Yechun portfolio
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This document is Yechun Fu's engineering portfolio summarizing his work experience and projects. It describes his master's degree from Cornell University and internship at W.L. Gore where he conducted CFD and FEA analysis on projects in automotive, filtration, and pharmaceutical industries. It also outlines his involvement in various engineering teams and competitions at Cornell, including roles in aerodynamics, intake manifold design, suspension modeling, apparatus design, and leadership of the chemical engineering car team.
![CU OPENLOOP, HYPERLOOP POD COMPETITION
SPRING 2016
0
0.05
0.1
0.15
0.2
0.25
Old Current de Laval
FlowRate[kg/s]
Increased mass flow rate by 73%
through redesign of outlet nozzles. As air
consumption increases linearly,
Monitored mass flux through front/back during 700 MPH operation to
estimate total air consumption given an upstream pressure regulator setting
of 13 kPa with free stream pressure of near-vacuum 1 kPa.
CAD assembly file courtesy
of CU OpenLoop
As a member of Cornell OpenLoop’s suspension subteam, my goal is to model and analyze the
behavior of the air skates suspension system. My work has primarily focused on minimizing air
consumption while maintaining a sufficient clearance distance of 3-4 mm between the skates and
the track. Simulations are performed using CFD in ANSYS Fluent. As part of the pre-machining
design process, I created new nozzle designs based upon literature studies on pre-existing
venture nozzles that ultimately increased thrust at the same upstream operating pressure.](https://image.slidesharecdn.com/yechunportfolio-160419061037/85/Yechun-portfolio-4-320.jpg)
Yechun portfolio
- 1. Engineering Portfolio Yechun Fu Cornell University Master of Engineering May 2016
- 2. W.L. GORE & ASSOCIATES, INC. JUNE 2016 – PRESENT W.L. Gore & Associates is a manufacturing company specializing in products derived from fluoropolymers. The company’s product line spans multiple industries, including fabrics, filtration, and pharmaceutical devices. As a modeling and simulation intern at Gore, I conducted CFD/FEA analysis on three different projects in three industries: 1. Automotive Venting in Headlamps 2. Turbine filtration with porous media 3. Microstructure Membranes Automotive Headlamp Turbine Filtration 1 2 Microstructure Modeling3 Created conjugate heat transfer simulations in ANSYS CFX to model heat sinks, heat sources, bulb type, and fans. Simulates various operating conditions (car idling, car driving on highway, car parked outside, etc). Physics capabilities developed include natural/forced convection, heat conduction, moisture transport, relative humidity tracking, and mass transfer through porous media. Simulated numerous case studies for the V- panel turbine filters. Responsibilities include working with design engineers to minimize high velocity regions, evenly distribute airflow across porous area, and compare efficiency results with wind tunnel experiments. CFD studies include researching laminar- turbulence transition zones, conducting mesh refinement studies up to 30-40 million elements, and implementing user functions for automation. Modeled virtual microstructure membrane geometries to research material behavior. Obtained new material information on tortuosity, porosity, and permeability values from CFD results and particle injection studies, using Python to post-process millions of lines of data. Conducted FEA studies using ANSYS mechanical to determine the dependence of membrane flow properties on compression. Created 2-way coupled fluid-structure interaction (FSI) simulations to develop the capability to research permeability and structural compression correlations. From www.gore.com From www.gore.com From www.gore.com Note: CAD models & simulation results are not shown to protect the IP of W.L. Gore.
- 3. CORNELL FORMULA SAE FALL 2015 – SPRING 2016 Analyzed stability of front wing stability and variation of lift during operation to prevent wake traction loss during operation. Increased lift coefficient rear wing by 11% by modifying endplate design and airfoil gap sizing through CFD parameterization. Defeatured Geometry Mesh Generation Predicted side-feed intake manifold performance to ensure equal distribution of air into engine while varying inlet diameter and bellmouth location Full Car Body Simulation CAD assembly file courtesy of Cornell FSAE As the CFD Specialist of the Cornell FSAE project team, I was involved with two major subteams. The first, with the aerodynamics subteam, involved maximizing downforce on the front and rear wings to improve acceleration, steering, and braking performance. It was my job to parameterize the design of airfoil and endplate shape, angle of attack, and location. The second project I took on involved optimizing the design of the intake manifold for the flow subteam. Because the team was switching to a side-feed intake, my job was to evenly balance the distribution of air through the four plenums. This involved programming in C to set up oscillating boundary conditions at the outlet of the four runners to simulate the engine pressure during peak-RPM.
- 4. CU OPENLOOP, HYPERLOOP POD COMPETITION SPRING 2016 0 0.05 0.1 0.15 0.2 0.25 Old Current de Laval FlowRate[kg/s] Increased mass flow rate by 73% through redesign of outlet nozzles. As air consumption increases linearly, Monitored mass flux through front/back during 700 MPH operation to estimate total air consumption given an upstream pressure regulator setting of 13 kPa with free stream pressure of near-vacuum 1 kPa. CAD assembly file courtesy of CU OpenLoop As a member of Cornell OpenLoop’s suspension subteam, my goal is to model and analyze the behavior of the air skates suspension system. My work has primarily focused on minimizing air consumption while maintaining a sufficient clearance distance of 3-4 mm between the skates and the track. Simulations are performed using CFD in ANSYS Fluent. As part of the pre-machining design process, I created new nozzle designs based upon literature studies on pre-existing venture nozzles that ultimately increased thrust at the same upstream operating pressure.
- 5. CHEMICAL ENGINEERING CAR TEAM FALL 2013 - SPRING 2015 Designed a hydrogen-safe, 2000 PSI pressure rated manifold system with a 200 PSI pressure relief valve to regulate hydrogen flow into a fuel cell power source. Fabricated a new chassis using laser cut acrylic to reduce lateral drift during operation down to under 10 inches over a distance of 100 feet. Calibrated the fuel cell and drivetrain system using test data to for competition, taking into account temperature, floor friction, and car weight. Created new calibration method that improved accuracy of car performance by over 50%. CAD files made by: Yechun Fu Additional CAD Projects Battery Car 2012 I helped create the battery box that held the zinc-air batteries. Won 1st place at the 2012 Nationals Competition. Battery Car 2013-2015 Along with the full CAD assembly, I worked with the battery subteam to calibrate and run the car during competition. Fuel Cell Car 2013 – 2014 I dedicated the majority of my undergraduate time to the Cornell ChemE Car project team, leading the entire team as Senior Captain on my last year. During my time in the mechanical subteam I designed the chassis for a new car and created a new velocity calibration model that significantly improved results prediction during competition. As senior captain I oversaw the design of all cars powered by different fuel sources while supervising calibrations and FMEA development across all subteams, leading the team to place 1st at the 2015 regionals competition with its battery-powered car.
- 6. CHEMICAL ENGINEERING CAR TEAM FALL 2013 - SPRING 2015 One of my most important contributions to the team is my work on the compressed air manifold for the pressure subteam. Because the pressure subteam was still an up and coming power team without a feasible power source, my job involved working directly with the subteam leader in creating a bill of materials for the entire manifold system, ensuring all design and performance specifications are met, and conducting analysis to prevent leaks and both mechanical and chemical safety hazards. Machined parts for the pressure manifold safety rated to 440 PSI to meet both safety and performance specifications. CAD files made by: Yechun Fu Created bill of materials ensuring all pressure regulators, gauges, relief valves, and flow controllers meet safety and chemical safety standards. Designed several chemical delivery mechanisms for the reaction between citric acid and sodium bicarbonate inside of airtight manifold. Calculated total power source runtime given thermochemistry power source to choose an air motor/air ratchet with the required torque and RPM output
- 7. Designed and machined an alpha-type Stirling heat engine. A temperature difference of 300 Kelvin is required to run the engine continuously with an estimated thermodynamic efficiency of 13.2%. Designed o-ring seals to ensure airtight fit during operation. 3D printed parts of crankshaft to save time and manufacturing costs. To satisfy the open-ended design project requirement, I led a team of six in designing, fabricating, and testing an alpha-type Stirling heat engine. This required successfully meeting tight constraints in design to ensure no air leaks or other faults occur as well as maintaining a total material cost of under $200. Extensive material selection, rapid prototyping, and machining skills were utilized in order to manufacture a successfully running engine. MAE 4300 Professional Practice in Mechanical Engineering FALL 2014 CAD files made by: Yechun Fu
- 8. Under the guidance of Professor Roseanna Zia, I played a major role in developing fluid mechanic apparatuses as laboratory equipment used to demonstrate principles of fluid behavior. A total of four prototypes were created to demonstrate hydrostatics, Bernoulli’s principle, viscoelasticity, and conservation of momentum. ROSEANNA ZIA DESIGN AND BUILD TEAM SUMMER 2014 – SUMMER 2015 The Pressure Tower, designed by a team of three students, is an experimental equipment that aims to verify the fundamental equation of hydrostatics. Boyle’s Law is used to verify pressure’s linear variation with depth in a fluid. The three feet tall tower is machined to be watertight, but at the same time be able to fully disassemble for repair and maintenance. The air chamber lowered into the water is glass blown using soda- lime glass.
- 9. EARLY DESIGN PROJECTS FIRST Robotics 2009 | Marketing Project 2010 CAD files made by: Yechun Fu CAD files made by: Yechun Fu Over the course of six weeks, students on FIRST Robotics design, build, and test a functional robot that completes a challenge given at the beginning of the six week period. Because the challenges change every year, my team was constantly adapting each season to new demands. As the CAD subteam leader, I oversaw the design of the robot during the first two weeks and managed dimensioning and construction of all components that needed to be machined and tuned. This project involved coding a JAVA application for a hypothetical toy-company and helping customers visualize what kind of products the company has in stock. The team worked on both coding the application and marketing while I was in charge of the visual design of the toy. The complete CAD is made in Autodesk Inventor, consisting of over 200 part files, with the entire assembly finished in a week.
- 10. Thank You for your time Contact yf89@cornell.edu 443-535-1258