1. PORFOLIO KHOA TON Master in Mechanical Engineering San Jose State University Specialize in Mechanical Design/FEA/CFD

2. Project DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL (team member) OPTIMIZATION OF FINESS RATIO OF VLLA AIRSHIP (team leader) WHEEL DESIGN (own project) CAN CRUSHER design (own project) REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN (team leader) FOUR DEGREE OF FREEDOM MECHANISM (team member) Enclosure design for a three-wheel electric scooter (own project in progress)

3. 1. DESIGN APPROACH TO LOW SPEED SUBSONIC WIND TUNNEL

5. 2. OPTIMIZATION OF FINESS RATIO OF AN AIRSHIP Optimize the shape of the airship by varying finesse ratio (L/D) to meet requirement of cabin size and minimum drag. Benchmark theoretical drag against CFD-based drag Airship with the cabin size

6. Topology 3D Meshing Boundary Condition

7. Total Pressure Velocity CFD based Drag Force Theoretical Drag Force

8. 3. WHEEL DESIGN Blade Collection Motor-bike Wheels

9. 4. CAN CRUSHER

10. Von-Mises Stress Max Displacement (0.525 mm) Safety Factor Strain

11. 5. REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN

12. REDESIGN A BREMBO GT BRAKE (380mm x 32mm) FOR A 2002 BMW M5 SPORT SEDAN Objective: Weight reduction by redesign the rotor hat Original rotor hat Cyclic Symmetry Model Optimize rotor hat Displacement (max 0.0077 mm) Von Mises Stress 17.4 MPa

13. Thermal Analysis Rotor Disc Tmax649 F Rotor Hat Tmax605 F

14. 6. FOUR DEGREE OF FREEDOM MECHANISM Feature & Specification Two translational & two rotational degrees of freedom All 4 DOF occurs on the same plate Springs provide preload for displacement in opposite directions 2-2-2 Kinematic Kelvin mount Material is 6061-T6 Aluminum Vacuum compatible material; low out-gassing rate Easy to machine Cheap Mass is ≤ 2 Kg Dimension is 154 mm x 200 mm x 200 mm

16. Position a 50-mm cube having 0.5 Kg mass

17. Provide clearance for a Ø10-mm light beam propagating from one surface of the 50-mm cube to beyond the 4 DOF mechanism

18. Angular Range ≥ 20 mrad

19. Translational Range ≥ 4 mm

20. Resolution ≤ 5 μrad, ≤ 2 μm

21. Accuracy (Repeatability) ≤ 10 μrad, ≤ 10 μm

22. Pointing Stability over entire Operating Temp Range ≤ 12 μrad, ≤ 15 μm

23. Fundamental Frequency ≥ 50 Hz

24. Dimensions (to be minimized) ≤ 200 mm x 200 mm x 200 mm

25. Mass (to be minimized) ≤ 5 Kg

26. Detachable and replaceable to ≤ 10 μm & ≤ 100 μrad

27. Survive 10 ºC < T < 30 ºC; Operate in 18 ºC < T < 22 ºC

28. Mounting Surface Steel

29. Vacuum compatible

30. 38 mrad

31. 4.2 mm

32. Yes

33. Yes

34. 13 μm, negligible

35. 51 Hz

36. 154x200x200

37. 2 kg

38. Yes

39. Yes

40. Yes

42. Inner joints = 06 mmY X X -displacement Y -displacement 12/2010

43. 12/2010 Optimization conflicts to frequency test Inner leaf flexure Outer leaf flexure

44. 12/2010 Stress Analysis (Translation Displacement) Result: F=15 N X disp = 2.4 mm Stress= 118.3 Mpa F=15 N Y disp = 2.3 mm Stress= 126.9 Mpa Y X X -displacement Y-displacement

45. 12/2010 Stress Analysis (Angular Displacement) Pitch: F= 30 N Stress= 73.2 MPa X=0.0107 rad MOS= 0.734 Y X Pitch Yaw: F= 40 N Stress= 92.9 Mpa Y= 0.01005 rad MOS= 0.6622 Yaw

46. 7. Enclosure design for a three-wheel electric scooter TRIKE III AFTER BEFORE Concept Design 09/2010

47. 3D Design Enclosure 09/2010

48. Result Pressure Distribution Velocity Distribution 09/2010

49. Structural Evaluation of The Enclosure Displacement Distribution Max disp = 0.45 mm Von-Mises Stress Distribution Max Stress = 0.9 Mpa (vs Yield = 55 Mpa) 09/2010