IMPLEMENTATION OF A NEW MECHANICAL ENGINEERING PROPULSION DETAIL DESIGN CAPSTONE COURSE

This is one of two papers describing the propulsion capstone design experience at Embry-Riddle Aeronautical University in Prescott, Arizona. In 2007, we began accepting freshmen for the first time into our Mechanical Engineering (ME) program. In the 2010-2011 academic year, we offered for the first time the new ME capstone design courses with concentrations in either air-breathing propulsion or robotics. This paper describes the propulsion detail design course; a second paper will focus on the initial propulsion preliminary design course(1). The first graduating class of ME majors included three students in the propulsion track. The propulsion detail design course follows the preliminary design course which involved aero-thermodynamic propulsion system design and matching to an aircraft system. The detail design course focused on propulsion component design, hardware fabrication and component testing. This approach, using student created hardware, is unique in propulsion capstone design. This paper discusses the team's efforts in the detail design of rotating components, the fabrication of a prototype first stage jet engine compressor blade using rapid prototyping techniques, the development of in-house aluminum casting techniques, and the subsequent vibrational analysis and the use of Campbell Diagrams. In addition, the assessment of the course outcomes: demonstrating communication competence and proficiency in engineering design via a capstone experience with comments by members of our Industrial Advisory Board will be discussed. As this was the first time the course was offered with a small group of students, this paper will also discuss the lessons learned as well as future adaptations that will be implemented as the population of students within the propulsion track increases as the overall ME program grows.