Date of Graduation

5-2026

Document Type

Thesis

Degree Name

Bachelor of Science in Mechanical Engineering

Degree Level

Undergraduate

Department

Mechanical Engineering

Advisor/Mentor

Wejinya, Uche

Committee Member

Wejinya, Uche

Second Committee Member

Nutter, Darin

Abstract

Stamped steel paint can openers are simple tools but still require sufficient strength for the end user and low material consumption for the manufacturer. The goal of this project is to optimize the stamped design of a paint can opener by reducing material cost while maintaining structural rigidity and device performance. This was achieved in part by simplifying the tool’s geometry so that an equation for the mass could be developed analytically and checked against the simulation’s outputs. First, a 25-run design of experiments was created that varied the shaft length and the endloop diameter. Next, a CAD model for the conditions of each trial was created using SolidWorks, and a finite element analysis was performed to determine the maximum von Mises stress. Then, using quadratic regression analysis, a stress equation was created in terms of the shaft length and diameter. Finally, Excel Solver was used to finish the multidimensional constrained optimization problem. The project proved successful, reducing the tool’s mass by 43.53% compared to the baseline product, and maintaining a factor of safety of greater than 4.

Keywords

Design Optimization; Finite Element Analysis (FEA); Design of Experiments (DOE); Regression Modeling; Structural Analysis; Manufacturing Cost Reduction

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