2025 ASEE Annual Conference & Exposition

Mechanical engineering programs equip students with a wide range of skills and abilities. Some of the most important include the ability to conduct mechanical design, adhere to engineering standards, and verify that designs meet the required specifications. Many tasks for mechanical engineers in the industry involve addressing complex mechanical design challenges. The first essential skill for engineering students is the ability to carry out mechanical design. Most mechanical design products are created to serve society and customers. Numerous engineering standards, such as those established by ASME (The American Society of Mechanical Engineers), are in place to protect both society and customers, as well as maintain the reputation of the engineering profession. When conducting mechanical designs, students must understand and follow these standards. Thus, the second key skill for engineering students is the ability to comprehend and comply with relevant engineering standards. After completing a design, engineers must demonstrate that it meets the design requirements, which includes determining stress, strain, and the factor of safety. It is well known that calculating stress, strain, and the factor of safety for real components is challenging, if not impossible, due to complex shapes and loading conditions. However, this can be achieved through FEA (Finite Element Analysis) simulations. Therefore, the third critical skill for mechanical engineering students is the ability to perform FEA simulations. This paper presents a team design project that integrates all three of these skills in a simulation-based design course.
The simulation-based design course is a required, 15-week course in our mechanical engineering program. It is a 2-4-4 credit course, consisting of a 2-hour lecture and a 4-hour lab, totaling 4 credits. The course primarily focuses on using FEA simulations to determine stress, strain, and the factor of safety of mechanical components and assemblies under static loads. In week 10, students are assigned a major design project titled "Analysis of Bolted API Flange and Gasket." This is a team project with 2 to 4 members per group. The project involves connecting a tank, rated for 5000 psi, to a piping system using an API-rated flange. Each team is given a different flange configuration based on the innermost diameter. The project has four main tasks: (1) Students are asked to study the API-6A standard, which governs the design of flange connectors, and are encouraged to search for additional information online. (2) Teams will design the flange connectors according to their assigned configuration. This includes selecting materials, determining dimensions based on API-6A standards, and creating SolidWorks models of the components and assembly, followed by part and assembly drawings. (3) The primary function of a flange connector is to deliver high-pressure petroleum, such as at 5000 psi, through the connection without leakage. Students must run an FEA simulation to verify that their design will prevent leakage. (4) Finally, each team will write a technical report summarizing their work.
This paper will present the project’s implementation, feedback from students, and the results of student surveys regarding the project.