College - Author 1

College of Engineering

Department - Author 1

Mechanical Engineering Department

Degree Name - Author 1

BS in Mechanical Engineering

College - Author 2

College of Engineering

Department - Author 2

Mechanical Engineering Department

Degree - Author 2

BS in Mechanical Engineering

College - Author 3

College of Engineering

Department - Author 3

Mechanical Engineering Department

Degree - Author 3

BS in Mechanical Engineering

College - Author 4

College of Engineering

Department - Author 4

Mechanical Engineering Department

Degree - Author 4

BS in Mechanical Engineering

Date

6-2020

Primary Advisor

Peter Schuster, College of Engineering, Mechanical Engineering Department

Additional Advisors

Xuan Wang, College of Engineering, Industrial and Manufacturing Engineering Department

Abstract/Summary

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team redesigned is a bracket arm, which the team optimized for weight and manufacturability. The team improved the bracket both by completely removing portions of excess mass and by incorporating internal lattice structures into the part. After completing the bracket part redesign, the team further developed their AM design process through working on the second part—a thin-walled splash plate located in the combustion chamber which the team is using to study deflection in AM. The splash plate is currently in the critical design stage and ready for testing and validation. The team has run computer simulations modeling the part deflection and has successfully printed two copies of the part for quantitative comparison with the simulation. This document will provide further details as to the team’s research, design concepts, and conclusions from both the bracket and splash plate redesigns.

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