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
3-2021
Primary Advisor
John Fabijanic, College of Engineering, Mechanical Engineering Department
Abstract/Summary
The Enduro Campers senior project team (Formerly known as Lobo Campers senior project team) was recruited by Mr. Leif Stein to assist in the design, manufacturing, and testing of the materials and components of his company’s expedition box camper. The two main focuses of the project, divided into two sub-teams, were on the testing and manufacturing process of the materials used in the camper, and on the design and analysis of the camper’s access door, step box, and other subsystems.
The focus of the materials analysis and manufacturing team was based around the design parameter to use composite sandwich panels for the majority of the camper structure as set by Mr. Stein. This made the manufacturing and analysis of the camper much more complex than if a homogeneous material such as aluminum was used for the structure’s body. This increase in complexity is because composites are more difficult than homogenous materials to manufacture, test, and analyze. Because of this, the company needed a standardized physical testing procedure as well as an optimized bonding process for the sandwich materials. In order to choose the combination of materials for the sandwich panel construction, the project required a material analysis through physical testing and development of an FEA material model. The program ABAQUS was used to model the sandwich panel and can be applied to future analyses that Mr. Stein will need for larger, specific sections of the camper’s structure under different loading cases.
The sub-component design & analysis team delivered a design for the door and step box of the camper that allows for maximum accessibility while maintaining the camper’s structural integrity while sealing the cabin from the elements. This design is also aesthetically pleasing, as these are the main visible components on the expedition box product. The design derived by our team was based on input from Mr. Stein, as well as the findings from the materials research team through analysis and physical testing. The manufacturing process of the step box was started and plans were handed to Mr. Stein for completion.
This final design report goes over the project’s scope of work, concept design development, final design choices, manufacturing, design verification, project management, and the conclusions and recommendations the team has for Mr. Stein and his developing company. The report also includes recommendations for future analysis that can be helpful to better understanding the sandwich material used in the construction of the camper.
URL: https://digitalcommons.calpoly.edu/mesp/575
Included in
Applied Mechanics Commons, Computer-Aided Engineering and Design Commons, Manufacturing Commons