Internship
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Structural Analysis & Advanced Design of Tesla Vehicles Components
Problem: Analysis of metal stamping structural design of Tesla components for sheet metal formability and weakened regions to further improve the original design
Solution: Collaborated with a senior mechanical engineer to evaluate different approaches to surface design on Tesla vehicle components to ensure the rigidity and flow of metal, improve the overall performance of the components, and simplify the manufacturing process.
Testing: Forming software is used to analyze the formability and flow of metal before testing with Gigapress to verify its formability. Then, FEA Analysis software is used to ensure the structural rigidity of all components used to form the vehicle parts, and the results of the tryout are recorded to determine further improvements.
Notice: The images displayed on this site are used exclusively for visualization. I am committed to upholding intellectual property rights, ensuring these images do not expose any proprietary information.
Forging Load Calculation
Problem: High frequency of wrong estimation on initial forging load causing engineers and technicians to go through multiple trials
Solution: I implemented the Slab Analysis Method into a MATLAB code to estimate the initial forging load required for Closed-Die Forging, prior to using DEFORM Simulation.
Testing: To verify the calculation, I used Digital Wavelength Infrared Pyrometry to ensure the temperature was accurate and aligned with the Strength Coefficient of aluminum under the specified conditions. After that, I carefully and correctly coated the surface of the metal to allow the smooth flow of plastic metal. Then, I compared the testing load derived from the calculation with the previously proven correct testing load for validation.
Metal 3D-Print CNC Insert Holder
Problem: The large Titanium/Inconel CNC machine often crashes its tools into the part or fixtures, damaging the metal holder and incurring a replacement cost of roughly $500-750.
Solution: A junior engineer at PCC came up with the idea of using Metal 3D Printing for the CNC machine and asked me to assist with the analysis, printing process, and performance evaluation of the holder.
My Assist: Based on my calculations, using 3D-printed metal for this application is cost-effective, as it only costs approximately $10-40 per piece (including sintering), compared to the purchasing cost of $500-750 for traditional parts. With a budget of under $8,000, I selected the Ultimaker S7, while using PVA (soluble filament) for large draft structures. This approach improves surface finish, prevents warping, and reduces time spent on support removal. For the metal filament, we chose BASF Ultrafuse 316L Metal (Stainless Steel). To accommodate for size reduction during sintering, all parts in the z-axis dimension were designed slightly larger.