Mechanical projects

This video documents the hands-on training conducted as part of a mechanical engineering curriculum, focusing on modern manufacturing processes, CNC machining, and precision assembly. The project includes practical exercises using various industrial machines such as:

• HAAS Super Mini Mill: CNC milling for precise machining of aluminum components.
• EDM (Electrical Discharge Machine): Precision cutting for complex geometries in conductive materials.
• Laser Cutter: Fast prototyping of engraved and cut parts using laser technology.
• Conventional Milling Press: Manual shaping and adjustment of mechanical parts.
• Assembly Tools and Fixtures: Mechanical part assembly using vises, screws, pins, and jigs.

Key training outcomes include:

• CNC Programming: Toolpath creation and execution on HAAS controller interfaces.
• Material Processing: Mastery of machining parameters, tool selection, and surface quality control.
• Precision Measurement: Use of calipers, gauges, and visual inspection during assembly.
• Mechanical Assembly: Fine manual fitting, insertion, and testing of machined components.

This project strengthens practical skills in mechanical fabrication and prepares students for industry-level tasks involving CNC machinery, prototyping, and mechanical system assembly.

This project is a 3D mechanical design and assembly I created using SolidWorks. It focuses on modeling and assembling key components of an internal combustion engine's reciprocating mechanism, specifically a crankshaft and piston system.

• Software Used: Developed in SolidWorks, a professional software for 3D mechanical design and engineering analysis.
• Individual Component Modeling: The project includes detailed 3D models of several crucial parts:
  • Piston (`1.Piston`)
  • Piston Rings (`2.Piston ring`)
  • Connecting Rod (`4. Connecting rod`)
  • Piston Pin (`6. Piston pin`)
  • Crankshaft (Vilebrequin) (`3. Crankshaft`)
• Assembly Design: The individual components are brought together in an assembly (`Assemblage1`) to demonstrate their spatial relationships and how they connect within the engine mechanism.
• Motion Study/Animation: The assembly includes a motion study (`Etude de mouvement 1`) to visualize the dynamic movement of the pistons, connecting rods, and crankshaft as they would operate in a running engine.
• Detailed Design Elements: Models include various features (Boss-Extrude, Cut-Extrude, Revolve, Fillets, Chamfers) demonstrating proficiency in SolidWorks part modeling.

This project demonstrates my skills in 3D CAD design using SolidWorks, including detailed part modeling, creating mechanical assemblies with appropriate mates, and conducting basic motion studies to simulate component movement. It showcases my ability to design and visualize mechanical systems.

This project is a Finite Element Analysis (FEA) simulation of a structural I-beam, conducted using the SolidWorks Simulation module. The goal is to analyze the stress and deformation of the beam under a specific load and with defined supports.

• Software Used: The analysis was performed in SolidWorks, utilizing its integrated Simulation module for FEA.
• Model: A 3D model of a standard I-beam (named "Poutre").
• Simulation Setup & Analysis: This project demonstrates a complete FEA workflow:
  • Material: The beam is assigned AISI 304 Stainless Steel, which has a defined yield strength (shown in the results).
  • Fixtures (Boundary Conditions): The ends of the beam's lower flange are fixed, simulating simple supports.
  • Loads: A downward force (1000 kgf) is applied to the top center surface of the beam.
  • Meshing: The solid body is converted into a finite element mesh (triangular elements) to prepare it for analysis. The quality of the mesh is also reviewed.
• Results Visualization: After running the solver, the results are analyzed:
  • Von Mises Stress: The primary result shown is a Von Mises stress plot, which visualizes the stress distribution throughout the beam. The maximum stress is identified at the point of load application and is shown to be well below the material's yield strength.
  • Deformation: The plot shows an exaggerated deformation shape, illustrating how the beam bends under the load.
  • Animation: A motion animation is created to dynamically show the progression of deformation and stress as the load is applied from zero to its maximum value.

This project showcases the ability to perform a static structural analysis using SolidWorks Simulation. It covers the entire process from setting up the study with materials, fixtures, and loads, to meshing the model, running the solver, and interpreting the stress and deformation results. It is a practical demonstration of how FEA is used to validate the structural integrity of a mechanical component.

This project is a 3D mechanical design of a turbofan jet engine, created and animated in SolidWorks. It models the primary components of the engine, assembles them, and includes a motion study to simulate the rotation of its core parts. The engine features a custom "FOFOU KANKEU ALAIN AIRLINES" livery, personalizing the design.

• Software Used: Developed in the SolidWorks Education Edition, a professional CAD software used for 3D design, assembly, and motion simulation.
• Component Modeling: The assembly is built from several key parts designed individually:
  • Housing (`3.Housing`): The external nacelle (casing) of the engine, which is fixed in the assembly.
  • Propeller/Fan (`1.Propeller`): The large fan blade assembly at the front of the engine.
  • Shaft (`2.Shaft`): The central rotating shaft, which includes the compressor and turbine stages, all modeled as a single component.
• Assembly Design: The individual components are brought together in an assembly (`Assemblage1`). Mates (`Contraintes`) are used to define the concentric relationships between the housing and the rotating shaft/fan, allowing for correct mechanical movement.
• Motion Study & Animation: The project features a motion study (`Etude de mouvement 1`) that simulates the primary function of the engine:
  • A motor is applied to the shaft to drive its rotation.
  • The animation visualizes the fan and internal turbine stages spinning inside the housing.
  • The housing is made transparent during the animation to provide a clear view of the internal moving parts.
• Visualization & Detailing: The project includes custom appearances and decals to create a finished look, including the colorful spiral on the nose cone and the airline branding on the nacelle.

This project demonstrates strong skills in SolidWorks, covering part modeling, the creation of complex mechanical assemblies, and the use of motion studies to animate and simulate dynamic systems. It highlights the ability to not only design functional components but also to present them in a visually clear and engaging manner.

This project is a Finite Element Analysis (FEA) performed in SolidWorks Simulation to examine the stress distribution on a rectangular steel plate with two holes, subjected to a bending load. The primary goal is to identify areas of high stress, particularly the stress concentration effect around the holes, and to verify if the plate can withstand the applied force without yielding.

• Software Used: The analysis was conducted using the SolidWorks Education Edition, specifically its integrated Simulation module for FEA.
• Model: The subject of the analysis is a simple rectangular plate (`Pièce1`) featuring two circular cutouts (holes).
• Simulation Setup & Analysis: This project follows a standard static analysis (`Etude Statique`) workflow:
  • Material: The plate is made from AISI 4130 Annealed Steel (`Acier recuit`), with a defined yield strength of 460 MPa (`Limite d'élasticité`).
  • Fixtures (Boundary Conditions): One of the long edges of the plate is completely fixed (`Fixe-1`), simulating a cantilever or rigidly mounted condition.
  • Loads: A total force of 1500 N is applied uniformly across the opposite long edge, creating a bending moment on the plate.
  • Meshing: The model is discretized into a finite element mesh to enable the numerical calculation.
• Results & Interpretation: The simulation results are visualized and inspected to understand the plate's behavior:
  • Von Mises Stress Plot: A color plot shows the distribution of Von Mises stress across the plate. The maximum stress is observed to be significantly higher around the edges of the holes.
  • Stress Concentration: The animation and close-up views clearly demonstrate the phenomenon of stress concentration, where the stress is amplified around the geometric discontinuity (the holes).
  • Quantitative Analysis: The Probe tool (`Sonder`) is used to measure the peak stress at a node near one of the holes, showing a value of approximately 419.7 MPa. This value is compared against the material's yield strength (460 MPa) to assess the design's safety.
  • Animation: The results are animated to show how the stress field develops as the load is gradually applied, providing an intuitive understanding of the component's response.

This project effectively demonstrates the process of conducting a static structural FEA in SolidWorks. It highlights key engineering concepts such as setting up boundary conditions, analyzing results, and, most importantly, identifying and quantifying stress concentration in a part with geometric features. It is an excellent example of using simulation tools to predict potential failure points and validate a design under load.

This project is a detailed 3D design and animation of a multi-stage speed reducer gearbox, created in SolidWorks. It models the complete mechanical system, including gears, shafts, bearings, and the housing, and features both an exploded view and a functional motion simulation to demonstrate its construction and operation.

• Software Used: Developed in the SolidWorks Education Edition, a professional CAD software for creating complex mechanical assemblies and motion simulations.
• Complex Mechanical Assembly: The project features a highly detailed assembly (`Assemblage2`) of a multi-stage speed reducer, comprising numerous components:
  • Housing (`7.Housing`): The external casing that encloses and supports the entire mechanism.
  • Gear Train: A series of meshing spur gears (`4.Input gear`, `5.middle gear`, `5.output gear`, etc.) arranged in multiple stages to achieve a significant speed reduction.
  • Shafts: Multiple shafts (`1.Input Shaft`, `2.Speed Shaft`, `3.Middle Shaft`, `5.Output Shaft`) that hold the gears and transmit power through the gearbox.
  • Bearings: The design includes standard components like `radial ball bearings` and `angular contact ball bearings` to support the rotating shafts, demonstrating a realistic and robust design approach.
• Animations & Motion Study: The project effectively uses animation to visualize the design:
  • Exploded View Animation: The video showcases an animated exploded view, which systematically disassembles the gearbox to clearly display each internal component and its position within the assembly.
  • Motion Study (`Etude de mouvement 1`): A functional motion study simulates the gearbox in operation. A motor is applied to the input shaft, and the animation demonstrates the transmission of motion through the gear train, visualizing the speed reduction from the high-speed input to the low-speed output shaft.

This project is an excellent demonstration of advanced SolidWorks skills, including intricate part modeling, the management of a large assembly with precise mates (`Contraintes`), and the creation of sophisticated animations. It effectively visualizes both the construction and the kinematic function of a mechanical speed reducer, showcasing a comprehensive understanding of mechanical design principles.

This project is a Finite Element Analysis (FEA) of a modern cantilever chair frame made from bent steel tubing. The simulation, performed in SolidWorks, aims to analyze the structural response of the chair under a typical load, identifying areas of high stress and deformation to validate its design integrity.

• Software Used: The analysis was conducted using the SolidWorks Education Edition and its integrated Simulation module.
• Model: The subject of the analysis is a chair frame (`Pièce3`) constructed from a continuous, bent steel tube, a common design for cantilever chairs.
• Simulation Setup & Analysis: This project demonstrates a complete static structural analysis (`Etude Statique 1`):
  • Material: The frame is assigned AISI 1020 Steel, a common carbon steel.
  • Fixtures (Boundary Conditions): The base of the frame is fixed (`Fixe-1`), realistically simulating the chair resting securely on the floor.
  • Loads: A downward force of 1500 N is applied to the upper tubes that form the seat, representing the weight of a person.
  • Meshing: The tubular frame is converted into a finite element mesh (solid tetrahedral elements) to prepare it for the analysis solver.
• Results & Interpretation: After running the simulation, the results are visualized and analyzed:
  • Deformation Plot: A plot shows the exaggerated deformation of the frame, illustrating how it flexes under the load.
  • Von Mises Stress Plot: A color plot reveals the stress distribution throughout the chair frame. As expected, high-stress concentrations (shown in red and orange) appear at the sharp bends near the base and at the junction where the seat portion meets the vertical supports.
  • Design Validation: The maximum stress is identified as approximately 240.5 MPa (`2.405e+08 N/m^2`). This is compared against the material's yield strength of 351.6 MPa (`3.516e+08 N/m^2`), confirming that the peak stress is well within the safe operating limit.
  • Animation: The results are animated to provide a dynamic visualization of how the stress develops and distributes across the frame as the load is applied.

This project effectively showcases the use of FEA as a tool for product design and validation. It demonstrates the entire workflow from setting up a realistic simulation with appropriate materials, fixtures, and loads, to interpreting stress and deformation results to ensure a product is safe and functional for its intended use.

This project demonstrates the complete workflow for generating CNC machining instructions from a 3D model using SolidWorks CAM. It covers the setup of machining operations, toolpath simulation for a milled part, and the final post-processing step to create the machine-readable G-code.

• Software Used: Developed in the SolidWorks Education Edition, utilizing the integrated SolidWorks CAM module to bridge the gap between 3D design and physical manufacturing.
• CAM Process Workflow: This project walks through the essential steps of preparing a part for CNC milling:
  • Machining Operations: Multiple milling operations are defined to create the part's features, including rough milling (`Fraisage d'ébauche`), contour milling (`Fraisage de contour`), and center drilling (`Foret à centrer`) for the various pockets and holes.
  • Toolpath Simulation: The entire machining process is visually simulated. This shows the virtual cutting tool (an end mill) removing material from the stock block to produce the final part geometry.
  • Stock Comparison: The simulation includes a stock comparison feature, which uses a color map to show the remaining material after each operation, helping to verify that the part is machined to the correct dimensions.
  • Post-Processing & G-Code Generation: After the toolpaths are verified, they are post-processed. This critical step translates the visual toolpaths into machine-specific instructions.
  • Final Output: The final output is a Cutter Location (CL) file (`Mill.clt`), which contains the G-code and M-code commands (e.g., `GOTO`, `CIRCLE`, `RAPID`) that control the CNC milling machine's movements, speeds, and tool changes. The raw code is shown in a text editor at the end.

This project demonstrates a practical application of the full design-to-manufacturing process. It showcases skills in defining machining setups, generating various toolpaths, simulating material removal, and post-processing to create the G-code necessary for automated manufacturing. It highlights the ability to prepare a digital 3D model for physical production using industry-standard CAM software.

This project is a Computational Fluid Dynamics (CFD) study performed using the SolidWorks Flow Simulation module. It analyzes the thermal mixing of hot and cold fluid streams within a T-shaped pipe junction. The simulation visualizes the resulting flow patterns, particle trajectories, and temperature distribution to understand the efficiency of the mixing process.

• Software Used: The analysis was conducted in the SolidWorks Education Edition, utilizing the powerful Flow Simulation add-in for CFD.
• Simulation Setup & Scenario:
  • Model: A 3D model of a T-pipe (`pipe`), which has been sectioned to provide a clear view of the internal fluid domain for analysis.
  • Boundary Conditions (`Conditions aux limites`): The simulation is set up with two inlets and one outlet.
    • Inlets: A hot fluid stream enters from the top inlet, while a cold fluid stream enters from the main side inlet, each defined with a mass flow rate (`Débit massique d'entrée`).
    • Outlet: The end of the pipe is defined with an environmental pressure condition, allowing the mixed fluid to exit the system.
  • Analysis Type: This is an internal flow analysis focused on fluid mixing and conjugate heat transfer.
• Results Visualization & Analysis: The simulation results are visualized using several advanced methods:
  • Flow Trajectories (`Lignes de courant`): The primary visualization shows flow trajectories colored by fluid temperature. This provides an intuitive look at how the hot (red) and cold (blue) streams interact and mix at the junction, creating a thermal gradient. The display is toggled between arrows (`Flèches`) and animated spheres (`Sphères`) to show particle paths.
  • Cut Plots (`Plans de visualisation`): A 2D cut plot is used to analyze parameters across a cross-section of the pipe.
    • A **Temperature Contour Plot** shows the thermal distribution, clearly highlighting the mixing zone between the hot and cold fluids.
    • A **Pressure Contour Plot** is also generated, illustrating the pressure variations within the pipe, particularly the pressure increase at the point where the two flows impinge.

This project effectively demonstrates the capabilities of CFD for analyzing thermal-fluid systems. It showcases the entire workflow, from setting up the fluid domain and boundary conditions to visualizing complex phenomena like flow trajectories and temperature profiles. This type of analysis is fundamental in many engineering fields for designing and optimizing mixing valves, heat exchangers, and industrial piping systems.