Designed a fabrication process to improve steel fiber composite sensors using additive manufacturing, vacuum chamber, Scanning Electron Microscope, and planetary mixer that increased the fiber uniformity by >97%.Developed a microscopic image analysis process using MATLAB and assembled an automatic image collector using Arduino, belt-drive motor, and a 3D Printed motor mount that reduced the image collection time by >75%.
Publications/Awards:Uniform Dispersion of Steel Fibers in Silicone Composites via an Externally Applied Magnetic Field - Materials Letters 2022. PublicationOn the Use of Magnetic Fields for Dispersing Steel Fibers in Silicone - ASME Materials 2022First Place at UofT Undergraduate Engineering Research Day 2021!
American Society of Mechanical Engineers SMASIS 2022 Conference
Vaccum Chamber used in the fabrication process
Experimental Setup (3D printed stand and neodymium magnets)
Measuring the Conductivity & Resistivity of the Samples Using a LCR Meter
Obtaining Images from a Fiber Optic Microscope (left) and a Scanning Electron Microscope (right)
Results/Lessons Learned
Successfully designed a 4-axis conceptual milling machine that met all specs, functions, and objectives as judged by the course teaching assistant.
In a system with lots of moving parts, the accuracy of the system is determined by the least reliable mechanism. Therefore, we need to weigh the tradeoffs between reliability, performance, and cost of a mechanism/part in regard to the whole design.
Rack and pinion may reduce the overall accuracy/precision of the system, but ball screws are more prone to buckle under vertical loads.
The ball screw mechanism was chosen over other mechanisms that can translate rotational motion to linear motion, such as a rack and pinion, due to its high accuracy and low backlash. As the ball bearings are contained within the nut, they are self-lubricating, leading to very low friction. Furthermore, as the bearings are enclosed, no debris can interfere with them, making them low maintenance.
Reverse engineering when choosing motors: based on the gear used, we can calculate the torque and required speed, and then check if specs are within the range of stepper motors. If a higher torque is needed, then look at servo motors. A gearbox is not required for any motors that can provide the speed and torque required. A gearbox can be used to reduce/increase speed.
When researching different mechanisms, it is super helpful to watch videos on existing systems.
When working on a group project, it's extremely important to communicate any issues that are preventing progress. Because our team didn't do this on time, it led to many delays in progress and rushed work towards the end.
