Projects
Welcome to Dylan Xiu's Portfolio! This is where I showcase my expertise in mechanical engineering, automotive, and manufacturing. Feel free to explore the projects I've worked on to get a better understanding of my skills and experience in the field.
EV DTI Welding Tabs
FSAE Enterprise
On the EV Team, I was tasked with attaching the DTI 550 to the EV Chassis By adapting the DTI mounts to fit the supporting rods, we enhanced the structural rigidity of the DTI compared to the standard supports, which are primarily designed for flat surfaces. I utilized the same chromoly material as the chassis for easier welding and employed Amesim to create a 3D model and conduct FEA, ensuring adequate support for the DTI.
EV - Emrax Mounts
FSAE Enterprise
On the EV Team, I was responsible for securing the Emrax 208 to the EV chassis by modifying the supplied Em mount to fit the new pick-up points. This updated motor mount features fewer holes and positions the Emrax at a vertical angle for the EV chassis. It draws inspiration from the original mount and is made of aluminum to reduce weight costs.
IC - F25 Control Arms
FSAE Enterprise
In the Formula SAE Enterprise, my partner and I took on the project of designing and manufacturing control arms for the F25 race car. We began by developing the control arms in NX, carefully refining the design to comply with Formula SAE regulations. Following this, we performed Finite Element Analysis (FEA) using Simcenter 3D to pinpoint areas of concentrated stress and potential failure. With these insights, we are now prepared to begin the manufacturing process in the coming weeks
HVAC System
Mechanical Engineering Practice II
In a team-based project focused on optimizing an HVAC system, we were tasked with improving airflow control. To achieve this, we designed and installed Flow Nozzles and Orifice Plates tailored to the system’s needs. Prior to installation, we used MATLAB to analyze and calculate the ideal bevel angles, thickness, and shape for the components, allowing us to determine the optimal design based on data we collected. This project enhanced my skills in applied design calculations, software-based analysis, and team collaboration within an engineering context.
Cantilever Crane Project
Mechanical Engineering Practice II
In a project focused on crane safety, my team was assigned to design a safety link intended to break at a specific load before the crane’s structural failure point. Each team member created a concept design, calculating material strengths and cross-sectional areas to meet the required load specifications. We used Finite Element Analysis (FEA) in Simcenter 3D to evaluate each design and selected the one that best aligned with our desired failure load. After finalizing our design, we 3D printed the link, installed it onto the crane, and conducted tests, achieving a 90% success rate.
Reverse Engineering Project
Mechanical Engineering Practice I
For this project, my team was tasked with reverse engineering a Nerf gun to analyze its inputs, outputs, and the components responsible for energy and mass transfer. We successfully deconstructed the Nerf gun and identified key components, such as springs and air chambers, that compress and release energy to propel the dart.
Bridge Truss Project
Mechanical Engineering Practice I
For this project, my team and I were tasked with designing a bridge beam that would fracture under 30 lbs of force. We began by analyzing the force applied to the beam and calculating the material strength required for the desired cross-sectional design. Using these calculations, we created a 3D-printed beam tailored to withstand close to the target load. As a result, our beam successfully fractured at 32 lbs, demonstrating the effectiveness of our design process.
Human Power Winter Vehicle
Engineering II
For this project, our team was tasked with designing a human-powered vehicle capable of rescuing individuals from a challenging environment. We chose to focus on a harsh winter setting, tailoring our design to navigate snowy and icy conditions effectively. After evaluating different methods of human-powered motion, we decided to base our vehicle on a rowing mechanism. This design choice was made to utilize a wide range of muscle groups, maximizing efficiency and power output.
To ensure the safety and comfort of the rescued person, we incorporated a sled attachment into the vehicle. This sled was designed to securely hold the individual while being lightweight and durable for maneuvering through difficult terrain. We created the complete design using Onshape, allowing us to refine and optimize the vehicle's features for the intended environment.
Mars Rover Project
Engineering I
For this project, our team was tasked with designing a device to retrieve crystals using mechanical energy solely from rubber bands, torsion springs, or other elastic components. To determine the best approach, we measured the force generated by varying displacement values and recorded the results in a table. After analyzing the data, we chose to use torsion springs for the design.
Using basic materials, we constructed the device with the requirement that it needed to return to its original starting position. To achieve this, we angled the front half of the device’s body to enable a full 360° rotation. This design allowed us to maximize the mechanical energy stored in the torsion springs and convert it efficiently into forward motion. As a result, our device successfully retrieved 10 out of the 10 crystals.
