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Fixture Design to Supplement Machining and Fuel Cell Education

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2016 ASEE Annual Conference & Exposition


New Orleans, Louisiana

Publication Date

June 26, 2016

Start Date

June 26, 2016

End Date

August 28, 2016





Conference Session

Subjects in Renewable Energy and Sustainability in ET

Tagged Division

Engineering Technology

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Paper Authors


Yeong Ryu State University of New York, Farmingdale

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YEONG S. RYU graduated from Columbia University with a Ph.D. and Master of Philosophy in Mechanical Engineering in 1994. He has served as an associate professor of Mechanical Engineering Technology at Farmingdale State College (SUNY) since 2006. In addition, he has conducted various research projects at Xerox Corporation (1994-1995), Hyundai Motor Corporation (1995-1997), and New Jersey Institute of Technology (2001-2003).
He has been teaching and conducting research in a broad range of areas of system identification and control of nonlinear mechatronic systems and vibrations in structures requiring precision pointing to eliminate the detrimental effects of such diverse disturbance sources. He has authored or co-authored more than 70 publications. His work currently focuses on the development and implementation of modeling and control of renewable energy systems, characterization of nanomaterials, photovoltaics, and nanoscale integrated systems. He is a member of the American Society of Mechanical Engineers (ASME), American Society for Engineering Education (ASEE) and the Materials Research Society (MRS).

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Hazem Tawfik State University of New York, Farmingdale

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Prof. Tawfik obtained his Ph.D. in Mechanical Engineering, from University of Waterloo, Ontario, Canada. He has held a number of industrial & academic positions and affiliations with organizations that included Brookhaven National Laboratory (BNL), Rensselaer Polytechnic Institute (RPI), Stony Brook University (SBU), Massachusetts Institute of Technology (MIT), Atomic Energy of Canada Inc., Ontario Hydro, NASA Kennedy, NASA Marshall Space Flight Centers, and the U.S. Naval Surface Warfare Center at Carderock, Md. Dr. Tawfik is the co-author of more than 60 research papers in the areas of Hydrogen Fuel Cells, Biomass Energy, Thermo- fluids and Two Phase Flow published in prestigious peer reviewed journals and conference symposiums. He holds numerous research awards and owns the rights to four patents in the Polymer Electrolyte Membrane (PEM) fuel cells area. Currently, Dr. Tawfik is a SUNY Distinguished Service Professor and the Director of the Institute for Research and Technology Transfer (IRTT) at Farmingdale State College of the State University of New York.

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Brandon Scott Weisberg Farmingdale State College

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Senior Mechanical Engineering Technology Student at Farmingdale State College

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Daniel Joseph Boss


Gonca Altuger-Genc State University of New York, Farmingdale

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Dr. Gonca Altuger-Genc is an Assistant Professor at State University of New York - Farmingdale State College in the Mechanical Engineering Technology Department. She is serving as the K-12 STEM Outreach Research and Training Coordinator at Renewable Energy and Sustainability Center at Farmingdale State College.
Her research interests are engineering education, self-directed lifelong learning, virtual laboratories, and decision-making framework development for design and manufacturing environments.

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A vital part of enhancing the ability of students to learn is identifying the barriers associated with the student’s achievement in his/her field of study. In the Manufacturing and Mechanical Technology fields, like others, there exists an intimidating experience barrier between faculty, professionals, or technical experts and novice students. The participation of students in the design and fabrication of a Proton Exchange Membrane (PEM) bipolar plate machining fixture aids in eliminating this barrier by making Fuel Cell production possible even to inexperienced technology students. The process of manufacturing a fixture for the production of hydrogen fuel cell and hydrogen purifier plates requires careful planning. Through the use of our designed fixture it is possible to teach students how to use a CNC milling machine with relative ease while allowing for precision part machining. The setup of the fixture allows students to observe the necessary measures to properly machine a part while also teaching them the benefits of fixtures in the manufacturing industry. The design of the fixture is a multi-disciplinary utilization of resource in a learning environment. The Fuel cell plates that were to be machined on the fixture were made of a variant of Low-Carbon Steel. The choice made to machine the fixture out of High-Carbon Steel was made in order to prevent deformation of the fixture. The resistance to deformation of the fixture was essential in the quality control and assessment process. The resulting consequences of using this material for the fixture pose significant issues in the fabrication process. This introduces the students in the manufacturing technology discipline to tooling setup to form the fixture in an accurate and economical fashion. The High Carbon Steel fixture necessitated the use of Carbide cutting tools in order to maintain the desired tolerances throughout the part manufacturing. Once the manufacturing process of the fixture was complete, assessment of performance consists of the utilization of this fixture to machine multiple fuel cell plates. Students were asked to setup the fixture and utilize such in the fuel cell machining process to test their understanding of the logic and methods that establish fixture use in the industry. Student utilization of the fixture proved to be useful to students in order to gain a thorough comprehension of the associated manufacturing process. Students will be assessed based upon their achievement, efficiency and precision in setting up the fixture and the following execution of the fuel cell plate machining process. A student evaluation survey will be administered to a participating group and nonparticipating to measure the benefits of this approach described in this paper.

Ryu, Y., & Tawfik, H., & Weisberg, B. S., & Boss, D. J., & Altuger-Genc, G. (2016, June), Fixture Design to Supplement Machining and Fuel Cell Education Paper presented at 2016 ASEE Annual Conference & Exposition, New Orleans, Louisiana. 10.18260/p.26916

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