Industry Experience

The glowing burner running in vacuum with thermocouples installed. The thin sheet of nanophotonic material (not shown) would be brazed around burner tube.

Small section of Python methods used to account for heat-transfer from fins brazed inside the burner.

Custom Python Thermofluids Simulation at Mesodyne

  • Problem and Background

    • Mesodyne is in the R&D phase of a new thermophotovoltaic (TPV) which takes energy from combustion to heat a nanophotonic material

    • The thermal radiation from the nanophotonic material is captured with a photovoltaic cell

    • To make a successful TPV, the heat needs to be distributed efficiently and evenly across the photonic crystal

  • Solution

    • I wrote an object-oriented custom simulation code to converge a temperature distribution out of many input parameters

    • Combined the discretization and time stepping methods that I used in CFD research with heat transfer equations

    • Used the Cantera python package to calculate chemical equilibriums in the high temperature flue gas

  • Results

    • Simulation is able to run parameter sweeps to see how changing combustor parameters effects power output of the device

    • The code will help inform design decisions and estimate performance without the need for as many time consuming and expensive experiments

    • Validated with experimental results

The new PW1000G gear turbofan engine

Process flow map in order: Template folder, NX model prep, Excel calculators, Ansys Thermal FEA model, and Ansys Structural FEA model

Induction Assembly Analysis at Pratt and Whitney

  • Problem and Background

    • Many steps in jet engine manufacturing use a "snap" interference fit between parts

    • The inside of one part must be heated to expand it so that it can be mated to the outside of another part

    • The main way that heat is delivered to target areas is with induction coils

    • How the coil's power level is controlled over the process, called the "recipe," was made with trial and error and took longer than needed to run

  • Solution

    • I decided that instead of simply using guess and check I could use Ansys analysis to make the recipe run faster

    • Defined a new process for Ansys thermal and structural FEA for induction heating assembly steps

  • Results

    • Minimized process time while ensuring that the parts expanded sufficiently for assembly but had no structural damage

    • Made complicated process accessible with:

      • Template files

      • Built in excel calculators

      • Step-by-step documentation

    • Process under review to be added to Standard Work documentation

    • New coil designs set to cut up to a half hour off of process times in two lines once funding becomes available

Scoop and fold motion (shown in upper left) is made using a slotted bearing and lever arm

Tab Lock Washer Bending Tool Design at PW

  • Problem and Background

    • Tab lock washers are used inside the engine on bolts to prevent back out

    • Tabs are folded to contact the sides of the bolt

    • In this build, they are located in a very hard to reach location

    • Before my tool, mechanics used a pair of shaved down channel locks (it is so tight that they need to be shaved to fit)

    • Mechanics were frequently slipping and hurting their hands for a process time of about 45 minutes to get all of the tabs bent

  • Solution

    • Work with mechanics to design an improved tool

    • It would offer superior mechanical advantage and scoop+fold the tab in one motion

    • Took many 3D printed rapid prototypes to perfect the design

  • Results

    • Cut process time by ~60%

    • Ergonomic design prevented the hand injuries common to the old process

    • Patent application is being processed

    • Final tool to be made out of hardened steel

Current Argo model attached to a bicycle

Close up of CAD work in Fusion 360

Freelance Design For Argo Bikes

  • My work

    • Creating parts and assemblies for new product release from Argo Bikes

    • Two patents in the filing process for new designs and configurations

    • Files will be sent to Taiwan or China for production and assembly

    • Currently working on suspension and kickstand components

    • Unfortunately, most of the details and images need to be kept proprietary

  • Current Product