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Potato Slicer
Objectives
Objectives
To reverse engineer a mechanical potato slicer and generate full engineering documentation, including CAD models, stress analysis, and design of experiments (DOE) for a critical component. The project focused on validating the structural safety of the long arm using parametric FEA modeling and fatigue analysis. Completed in MAE 4344: Computer Aided Engineering at UT Arlington.
Quick Summary
Quick Summary
Project Type: Team (7 members)
Team Members: Aaron Cupps, Campbell Gray, Ransom Kennelly, Fernando Lopez, Joshua Olaekeji, John Skiba
Duration: ~6 weeks
Tools: SolidWorks, ANSYS Workbench, Design of Experiments (DOE)
Focus: Structural stress and fatigue analysis of the long arm component under two load scenarios
Outcome: Complete reverse engineering package including CAD models, mesh refinement, FOS evaluation, and parametric DOE results (presentation only)
Technical Details & Skills
Technical Details & Skills
Identified the long arm as the primary load-bearing component for structural analysis
Built ANSYS Workbench setup: mesh refinement, support constraints, and multi-load FOS evaluation
Configured DOE study with 5 geometric parameters and 1 material input (Young’s Modulus)
Defined output metrics: maximum equivalent stress, total deformation, and minimum safety factor
Completed independent FEA and DOE setup, but team used alternate simulation results in final analysis
Parametric relationships between inputs and output trends were explored during DOE setup and review
Design Overview & Features
Design Overview & Features
Device: Manual potato slicer with five key mechanical parts
Critical Component: Long lever arm subjected to combined bending and shear loads
Team Deliverables:
Assembled and exploded SolidWorks CAD views highlighting the long arm
Free body diagrams (FBDs) to visualize applied forces and constraints
Static stress analysis and DOE simulations for the long arm (final results based on team data)
Simulation & Engineering Decision
Simulation & Engineering Decision
ANSYS mesh and loading configuration for long arm under two load cases:
• Load Case 1 – Vertical bending force
• Load Case 2 – Horizontal shear force
*Each case simulated independently to evaluate structural behavior.*
Simulation Setup: ANSYS Workbench used to model the long arm under two independent loading scenarios
Validation Goals: Confirm equivalent stress, total deformation, and safety factor across geometric/material variations via DOE
DOE Input Parameters:
Thickness: affects bending stiffness via moment of inertia
Hole Diameters (Top, Middle, Bottom): introduces localized stress concentrations
Young’s Modulus: varies material stiffness and deflection response
Output Metrics:
Max equivalent stress
Total deformation
Minimum factor of safety (FOS)
Boundary Conditions:
Cylindrical supports at pin contact regions
Pin-mounted boundary conditions approximate real-world constraints.
Load Cases (run separately):
Case 1: Downward bending force
Case 2: Orthogonal shear load
DOE Sensitivity Range:
Geometry: ±0.5% variation
Material stiffness: ±5% variation
DOE Summary
DOE results: Equivalent stress under ±30N load cases
DOE results: Equivalent stress under +100N load cases
DOE results: Total deformation under ±30N load cases
DOE results: Total deformation under +100N load cases
DOE results: Minimum safety factor under under ±30N load cases
DOE results: Minimum safety factor under +100N load cases
Drawings & Documentation
Drawings & Documentation
SolidWorks model of the full potato slicer assembly
DOE correlation matrix showing geometric/material inputs vs stress, deformation, and safety factor.
Exploded view identifying long arm and key components
Challenges & Iteration
Challenges & Iteration
Estimated loading conditions from limited slicer documentation and assumptions
Complex long-arm geometry required iterative meshing for accurate curvature representation
Contributed alternate analysis setup; final presentation used a different team-developed configuration.
Collaborated to ensure consistent constraints, boundary conditions, and DOE logic
Supported team-wide integration by aligning my initial setup with final simulation goals
Outcomes & Contributions
Outcomes & Contributions
Contributed ANSYS FEA setup and parametric DOE framework for long arm analysis
Supported stress validation planning through mesh refinement and boundary condition design
Developed original fatigue analysis tree with 3 supports and 2 independent load paths
Documented DOE structure, input variables, and interpretation of failure metrics
Skills Applied
Skills Applied
Structural FEA · Mesh Refinement · DOE Configuration · Safety Factor Analysis · Parametric Sensitivity Evaluation · SolidWorks Assembly Modeling · Engineering Documentation · Team-Based Analysis Communication
Reflection
Reflection
This project deepened my ability to translate real-world components into parametric FEA models, and I gained valuable experience configuring mesh settings, loading conditions, and fatigue studies. The process also taught me how to contribute effectively to a team, and strengthened my skills in constraint application, design factor sensitivity, and upstream collaboration which are key elements in real-world engineering analysis workflows.
*Note: Final presentation includes fatigue analysis, parametric studies, and FEA-based validation of a critical component (long arm). A downloadable PDF of the team presentation is available below.*
Download Project PDF
View or Download Project Report (PDF)
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