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HRL Labs

During my second co-op at HRL, I worked on projects for Boeing and General Motors. I was responsible for designing and analyzing a multi-part assembly made of metal with a composite skin. I also layed up composites and performed material tests in Instron machines to validate FEA assumptions. 


In addition to the structure, I performed numerous electromagnetic simulations to match experimental results and validate existing models. 

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Tools Used: SolidWorks, SolidWorks FEA, COMSOL, Instron Machines, Composites

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Note: All images are sourced online and are only to provide visual aid to descriptions.

HRL Campus.jpg

Structure Design

The Problem

  • A structure needed to be designed for aerial operation that was cheaper than the existing solution

  • The structure is subject to high multi-axial loading, but is only single use

  • Material properties needed to be confirmed for composite being used in the structure

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Solution

  • Designed and iterated on a 20-foot-long glass fiber composite reinforced metal structure in SolidWorks with over two dozen components

  • Performed FEA in SolidWorks and optimized the structure for the lowest cost using easily manufacturable components 

  • Created composite samples and tested properties in Instron machines to validate FEA assumptions


Result

  • A master model drivel assembly was created for ease of future revision

  • Drawings were created for each of the parts for future orders

  • Parts were ordered for initial prototyping of design 

HRL Solid FEA.jpg

Example of SolidWorks FEA

Electromagnetic Simulations

The Problem

  • During high power operation, magnets in electromagnetic systems can demagnetize which limits their temperature and power operating range

  • Experiments have been run testing different magnet configurations, but they are lengthy and there isn’t enough time to try out every configuration


Solution

  • B-H curves from experimental data were imported into COMSOL and a magnetic environment was created

  • A reverse field was applied to the magnet model to test the resistance to demagnetization

  • Models were created to test different arrangements as well as different materials


Result

  • Using results from one set of tests, a model was able to be created that could be used to characterize demagnetization in multiple new configurations saving time in running experiments

  • Different configurations were proven to show varying resistance to demagnetization that could be used to improve performance

HRL COMSOL Demag.png

Example of COMSOL EM Simulation

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