ME 107B, Spring 2008

ME 107B,
Mechanical Engineering Laboratory

Spring 2008

Prerequisite: ME 107A

First lab. orientation class, Friday, February 1, check lab section for location and time (both sections should be at the same time and place)

Sec 1 Mon 1-5 and Fri 1-3
Sec 2 Wed 1-5 and Fri 1-3

Course Coordinator

Professor Jyh-Yuan Chen
email: jychen@me.berkeley.edu
6163 Etcheverry Hall, 642-3286
Office Hours: WF 10:30-12:00

SAFETY - READ THIS FIRST AND SIGN THE FORM AND GIVE TO THE INSTRUCTOR OF YOUR FIRST LABORATORY

NOTE ABOUT SAFETY GLASSES: Most of the experiments require you to wear safety glasses, which you will have to supply yourself and bring to class. Safety glasses cost about $5+ and can be obtained - while supplies last - from the Student Machine Shop, Student Union, and local hardware stores. You cannot attend the experiments without your safety glasses.

NOTE ABOUT REGISTRATION: In order to register for this course, you first have to ensure that you are on the correct waitlist (Section 1 or Section 2). If you need to change your section, drop your current section via Telebears and add the new section. Add the appropriate section via Telebears if you never made the waitlist. This should be done immediately. If you are on the correct wait list, you don't have to do anything. All students will be automatically registered for the course.

Experiments

ME 107b Experiment Offerings For Spring 2008 (subject to change)

1)
MF&WF

SERVO CONTROL TUNING: Edgar Ergueta eergueta@newton.berkeley.edu
Lab: 2170 Etch (MF and WF)
In this lab, students tune the gains of a Proportional-Integral-Derivative (PID) controller for a drive position servo system to achieve a satisfactory step
response. They will establish the concept of feedback and understand the advantages of feedback controls. They will learn the criteria to evaluate the step responses of a mechanical servo system. They willalso tune the gains of a PID controller, which is widely used, to achieve a good step response. The system performances are evaluated by the criteria introduced in the lab and through MATLAB simulations and a real mechanical system. After this experiment, students will have a clear qualitative sense of the effect of each action (P, I, or D) in the PID controller on the system step responses.

First orientation class: Friday 1 p.m., 2170 Etcheverry

2)
MF&WF

SHOCK ABSORBER DYNAMOMETER Gregory Chin
gchin@berkeley.edu
Lab: 49 Hesse (MF and WF)
The objective of this experiment is to evaluate the behavior of a gas-filled shock absorber. In order to characterize the behavior of the shock absorber, data will be obtained using a custom fabricated dynamometer and Pentium based PC. A baseline set of data will be collected first, and then additional sets of data will be collected after changing one parameter at a time. The parameters available to be modified are: flexible shim stack/valve arrangement, oils of different viscosities, externally adjusted compression and rebound dampening valves, pressure of gas charge within the shock, temperature of shock, the rotational speed of the faceplate, and the amplitude of the shock stroke.

First orientation class: Friday 1 p.m., 3110 Etcheverry

3)
MF&WF

REFRIGERATION PERFORMANCE Li-Chun Chien
lcchien@me.berkeley.edu
Lab: 70 Hesse (MF and WF)
A vapor compression cycle is to be used for a refrigeration system. The system elements are a compressor, expansion valve, condenser and evaporator. The expansion valve is controllable, as is the flow rate of coolant through the condenser, and the flow rate of a cooled liquid. A pre-cooling circuit also exists in order to study its possible effects on compression efficiency. The experiment involves the determination of the system performance by evaluating data taken at different operating conditions.

First orientation class: Friday 1 p.m., 6101 Etcheverry

4)
MF&WF

WIND TUNNEL Elias Patten
epatten@gmail.com
Lab: 50 Hesse (MF and WF)
Although computational fluid dynamics (CFD) has replaced much of the wind tunnel testing necessary for product development and research, uncertainties and limitations of CFD mean that wind tunnels will continue to play an important role. In this lab students will characterize a small, low-speed wind tunnel (65 mph in the 10"x12" test section), compare the results for basic shapes with those found in literature, and evaluate the performance of new and existing airfoils. This lab will combine aspects from multiple fields, including fluid dynamics, aerodynamics, instrumentation, statistics, statics, and mechanics of materials. Students will have the opportunity to strengthen their understanding of many engineering principles through application while developing critical technical writing and presentation skills.

First orientation class: Friday 2 p.m., 6153 Etcheverry

5)
MF&WF

CMP EXPERIMENT Joshua Chien
jmchien@berkeley.edu
Lab: 1176B Etcheverry
Chemical Mechanical Planarization(CMP) is a technique used to planarize the surface of deposited layers on a wafer in IC and MEMS manufacturing processes. In this lab, students will polish test wafers with a bench top CMP machine, measure material removal rate, and investigate the validity of a basic theory (Preston's Equation) for material removal rate. An overview of IC and MEMS processes will be also given at the beginning of the class to help students understand the greater role of CMP.

First orientation class: Friday, 2 p.m., 1115 Etcheverry

6)
MF & WF

INTERNAL COMBUSTION ENGINE Vi Rapp vhrapp@berkeley.edu
Lab:43 Hesse
The objective of this laboratory is to determine performance and air pollution characteristics of a spark ignition engine. The power, torque, efficiency and hydrocarbon emissions will be determined over a wide range of operating conditions. Engine losses are to be assessed on the basis of an energy balance. Performance characteristics of a vehicle powered by this engine are to be determined.

First orientation class: Friday, 1 p.m., 74 Hesse

7)
WF only

Car Roll: An Exercise in Building Numerical Models
Bryan Edward
bryan.boyce@berkeley.edu
Lab: 50 Hesse
A review of basic concept of how and when to build models of a process. Should the model be analytic or numerical and what is the difference? What experiments should be done given the usual constraints of budget and of time (redundant?). In this lab, you build an analytic and numerical model of a small car that rolls down a track. The model includes bearing friction, air drag, and gravity, as well as a variable mass of the roll car. For your final grade, you use your model, developed from theory and experimentation, to predict how your roll car will perform; and then we test your prediction. Better models make predictions and thus get better grades.

First orientation class: Friday 2 p.m., 74 Hesse

8)

Rocket Science: Deeper Understanding of Water Rocket
Adrien Poulizac
a.poulizac@berkeley.edu
Lab: 70A-1 Hesse
In this lab, we build a numerical model of the toy water rocket. Experiments are then performed to define terms in the numerical model. The numerical model is then used for predictions that are tested by experiment. For example, give a toy water rocket, what is the optimal amount of water (% volume) for maximum height of rocket? Clearly zero percent water is too little (rocket is all compressed air) and 100% water is too much water (no room for compressed air). Your numerical model of the water rocket will guide to the optimum amount of water.

First orientation class: Friday 2 p.m., 5108 Etcheverry

9)

Valve and Cam Dynamics
Dusan Coso
d_coso@berkeley.edu
Lab: 40 Hesse
Students will have the opportunity to evaluate the dynamic performance of an overhead camshaft valve train. They will design, fabricate and experimentally test modifications to the valve train in order to increase its performance. A modified late model overhead cam engine fitted with force transducers will be used for this investigation. Students should be prepared to apply a broad range of skills to this experiment including sound experimental techniques, dynamic modeling, innovative thinking, mechanical fabrication skills and team values.

First orientation class: Friday 1 p.m., 5108 Etcheverry

10)

Machining and Surface Metrology Laboratory
Chris Yuan
chrisyuan@berkeley.edu
Lab: 1172 Etcheverry
The purpose of this experiment is to develop a relationship between the machining parameters for a turning operation of a cylindrical surface and the surface roughness generated. An oscillating stylus-type precision surface profilometer will be used to measure the surface profile of the machined surfaces produced under varying machining conditions with different radii tools. From the surface profile data, parameters characterizing the surface roughness will be calculated and the relationship determined. Students will calibrate the instrumentation for surface measurement, machine the specimens, make measurements of the profile using a PC-based data acquisition system interfaced with the profilometer, analyze the data using standard software as well as some they will write and develop the relationship.

First orientation class: Friday 1 p.m., 1115 Etcheverry

11)

Canister Combustor
J. Y. Chen
jychen@me.berkeley.edu
Lab: 34 Hesse
The thermodynamics of a combustion process are considered in terms of measuring the operating characteristics of a "can" type combustor typical of gas turbine practice. The combustion process involves an exothermic chemical reaction which yields high temperature products. Instrumentation is provided for the measurement of flow rates, temperatures, and the CO and NOX (pollutant) content of the exhaust gas. Data are collected which allows the following parameters to be evaluated in terms of the equivalence ratio: product temperature, heat loss, combustion efficiency, and CO and NOx emissions.

First orientation class: Friday 1 p.m., 6153 Etcheverry

12)

Material Testing
David Lettier
dlettier@berkeley.edu
Lab: 70 Hesse
The main objective of this lab is to introduce the concepts of tensile strength (stress & strain) testing for design limitations of various metals, polymers and composites; along with design applications and modifications from an engineering approach. With the Instron 5583 tensile testing apparatus, students will conduct an investigation into the material and mechanical properties of 6061-T6 aluminum, acrylic (PMMA), polycarbonate (PC), and a number of carbon fiber and Kevlar composite structures. The effects of strain rate, temperature gradients, heating and cooling cycles and stress raisers will be determined for each sample. Material will be categorized according to deformation modes and fracture modes. A method for predicting Young's Modulus for a composite material will be developed for quantifying the results.

First orientation class: Friday 2 p.m., 6101 Etcheverry

Class Details...

Course Outline and Schedule: Monday Friday Sec. 1

Course Outline and Schedule: Wednesday Friday Sec 2

Course Instructions

Lab Assignment: Monday Friday Sec. 1

Lab Assignment: Wednesday Friday Sec. 2

1) MF&WF	SERVO CONTROL TUNING: Edgar Ergueta eergueta@newton.berkeley.edu Lab: 2170 Etch (MF and WF) In this lab, students tune the gains of a Proportional-Integral-Derivative (PID) controller for a drive position servo system to achieve a satisfactory step response. They will establish the concept of feedback and understand the advantages of feedback controls. They will learn the criteria to evaluate the step responses of a mechanical servo system. They willalso tune the gains of a PID controller, which is widely used, to achieve a good step response. The system performances are evaluated by the criteria introduced in the lab and through MATLAB simulations and a real mechanical system. After this experiment, students will have a clear qualitative sense of the effect of each action (P, I, or D) in the PID controller on the system step responses. First orientation class: Friday 1 p.m., 2170 Etcheverry
2) MF&WF	SHOCK ABSORBER DYNAMOMETER Gregory Chin gchin@berkeley.edu Lab: 49 Hesse (MF and WF) The objective of this experiment is to evaluate the behavior of a gas-filled shock absorber. In order to characterize the behavior of the shock absorber, data will be obtained using a custom fabricated dynamometer and Pentium based PC. A baseline set of data will be collected first, and then additional sets of data will be collected after changing one parameter at a time. The parameters available to be modified are: flexible shim stack/valve arrangement, oils of different viscosities, externally adjusted compression and rebound dampening valves, pressure of gas charge within the shock, temperature of shock, the rotational speed of the faceplate, and the amplitude of the shock stroke. First orientation class: Friday 1 p.m., 3110 Etcheverry
3) MF&WF	REFRIGERATION PERFORMANCE Li-Chun Chien lcchien@me.berkeley.edu Lab: 70 Hesse (MF and WF) A vapor compression cycle is to be used for a refrigeration system. The system elements are a compressor, expansion valve, condenser and evaporator. The expansion valve is controllable, as is the flow rate of coolant through the condenser, and the flow rate of a cooled liquid. A pre-cooling circuit also exists in order to study its possible effects on compression efficiency. The experiment involves the determination of the system performance by evaluating data taken at different operating conditions. First orientation class: Friday 1 p.m., 6101 Etcheverry
4) MF&WF	WIND TUNNEL Elias Patten epatten@gmail.com Lab: 50 Hesse (MF and WF) Although computational fluid dynamics (CFD) has replaced much of the wind tunnel testing necessary for product development and research, uncertainties and limitations of CFD mean that wind tunnels will continue to play an important role. In this lab students will characterize a small, low-speed wind tunnel (65 mph in the 10"x12" test section), compare the results for basic shapes with those found in literature, and evaluate the performance of new and existing airfoils. This lab will combine aspects from multiple fields, including fluid dynamics, aerodynamics, instrumentation, statistics, statics, and mechanics of materials. Students will have the opportunity to strengthen their understanding of many engineering principles through application while developing critical technical writing and presentation skills. First orientation class: Friday 2 p.m., 6153 Etcheverry
5) MF&WF	CMP EXPERIMENT Joshua Chien jmchien@berkeley.edu Lab: 1176B Etcheverry Chemical Mechanical Planarization(CMP) is a technique used to planarize the surface of deposited layers on a wafer in IC and MEMS manufacturing processes. In this lab, students will polish test wafers with a bench top CMP machine, measure material removal rate, and investigate the validity of a basic theory (Preston's Equation) for material removal rate. An overview of IC and MEMS processes will be also given at the beginning of the class to help students understand the greater role of CMP. First orientation class: Friday, 2 p.m., 1115 Etcheverry
6) MF & WF	INTERNAL COMBUSTION ENGINE Vi Rapp vhrapp@berkeley.edu Lab:43 Hesse The objective of this laboratory is to determine performance and air pollution characteristics of a spark ignition engine. The power, torque, efficiency and hydrocarbon emissions will be determined over a wide range of operating conditions. Engine losses are to be assessed on the basis of an energy balance. Performance characteristics of a vehicle powered by this engine are to be determined. First orientation class: Friday, 1 p.m., 74 Hesse
7) WF only	Car Roll: An Exercise in Building Numerical Models Bryan Edward bryan.boyce@berkeley.edu Lab: 50 Hesse A review of basic concept of how and when to build models of a process. Should the model be analytic or numerical and what is the difference? What experiments should be done given the usual constraints of budget and of time (redundant?). In this lab, you build an analytic and numerical model of a small car that rolls down a track. The model includes bearing friction, air drag, and gravity, as well as a variable mass of the roll car. For your final grade, you use your model, developed from theory and experimentation, to predict how your roll car will perform; and then we test your prediction. Better models make predictions and thus get better grades. First orientation class: Friday 2 p.m., 74 Hesse
8)	Rocket Science: Deeper Understanding of Water Rocket Adrien Poulizac a.poulizac@berkeley.edu Lab: 70A-1 Hesse In this lab, we build a numerical model of the toy water rocket. Experiments are then performed to define terms in the numerical model. The numerical model is then used for predictions that are tested by experiment. For example, give a toy water rocket, what is the optimal amount of water (% volume) for maximum height of rocket? Clearly zero percent water is too little (rocket is all compressed air) and 100% water is too much water (no room for compressed air). Your numerical model of the water rocket will guide to the optimum amount of water. First orientation class: Friday 2 p.m., 5108 Etcheverry
9)	Valve and Cam Dynamics Dusan Coso d_coso@berkeley.edu Lab: 40 Hesse Students will have the opportunity to evaluate the dynamic performance of an overhead camshaft valve train. They will design, fabricate and experimentally test modifications to the valve train in order to increase its performance. A modified late model overhead cam engine fitted with force transducers will be used for this investigation. Students should be prepared to apply a broad range of skills to this experiment including sound experimental techniques, dynamic modeling, innovative thinking, mechanical fabrication skills and team values. First orientation class: Friday 1 p.m., 5108 Etcheverry
10)	Machining and Surface Metrology Laboratory Chris Yuan chrisyuan@berkeley.edu Lab: 1172 Etcheverry The purpose of this experiment is to develop a relationship between the machining parameters for a turning operation of a cylindrical surface and the surface roughness generated. An oscillating stylus-type precision surface profilometer will be used to measure the surface profile of the machined surfaces produced under varying machining conditions with different radii tools. From the surface profile data, parameters characterizing the surface roughness will be calculated and the relationship determined. Students will calibrate the instrumentation for surface measurement, machine the specimens, make measurements of the profile using a PC-based data acquisition system interfaced with the profilometer, analyze the data using standard software as well as some they will write and develop the relationship. First orientation class: Friday 1 p.m., 1115 Etcheverry
11)	Canister Combustor J. Y. Chen jychen@me.berkeley.edu Lab: 34 Hesse The thermodynamics of a combustion process are considered in terms of measuring the operating characteristics of a "can" type combustor typical of gas turbine practice. The combustion process involves an exothermic chemical reaction which yields high temperature products. Instrumentation is provided for the measurement of flow rates, temperatures, and the CO and NOX (pollutant) content of the exhaust gas. Data are collected which allows the following parameters to be evaluated in terms of the equivalence ratio: product temperature, heat loss, combustion efficiency, and CO and NOx emissions. First orientation class: Friday 1 p.m., 6153 Etcheverry
12)	Material Testing David Lettier dlettier@berkeley.edu Lab: 70 Hesse The main objective of this lab is to introduce the concepts of tensile strength (stress & strain) testing for design limitations of various metals, polymers and composites; along with design applications and modifications from an engineering approach. With the Instron 5583 tensile testing apparatus, students will conduct an investigation into the material and mechanical properties of 6061-T6 aluminum, acrylic (PMMA), polycarbonate (PC), and a number of carbon fiber and Kevlar composite structures. The effects of strain rate, temperature gradients, heating and cooling cycles and stress raisers will be determined for each sample. Material will be categorized according to deformation modes and fracture modes. A method for predicting Young's Modulus for a composite material will be developed for quantifying the results. First orientation class: Friday 2 p.m., 6101 Etcheverry