https://www.rhilston.com/portfolio daily 0.75 2020-10-18 https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599616141629-V3PEEY4VBPJQPH0IY34T/Drag+Pressure+Coefficient+2020.JPG portfolio - 2020 Cooper Motorsports Aerodynamics For the 2020 FSAE season I further developed my aerodynamics package from my previous 2019 design iteration. Aerodynamic targets were revised after running OptimumL 1D lap time simulations of the 2019 FSAE Michigan Endurance track. All CFD simulations were meshed in Altair Hypermesh and run in Ansys Fluent after tuning the CFD with data from testing. The front wing was modified to increase flow to the undertray and to boost front end downforce. This helps shift the center of pressure forward for reduced understeer at high speeds. A downwash element was added to the nosecone to drive flow lower and produce a tip vortex to manage the front tire wake, allowing for a smaller sidepod inlet and improved downforce in the undertray and rear wing. An array of vortex generators were added to the leading edge of the undertray to improve downforce further. I worked closely with the cooling and exhaust teams to tightly package their systems within the undertray and sidepod to reduce drag. The rear wing efficiency was improved by reducing the flap size compared to the 2019 design and adding endplate cutouts to reduce the size of the tip vortex. General design changes were made to reduce manufacturing time and improve serviceability. For example, all mounting was redesigned with custom quick release fasteners so any component could be removed in under 10 seconds. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599616141629-V3PEEY4VBPJQPH0IY34T/Drag+Pressure+Coefficient+2020.JPG portfolio - 2020 Cooper Motorsports Aerodynamics For the 2020 FSAE season I further developed my aerodynamics package from my previous 2019 design iteration. Aerodynamic targets were revised after running OptimumL 1D lap time simulations of the 2019 FSAE Michigan Endurance track. All CFD simulations were meshed in Altair Hypermesh and run in Ansys Fluent after tuning the CFD with data from testing. The front wing was modified to increase flow to the undertray and to boost front end downforce. This helps shift the center of pressure forward for reduced understeer at high speeds. A downwash element was added to the nosecone to drive flow lower and produce a tip vortex to manage the front tire wake, allowing for a smaller sidepod inlet and improved downforce in the undertray and rear wing. An array of vortex generators were added to the leading edge of the undertray to improve downforce further. I worked closely with the cooling and exhaust teams to tightly package their systems within the undertray and sidepod to reduce drag. The rear wing efficiency was improved by reducing the flap size compared to the 2019 design and adding endplate cutouts to reduce the size of the tip vortex. General design changes were made to reduce manufacturing time and improve serviceability. For example, all mounting was redesigned with custom quick release fasteners so any component could be removed in under 10 seconds. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571585274437-3UMXRK6RECOPPY88FPTX/2019+Car+Michigan.jpg portfolio - 2019 Cooper Motorsports Chassis and Aerodynamics System In the 2019 season I was the chassis system lead for Cooper Motorsports with four subsystems: aerodynamics, bodywork, frame, and impact attenuator. The aerodynamics was my focus and was completely overhauled for 2019 to greatly increase downforce and minimally increase drag. The design was tailored to FSAE style tracks with low average speeds and both slow and fast corners. The frame was our first ever steel-composite hybrid space frame. The frame was redesigned to simplify manufacturing and improve stiffness under multiple load cases. The bodywork was integrated into the aerodynamics design and was styled to be both exciting and properly display sponsors. The result of our work was an improvement in our chassis design score at FSAE Michigan from 13/25 in 2018 to a 22/25 in 2019, the highest score given by our judges and the highest in our team’s history; This helped us in the overall design score to tie for 8th out of 120 teams. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1600648466242-OXMUCLO7IFVEFCK4Y9ZK/Senior+Project.JPG portfolio - Senior Project: FSAE Throttle Body Design and Control My undergraduate capstone project was to develop a throttle body design for a restricted FSAE engine intake. The existing butterfly throttle body and restrictor were tested using a team built flow bench. The experiment was recreated in CFD, where the model was correlated to within 5% of the pressure drop found using the flow bench at all actuation angles measured. The tuned CFD model was used to simulate alternative throttle designs. The barrel throttle was found to improve flow rate by 6% over the existing butterfly valve and gave a more linear relationship between flow rate and actuation angle. Due to COVID-19 we were unable to test a physical prototype, but were able to adapt and couple our 3D CFD with Ricardo WAVE 1D engine CFD. This showed that the barrel throttle improved power and torque linearity across throttle input to make the car more drive-able. Using lap time simulations and the simulated torque curves, the barrel throttle is predicted to give 6 more competition points at FSAE Michigan. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571586933282-00OW65ZNXZTIENI7WJ25/ST+Geom.PNG portfolio - Jacobs Engineering: Remodeling of Sound Transit's UWS In the summer of 2019 I interned with the tunnel ventilation group at Jacobs Engineering in Manhattan. My role was to create clean geometry for CFD and perform steady state and transient CFD analysis of train fires in tunnels and stations. The image shows the modular geometry I created for Sound Transit’s University of Washington Station using as built drawings. I performed mesh generation in Ansys Fluent using their new poly-hexcore meshing tool to reduce element count and improve solution accuracy. My time at Jacobs gave me an incredible experience in professional CFD using techniques in heat transfer and transient analysis. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544755669523-7ON7YA26JF78RN4ZMD2U/IMG_4723.JPG portfolio - Wind Tunnel Testing In Ford's DTF This was my first time in a full scale wind tunnel. I created a streamlined testing schedule to get the most out of my wind tunnel time. We tested the car with many different components from the 2018 car and prototypes for the 2019 car. It also allowed us to find how the car performed in pitch, yaw, and even running backwards to test for stability in a spin. The data is being used to help refine the 2019 package. This was an incredible experience for me and I can’t wait to do it again. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599614608192-AS0JWJQZ4D6WPTDKN88W/image-asset.jpeg portfolio - BWB Microjet Concept Study In Spring 2020 I designed a blended wing body microjet concept during my Aircraft Design course. The jet was initially sized using a class 1 weight estimation before going into more detail by sizing the engines and all aerodynamic surfaces for takeoff, climb, cruise, and landing. The rudder size, airfoil profile, wing location and engine location were iterated to make the plane aerodynamically balanced and naturally stable. Using the calculated dimensions, I created a conceptual surface model of the plane. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599519150850-OF9A1KYK744J1YE1F4VX/2020+Frame+Simulation.jpg portfolio - 2020 Hybrid Space Frame Design In Fall 2019 I designed a hybrid steel-composite space frame for Cooper Motorsports for the 2020 season. The cockpit structure was revised for improved ergonomics while reducing weight and improving stiffness. Carbon fiber composite panels were added and iterated in location and layup schedule to yield the minimum weight to meet our stiffness target of 10x the difference in front and rear roll stiffness. All non-structural tubes were re-evaluated compared to earlier designs, with many being reduced in size or eliminated, while others were added to improve load paths. The final design is 13% lighter than the 2019 design while being 50% stiffer and with reduced suspension compliance under braking. The completed frame was being tested using a team designed torsion testing rig as the COVID-19 pandemic hit and will be completed once the school reopens. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571584156717-YBDDB6ES2VTI9B66ZXO6/Half+Car+CFD+UT7+FW+Fence+Final+Front+Iso+Pressure.jpg portfolio - 2019 Cooper Motorsports Aerodynamic Development Over the course of the 2019 season I developed a specialized aerodynamics package though CFD analysis, wind tunnel testing, and on track testing. The package consists of an extreme outwash front wing, four element rear wing with a leading edge slat, an aerodynamically efficient Venturi tunnel undertray, a drag reducing engine shroud, and aerodynamically beneficial sidepods for improved cooling and aerodynamic performance. The CFD models were tuned using wind tunnel data. The components in the package were iterated though CFD by using Altair Hypermesh for controlled mesh generation, Ansys Fluent for simulation, and CFD-Post for post processing. The package was designed to work cohesively to maximize downforce and minimize drag, resulting in a downforce to drag ratio of 3.0. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571588010923-SCE3HDO28CNLH8XWYZHS/Turducken.JPG portfolio - Turducken Cooking Method Design The was my final project for my CAE course. We were tasked with developing a cooking method for a “genetically engineered monster turducken” which involved oven type, heating skewer design, and stuffing recipe. The model was meshed using Altair Hypermesh and was simulated using a transient thermal analysis in Ansys Workbench. We used hand calculations in Matlab to find thermodynamic properties and check our solution using a heat transfer model. The report can be found here: https://drive.google.com/file/d/1-LlfCOBk2J835qE6DkldO4lhG3cbqIXs/view?usp=sharing https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544758959679-K3QUUV2LO24OS6GN9I62/Aero-Body+Prelim+Render+2.JPG portfolio - Cooper Motorsports Chassis Systems I led Cooper Motorsports chassis systems for 2019. Chassis for us includes frame, bodywork, aerodynamics, and impact attenuator. We use a steel space frame and are starting to implement composite panels to reduce weight and increase stiffness. Frame weight and size was reduced by 10% this year with an improvement in torsional rigidity. Bodywork was integrated into aerodynamics for the first time with an enclosed cockpit and an engine cover. The aerodynamics system is my passion. The front wing features an outwash section that reduces total drag by 8% while still producing substantial downforce. The undertray is a venturi tunnel design. It provides tons of efficient downforce while having low ride height and pitch sensitivity. It was designed for maximum performance during yaw. The rear wing features a leading edge slat to improve flow attachment and efficiency. The venting reduces drag to improve aerodynamic efficiency further. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544756593642-2TPB8CAANN49KMVLZAJ3/CAE+Wind+Turbine.jpg portfolio - Wind Turbine Tower This was the midterm project from my CAE course. We designed and simulated a wind turbine tower and base using Ansys APDL and Workbench. The tower was submitted to a variety of conditions, from extreme temperatures and winds, to frequencies caused by a turbine blade failure. Everything from the bolt size to the tower material was chosen based on design parameters. The report can be found here: https://drive.google.com/file/d/1gTVT8dLWhqUf33__NcGyIQETkxWDStwb/view?usp=sharing https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544752971035-3FFYVF354ZCMHF6S7P8A/27+Riser+2-0+Full+Render.JPG portfolio - Barebow Riser and Limbs for Archery This is my passion project. I fell in love with archery when I was 13 and quickly wanted to make my own bow. The limb design is called a recurve because of the large hooks that curve away from the string. I created simulations of 100s of different limb designs to create something that stores over 20% more energy than any other recurve available today. It can even match compound bows despite being significantly lighter and with only two moving components. The riser (handle) was designed for FITA barebow regulations. It has an internal weighting system to comply with FITA regulations and is naturally balanced. The limb pockets are adjustable to help tune the limbs perfectly for every archer. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087045019-6PRGVG4T7Q1PWMV9BQXV/IMG_0188.JPG portfolio - RC Surveillance Boat "Murphey's Law" This was the project that made me learn CAD well. I designed all mechanical components from the ground up. The hull was rapid prototyped and features built in channels for propellers. It has a wireless camera that can live stream to a laptop and is powered by a lithium battery and two 20000 RPM motors. The motors have full speed control and a separate rudder system to steer. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087620143-J9F30BODIDESVFF86YMH/IMG_0513.JPG portfolio - Diffuser Prototype 2016 This was my first project for Cooper Motorsports as a freshman. We designed and manufactured a prototype undertray and diffuser for the 2016 car. We designed an extended jacking point that allowed the car to be serviceable even with a large diffuser in the back. This system doubled as mounting for the undertray as well. It wasn’t the most successful project, but it taught me a lot and set my passion for aerodynamics. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087094578-OZJMU1IXUZ7OSOL4JAT4/IMG_1973.JPG portfolio - 2018 Cooper Motorsports CM600 I worked on the aerodynamics, bodywork, and cockpit of the 2018 car. Our focus was on weight reduction, quality, and serviceability. The aerodynamics subsystem weight was reduced by over 50% and had more intuitive and fewer number of mounting members. The bodywork was made entirely in house for the first time ever. We created composite molds for all the components, which resulted in beautiful and light weight parts. The mounting was simplified so that the nosecone could be put on or taken off in under 10 seconds. The cockpit weight was reduced by nearly 70% due to a huge improvement in understanding of composites and higher quality components. https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531086215025-7HVIO5DFPR13GI2SCUKN/IMG_1973.JPG portfolio - 2018 Cooper Motorsports CM600 https://www.rhilston.com/engineering-portfolio daily 1.0 2023-06-09 https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599616141629-V3PEEY4VBPJQPH0IY34T/Drag+Pressure+Coefficient+2020.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571585274437-3UMXRK6RECOPPY88FPTX/2019+Car+Michigan.jpg Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1600648466242-OXMUCLO7IFVEFCK4Y9ZK/Senior+Project.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571586933282-00OW65ZNXZTIENI7WJ25/ST+Geom.PNG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544755669523-7ON7YA26JF78RN4ZMD2U/IMG_4723.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599614608192-AS0JWJQZ4D6WPTDKN88W/BWB+Microjet+2.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1599519150850-OF9A1KYK744J1YE1F4VX/2020+Frame+Simulation+New.jpg Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571584156717-YBDDB6ES2VTI9B66ZXO6/Half+Car+CFD+UT7+FW+Fence+Final+Front+Iso+Pressure.jpg Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1571588010923-SCE3HDO28CNLH8XWYZHS/Turducken.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544756593642-2TPB8CAANN49KMVLZAJ3/CAE+Wind+Turbine.jpg Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544752971035-3FFYVF354ZCMHF6S7P8A/27+Riser+2-0+Full+Render.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087045019-6PRGVG4T7Q1PWMV9BQXV/IMG_0188.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087620143-J9F30BODIDESVFF86YMH/IMG_0513.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1531087094578-OZJMU1IXUZ7OSOL4JAT4/IMG_1973.JPG Portfolio https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1650848887404-184XUALDZKBQY06CLE3Y/Cylinder+Barrel+Velocity.JPG Portfolio https://www.rhilston.com/contact daily 0.75 2020-10-18 https://www.rhilston.com/about daily 0.75 2020-10-18 https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544754334589-KQS36M53V1JPNS85ZXRY/IMG_4857.JPG about https://www.rhilston.com/contact-flatiron daily 0.75 2022-04-23 https://www.rhilston.com/about-flatiron daily 0.75 2022-04-23 https://images.squarespace-cdn.com/content/v1/5ae49ef83c3a532c02842824/1544754334589-KQS36M53V1JPNS85ZXRY/IMG_4857.JPG About - Make it stand out Whatever it is, the way you tell your story online can make all the difference.