This document is Yechun Fu's engineering portfolio summarizing his work experience and projects. It describes his master's degree from Cornell University and internship at W.L. Gore where he conducted CFD and FEA analysis on projects in automotive, filtration, and pharmaceutical industries. It also outlines his involvement in various engineering teams and competitions at Cornell, including roles in aerodynamics, intake manifold design, suspension modeling, apparatus design, and leadership of the chemical engineering car team.

1. Engineering Portfolio
Yechun Fu
Cornell University
Master of Engineering
May 2016

2. W.L. GORE & ASSOCIATES, INC.
JUNE 2016 – PRESENT
W.L. Gore & Associates is a manufacturing company specializing in products
derived from fluoropolymers. The company’s product line spans multiple
industries, including fabrics, filtration, and pharmaceutical devices.
As a modeling and simulation intern at Gore, I conducted CFD/FEA analysis on
three different projects in three industries:
1. Automotive Venting in Headlamps
2. Turbine filtration with porous media
3. Microstructure Membranes
Automotive Headlamp
Turbine Filtration
1
2
Microstructure Modeling3
Created conjugate heat transfer simulations in
ANSYS CFX to model heat sinks, heat sources,
bulb type, and fans. Simulates various
operating conditions (car idling, car driving on
highway, car parked outside, etc).
Physics capabilities developed include
natural/forced convection, heat conduction,
moisture transport, relative humidity tracking,
and mass transfer through porous media.
Simulated numerous case studies for the V-
panel turbine filters.
Responsibilities include working with design
engineers to minimize high velocity regions,
evenly distribute airflow across porous area,
and compare efficiency results with wind
tunnel experiments.
CFD studies include researching laminar-
turbulence transition zones, conducting mesh
refinement studies up to 30-40 million
elements, and implementing user functions for
automation.
Modeled virtual microstructure membrane
geometries to research material behavior.
Obtained new material information on tortuosity,
porosity, and permeability values from CFD
results and particle injection studies, using
Python to post-process millions of lines of data.
Conducted FEA studies using ANSYS
mechanical to determine the dependence of
membrane flow properties on compression.
Created 2-way coupled fluid-structure interaction
(FSI) simulations to develop the capability to
research permeability and structural compression
correlations.
From www.gore.com
From www.gore.com
From www.gore.com
Note: CAD models & simulation results are not shown to protect
the IP of W.L. Gore.

3. CORNELL FORMULA SAE
FALL 2015 – SPRING 2016
Analyzed stability of front wing stability and
variation of lift during operation to prevent
wake traction loss during operation.
Increased lift coefficient rear wing
by 11% by modifying endplate
design and airfoil gap sizing
through CFD parameterization.
Defeatured Geometry Mesh Generation
Predicted side-feed intake manifold
performance to ensure equal distribution
of air into engine while varying inlet
diameter and bellmouth location
Full Car Body Simulation
CAD assembly file courtesy
of Cornell FSAE
As the CFD Specialist of the Cornell FSAE project team, I was involved with two
major subteams. The first, with the aerodynamics subteam, involved maximizing
downforce on the front and rear wings to improve acceleration, steering, and
braking performance. It was my job to parameterize the design of airfoil and
endplate shape, angle of attack, and location.
The second project I took on involved optimizing the design of the intake manifold
for the flow subteam. Because the team was switching to a side-feed intake, my
job was to evenly balance the distribution of air through the four plenums. This
involved programming in C to set up oscillating boundary conditions at the outlet
of the four runners to simulate the engine pressure during peak-RPM.

4. CU OPENLOOP, HYPERLOOP POD COMPETITION
SPRING 2016
0
0.05
0.1
0.15
0.2
0.25
Old Current de Laval
FlowRate[kg/s]
Increased mass flow rate by 73%
through redesign of outlet nozzles. As air
consumption increases linearly,
Monitored mass flux through front/back during 700 MPH operation to
estimate total air consumption given an upstream pressure regulator setting
of 13 kPa with free stream pressure of near-vacuum 1 kPa.
CAD assembly file courtesy
of CU OpenLoop
As a member of Cornell OpenLoop’s suspension subteam, my goal is to model and analyze the
behavior of the air skates suspension system. My work has primarily focused on minimizing air
consumption while maintaining a sufficient clearance distance of 3-4 mm between the skates and
the track. Simulations are performed using CFD in ANSYS Fluent. As part of the pre-machining
design process, I created new nozzle designs based upon literature studies on pre-existing
venture nozzles that ultimately increased thrust at the same upstream operating pressure.

5. CHEMICAL ENGINEERING CAR TEAM
FALL 2013 - SPRING 2015
Designed a hydrogen-safe, 2000
PSI pressure rated manifold
system with a 200 PSI pressure
relief valve to regulate hydrogen
flow into a fuel cell power source.
Fabricated a new chassis using
laser cut acrylic to reduce
lateral drift during operation
down to under 10 inches over
a distance of 100 feet.
Calibrated the fuel cell and
drivetrain system using test data to
for competition, taking into account
temperature, floor friction, and car
weight. Created new calibration
method that improved accuracy of
car performance by over 50%.
CAD files made by:
Yechun Fu
Additional CAD Projects
Battery Car 2012
I helped create the battery box that
held the zinc-air batteries. Won 1st
place at the 2012 Nationals
Competition.
Battery Car 2013-2015
Along with the full CAD assembly, I
worked with the battery subteam to
calibrate and run the car during
competition.
Fuel Cell Car
2013 – 2014
I dedicated the majority of my undergraduate time to the Cornell ChemE Car project team, leading the
entire team as Senior Captain on my last year. During my time in the mechanical subteam I designed
the chassis for a new car and created a new velocity calibration model that significantly improved
results prediction during competition. As senior captain I oversaw the design of all cars powered by
different fuel sources while supervising calibrations and FMEA development across all subteams,
leading the team to place 1st at the 2015 regionals competition with its battery-powered car.

6. CHEMICAL ENGINEERING CAR TEAM
FALL 2013 - SPRING 2015
One of my most important contributions to the team is my work on the compressed air
manifold for the pressure subteam. Because the pressure subteam was still an up and
coming power team without a feasible power source, my job involved working directly
with the subteam leader in creating a bill of materials for the entire manifold system,
ensuring all design and performance specifications are met, and conducting analysis to
prevent leaks and both mechanical and chemical safety hazards.
Machined parts for the
pressure manifold safety
rated to 440 PSI to meet
both safety and
performance specifications.
CAD files made by:
Yechun Fu
Created bill of materials
ensuring all pressure
regulators, gauges, relief
valves, and flow controllers
meet safety and chemical
safety standards.
Designed several chemical
delivery mechanisms for the
reaction between citric acid
and sodium bicarbonate inside
of airtight manifold.
Calculated total power source
runtime given thermochemistry
power source to choose an air
motor/air ratchet with the
required torque and RPM output

7. Designed and machined an alpha-type
Stirling heat engine. A temperature
difference of 300 Kelvin is required to
run the engine continuously with an
estimated thermodynamic efficiency of
13.2%.
Designed o-ring
seals to ensure
airtight fit during
operation.
3D printed parts of crankshaft to
save time and manufacturing
costs.
To satisfy the open-ended design project requirement, I led a team of six in
designing, fabricating, and testing an alpha-type Stirling heat engine. This
required successfully meeting tight constraints in design to ensure no air
leaks or other faults occur as well as maintaining a total material cost of
under $200. Extensive material selection, rapid prototyping, and machining
skills were utilized in order to manufacture a successfully running engine.
MAE 4300 Professional Practice in Mechanical Engineering
FALL 2014
CAD files made by:
Yechun Fu

8. Under the guidance of Professor Roseanna Zia, I played a major role in
developing fluid mechanic apparatuses as laboratory equipment used to
demonstrate principles of fluid behavior. A total of four prototypes were
created to demonstrate hydrostatics, Bernoulli’s principle, viscoelasticity,
and conservation of momentum.
ROSEANNA ZIA DESIGN AND BUILD TEAM
SUMMER 2014 – SUMMER 2015
The Pressure Tower, designed by a
team of three students, is an
experimental equipment that aims to
verify the fundamental equation of
hydrostatics. Boyle’s Law is used to
verify pressure’s linear variation with
depth in a fluid.
The three feet tall tower is
machined to be watertight, but
at the same time be able to
fully disassemble for repair
and maintenance.
The air chamber
lowered into the water is
glass blown using soda-
lime glass.

9. EARLY DESIGN PROJECTS
FIRST Robotics 2009 | Marketing Project 2010
CAD files made by:
Yechun Fu
CAD files made by:
Yechun Fu
Over the course of six weeks, students on FIRST Robotics design, build,
and test a functional robot that completes a challenge given at the
beginning of the six week period. Because the challenges change every
year, my team was constantly adapting each season to new demands.
As the CAD subteam leader, I oversaw the design of the robot during the
first two weeks and managed dimensioning and construction of all
components that needed to be machined and tuned.
This project involved coding a JAVA application for a
hypothetical toy-company and helping customers visualize
what kind of products the company has in stock. The team
worked on both coding the application and marketing while I
was in charge of the visual design of the toy. The complete
CAD is made in Autodesk Inventor, consisting of over 200
part files, with the entire assembly finished in a week.

10. Thank You
for your time
Contact
yf89@cornell.edu
443-535-1258