For my junior year design project, I was paired with two random peers and tasked with developing an easily removable pump support structure that could handle a specific load and stay within the boundaries of allowable deflection. Over the course of the semester, the team had to validate the feasibility of our design through detailed mechanical analysis and documentation and by presenting a functional prototype to upper-level management for evaluation.

The team approached this problem by deriving an analytical solution to the problem. After calculating the fluid and mechanical power requirements, the team conducted a force and moment analysis using symbolic equilibrium equations. The resulting loads on each component were then used to generate shear and bending moment diagrams.

Next, the team identified the different stresses acting on each individual component of the design (platform, arms, pins). The team made sure to account for stress concentration factors when trying to identify critical stress locations. Further analysis was performed to determine expressions for factors of safety, critical buckling load, and maximum deflection. The team created a set of initial dimensions and then plugged these values into the expressions to obtain estimates. The team used ANSYS Granta EduPack to select an optimum material that satisfied the mechanical and operational criteria. The team ordered physical parts after iterating on the initial set of dimensions until all requirements were thoroughly satisfied.

The team created drawings for all designed and off-the-shelf components in Solidworks. An assembly was also produced to show how all the parts connect. Careful attention was applied to ensure that all parts were fully dimensioned and that an accurate bill of materials was produced.

Using the assembly created in Solidworks, the team ran simulations to perform finite element analysis. The team was able to determine the location of maximum stresses and deflections in each of the individual components of the design. Convergence plots and tabulated values were compared to the results derived from hand-written expressions.

After a few sessions of cutting and milling metal stock in the machine shop, the team assembled the physical prototype to be tested for the upper-level executives. The design was able to withstand the maximum loading and stayed well within the acceptable range of deflection.

To view the full report on the project, click here: Pump Support Report.