Department of
MECHANICAL ENGINEERING NEWSLETTER SPRING 2022
TABLE OF CONTENTS 3 A MESSAGE FROM THE DEO 4 ARTIFICIAL INTELLIGENCE, MODELING AND SIMULATION GRANT 6 SAMANTA AT PNW NATIONAL LABORATORY 8 IOWA BAJA 12 IOWA ROCKET CLUB 16 PROFESSOR RATNER RESEARCH LAB 17 SHOBON ROY AWARD 18 STUDENT AWARDS 19 ALUMNI SPOTLIGHTS
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A MESSAGE FROM THE DEO The 2021-2022 academic year, designated as “Year of Research,”
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coming to an end. This designation marked our endeavor to advance our graduate program. As a result, a group of ME faculty submitted a grant titled “Artificial Intelligence, Modeling and Simulation” (AIMS) Certificate Programs” to the Office of Postsecondary Education, US Department of Education in an effort to enhance the Modeling and Simulation (M&S) program. The AIMS grant was awarded in December 2021. The ME Department has an established M&S program on the design of mechanical systems and thermal-fluid systems. In 2018, the Department launched an initiative to add an autonomy area to the program. Autonomy
multidisciplinary field encompassing robotics, control, dynamic systems, cyber-physical systems, sensing, network and data science, artificial intelligence (AI) and machine learning (ML, a subfield of AI). The AIMS grant aims to strengthen our existing M&S program and grow the autonomy area by including important topical connections with AI, ML and M&S. M&S is a knowledge-based approach that develops models to generate data, while ML is a databased approach that learns from data to generate models. We used AI in the program title to emphasize: (1) the various types of combinations: M&S-assisted ML, ML-assisted M&S, and hybrid approaches, (2) the notion of using multiple models toward the design of intelligent complex machines (thus, AI), and (3) the importance of uncertainty quantification (UQ) in all methods. This grant allows us to create new courses in AI, ML and UQ, conduct research on new methodologies, and recruit students into this emerging field. Both AIMS undergraduate and graduate certificate proposals have been approved by the Provost in spring 2022. We are in the process of implementing both certificate programs. We will keep you posted on the progress in the near future. We hope that everyone can relax and enjoy a safe and pleasant summer.
Ching-Long Lin, DEO Edward M. Mielnik and Samuel R. Harding Professor
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NEW $1M GRANT TO BRIDGE EDUCATIO SIMULATION AND M
For decades, much of engineering research has focused on developing models and simulations based on physics and real-world properties that would produce data to confirm or reject a hypothesis. More recently, many engineering scholars have begun utilizing machine learning which relies on vast quantities of data and algorithms to eventually produce a hypothesis. Now, the United States Department of Education has awarded a $1 million-grant to Ching-Long Lin, Edward M. Mielnik and Samuel R. Harding Professor and chair of the Department of Mechanical Engineering at the University of Iowa, to develop artificial intelligence,
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modeling and simulation (AIMS) programs that will bridge the gap between these two research approaches. “As we train the next generation of engineers, we want to ensure that they have the full suite of research tools available to them,” said Lin. “By integrating modeling and simulation work with machine learning, we can apply the physical principles that are central to modeling and simulation with smart, intelligent machines that do not have access to real-world interactions.” This integration will result in a physics-informed neural network which will use physical principles in the
ONAL GAPS BETWEEN MODELING AND MACHINE LEARNING
machine learning process. The hybrid research approach will be incorporated into existing MS and PhD coursework in the Department of Mechanical Engineering, enhancing professional preparation in areas such as product design, computer aided engineering, and propulsion engineering. In addition to enriching existing courses, the grant will support certificate programs for students transitioning directly from undergraduate to graduate programs. Other activities associated with this grant might include workshops and hackathons, examples of active learning that have been successful in variety of engineering disciplines.
“We are excited to create these programs to both modernize our existing courses as well as offer new opportunities for certificate completion,” said Lin. “We expect that this new approach will help recruit new students who want to combine physical and data-centric approaches.” Lin’s team on the grant includes: Sharif Rahman and Jia Lu, UI professors of mechanical engineering; Shaoping Xiao, a UI associate professor of mechanical engineering; Rachel Vitali, a UI assistant professor of mechanical engineering; and Jane Russell, director of research and analytics in the UI Office of Teaching, Learning, and Technology.
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AVIK SAMANTA: UI TO PACIFIC NORTHWEST NATIONAL LABORATORY Avik Samanta, an alumnus from UI Mechanical Engineering, is currently associated with the Pacific Northwest National Laboratory (PNNL) as a postdoctoral researcher. Avik was a Ph.D. student and postdoctoral researcher at the Laser Materials Processing Lab at the University of Iowa, mentored by Prof. Hongtao Ding. Avik sat down remotely for a Q&A.
Q: Please describe your research. In simple terms, why does this research matter?
Q: Do you feel that your experiences at the UI have set you apart? Helped prepare you for what is next?
A: It always fascinates me to learn new ways of processing materials. My work at PNNL focuses on employing friction stir processing (FSP) to improve the mechanical strength, ductility, and fatigue strength of light metal alloys so that heavier steel structural components of vehicles can be replaced with more lightweight materials to boost fuel efficiency and cut down carbon footprint. In addition, my doctoral research at UI used a laser to alter the wettability of engineering metal alloys so they can repel water (super hydrophobicity) or attract water (super hydrophilicity), impacting icing, bacterial contamination, corrosion damage, lubrication, heat transfer, etc. The goal of my research is always to develop innovative ways of processing materials to improve their performance and operational life in realworld engineering applications, thereby reducing the risk of failure.
A: I believe the all-around growth and development of an individual is important to becoming a successful researcher. UI provided a healthy, collaborative, and productive environment to continuously grow and develop skills that are helping me immensely going forward. Because it is a relatively smaller engineering school, it was easier to reach out to faculty members to seek interdisciplinary support for research collaboration. I was fortunate to have amazing mentors to guide me through the process. The experience of working with researchers from different disciplines is helping my research at PNNL. In addition, the ME department was extremely helpful and supportive in fostering my teaching skills. Last but not least, support from administrative staff was very productive to help me grow as a researcher.
Q: What do you enjoy most about your research? What first got you interested in this area? A: I was always curious about how machines and devices are manufactured and how material processing history influences their properties. When I enrolled for my master’s study at the Indian Institute of Technology Bombay, I first got a taste of material processing using a laser. I was immediately intrigued with the complexity of physical and chemical phenomena that led to an overall property change. Later, when I joined a semiconductor manufacturing industry in Taiwan, it amazed me how important manufacturing research is to enhancing the overall functionality of the final product and reducing its cost. Research provides the chance to learn new things, generate new ideas, and work with people from different backgrounds to open different perspectives.
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Q: What achievements or experiences are you most proud of? A: Research ideas based on my Ph.D. work helped our group receive two NSF grants. Moreover, I published several high-impact journal articles, including one front cover, in American Chemical Society (ACS) Applied Materials & Interfaces, Royal Society of Chemistry (RSC) Chemical Communications, Applied Surface Science, Materials & Design, and Journal of Manufacturing Processes. Additionally, I received the Graduate College Post-Comprehensive Research Fellowship, the Outstanding Teaching Assistant Award, and the Rajyalakshmi & Shankar N. Planjery Award. My research was featured in the Dare to Discover campaign by the Office of the Vice President for Research, and I won three consecutive Best Graduate Poster Awards at the CoE Research Open House. I still cherish them.
Q: What is your favorite/most memorable experiences in the Department of Mechanical Engineering? Or CoE? A: I thoroughly enjoyed my amazing Ph.D. journey in the Department of Mechanical Engineering under Prof. Hongtao Ding’s mentorship. I still remember the feeling of relief defending my Ph.D. thesis in 2020 in the middle of the COVID pandemic. I used to enjoy the responsibilities of a teaching assistant, including delivering solid modeling lectures and conducting manufacturing lab sessions for undergraduate students. It was fascinating to see how students demonstrated their final course projects in front of all CoE students. I still cherish those moments. I also relished the annual research open house held by CoE; it was a good time and an opportunity to connect with fellow researchers and faculty. Q: What advice do you have for students who are interested in becoming involved in research? A: When I was an undergrad, the concept of research was
incredibly intimidating to me, and I thought I would join the industry. In my senior year, someone said, “You know, you might enjoy research.” When I got into the master’s program and got a little taste of research, I felt immensely intrigued. However, I was unsure about having a research career and started my industrial career instead. Spending three years in the industry made me realize I enjoyed research more than industry. Therefore, my recommendation would be to allow yourself to be exposed to some research, even in an undergrad setting. The broader the experience you get, the more comfortable and confident you will be in your career choices. My research journey also makes me realize the importance of humility, gratitude, hard work, and resilience in life. It also taught me that there are more failures than success and that learning from failures makes you a better researcher. Finally, my experience taught me that it is always a good idea to engage in constructive discussion with fellow researchers and seek help if you are stuck somewhere; you never know when there might be someone with a solution next to you.
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IOWA BAJA: OFF TO THE RACES!
Iowa Baja is a group consisting of mainly mechanical engineering students, but we are open to students of all disciplines. As a team, we work collaboratively to design, build, and test off-road buggies which we take to numerous competitions around the United States. Each year we attend a small handful of regional races where we take our previously constructed buggies. At these races, we try to take as many members as possible and get them some time behind the wheel of our buggies. The first race we attended this year was at UW Stout in Wisconsin. Stout threw
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in a little twist and had a six-hour endurance race, typical races are four-hours long. At the end of the six hours, our oldest buggy placed 1st and brought home a trophy! This past February, we traveled up to the U.P. of Michigan to Houghton and raced on Michigan Tech’s campus in the snow with the same 3 buggies we took to Stout. For their dynamic event, a driver started on one end of the track and drove about 200 yards through technical maneuvers. Once through that, the driver stopped in a small box, shut off the buggy, exited the buggy as quickly as possible, then tagged a team member beside the box. That team member then ran 50 yards to a
table where he had to eat a spicy pickled egg as quickly as possible. As with most previous years, we won this dynamic event, which placed us in 1st to start the four-hour endurance race. This race was a little more brutal on our buggies with the jumps they incorporated, but at the end of the 4 hours, we secured another 1st pace finish! As fun as these races are, we spend a lot of our time designing and fabricating our new buggy which goes to competition in the spring. Over the last few years, the Society of Automotive Engineers (SAE) which oversees the entire SAE Baja competition made a large change in rules, making 4WD mandatory. Last year we decided as a team to construct our very first 4WD buggy. That year was full of trouble shooting and problem solving as none of the team members knew that much about 4WD. This year, we are currently in the process of building a whole new revamped 4WD buggy. Currently, the two seniors on the team took advantage of
what they have learned in classes while in the Mechanical Engineering program to develop Iowa Baja’s first transfer case which includes a handful of gears to obtain an adequate gear ratio for torque and top speed, as well as transfer power to the front tires. Together, they’ve done gear calculations, integrated the entire 4WD system into a chassis so that other subsystems (such as suspension) can meet their goals, and measured torque in preexisting buggy to optimize the center driveshaft. As a team, we teach our members all the skills necessary to succeed in the club consisting of the hands-on skills needed to fabricate and service the buggies, soft skills which are used for presentations at our national’s events in the spring, and many skills that they’ll learn within the College of Engineering. Altogether, we work to build better engineers that will thrive in the professional engineering setting.
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American White Pelicans seen along the Iowa River in Coralville, Iowa.
ROCKET CLUB: THE SKY IS THE LIMIT
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The University of Iowa chapter of the American Institute of Aeronautics and Astronautics, AIAA or Rocket Club, for short, serves as a collaborative hub for Iowa’s aerospaceinclined students. Through its annual rocketry projects, the members of AIAA gain hands-on experience in the conceptualization, design, manufacture, and launch of high-power solid-fuel rockets. The club competes in the Midwest High-power Rocketry Competition hosted by the University of Minnesota in North Branch, MN. After a twoyear COVID-caused hiatus, the competition has resumed for the 2021-2022 school year and AIAA is hard at work on this year’s launch vehicles. Although under the umbrella of the Department of Mechanical Engineering, the club is open to all majors, and members come from a wide array of educational backgrounds. Representing physics, astronomy, and five different types of engineering, club members use their combined expertise to develop aerodynamic airframes, custom-built avionics, and secure recovery systems for each rocket. While a successful launch is the ultimate goal, the knowledge and experience gained from participating in a long-term engineering project from start to finish is the most significant and persistent impact of the club’s work. This year, the competition has challenged teams to develop a fleet of rockets technically diverse from one another. After a crash course (no pun intended) on rocket science for new members, AIAA created a set of unique and challenging problems to be consolidated into projects. Club members have been divided into three main teams, one for each group-constructed rocket. For the duration of the fall semester, each sub team identified the key design components associated with each project and conceptualized actionable technical solutions, which they have spent the spring semester building and refining. Undertaking a unique challenge this year, the club is constructing a rocket entirely through the use of 3D printing. Named “Project Hammerhead”, the rocket will have an active flight control system, allowing for the rocket to achieve stability in a controlled fashion during flight. 3D
printing a rocket allows for a great degree of flexibility in manufacturing but also creates several challenges for the team including maximum part size, thermal considerations with the propulsion motor, weight distribution, and more. To address all of these properly, the team spent several months refining the solid model of the rocket and doing a wide variety of analyses. “We started in a similar way as all the other rockets, modeling the rocket in an open-source design suite called OpenRocket, which gave us an idea of our performance characteristics,” said Jack Sieleman, club vice president and design lead for Project Hammerhead. “After that, we started making the parts in CAD and applying the correct masses and center of gravity locations to the model to make sure our stability was acceptable.” Ensuring the theoretical stability was important, but it wouldn’t matter if the 3D printed components couldn’t stand up to the forces acting on the rocket during flight. To solve this problem, the team turned to computational fluid dynamics (CFD). Knowing the rocket’s geometry and flight speed, the team was able to use CFD to study the aerodynamic stresses on the rocket and study the airflow over the fins, which is a critical step to ensure the operational capability of the active flight control system. After determining the stresses on the rocket, the team used finite element analysis, or FEA to apply the stresses to the rocket’s components and ensure no stresses would result in failure, and that no parts would deform during flight. Iterating through this process allowed the team to refine the geometry of each part to the best possible solution to maximize the rocket’s performance. With each rocket focusing on unique design characteristics, another rocket named “Project Sneaky” aims to reach maximum speed and altitude results through optimization of its design. Through multiple iterations and precise detailing in OpenRocket, Sneaky is predicted to reach Mach 1.4—faster than the speed of sound—and a maximum altitude of 9,343 feet. With an additional focus on aesthetics, Project Sneaky will include custom carbon fiber fins, a clear section of body tubing, and a 360-degree camera. One of the main design challenges of Project Sneaky includes keeping the rocket stable at its simulated
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supersonic speed. “Once rockets reach extremely high speeds, keeping the stability higher than normal and paying attention to problems such as fin flutter and increased drag forces are imperative to a rocket’s success,” explained Geraldine Kelderhouse, the club’s Treasurer and design lead for Project Sneaky. Kelderhouse also aims to analyze the effect of surface finishes on a model rocket’s drag coefficient as a class final project and apply the results to the club. Another challenge for Project Sneaky includes securing the 360-degree camera safely inside the clear tubing while still allowing it to be detachable. Special pieces designed in Creo by project members have been able to get through these unique challenges. “The utilization of 3D printing has also been very useful for Project Sneaky, as multiple custom pieces have been easily modeled and fitted to design complications that arise in the build process,” said Ian Silva, a team member under Project Sneaky. One of Silva’s designs includes a special interlocking piece to keep multiple sections of the rocket together without applying permanent or external attachments. He credits intermediate design classes such as Product Design and Realization taught by Phil Deierling for teaching advanced Creo modeling and FEA with emphasizing design creativity. With an open-ended rocket design challenge, the members of Project Sneaky have been able to expand their modeling experience outside of class and actively problem-solve obstacles throughout the stages of rocket building. One of the requirements of this year’s competition is a rocket that is built from a designated kit purchased from a vendor. All teams participating in the competition must construct the same rocket. To make it interesting, though, each team must improve on the original design as much as possible, as well as provide an estimate on flight metrics such as maximum altitude, maximum velocity, and total flight time to the best of their ability. The club’s version of this kit rocket, “Project Casanova”, aims
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to nail these numbers as close as possible. Some of the improvements to the kit include forged eye bolts, stronger kevlar shock cords, several redundant methods of obtaining precise and accurate in-flight data, and wrapping the provided plywood fins in fiberglass. Though seemingly small and insignificant on their own, Project Casanova’s improvements aim to significantly improve the rocket over its original performance level. In January, the club received a grant from the Iowa Space Grant Consortium (ISGC) for $4,100 to enable the club to compete in this year’s competition. These funds were used to purchase the material and equipment used to make all of these projects possible. For the grant application, as well as the competition itself, extensive documentation was written to show the design, manufacturing methods, and expected performance of each rocket. In addition to technical projects, AIAA puts a focus on professional development as a chapter of a national-level professional organization. In the Spring 2021 semester, the club hosted the Region V Student Paper Conference, a region-wide aerospace research symposium facilitated by the national organization. In part due to participation in the club, members have been able to secure internships and post-graduation full-time positions at companies such as Collins Aerospace. “The University of Iowa doesn’t have an aerospace engineering major,” said club President Kyle Lastine, a computer science and engineering major, “but for a group of students with diverse technical backgrounds like software, hardware, or physics to work on a project like this, I think that’s even better.” This year’s rocketry projects are nearing completion, and their launch will mark the first competition entry for the club in quite some time. In the coming years, the club hopes to reach new heights with expertise gained from participating.
The University of Iowa doesn’t have an Aerospace Engineering major, but for a group of students with diverse technical backgrounds like software, hardware, or physics to work on a project like this, I think that’s even better.
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CONVERTING BIOMASS INTO SUSTAINABLE ENERGY
At the Oakdale Powerplant in Coralville, Iowa, University of Iowa Technology Institute student research assistants are working on a project to convert woodchipped railroad ties, telephone poles, and other biomass into environmentally friendly sustainable energy. Using a biomass gasifier, the team from the Ratner Research Group takes bio-based feedstock and converts it into a synthesis gas. The synthesis gas is then used as a fuel source for the powerplant’s boiler operation, which boils water to create steam and power the turbines. The process can replace the consumption of natural gas from the boiler. “The synthesis gas is much more environmentally friendly compared to natural gas,” said Sazzad Parveg, a graduate research assistant at ITI and a third-year PhD candidate in mechanical engineering in the College of Engineering. “It can produce energy as well as reduce the emissions that come from the use of conventional fossil fuels and, in this case, natural gas fuel.” This project is one of several aimed at reusing waste products, at times contaminated waste products, and converting them into energy. The hope is to advance the research and scale it to where it can displace a portion of other energy sources. Parveg is among several students who work under the mentorship of Albert Ratner, a UI professor of mechanical engineering and ITI faculty affiliate. The group also includes undergraduate research assistants Nicholas Hentges and Nitin Nagarkar and graduate research assistant Rahat Mollick.
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Previously, the team had focused on burning corn, refusederived fuel (RDF), and other municipal solid waste (MSW) in the gasifier to create the synthesis gas. Now, Ratner’s group is working on a new project to burn creosoted woodchips derived from shredding old telephone poles and railroad ties. “Creosote is a carbonous product that is very harmful for the environment,” Parveg said. “We are exploring a way to sustainably reuse the creosoted woodchips as well as produce energy.” Typically, creosoted wood chips cannot be burned without releasing harmful chemicals. However, running the woodchips through the gasifier traps the harmful materials in charcoal and allows the wood chips to be burned as a clean source of fuel. The group’s recent work has included analyzing the gas samples from feeding a combination of corn and creosoted woodchips into the gasifier to assess the effectiveness of this combination in producing energy and reducing emissions. The gasification process also creates a charcoallike end product known as biochar. This biochar can be used in cement production, water filtration, and for mining rare Earth metals. “A benefit of this research is that we can reuse the waste as a way of producing energy,” Parveg said. “Normally waste is dumped into landfills, which is very harmful for the environment, but we can create value from that waste. We are making green fuel, we are reusing waste, and we are making the environment better.”
GRADUATE STUDENT RECEIVES AWARD AT ISEM 2021 Shobhan Roy, a third-year Ph.D. student in the Department of Mechanical Engineering, received the Excellent Presentation Award on November 18th, 2021, at the ISEM 2021 conference in Tokyo, Japan. Roy was granted this award for his “excellent presentation at the 7th International Symposium on Energetic Materials and their applications.” Roy is studying the shock response of energetic materials, such as those used in rockets and missiles. “My work is in computation modeling and understanding how these sensitive materials deform at the micro-scale due to impactinduced stresses, which will enable designers to augment the safety and performance of these materials,” he said. The computational work is part of a large AFOSR-MURI project and is performed, “tandem with experiments conducted by our collaborators at the University of Illinois, Urbana-Champaign.” Roy is currently working with Professor H.S. Udaykumar as a graduate research assistant at IIHR-Hydroscience & Engineering. He is also a College of Engineering Dean’s Fellow.
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CONGRATULATIONS
SPRING 2022 PHD GRADUATES
The Graduate Committee asked all of the PhD candidates who are graduating in May 2022 to present at the ME:6191 graduate seminars during the spring 2022 semester. (Pictured L-R) Mehedi Hasan Bappy presented on March 3, 2022. Title: Using Subgrid Scale Pressure Fluctuations for Statistical Modeling of Cavitation Inception Isaac Di Napoli presented on April 28, 2022.
Title: Sensing and Modeling of a Hydroelastic Lifting Body Ben Yuan presented on March 31, 2022. Title: Turbulent Bubble Entrainment Modeling in Ship Hydrodynamics Thomas James (TJ) Williams presented on February 17, 2022. Title: Gravity Effects on Microstructure Formation and the Columnar to Equiaxed Transition in Aluminum Alloys
UNDERGRADUATE STUDENT SCHOLARSHIP RECIPIENTS Sayre Satterwhite Rylie Tu Luke Weger Dorian William Abigail Temple
Sarah Smith Brady Kakert Jacob Gault Madison Drilling Nicole Frisbe
Thanks to the genorosity of our donors, these scholarships will help assist mechanical engineering students in funding their education! If you are interested in donating, scan the QR code on page 2 or visit me.egineering.uiowa.edu for more information.
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ALUMNI SPOTLIGHTS: WHERE ARE THEY NOW?
JESSLYN COGHLAN
ROB POHREN
CLASS OF 2019
CLASS OF 2019
I graduated from Iowa in May of 2019 with a BSE in Mechanical Engineering. I now work as a systems engineer at Collins Aerospace in Cedar Rapids, Iowa where I work at the intersection of hardware and systems engineering. I support various product lines, including new autonomy ventures as well as military training and test equipment. My time at Collins has allowed me opportunities to lead all stages of our processes – from setting requirements, to designing, testing, and building our new technologies. The strides I have made in these areas are thanks to the critical problem-solving and communication skills I developed as a young engineer at Iowa. My time at Iowa afforded me several opportunities, allowing me to explore my passion for aerospace engineering. After my sophomore year, I had the opportunity to work as a mechanical engineer at the Department of Physics and Astronomy on various NASA programs, including their current program, TRACERS. This work, with the assistance of Iowa Engineering faculty, culminated in an honors thesis. As an undergraduate, I also got involved as a teaching assistant for various mechanical engineering courses and participated in student orgs such as SWE and ASME. The many different experiences I was exposed to during my time at Iowa built a strong foundation on how to be a leader and an effective communicator. Without my time at Iowa, I would not have discovered my passions, which led me to where I am at today.
I graduated in December of 2019 with a BSE in Mechanical Engineering then started right away at John Deere. I work in Dubuque, Iowa as the Engine Integration and Cooling Design Engineer for Motor Graders. I ensure the components that make up the powertrain system such as fuel tanks, heat exchangers, and engines function to meet Deere’s rigorous vehicle performance goals. This position gives me ample opportunities to leverage my technical skills such as sizing heat exchangers or introducing a pneumatic system to an existing platform. Personal skills are also required to resolve conflicts that arise when leading new product development and investigatory projects. Both skill sets were enhanced through experiences gained while at the University of Iowa. The opportunities I had through the Iowa Baja team provided the chance to grow my personal and professional skill sets. During my Baja leadership, the soft skills acquired, and interpersonal challenges faced helped prepare me for working effectively with international teams. The technical failures and successes were excellent learning opportunities for honing my design skills before doing it “in the real world”. Reflecting back, I believe my extracurricular experiences were crucial in my personal and professional development. My best advice is to get involved and don’t ask what the org can do for you, but instead what you can do for it. Be something more - Go Hawks!
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