewable energy, user interface, and biomedical technologies. WCE functions much like an engineering company with a variety of different project teams. These small project teams allow team members to be involved in project work and provide ample opportunity to gain technical skills, business presentation skills, and leadership experience.

OverviewThis year, WCE worked on a variety of internal and sponsored projects, including the continuation of Ford-sponsored project EV Coach, which determines ways to improve someone’s driving by taking data from an electric vehicle. The VPA project has continued this academic year and involves using MIDI systems to create wireless triggers for on-stage effects. This year also saw the beginning of a HGST-proposed project to design an automated robot to apply mounting hardware that secures a hard drive tray to a hard drive. Real Food Ranch tasked the team with creating a mobile application and database for tracking statistics about livestock. Another new project for Little Brothers is developing an online resource management system for volunteers.

Testing the radio module and gateway for the wireless trigger system

116Wireless Communication


Team LeadersDavid Mohrhardt and Eric Moore, Computer Science

AdvisorScott Kuhl, Computer Science

SponsorsPavlis Honors College

BackgroundHusky Game Development (HGD) is a student-run enterprise focused on developing video games. Each year, HGD breaks up into subteams of around six students who experience a full game-development cycle, including ideation, design, and end product. HGD explores a wide variety of video game engines and platforms, including Windows, Android, Xbox, and an experimental display wall.

OverviewThroughout the year, several teams work on their own original IPs in the hopes of having a fully functional and marketable video game by the end of the semester. This year, many advanced HGD members created highly detailed projects, such as a 3-D office space simulator, an asymmetrical multiplayer experience, and a full-blown character fighter engine.

Project Abacus

117Husky Game Development


Enterprise

Team LeadersJacob Soter, Electrical Engineering, and Lorne Newhouse, Mechanical Engineering

AdvisorAndrew Barnard, Mechanical Engineering-Engineering Mechanics

SponsorsOffice Of Naval Research (ONR), Great Lakes Research Center (GLRC), Keweenaw Bay Indian Community (KBIC)

BackgroundThe SENSE Enterprise’s mission is to enable the workforce of tomorrow to redefine the boundaries for air, land, sea, and cyber supremacy through experiential learning and discovery. Students design, build, and test engineering systems with a focus on Navy applications in all domains: space, air, land, sea, and undersea. They get hands-on experience with cutting-edge defense technologies that directly impact the safety and success of the armed forces. They prepare for civilian employment opportunities in Department of Defense research labs or with DoD contractors.

OverviewSENSE’s first project as an official enterprise is the Near Shore Water Rescue Device. Sponsored by the KBIC and ONR, the device is intended to help reduce drowning in the Great Lakes. The rescue device is a remote-controlled life raft that can be quickly deployed to assist swimmers in distress. The device is comprised of mostly off-the-shelf components, making it much more affordable for smaller communities.

The Near Shore Water Rescue Device

118Strategic Education through Naval Systems Experiences (SENSE)


Team LeadersRyan Logan and Kody Nutting, Mechanical Engineering

AdvisorIbrahim Miskioglu, Mechanical Engineering-Engineering Mechanics

SponsorsEnterprise Manufacturing Initiative funded by the GM Foundation, Plasan, Rampf

BackgroundBoardSport Technologies (BST) focuses on the engineering, design, and manufacturing of skis, snowboards, skateboards, longboards, wakeboards, and other boardsport-related products. Through integration of composite materials and a creative design approach, the team strives to refine existing boardsport technology and produce new and innovative products.

OverviewBoardSport Technologies continues to improve and innovate the manufacturing methods of boardsport products with every semester. Recent projects include carbon-fiber-wrapped skateboard trucks, a splitboard with a set of custom bindings, a CNC router table, modular ski dies, a portable modular skatepark, a redesigned wakeboard binding, a swallow tail powder snowboard, a ski design utilizing an aramid honeycomb matrix core, and a performance longboard with a composite torsion bar.

Capstone project: modular skatepark panel model

119BoardSport Technologies


Enterprise

Team LeadersDenzil Cotera and Brennan O’Brien, Mechanical Engineering

AdvisorPaulus Van Susante, Mechanical Engineering-Engineering Mechanics

SponsorStoneco, Cummins

BackgroundThe Mining INnovation Enterprise (MINE) seeks to design, test, and implement mining innovation technologies for industry partners. MINE works in interdisciplinary subteams to solve current and future challenges in the traditional mining industry, as well as the emerging mining fields of deep sea and space mining. Opportunities include the improvement of safety and working conditions, increasing productivity and efficiency, as well as mine and equipment design and optimization.

OverviewThe Stoneco Bauer Pit Mine Project team is evaluating a prospective sand and gravel operation in St. Johns, Michigan, for Stoneco. The goals are to create a reserve study, hydrology study, plant design, economic study, safety plan, and production schedule and timeline. This will be accomplished by using safety and economic considerations, and mine design and plant optimization activities. The Rover Project team is creating a robust rover that will be used for new mining technologies by future MINE members. The rover will serve as a “plug and play” platform, where it can be used with many types of payloads. These payloads could be used in a variety of mining applications, and their only constraint would be fitting on the rover.

Measuring the forces required to excavate a buried or partially buried rock in sands

120Mining INnovation Enterprise (MINE)


Team LeadersSam Baxendale, Mechanical Engineering, and Jared Burbey, Electrical Engineering

AdvisorL. Brad King, Mechanical Engineering-Engineering Mechanics

SponsorsNASA, Air Force Research Laboratory, SpaceX, FLIR, Clyde Space, Bright Ascension, Novatel, Advanced Circuits, Space Dynamics Laboratory, Tethers Unlimited, Analytical Graphics Inc.

BackgroundThe Aerospace Enterprise provides hands-on aerospace education and experience to Michigan Tech undergraduate students. The team works together on innovative and relevant aerospace-related projects, with all members contributing toward specific project goals. Aerospace Enterprise places an emphasis on space mission design and analysis, vehicle integration, systems engineering, and comprehensive ground testing and qualification.

OverviewIn 2016, Aerospace Enterprise was awarded contracts to develop small satellite missions for NASA and the US Air Force. Undergraduate team members are responsible for managing the design, testing, and integration of the spacecraft, as well as planning and developing their respective mission operations. Stratus, a 3U cubesat funded by NASA’s University Student Instrument Project, will host an on-board thermal imager and be launched into a low-earth orbit, where it will capture and transmit images of weather clouds. Auris, a 50kg-class microsat, is tasked with listening to radio frequency emissions from spacecraft in a high orbit and spatially mapping the power radiated from these satellites to analyze how it will impact ground receivers.

Aerospace Enterprise designs, tests, and integrates small satellites for NASA and the US Air Force.

121Aerospace


Enterprise

Team LeaderSteven Landry, Psychology

AdvisorRobert Pastel, Computer Science


BackgroundThe members of Humane Interface Design Enterprise (HIDE) come together to design, develop, and evaluate interfaces. The goal is to make daily work more efficient and easier to manage. The team works together to design and test different applications for industry sponsors that can be used on Android, iPhone, and other devices. HIDE accomplishes these projects by combining knowledge from multiple disciplines (e.g., computer science, psychology, and human factors). HIDE team members can get involved in various stages of the design process, from developing an app by programming, to evaluation by designing usability tests and analyzing data.

OverviewHIDE is presenting three projects at Design Expo that the team has been working on this semester. CoCoTemp is a temperature sensor plus website database for citizen science projects that investigate the temperature of micro climates. The Skiboot app is a website/interface for viewing and syncing data from a pressure sensor device worn in the boots of the US Olympic Ski Jumping team. The Michigan Tech Undergraduate Student Government (USG) Voting Booth is hardware/software for a novel method to increase student response rates to USG surveys.

Ski-boot app interface for viewing force data from a ski jump event, developed for and used by US Olympic ski jumping team athletes and coaches.

122Humane Interface Design Enterprise (HIDE)


Team LeadersAubrey Woern, Mechanical Engineering, and Joseph McCaslin, Electrical Engineering

AdvisorJoshua Pearce, Materials Science and Engineering

SponsorsArcelorMittal, Ford College Community Challenge, Little Brothers—Friends of the Elderly

BackgroundOpen Source Hardware specializes in building low-cost alternatives to expensive hardware/software, and then sharing the designs with the commons so that collaborative improvements can be made rapidly. Anyone can make changes or updates to the designs the Enterprise team creates—through this process, designs are improved at a much higher rate than would be possible within the Enterprise alone. Open source is all about collaboration.

OverviewThis year, the Open Source Hardware team worked on completing the recycled plastic granulator and extruder to create filament for 3-D printers out of waste plastic. The team worked with the Little Brothers – Friends of the Elderly in Hancock, Michigan, to develop a way for the elderly to continue to use computers when their vision deteriorates. Finally, the open source team took steps to become a self-sustaining enterprise by developing a business plan, obtaining artistic rights, and selling 3-D printed Husky statues to a Michigan Tech Department.

Joseph McCaslin working on Filament Extruder

123Open Source Hardware


Enterprise

Team Leader Georgia Hurchalla, Materials Science and Engineering

AdvisorPaul Sanders, Materials Science and Engineering

Sponsors ArcelorMittal, Eck Industries, General Motors, Mercury Marine, Steel Market Development Institute

BackgroundAdvanced Metalworks Enterprise (AME) is composed of a diverse team of students who execute research and development projects for industrial sponsors. Interdisciplinary teams of four to five students model, fabricate, and characterize metallic systems, such as aluminum, iron, zinc, titanium, and nickel-based alloys. AME helps industry sponsors increase productivity, identify causes of material failures, design near-net castings, develop advanced material modeling techniques, and more.

OverviewThis year’s projects range from adapting the lost foam casting process for rapid prototyping (Mercury Marine) to determining correlation between metallurgical factors and machinability data (SMDI). One team studies the influence of processing on the final microstructure and properties of press hardened steel to maximize safety performance in automobiles (ArcelorMittal), while another evaluates HSLA steels to determine the cause of premature failure in ferritic nitrocarburized treated parts (General Motors). A multi-year project is culminating in analysis of pressure causing the growth of damaging nodules (ArcelorMittal). One senior team is improving feeding efficiency in cast aluminum alloys (Eck Industries), while the other is writing a venting channel guidebook that details channel features and effects in the HPDC process (Mercury Marine).

Members of the Rapid Prototyping team pour molten aluminum into their lost foam evaporative molds. The interior of the molds was created using 3-D printing.

124Advanced Metalworks


Team LeadersMadison Olmstead, Civil Engineering, and Zach Jensen, Electrical Engineering

AdvisorChristopher Wojick, Civil and Environmental Engineering

SponsorPavlis Honors College, Cummins

BackgroundThe goal of Green Campus Enterprise is to annually measure the carbon footprint of Michigan Tech, and design and implement projects to improve the sustainability of the Michigan Tech campus. Green Campus works closely with the Michigan Tech administration to effectively engage the university community in reducing its carbon footprint.

OverviewGreen Campus Enterprise strives to meet the overarching goal of shrinking Michigan Tech’s carbon footprint through a variety of projects. The Clean Air-Cool Planet team calculates the annual carbon footprint of Michigan Tech. The Wind team is determining the feasibility of powering Mont Ripley with a wind turbine. The Compressed Natural Gas team investigates the effects of converting the campus transportation fleet to run on compressed natural gas (CNG). The Great Lakes Research Center team explores how to cool the GLRC by utilizing the Portage Waterway. The Solar team is testing ways to preheat makeup water for boilers using solar energy. The High-Rise Buildings team is looking into excess energy use in the Dow building on campus. Finally, the Campus Culture team strives to create a more sustainable mindset throughout the Michigan Tech campus.

Green Campus members winterizing a local home to help reduce its energy consumption and costs

125Green Campus

ENERGIZING MICHIGAN’S

Future

Building the electric transmission infrastructure that will power the future.

Energy is essential to the way we live,

work and play.

ITC operates, builds and maintains

the region’s electric transmission

infrastructure. We’re a Michigan-based

company working hard to improve

electric reliability, increase electric

transmission capacity, and keep efficient,

reliable energy flowing to homes and

businesses across the state.

www.itc-holdings.com

32 • Senior Design 2017

201iConnect Lab Training Enhancement—Data Acquisition and Control Hardware Briefcase

202Friction Stir Back Extrusion

203Fault Location Identification on a Transmission Line Using Traveling Wave Theory and Protective Relaying

Team MembersAndrew Dorton, Austin Ostipow, Richard Fowler, and Branden DeVries, Electrical Engineering Technology

AdvisorsSeyyedmohsen Azizi and Weican (Vincent) Xiao, School of Technology

SponsorA&D Technology Inc.

Project OverviewOur team has designed a hardware briefcase for A&D Technology Inc., a producer of advanced measuring, monitoring, controlling, and testing instruments in the automotive testing field. The company offers data acquisition and control platform software through the iTest software and iConnect hardware platforms. Currently, A&D Technology offers iTest training classes with in-depth software training. This project will add a hardware training component to A&D’s training curriculum. The hardware briefcase features the iConnect Distributed I/O system as well as other discrete and analog components. The company will use this hardware briefcase to train customers.

Team MemberAlexander Holihan, Mechanical Engineering Technology

AdvisorScott Wagner, School of Technology

SponsorArcelorMittal

Project OverviewFriction Stir Back Extrusion (FSBE) is a process in which tubes can be made with a tool and die. A spinning tool makes contact with the extruding material and causes friction, turning the material into a plastic state that can be formed into tubular structures.

Team MembersGarrett Jensen, Shawn Kaschner, Maxwell Madden, Brian Shane, and Casey Strom, Electrical Engineering

AdvisorJohn Lukowski, Electrical and Computer Engineering

SponsorsAmerican Transmission Company

Project OverviewOur team continues the work of last year’s ATC Senior Design Project, Traveling Wave Fault Detection. The primary goal of our project is to use traveling wave theory to improve the traveling wave fault algorithm using fault data from the Blaney Park to Munising Transmission Line. This would allow ATC to verify that the SEL-411L relay and traveling wave theory can be used to identify where a fault occurs on a line, so it can be used for the rest of ATC’s transmission lines.

Underside view of data acquisition and control panel—image shows I/O modules and other components

FSBE cross-section setup

On site at Munising Substation with our sponsor, Joe Kysely

Recreate PMS


Senior Design

204Posture Correction Device with Haptic Feedback for Parkinson’s Disease

205Rapid Prototyping of Ultrasound Elastography Phantom

206Customizing Transcatheter Nitinol Stents for Treatment of Hypoplastic Left Heart Syndrome in Infants

Team MembersDakota Anderson, Noah Doyle, Maxwell Hultquist, and Hannah Marti, Biomedical Engineering

AdvisorSmitha Rao, Biomedical Engineering

SponsorDepartment of Biomedical Engineering

Project OverviewParkinson’s disease involves the gradual degeneration of dopamine-producing nerve cells which control body movement. Symptoms include freezing gait, tremors, bradykinesia, and postural instability. Appropriate feedback can correct postural instability, in turn improving mobility and decreasing risk of injury. The proposed system monitors posture and provides haptic feedback for posture correction. The system uses dynamic data from onboard sensors and can be personalized to patients’ needs. It is safe, easy to use, low cost, and usable by a multitude of individuals with motor-control-related conditions.

Team MembersMadeline Faust, Corinn Gehrke, Morgan Herzog, Karry Modolo, and Armani Salary, Biomedical Engineering

AdvisorsJingfeng Jiang and Rupak Rajachar, Biomedical Engineering

SponsorMaterialise

Project OverviewUltrasound elastography phantoms evaluate and calibrate the performance of ultrasound devices. Elastography is a method that performs digital palpation of pathology. Existing ultrasound phantoms are often not complex enough to challenge imaging devices. Weaknesses in ultrasound elastography methods means ultrasounds cannot be truly tested without costly clinical trials. More complex phantoms need to be developed to challenge ultrasound elastography devices. To achieve this, additive manufacturing is being explored using cheap, polymer materials that mimic the elastic modulus and density of normal and cancerous breast tissues. This project focuses on applying this technology to model invasive ductal carcinoma (IDC) and normal breast tissues.

Team MembersEmma Davis, Kat Farkas, Amanda Gogola, and Ami Kling, Biomedical Engineering

AdvisorsJeremy Goldman and Smitha Rao, Biomedical Engineering

SponsorSpectrum Health Innovations—Helen DeVos Children’s Hospital

Project OverviewHypoplastic left heart syndrome (HLHS) is a congenital heart defect that is mainly characterized by the underdevelopment of the left ventricle. Currently, multiple open heart surgeries are performed to correct this problem. Our team’s goal was to help eliminate the need for the first surgery by designing and testing catheter deployment of a modified nitinol stent with improved patient matching. The idea of deforming the stent with a microsphere to better fit anatomically relevant infant heart geometries was explored, as well as the feasibility of the use of this deformed shape.

Proposed device for posture monitoring in Parkinson’s disease

Model of normal breast tissue from an MRI scan in Materialise Mimics Innovation Software

Proposed design of modified nitinol stent in heart with hypoplastic left heart syndrome


207Tooth Movement Simulation Instrument

208Contrast Valve Characterization

209Jump Starter Cart

Team MembersBrendan McNamara, Alex Moore, Jason Smith, Biomedical Engineering, and Chad Pollock, Electrical Engineering

AdvisorsMegan Frost and Bruce Lee, Biomedical Engineering

Sponsor3M

Project Overview3M is developing orthodontic appliances to move teeth in order to correct malocclusions. Testing these orthodontic appliances is necessary to prepare them for in vivo studies and understand the appliances’ capabilities. The current testing method requires high processing temperatures that create unwanted stress on the appliances, and the measurements are not quantitative. The team created a prototype that demonstrates a more realistic tooth movement as well as a quantitative measurement of the displacement. This was achieved by creating a copolymer blend to lower the processing temperatures while simulating the tooth-tissue interface. The displacement is measured quantitatively through image cross-correlation using images taken by a camera system.

Team MembersJacob Altscheffel, Sydney Chaney, Miguel Solis, Biomedical Engineering, and Zachary Garavet, Computer Engineering

AdvisorSean Kirkpatrick, Biomedical Engineering

SponsorACIST Medical Systems

Project OverviewACIST manufactures high pressure contrast injection pumps and the high volume disposable kits that go with them. As ACIST has grown, additional tools and contract manufacturers have come on board to help sustain consumable demands. While the designs are the same, they periodically show differences in performance. ACIST has tasked our team with designing a prototype to test the quality of each manufacturer’s syringe valve, where the most variance in performance is shown.

Team MembersThomas Whitaker and Sam Smit, Electrical Engineering; Matthew Linenfelser, Computer Engineering; Wesley Sialek and Nick Dubiel, Mechanical Engineering; Jenna Crouch, Electrical Engineering Technology

AdvisorDuane Bucheger, Electrical and Computer Engineering

SponsorAdvanced Power Systems Laboratories (APS LABS), Department of Electrical and Computer Engineering

Project OverviewThe jump starter cart is an all-in-one jump-starting system for large and small vehicles. It is capable of charging and jump starting 12-volt and 24-volt automotive systems. It also features polarity protection with automatic shut off to protect the user of the cart. In addition to charging, it has a 2-kilowatt power inverter to supply power to tools and work lights when needed. The cart is easily contained with the whole system attached to a garden cart with pneumatic wheels to cross varied terrains.

Camera system

Team photo

Team photo


Senior Design

210High Speed Bearing Temperature Profiling with Axial and Radial Loading

211Drill Attachment Coupling Mechanism

212Combination Patient Warming and Transfer Device

Team MembersKen Barr and Kyle Rautio, Electrical Engineering; Don Bowlby and Joe Goudzwaard, Mechanical Engineering

AdvisorAneet Narendranath, Mechanical Engineering-Engineering Mechanics

SponsorStryker Instruments

Project OverviewOur team has designed and built a bearing test fixture capable of spinning a high speed bearing under load and capturing temperatures under use.

Team MembersTabitha Gillman, Cole Aukee, Harry Hutton, Meridith Murley, and Hans Steven Creutz, Mechanical Engineering

AdvisorWilliam Endres, Mechanical Engineering-Engineering Mechanics

SponsorStryker Instruments

Project OverviewThis project gives students the opportunity to improve an existing product. The current motor-accessory interface design of a medical drill manufactured by Stryker Instruments has been on the market for several years, and competing companies have started to shift to new products. To surpass the competition, our team is designing and assembling a new interface. The new design will help surgeons interchange drill accessories quickly, and the instrument will produce little noise while in use.

Team MembersJenna Burns, Electrical Engineering; Kemin Fena, Elizabeth Martin, Zach Nelson, and Rebecca Rutherford, Biomedical Engineering

AdvisorOrhan Soykan, Biomedical Engineering

Sponsor3M

Project OverviewNurses face two main challenges when moving a patient. Studies show that nurses naturally lose their strength over time, and a greater number of patients are becoming more obese, making them harder to lift. The combination of these factors can injure nurses on the job. This project focuses on moving a patient into and out of a surgical suite. These suites tend to be cold and can lower the patient’s core body temperature. It is important to warm the patient so they maintain their normal core temperature. Keeping the patient warm helps prevent illness. Our team has created a working prototype of a heated patient transfer device.

CAD model of test rig Exploded view of drill attachment coupling mechanism proposed design

Design concept for patient warming and transfer device


213Wide Bandwidth, High-Voltage Data Acquisition System

214Instrumentation of Manual Medical Devices

215Truck Bed Storage System

Team MembersPatrick Leaske, Tyler Grifka, Adam Flaim, and Daniel Olson, Electrical Engineering; Kavan Ferguson and Frederick Perrett, Computer Engineering

AdvisorDuane Bucheger, Electrical and Computer Engineering

SponsorsAdvanced Power Systems Laboratories (APS LABS), Department of Electrical and Computer Engineering

Project OverviewThe modern field of engine design is increasingly dependent on small upticks in efficiency and precision. This requires increased reliance on data analysis. The spark-plug (a crucial component of SI engines) has remained generally untouched while a multitude of sensors have become standard elsewhere in the engine block. Our mission was to develop a compact, standalone sensor/data acquisition system that would allow the user to analyze the high voltage signal across the spark-plug gap. The system required extreme precision—allowing an initial voltage curve peaking up to 40kV at frequencies in the MHz range to be read without distortion by a standard DAQ at a voltage range 10,000 times less.

Team MembersDerryl Poynor, Justin Harthorn, and Corey Fase, Biomedical Engineering; Gabriel Wykle, Electrical Engineering

AdvisorsJeremy Goldman and Feng Zhao, Biomedical Engineering

SponsorBoston Scientific

Project OverviewThe most common vascular catheterization techniques require manual manipulation of an intravascular guidewire by a physician, who receives feedback from qualitative real-time X-ray imaging and physical resistance. There is currently no reliable method to measure the forces generated during manual manipulation of the guidewire. The objective of this project is to instrument a modified torque clamp to quantify the physician’s interaction with an intravascular guidewire for additional electronic operator assessment. We anticipate the real-time, quantitative feedback of the force applied down the shaft of a guidewire will help train physicians to prevent vessel perforation and tip failure from excessive applied force.

Team MembersSarah Corrion, Erica Huhta, Jake Kendziorski, Nick Kremkow, Justin McPherson, and Cameron Olsen, Mechanical Engineering

AdvisorAntonio Gauchia Babe, Mechanical Engineering-Engineering Mechanics

SponsorMahindra North America

Project OverviewOur team was tasked with designing a truck bed storage system that can meet unique demands while still providing the necessary space optimization needed for everyday projects. By researching customer specific needs, Mahindra North America has deemed the current storage system solutions inadequate, pushing to create a new system that can optimize the bed space trucks provide. Implementing an actuating 90-degree storage system with translational motion would be a game changer in the consumer truck industry. This system would potentially allow modification for additional attachment systems by using a versatile plate.

Prototype circuit test

Designed guidewire torque clamp Deployed truck-bed storage system


Senior Design

216Fly Ash Hopper Clearing Device

217Improved Inline Component Cleaning System

Team MembersAlex Piotrowski, Brendan Hufnagel, Luke Peters, Ryan Warsen, and Nickolas Kill, Mechanical Engineering


SponsorDTE Energy

Project OverviewFly ash is the remaining material left over from the combustion of coal. To meet current EPA guidelines, coal-fired power plants must utilize selective catalytic reduction systems and Flue Gas Desulfurization systems or a Dry Sorbent Injection, which causes increased amounts of fly ash. This places a strain on the fly ash collection systems, and causes pluggage of the collection hopper. It can also cause grounding of the precipitator sections. The customer identified a need for a specifically designed tool that can clear plugged hoppers safely.

Team MembersKat Donovan, Todd Krieger, Connor LeBombard, Thomas Mehall, and Stasia Rogers, Mechanical Engineering


SponsorMacLean-Fogg Component Solutions

Project OverviewOur team is designing and prototyping a cleaning system for threaded components suitable for inline integration. Our system must store, feed, clean, dry, and convey a variety of parts, and be adaptable for the tappers, screw machines, and lathes.

Detailed clearing device drawing

CAD representation of cleaning system

218Lighting Control Unit

Team MembersAlex Herbst and David Pariseau, Electrical Engineering; Garrett Hutcheson, Blake Martin, Aaron VanderWeide, and Sam Wachowski, Mechanical Engineering


SponsorGHSP

Project OverviewOur team was tasked with creating a testing apparatus for GHSP that would activate and evaluate the functionality of LEDs mounted in the gear shifter housing on various vehicles. The primary goal of this project was to design a Lighting Control Unit (LCU) that can be used across multiple vehicle applications. This requires individually powering various configurations of LEDs with multiple control inputs and reporting specific electrical characteristics of the circuit. The LCU tests the function of each LED by using multiple PWM dimming presets to test for various driving and parked lighting conditions.

Lighting control unit PCB board that controls PWM output to the LED board


219Assessment of Methods to Visualize and Remove Biofilm Layer on Orthopedic Implants during Surgery

220Blubber-Only Implantable Satellite Tracking Device for Humpback Whales

Team MembersBreeanne Spalding, Carly Joseph, Jonathan Kelley, and Joy Collard, Biomedical Engineering

AdvisorMegan Frost, Biomedical Engineering

SponsorsDepartment of Biomedical Engineering, Dr. Jennifer Bow, Surgical Consultant

Project OverviewEach year, nearly one million hip and knee arthroplasties are performed in the United States. An artificial joint can significantly improve a patient’s quality of life, but failure of the prosthetic can result in patient morbidity and a gross increase in medical expenses. A major cause of failure is infection, which occurs when a bacterial biofilm develops on the implant. Bacterial strains that grow into biofilms are generally less susceptible to antibiotics and host defenses than the same organisms in their planktonic forms. This continuation project seeks to visualize mature, infectious biofilms on orthopedic implants and to determine the most effective method to remove these biofilms during surgery.

Team MembersJustin Batchelor, Hannah Fisher, Paul Shelcusky, and Nathaniel Smith, Biomedical Engineering

AdvisorsRupak Rajachar and Bruce Lee, Biomedical Engineering

SponsorNational Oceanic and Atmospheric Administration

Project OverviewThe goal of our project is to create a novel blubber-only implantable satellite tracking tag for monitoring whale movement patterns over extended periods of time. Current tags are known for causing irritation issues in the whales that lead to premature rejection of the tags. Our team worked to design a tag that would be less invasive and more biocompatible than existing products. This meant designing smaller tags with design attributes that would promote better adhesion in a more biologically sensitive manner. We proposed 10 designs, of which six were prototyped and four were tested and analyzed.

SEM image of a Staphylococcus epidermidis biofilm grown for 48 hours

Paul Shelcusky, Nathaniel Smith, Justin Batchelor, Hannah Fisher

221Fused-Cutout Mechanical Testing System

Team MembersDerrick Baer, Owen Buckley, Joel Olsen, Brandon Sparks, and Frank Worrell, Mechanical Engineering


SponsorMacLean Power Systems

Project OverviewThe goal of this project was to characterize the mechanical forces seen on a fused cutout during a power surge. Because of these forces, components of the fused cutout have been experiencing failure in bending. Due to the high voltage and current flowing through the fused cutout during a power surge, traditional methods of measuring mechanical forces are much less reliable. To work in this strong electromagnetic-interference environment, the team used cantilever beam theory and digital image correlation to characterize the forces in the fused cutout. With this information, Maclean Power Systems can address the component failures in the fused cutout and work towards a solution.

Electrical testing setup


Senior Design

222Enhanced Measurement and Analysis of Gait Disturbances

Team MembersJustine Reed-Sandrum and Dex Driggers, Biomedical Engineering; Sonja Hedblom, Mechanical Engineering; Nic Schweikart, Computer Engineering

AdvisorJingfeng Jiang, Biomedical Engineering

SponsorAspirus Keweenaw

Project OverviewWith this project, our team seeks to reduce the time duration of full patient recovery from hip and/or knee orthopedic surgery. As a result of infrequent physical therapy appointments, the recovery of postoperative patients relies heavily on unsupervised practice outside of the clinic. When patients exercise out of the clinic, they do not have professional gait corrective feedback readily available. We designed a device to monitor a patient’s upper body and legs. It provides real-time scientific gait feedback, logs data of a patient’s progress, encourages proper gait form, and ultimately accelerates recovery.

Illustration of the full team-designed system in use

223Paper Machine Simulation for Training Purposes

Team MembersChristopher Coppernoll, Zackary Posz, Zachary Couture, Dylan Brosseau, and Florian VanKampen-Wright, Computer Engineering

AdvisorTrever Hassell, Electrical and Computer Engineering

SponsorBoise Paper (a division of Packaging Corporation of America)

Project OverviewIn an effort to improve training and create a safer working environment, our team was tasked with creating a new training simulation for Packaging Corporation of America. Although a training program currently exists, it doesn’t contain all of the information that is pertinent to training on a paper machine. Our goal is to create a new simulation that improves upon the previous one in the areas of familiarity, appearance, usability, and realism. The training simulation will provide a comprehensive understanding of the paper machine, resulting in more capable and comfortable operators.

A screen shot of the Simulation’s landing page

224Surgical High-Speed Drill Rotor Position via CAN Bus

Team MembersElliott Meese, Danny Bragg, and Julio Saint-Felix, Electrical Engineering; Hailey Trossen and Yuguang Wang, Computer Engineering

AdvisorTrever Hassell, Electrical and Computer Engineering

SponsorsStryker Instruments

Project OverviewIt is common to drive high-speed brushless DC electric motors with a back electromagnetic force (EMF) signal at high speeds. But at low RPMs, back EMF becomes unreliable and other methods have to be used. With this project, Stryker Instruments hopes to learn whether it is possible to use a Control Area Network (CAN) to get consistent sensor readings. CAN is robust and reliable, but it is not the fastest form of communication. The goal of this project is to learn whether the latency and delay are small enough to transmit motor sensor feedback.

Getting feedback from the hall effect sensors, and viewing the CAN communications

PMS 288


225Tailgate Debris Management and Adjustable Lift Assist

226Aircraft Refueling Stand System

Team MembersSteven Alvey, Michael Fisher, Kendra Gburek, Riley Long, Max Mager, and Lauren Tetzloff, Mechanical Engineering

AdvisorKevin Johnson, Mechanical Engineering-Engineering Mechanics

SponsorsFiat Chrysler Automobiles (FCA)

Project OverviewFCA has tasked us with creating a debris management system to be used on the back of new and existing Dodge pickup truck models. Currently, gravel, sand, and mulch fall into the gap. This causes scratches and can lead to lost material. Our team was also tasked with creating an adjustable counterweight system to assist with a former senior capstone design project—a storage system within the tailgate that stores up to 30 lbs. This additional weight can interfere with closing the tailgate. Together, these products will add user ease to the Dodge brand.

Team MembersMichael Hoffman, Ellaina Cook, Jason Scott, Brenda Sauer, and Evan Frank, Mechanical Engineering

AdvisorPaul van Susante, Mechanical Engineering-Engineering Mechanics

SponsorBETA Fueling

Project OverviewOur team has been tasked by BETA Fueling Systems to design, build, and test a prototype variable-height aircraft refueling stand with a modular nozzle-assist system. The stand is to be used in airports across the country, in all climates and conditions, to assist operators in refueling small- to medium-sized commercial jets. In addition to providing a spring-assisted adjustable height platform, our team has designed a pneumatic-piston mechanical arm that lifts the fueling nozzle with minimal operator effort.

Refining our prototypes Mega Desk

227dSPACE Hardware in the Loop Development and Testing—Year 3

Team MembersKevin Cashen II, Yuzhou Tang, Brenton Johnson, and Nathan Schapka, Electrical Engineering;Marlaina Wunderlich, Computer Engineering

AdvisorTony Pinar, Electrical and Computer Engineering

SponsorsNexteer Automotive

Project OverviewThe project goal is to develop an Electric Power Steering dSPACE Hardware-in-the-Loop testbench to accurately test vehicle EPS systems early in development, making any problems easier and much cheaper to troubleshoot. With the HiL testbench, these tests can be performed in conjunction with vehicle development and save the company time and resources. The project’s purpose is to use the HiL testbench provided by Nexteer to learn the system and all peripherals, perform software testing, and develop methods for collecting and analyzing data for a set list of handwheel tests.

HiL dSpace setup


Senior Design

228HMI Annunciator Replacement

Team MembersConnor Bruns, Tristan Gault, Joshua Prewett, and Timothy Radtke, Computer Engineering; Justin Jacobs and Michael Rader, Electrical and Computer Engineering

AdvisorTony Pinar, Electrical and Computer Engineering

SponsorsITC Holdings

Project OverviewThe Annunciator human machine interface (HMI) is the primary interface between technicians and their substations. Using the Annunciator, operators can monitor the states of devices from one central location. Running WindowsXP and bulky enterprise software on legacy hardware with stringent disk and processing constraints, ITC requested a software upgrade on a new operating system, allowing for continued use of the hardware and long-term support. Running on TinyCore, a space-saving Linux distribution, the new software operates in three layers: a communications layer to talk between the master station and outstations, an alarm state layer that saves the status of monitored devices, and a touchscreen user interface for simple human interaction.

Software alerts operators of unacknowledged alarms

229SCADA LTLS Coding and Control Monitoring Upgrade Qualification

Team MembersKate Nowosad, Katherine Myers, Yilin Wang, Zach Smale, and Britton Borlace, Electrical Engineering; Avery Bailey, Computer Engineering

AdvisorsChee-Wooi Ten, Electrical and Computer Engineering

SponsorsDTE Energy

Project OverviewSubstation automation has become ubiquitous in today’s technologies with Ethernet-based communication features for remote control and monitoring. The functionalities of deployed instrumentation units can vary from vendor to vendor and are often justified based on the costs and interoperability of a device manufacturer. This design project investigates and assesses a new model’s capabilities and equivalents with two existing units. We will conduct intensive testing for this implementation stage in order to determine the feasibility of the equivalents. This study could provide an engineering justification, in terms of performance and costs associated with engineering hours, as a future reference of substation deployment.

Our team at the new substation

230Single-Seat, Propane-Powered Hovercraft

Team MembersHasan Quazi, Ross Samuelson, and Andrew Vertein, Mechanical Engineering Technology

AdvisorJohn Irwin, School of Technology

SponsorsSchool of Technology, ArcelorMittal, Kohler

Project OverviewOur objective is to adjust the hovercraft design so the driver can steer the craft around the SDC gymnasium for at least a single lap under its own power. We rebuilt the frame to rebalance the craft. The propulsion will be powered and controlled by duct fans that the driver can independently rotate. This vehicle will eventually be used as a piece of lab equipment in the study of flow. It must also meet all relevant OSHA standards for such a vehicle.

Frame design in NX


231Design of a 2 GHz Transimpedance Amplifier

Team MembersJeffrey Beck, David Schultz, and Novia Berriel, Electrical Engineering

AdvisorChristopher Middlebrook, Electrical and Computer Engineering

SponsorElectro-Optics Technology

Project Overview We are designing a transimpedance amplifier (TIA) as a drop-in replacement for a similar device that is no longer being manufactured. It must be able to amplify signals by 26 dB over a frequency range from approximately 5 kHz to 2 GHz, and must do so with less than 3.8 dB of noise. This device will serve as a low-noise amplifier that amplifies the signal from a photodiode for a photodetector to process. Similar devices currently on the market are unable to replace this device because of the difference in number of pins and difference in sizes.

A photodetector that could use our TIA

232Laboratory Assessment of Automotive Tread Cracking

233Snowmobile Chassis Magnesium Component Design

Team MembersTori Keerl, Kylie Lettow, Wyatt Hurst, and Peter Seim, Materials Science and Engineering

AdvisorErik Herbert, Materials Science and Engineering

SponsorFord Motor Company

Project OverviewTire tread surface degradation is a type of failure that occurs between tread surfaces on a tire. This type of cracking is not structurally compromising, but cosmetic issues are displeasing to customers. Currently, there is no accelerated laboratory test method to accurately replicate this failure mode. The team will develop and test a method in order to determine crosslink density with applied load and environmental conditions. The results from this test will determine what tire will degrade quicker and help establish which should be used in order to best serve customers.

Team MembersAdam Patrick, Alyssa Gafner, Drew Cederquist, Erika Harris, Greg Peters, and Nicholas Grygleski, Mechanical Engineering


SponsorsPolaris Industries

Project OverviewAt a dry weight of 408 pounds, the 2017 Polaris 800 Pro-RMK 155 snowmobile is the lightest and strongest mountain snowmobile on the market. Polaris has tasked our team to help them remain the market leader of light and durable mountain snowmobiles. Mass reduction of the Polaris RMK chassis will be accomplished by investigating replacement of current aluminum cast components with magnesium cast components along with geometry changes. Our team is working towards achieving maximum mass reduction of the tank hold-down cast component specifically.

Crosslink density test in progress

Redesigning the RMK tank hold-down casting aluminum component


Senior Design

234Electric Bicycle

Team MembersSarah Pugh, Justin Bunzeluk, Jacob Sellhausen, Katie May Birach, and Jacob Rissi, Mechanical Engineering Technology

AdvisorDavid Wanless, School of Technology

SponsorSchool of Technology

Project OverviewOur initial objective was to incorporate electrical components to motorize a wooden bicycle frame. As of January 2017, the frame is no longer wood and to be re-engineered from steel incorporating recycled bicycle components. This new frame will be utilized to house the required electrical components to motorize the bicycle. The electrical components being utilized in this design are two 12-volt Optimum Glass Matt batteries, a Sabertooth 2x32 controller, and an EV Warrior Motor. The bicycle needs to be able to traverse 100 miles on a single charge. In addition, the bicycle has to stay within current US federal law limits of 750 Watts and 20 MPH.

Preliminary design that locates electrical components onto the frame

235Mitigation of Galvanic Corrosion in Aluminum—Copper Busbars

Team MembersEmily Petersen, Catherine Galligan, George Castle, and Jonathan Vajko, Materials Science and Engineering

AdvisorDouglas Swenson, Materials Science and Engineering

SponsorYazaki Corporation

Project OverviewPressure to optimize fuel efficiency has challenged automotive industry suppliers’ ability to transition to lightweight materials. Traditional copper busbars are being replaced with aluminum alloys, with particular attention to conductivity and corrosion resistance. This study serves to build upon prior work in which aluminum was alloyed with tin. Existing literature suggests alloy improvement by the addition of a third element to minimize the difference in electrical potential of pure aluminum and copper, as well as create a corrosion-resistant passivation layer. Metallography, conductivity, mechanical testing, and salt-fog corrosion were performed and the result compared to the sponsor’s current copper alloy.

Vacuum induction melting of aluminum alloy

236Undersized Forging Detection System

Team MembersCayman Berg-Morales, Devin Livingston, Rachel Pohlod, Brandon Rouze, and Evan Wallin, Mechanical Engineering


SponsorMacLean-Fogg

Project OverviewOur team is working with MacLean-Fogg’s Metform division to create an inspection for transmission gear blanks that takes place as the gear blanks are manufactured to detect any underfilled blanks and remove them from the production line. The inspection system is being designed and prototyped to be fully autonomous, and to fit within the current manufacturing process at Metform’s machining facility.

A CAD representation of our gear blank inspection system


237Corrosion of Modified 6082 Aluminum Alloys for Automotive Applications

Team MembersPhilip Bednarczyk, Joshua Cicotte, Janine Erickson, and Violet Thole, Materials Science and Engineering

AdvisorDan Seguin, Materials Science and Engineering

SponsorFord Motor Company

Project OverviewFord utilizes an extruded aluminum rocker bar as a structural component of their F150 trucks. They have experienced inconsistent quality of the material’s corrosion resistance when sourced from different suppliers. This study investigates the effects of composition and processing parameters of 6082 extruded aluminum on corrosion resistance. Billet homogenization practices, composition, and post-extrusion thermal processes were systematically varied to examine how these factors may influence the microstructure and corrosion resistance in the material.

Intergranular corrosion of T6 aluminum extrusion

238Improved Snow Bucket

239In-Cab Airborne Chemical Sensing System

Team MembersHoratio Babcock, Kevin Kyle, Jay Pietila, Donald Shaner, Jiaqi Tang, and Kun Zhang, Mechanical Engineering


SponsorBobcat Company

Project OverviewBackdragging is the most common way snow is removed from areas near structures. When performed by skid-steer operators, backdragging is accomplished by lifting the snow bucket into the air, slowly approaching the structure, lowering the cutting edge until it contacts the ground, and then backing away from the structure. When a large capacity bucket is lifted into the air, the act of approaching a structure while maintaining sight of both the structure and the cutting edge becomes difficult. The design team created an accessory that will mount to the customer’s existing snow buckets in order to enhance visibility during backdragging operations and not cause damage to structures during use.

Team MembersDavid Stephan, Nick Squanda, and Tom Price, Mechanical Engineering; Maegan Neil and Sevin Dennis, Computer Engineering


SponsorRichard W. Job

Project OverviewEnvironmental cab enclosures included on modern agricultural and mining equipment help to greatly reduce the exposure of operators to atmospheric dust and/or agricultural/industrial chemicals by operating at a positive pressure and filtering the air entering the cab enclosure. However, the filtering system can fail occasionally because of improper installation or structural damage to the filter. In this case, the operator may have no idea that their filter system has been compromised. The objective of this project was to design a system that would periodically challenge the filter system to determine its effectiveness and alert the operator if the concentration exceeds predetermined levels.

Bobcat Skid-Steer with raised snow bucket during snow removal

Team working on user interface and sensor interaction with controller


Senior Design

240Machinability of Additively Manufactured Cobalt-Based Superalloy Components

Team MembersJeffrey Brookins, Ben Gruber, Emily Hunt, and Zach Verran, Materials Science and Engineering

AdvisorWalt Milligan, Materials Science and Engineering

SponsorGE Aviation

Project OverviewGE Aviation is using additive manufacturing (AM) processes to produce intricate parts from a cobalt-based superalloy for their next-generation aircraft engines. However, within these components there is a requirement for threaded holes to be machined after AM production. Currently, GE utilizes a time-consuming machining process to create threaded holes within their additively manufactured parts. Our team was tasked with investigating the material properties of the alloy in order to develop a faster, tapping-based machining process. By characterizing the deformation process of the alloy, tooling and process recommendations can be made to GE Aviation.

The GE Aviation senior design team (from left): Jeff Brookins, Emily Hunt, Ben Gruber, and Zach Verran

241Objective Method to Measure Chronic Pain

Team MembersJacob Brown, Kari Helminen, and Thomas Spicuzza, Biomedical Engineering; Adam Reese, Electrical Engineering

AdvisorKeat Ghee Ong, Biomedical Engineering

SponsorMedtronic

Project OverviewFor many years, pain level in chronic pain patients has been determined by asking the patient to report their pain level. Whether this pain is reported by choosing a pain level on a scale of 1-10, or by choosing an image of a face that describes their pain level, the patient’s subjective input has been crucial. Our team’s goal, with the help of our sponsor, is to design a pain measurement protocol that reports a patient’s pain level with minimal subjective input from the patient. Through a wearable device, the use of computer programing, and real patient data, an objective pain measure can be calculated to allow physicians to better treat their patients.

The Fitbit Charge 2, used to collect biometric data

242Delivering and Fixing a Lead into the LV Myocardium

Team MembersRoss Michaels, Jared Johnson, Sean Casey, and Emily Morin, Biomedical Engineering

AdvisorsRupak Rajachar and Feng Zhao, Biomedical Engineering

SponsorMedtronic

Project OverviewThe general design for this project is to create a system in which a lead is delivered from the epicardial surface through the myocardium, but not penetrating into the LV chamber. This requires a delivery system and a method to penetrate the epicardial layer and then direct the lead to the endocardial surface. Our goal is to accomplish this with a minimally invasive surgical approach.

Hard at work in the biomedical senior design lab


243Automated Laser Marking System

Team MembersJoseph Halford, Mariana Caamano, and Jack Shepard, Mechanical Engineering; Kyle McGurk and Jacob Cavins, Electrical Engineering Technology

AdvisorEddy Trinklein, Mechanical Engineering-Engineering Mechanics

SponsorNexteer

Project OverviewOur team is designing and creating an automated laser marking system to etch personalized markings onto aluminum objects.

Laser marking system

244Small 3-D Printer—Compact Portable Printing (CPP)

245Apollo 3-D Printer

Team Members Ryne Hass and Michael Van Rite, Mechanical Engineering Technology; Serife Basbayandu, Industrial Technology


SponsorsArcelorMittal, MC Manufacturing

Project OverviewOur team is designing and building a small Athena 3-D printer that is more compact and portable than the original. Keeping the same features as the original is one of the design requirements.

Team MembersMatt Coobac and Kyle Rosenthal, Mechanical Engineering Technology


SponsorsArcelorMittal

Project OverviewThe Apollo 3-D printer is a delta-style 3-D printer enlarged from the Athena 3-D printer kit. Our design sought to upscale the Athena by 1.5X, increasing the print area horizontally and vertically while retaining all the existing printer capabilities. The Apollo also includes a heated print bed, making it capable of printing with multiple materials.

Small Athena 3-D printer

End effector shell subassembly for Apollo 3D Printer


Senior Design

246DROP BEAR

Team MembersSteven Abramczyk, Helen Karsten, Jon Markl, Robert Minger, and Eric Passmore, Mechanical Engineering


SponsorsAir Force Research Labs, Munitions Directorate, Fuzes Branch

Project OverviewResearchers in the Air Force Research Laboratory, Munitions Directorate, Fuzes Branch are actively investigating the dynamics of structures/systems that reconfigure their response during the harsh environments of impact, penetration, and terminal ballistics. In order to develop technologies for sensing and adapting to this environment, we need to address a technical gap. Our laboratory needs an experimental testbed for implementing sensors and algorithms to predict/estimate time-varying dynamic responses during impact events and vibrational responses. A previous joint NSF-funded project between Michigan Tech and University of Massachusetts-Lowell, called the BEaR (Beam Excitation and Response), was developed to provide a tunable experimental testbed for modal analysis and structural dynamics courses. This previous effort is the inspiration for our project.

3-D model of DROP BEAR apparatus

247High Pressure Die Casting Vent Optimization

248Maximizing Feeding Efficiency of 3xx Series Aluminum Alloys

Team MembersJulia Scruton, Materials Science and Engineering, and Stephen Hanley, Mechanical Engineering

AdvisorRuss Stein, Materials Science and Engineering

SponsorMercury Marine—Mercury Castings

Project OverviewHigh Pressure Die Cast (HPDC) tooling requires venting channels to be incorporated into their design to allow air to escape during the casting process. The channels must also manage the flow of metal to maintain pressure and properly fill the part during solidification. If the venting channel has a low restriction, the metal flows too fast and will exit the vents. If the venting channel is overly restrictive, the trapped air will introduce porosity in the cast part. A process design method will be developed with the understanding of how various venting channel features affect the complete venting design. This will lead to a faster design process of venting channels on future parts.

Team MembersJohn CI Smith, Evan Olson, Hao Qin, and Georgia Hurchalla, Materials Science and Engineering

AdvisorThomas Wood, Materials Science and Engineering

SponsorEck Industries

Project OverviewEck Industries is interested in minimizing the amount of strontium in 3XX series aluminum alloys to reduce production costs. Strontium is added to modify the eutectic silicon phase, which improves both ductility and feeding efficiency. However, high levels of strontium are associated with increased gas porosity and thus inferior mechanical properties. It has been shown that additional grain refiner is another potential way to improve feeding efficiency. Our team has been working to minimize the strontium additions necessary to produce high quality castings by alloying with additional grain refiner.

MAGMA model of venting channels

Eutectic silicon phase with Sr modification


249Single Point Incremental Forming (SPIF)

250Process and Capability Improvement of Ductile Iron Casting at Michigan Tech Foundry

251High Temperature Stability of Austempered Ductile Iron

Team MembersMac Sandberg, Saywer West, and Michael Bereczky, Mechanical Engineering Technology

AdvisorScott Wagner, School of Technology

SponsorArcelorMittal

Project OverviewOur team is combining the use of CNC vertical mills with a specialized fixture, a force dynamometer, and LabView programming to better understand the dynamic forces that occur during the single point incremental forming process. With this data we are able to test different process variables. Our goal is to achieve a reliable process that could be used to allow prototyping or create one-off parts from different metals without the use of expensive stamping dies.

Team MembersNicholas Verhun, Materials Science and Engineering; Matt Gleason and Karl Hamina, Mechanical Engineering

AdvisorRussell Stein, Materials Science and Engineering

SponsorDepartment of Materials Science and Engineering

Project OverviewCasting ductile (nodular) iron, in comparison to other cast irons, requires much more strict variable and process control. Industry leaders use a 24/7 manufacturing process and specialized infrastructure to obtain high control and production. The foundry at Michigan Tech, as a small-scale research foundry, must find a way to obtain similar controls to perform precise casting research. Our team is evaluating the ductile iron casting process and equipment on campus for possible areas of improvement in order to increase consistency, quality, and variable control of ductile iron casting research.

Team MembersCameron Smith, Erin Neil, and Carson Williams,Materials Science and Engineering

AdvisorJoseph Licavoli, Materials Science and Engineering

SponsorDepartment of Materials Science and Engineering

Project OverviewAustempered ductile iron (ADI) exhibits improved physical and mechanical properties over ordinary cast ductile iron; these properties include increased hardenability, strength, and ductility. However, at high temperatures the ausferrite microconstituent—the structure primarily responsible for ADI’s desirable properties—transforms into bainite, resulting in less favorable properties. Certain alloying additions, such as molybdenum or nickel, can mitigate this performance loss and stabilize ADI at high temperatures. This project aims to expand upon previous alloying and to explore new options to increase the thermal stability of ADI.

Laser marking system mill touching off at the part zero point Filling ductile iron pouring basins for casting

with in-stream inoculation in the Michigan Tech foundry.

Typical ADI microstructure. Photo credit: Kathy Hayrynen, Applied Process, Inc.

Undergraduate Randy Wilharm holds a flask containing a ligand complex that may help create a biomass fuel.

In the Pavlis Honors College at Michigan Technological University, student success is more than GPA. Self-motivation. Independent thinking. Taking charge.

Students design their own unique path. Learning extends beyond the classroom. Support is offered for personal and professional goals.

Find out why success means more than GPA.

honors.mtu.edu@michigan_tech

@michigantech

50 • Michigan Tech Design Expo 2017

At American Transmission Co. there is a special energy among employees

– a positive energy. Our employees like it here. In fact, we were named

a Best Small and Medium Workplace in the United States by FORTUNE

magazine for the past two years. If a great workplace with a positive energy

sounds good to you, check out our job openings at atcllc.com/careers.

Positive EnergyA T C C A R E E R S

ATC owns, builds, maintains and operates the electric transmission system in portions of Wisconsin, Michigan, Minnesota and Illinois. We have offices in Pewaukee, Madison and De Pere, Wis., and Kingsford, Mich.

ATC is an equal opportunity employer functioning under an affirmative action plan. We encourage women, minorities, veterans and individuals with a disability to apply.

800-205-7186 | codeblue.com

Code Blue has strived to mold the latest technology into innovative products designed to help keep people safe. It’s who we are.

TTo help foster the next generation of innovation, Code Blue is proud to support Michigan Tech at Design Expo 2017.

For nearly three decades

HERE TO HELP


Half page Horizontal 7.25˝ x 4.75˝ 43p6 x 28p6

Ad Received at CRM: Large PDF rec’d 6-3-15; resized to fit (with horizontal float) CRM’s half page

Confirmation PDF Created: 6-3-15

Miller® is about building things that matter. We lead the welding industry in building advanced, solution-focused products and meeting crucial needs for welding safety and health. We’re about the partnership and the work. Our products are designed with our users for manufacturing, fabrication, construction, aviation, motorsports, education, agriculture and marine applications. Miller Electric Mfg. Co., is headquartered in Appleton, Wisconsin, and wholly owned by Illinois Tool Works (NYSE: ITW). The company maintains its industry leadership by setting the standard for reliability, quality and responsiveness. The company began with an innovation that responded to customer needs, growing from a one-man operation in 1929, to the world’s largest manufacturer of arc welding products. Miller keeps the tradition alive by focusing on its top priority: people. Learn more at Millerwelds.com.

52 • Michigan Tech Design Expo 2017

EXPLORE CAREER OPPORTUN IT I E S

ANNARBORUSA.ORG/WORK-HERE

Join the cross-section of the world’s brightest minds to help

build out the Silicon Valley of the Midwest while enjoying many

of the same outdoor activities you love in Houghton.

We can even point you to the nearest pasty!

International Culture. Urban Living. Small Town Feel.Build your career in Ann Arbor.

AnnArborUSA.org

MEET THESE COMPANIES AT DESIGN EXPO 2017!


Partneringwith Michigan Tech

Michigan Technological University fosters an environment of industry collaboration and partnership by providing innovative solutions for talent, research, technology, and professional development.

The Office of Innovation and Industry Engagement helps connect the strategic interests of your organization to the appropriate campus programs and constituents, including research, facilities, continuing education, student and alumni talent, and strategic giving opportunities.

Contact us: Office of Innovation and Industry Engagement

906-487-2228 • [email protected] • mtu.edu/industry

Learn more by visiting mtu.edu/industry

expo.mtu.edumtu.edu/honors/ice

YOU MAY NOT SEE US AND WE’RE OKAY WITH THAT.

In fact, we take pride in it.

At Black & Veatch we work with our clients to design, build and operate the things that deliver the energy, water and communications services you use every day.

So, when you turn on a light, the tap or use your smart phone, chances are we’re behind it. And everything will work just like we planned and how you expect.

Visit bv.com/careers to learn more.


Directing PartnerITC Holdings

Supporting PartnersBlack & VeatchMichigan Tech Career ServicesSPARK

Collaborating PartnersATC American Transmission Co.Code BlueICEKimberly-ClarkMichigan Tech Office of Innovation and

Industry Engagement (IIE)

Innovating PartnerMiller Electric

Enterprise and Senior Design Team Sponsors3MA&D TechnologyACIST Medical SystemsAdvanced CircuitsAdvanced SleeveAltairAnalytical GraphicsAPS LABSAramcoArcelorMittalAspirus KeweenawATC American Transmission CompanyBETA FuelingBright AscensionBritten StudiosBobcat CompanyBoise PaperBoschBoss SnowplowBoston ScientificJennifer Bow, Surgical ConsultantCaterpillarCentral Michigan UniversityChurning Rapids Snow Bike Trails ClubClyde SpaceCumminsDENSODTE Energy

Eck IndustriesElectro-Optics TechnologyFEVFiat Chrysler Automobiles (FCA)FLIRFord College Community ChallengeFord Motor CompanyGE AviationGeneral MotorsGeorgia PacificGHSPGM FoundationGreat Lakes Sound and VibrationHalla MechatronicsHARMAN InternationalHelen DeVos Children’s HospitalITCJohn DeereRichard W. JobKA WoodKeweenaw Bay Indian Community (KBIC)Kimberly-ClarkKohlerLittle Brothers-Friends of the ElderlyMacLean Power SystemsMacLean-Fogg Component SolutionsMahindra North AmericaMaterialiseMC ManufacturingMedtronicMercury Marine—Mercury CastingsMeritorMichigan Technological University Biomedical Engineering Electrical and Computer Engineering Great Lakes Research Center Kinesiology and Integrated Physiology Materials Science and Engineering Office of Alumni Engagement Pavlis Honors College School of Business and Economics School of Technology Transportation Services William G. Jackson Center for

Teaching and LearningMilwaukee ToolMitsubishi ElectricNanoMagNexteer AutomotiveNovatel

Oshkosh CorpPCB PiezotronicsPlasanPolaris IndustriesRampf GroupRazors EdgeRhythm Bike & BoardSociety of Women EngineersSpace Dynamics LaboratorySpaceXSpectrum Health InnovationsSteel Market Development InstituteStonecoStryker InstrumentsTE ConnectivityTethers UnlimitedUP Health System—MarquetteUS Air Force Research Laboratory (AFRL)US National Aeronautics and Space

Administration (NASA)US National Oceanic and Atmospheric

Administration (NOAA)US Office of Naval Research (ONR)Village of L’AnseWPPI EnergyYamaha Motor CompanyYanfeng Automotive InteriorsYazaki Corporation

Bronze Husky statue by sculptor Brian Hanlon.

A HUGE thank you to all Design Expo 2017 Partners and SponsorsAcknowledgements

WE ARE PROUDTO RECOGNIZE OUR

MICHIGAN TECH DESIGN EXPO 2017 PARTNERS

expo.mtu.edu

Directing Partner

Collaborating Partners

Supporting Partners

Michigan Technological University is an equal opportunity educational institution/equal opportunity employer, which includes providing equal

opportunity for protected veterans and individuals with disabilities.

Innovating Partner

a showcase of enterprise and senior design student · pdf fileenterprise and senior design ......

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