Engineering challenges in design, manufacturing, and testing must be overcome for a successful development of micro turbomachinery. This session lists the broad categories and tentative projects for summer 2008. Participants will work in Turbomachinery Lab, Haas Lab, or Micro/nano Manufacturing Lab at TAMU.

ADDVANCED MANUFACTURE

1. Micromilling of 316L stainless steel.
   You will investigate and optimize parameters for micromilling of stainless steel, develop models, and predict performance of microtools under minimum lubrication conditions. Advanced UNIST microdroplet injection system, Haas Office Mill system with 50k rpm and sophisticate instruments are available for your study.
   Sponsor: Haas Automation Inc. and Unist Inc.
2. Electrical discharge and laser microdrilling of superalloys.
   New techniques are explored to produce high aspect ratio microholes on superalloys since these materials are difficult to drill. You will investigate and compare microholes produced by laser micromachining and electrical discharge micromachining (µEDM). You will also experience with statistical engineering experiments and material characterization techniques upon completion of the program. You will utilize the state of the art IPG fiber laser and Sodick µEDM systems in your study.
3. Five-axis micromachining.
   You will use computer to design and manufacture tiny components with complex three-dimensional shapes. You will first learn the ProE or SolidWorks CAD/CAM software and stretch your creativity to fabricate fun micro objects. You then team with other students designers to manufacture prototypes of microturbines using sophisticate 5-axis Haas micromachining system.
   Sponsor: Haas Automation Inc.

EXPERIMENTAL INVESTIGATIOIN

You will collaborate with teams of seasoned graduate and undergraduate students performing state of the art research (modeling and experimental verification). In both projects, you will learn to use vibration instrumentation and perform impact tests to record mode shapes of turbocharger rotors. You will use computer programs to predict the mode shapes and natural frequencies and to make comparisons with measurements. Extensive technical reporting is expected. Students with excellent communication skills (oral and written) are sought.
More information, please visit http://phn.tamu.edu/TriBGroup

1. Oil-Free Bearings for Automotive Turbochargers.
   You will assist in the construction, trouble shooting and operation of a high speed turbocharger driven test rotor for performance evaluation of metal mesh bearings and foil bearings. You will perform measurements to determine the structural properties of test bearings (stiffness and damping). You will learn to manufacture miniature foil bearings for high speed applications.
   Sponsors: Turbomachinery Research Consortium, Honeywell Turbocharging Technologies.
2. High temperature Foil Bearings for Micro Gas Turbines.
   You will assist in the construction, trouble shooting and operation of a high speed, high temperature test rig for evaluation of rotordynamic performance of gas foil bearings to be applied on the hot side of micro gas turbines. You will perform rotordynamic measurements to determine modal damping ratio and critical speeds of test rotor supported on two state of the art foil bearings.
   Sponsors: NASA GRC, Capstone Turbine Corp., Turbomachinery Research Consortium.

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