PORFOLIO<br />KHOA TON<br />	Master in Mechanical Engineering <br />	San Jose State University<br />	Specialize in Mechani...
Project<br />DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL (team member)<br />OPTIMIZATION OF FINESS RATIO OF VLLA AIR...
1. DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL<br />
2. OPTIMIZATION OF FINESS RATIO OF AN AIRSHIP<br />Optimize the shape of the airship by varying finesse ratio (L/D) to mee...
Topology<br />3D Meshing<br />Boundary Condition<br />
Total Pressure<br />Velocity<br />CFD based Drag Force<br />Theoretical  Drag Force<br />
3. WHEEL DESIGN<br />Blade Collection Motor-bike Wheels<br />
4. CAN CRUSHER<br />
Von-Mises Stress<br />Max Displacement (0.525 mm)<br />Safety Factor<br />Strain<br />
5. REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN <br />
REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN <br />Objective: Weight reduction by redesign the ...
Thermal Analysis<br />Rotor Disc<br />Tmax649 F <br />Rotor Hat<br />Tmax605 F <br />
6. FOUR DEGREE OF FREEDOM MECHANISM<br />Feature & Specification<br />Two translational & two rotational degrees of freedo...
Design Requirements Vs. Results<br /><ul><li>Design a 4 DOF Mechanism
Position a 50-mm cube having 0.5 Kg mass
Provide clearance for a Ø10-mm light beam propagating from one surface of the 50-mm cube to beyond the 4 DOF mechanism
Angular Range 				≥ 20 mrad
Translational Range 			≥ 4 mm
Resolution 				≤ 5 μrad, ≤ 2 μm
Accuracy (Repeatability) 			≤ 10 μrad, ≤ 10 μm
Pointing Stability over entire Operating Temp Range 	≤ 12 μrad, ≤ 15 μm
Fundamental Frequency 			≥ 50 Hz
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Porfolio_Khoa Ton

  1. 1. PORFOLIO<br />KHOA TON<br /> Master in Mechanical Engineering <br /> San Jose State University<br /> Specialize in Mechanical Design/FEA/CFD<br />
  2. 2. Project<br />DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL (team member)<br />OPTIMIZATION OF FINESS RATIO OF VLLA AIRSHIP (team leader)<br />WHEEL DESIGN (own project)<br />CAN CRUSHER design (own project)<br />REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN (team leader)<br />FOUR DEGREE OF FREEDOM MECHANISM (team member)<br />Enclosure design for a three-wheel electric scooter (own project in progress)<br />
  3. 3. 1. DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL<br />
  4. 4.
  5. 5. 2. OPTIMIZATION OF FINESS RATIO OF AN AIRSHIP<br />Optimize the shape of the airship by varying finesse ratio (L/D) to meet requirement of cabin size and minimum drag.<br />Benchmark theoretical drag against CFD-based drag <br />Airship with the cabin size<br />
  6. 6. Topology<br />3D Meshing<br />Boundary Condition<br />
  7. 7. Total Pressure<br />Velocity<br />CFD based Drag Force<br />Theoretical Drag Force<br />
  8. 8. 3. WHEEL DESIGN<br />Blade Collection Motor-bike Wheels<br />
  9. 9. 4. CAN CRUSHER<br />
  10. 10. Von-Mises Stress<br />Max Displacement (0.525 mm)<br />Safety Factor<br />Strain<br />
  11. 11. 5. REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN <br />
  12. 12. REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN <br />Objective: Weight reduction by redesign the rotor hat<br />Original rotor hat<br />Cyclic Symmetry Model<br />Optimize rotor hat<br />Displacement (max 0.0077 mm)<br />Von Mises Stress 17.4 MPa<br />
  13. 13. Thermal Analysis<br />Rotor Disc<br />Tmax649 F <br />Rotor Hat<br />Tmax605 F <br />
  14. 14. 6. FOUR DEGREE OF FREEDOM MECHANISM<br />Feature & Specification<br />Two translational & two rotational degrees of freedom<br />All 4 DOF occurs on the same plate<br />Springs provide preload for displacement in opposite directions<br />2-2-2 Kinematic Kelvin mount<br />Material is 6061-T6 Aluminum<br />Vacuum compatible material; low out-gassing rate<br />Easy to machine <br />Cheap<br />Mass is ≤ 2 Kg<br />Dimension is 154 mm x 200 mm x 200 mm<br />
  15. 15. Design Requirements Vs. Results<br /><ul><li>Design a 4 DOF Mechanism
  16. 16. Position a 50-mm cube having 0.5 Kg mass
  17. 17. Provide clearance for a Ø10-mm light beam propagating from one surface of the 50-mm cube to beyond the 4 DOF mechanism
  18. 18. Angular Range ≥ 20 mrad
  19. 19. Translational Range ≥ 4 mm
  20. 20. Resolution ≤ 5 μrad, ≤ 2 μm
  21. 21. Accuracy (Repeatability) ≤ 10 μrad, ≤ 10 μm
  22. 22. Pointing Stability over entire Operating Temp Range ≤ 12 μrad, ≤ 15 μm
  23. 23. Fundamental Frequency ≥ 50 Hz
  24. 24. Dimensions (to be minimized) ≤ 200 mm x 200 mm x 200 mm
  25. 25. Mass (to be minimized) ≤ 5 Kg
  26. 26. Detachable and replaceable to ≤ 10 μm & ≤ 100 μrad
  27. 27. Survive 10 ºC < T < 30 ºC; Operate in 18 ºC < T < 22 ºC
  28. 28. Mounting Surface Steel
  29. 29. Vacuum compatible
  30. 30. 38 mrad
  31. 31. 4.2 mm
  32. 32. Yes
  33. 33. Yes
  34. 34. 13 μm, negligible
  35. 35. 51 Hz
  36. 36. 154x200x200
  37. 37. 2 kg
  38. 38. Yes
  39. 39. Yes
  40. 40. Yes
  41. 41. Yes </li></li></ul><li>Plate Flexure Optimization<br />Results:<br />- m= 0.276 Kg<br /><ul><li> Plate thickness</li></ul>= 3.8 mm<br /><ul><li>Leaf flexure thickness</li></ul>= 1 mm<br /><ul><li>Outer joints = 10 mm
  42. 42. Inner joints = 06 mm</li></ul>Y<br />X<br />X -displacement<br />Y -displacement<br />12/2010<br />
  43. 43. 12/2010<br /> Optimization conflicts to frequency test <br />Inner leaf flexure<br />Outer leaf flexure<br />
  44. 44. 12/2010<br />Stress Analysis (Translation Displacement)<br />Result:<br />F=15 N<br />X disp = 2.4 mm <br />Stress= 118.3 Mpa<br />F=15 N<br />Y disp = 2.3 mm<br />Stress= 126.9 Mpa<br />Y<br />X<br />X -displacement<br />Y-displacement<br />
  45. 45. 12/2010<br />Stress Analysis (Angular Displacement)<br />Pitch:<br />F= 30 N <br />Stress= 73.2 MPa<br />X=0.0107 rad<br />MOS= 0.734<br />Y<br />X<br />Pitch<br />Yaw:<br />F= 40 N<br />Stress= 92.9 Mpa<br />Y= 0.01005 rad<br />MOS= 0.6622<br />Yaw<br />
  46. 46. 7. Enclosure design for a three-wheel electric scooter TRIKE III<br />AFTER<br />BEFORE<br />Concept Design<br />09/2010<br />
  47. 47. 3D Design Enclosure<br />09/2010<br />
  48. 48. Result<br />Pressure Distribution<br />Velocity Distribution<br />09/2010<br />
  49. 49. Structural Evaluation of The Enclosure<br />Displacement Distribution<br />Max disp = 0.45 mm<br />Von-Mises Stress Distribution<br />Max Stress = 0.9 Mpa<br />(vs Yield = 55 Mpa)<br />09/2010<br />

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