Manufacturing Commons^™

Mechanistic Modeling Of High Velocity Micro-Particle Impacts: Application To Material Deposition By Cold Spray Process, Baran Yildirim

Mechanical Engineering Dissertations

The cold spray process is an additive manufacturing technology primarily suited for ductile metals, and mainly utilized in coating surfaces, manufacturing of freeform parts and repair of damaged components. The process involves acceleration of solid micro-particles in supersonic gas flow and coating build-up by metal bonding upon high velocity impact (300-1200 m/s) onto a substrate. Coating deposition relies on the kinetic energy (impact velocity) of the particles. The main objective of this research was to investigate the mechanics of metal bonding upon high strain-rate deformation in order to improve the technological implementation of the process. The research covers a ...

An Observational Study Of The Methods And Progress In Enterprise Lean Transformation At A Learning Health Care Organization, Christopher Michael Rosenbaum

Theses and Dissertations--Manufacturing Systems Engineering

The health care industry in the United States is increasingly pressured to improve safety and quality performance and increase revenue. In response, many health care institutions are moving to redesign their processes and practices in an effort to decrease costs and provide safer, higher quality, and more efficient care. The purpose of this paper is to document the Lean implementation strategy and progress in implementation at a large teaching health care organization undergoing Lean transformation in order to understand enterprise transformation strategies and the impact of leadership involvement on culture development and Lean implementation. Through direct observations and involvement and ...

Formula Sae Turbocharger Engine Development, Eric Griess, Kevin Mccutcheon, Matthew Roberts, William Chan

Mechanical Engineering

This project, Formula SAE Turbocharger System Development, was sponsored by the Cal Poly, San Luis Obispo Formula SAE team. The team proposed this project in order to have a powerful yet lightweight engine so they can be extremely competitive at their competition. The baseline output of the single cylinder 450cc engine (2006 Yamaha WR450F) was 46 horsepower and 27 ft-lb of torque. The goal of this project was to increase the output of that engine to 60 horsepower and 35 ft-lb through the use of a turbocharger.

Design And Optimization Of A Keycard Encoding Machine, Elliott Oberg

Biomedical Eng/General Eng.

Security on college campuses is a good thing, especially when it comes to your dorm room or apartment building. But due to high initial cost, the Housing and Business Department at Cal Poly, San Luis Obispo, has opted for a proprietary door lock system which requires encoding new keycards manually for every resident, every year. The goal of this project is to offset this labor cost and drain on resources by automating the keycard encoding process. This project will address the design specifications and economic advantages of automation while also exploring and comparing alternative solutions.

Supplier Sustainability Evaluation Utilizing Multi Attribute Utility Modeling, Scott E. Ladd

Theses and Dissertations--Manufacturing Systems Engineering

Conventionally, the focus during supplier evaluation has been to assess cost, quality and delivery effectiveness due to their impact on profitability. In recent years, there has been increased emphasis on promoting more sustainable business practices that focus on reducing environmental impact and improve societal well-being, in addition to economic benefits. However, most of the existing supplier evaluation methods in literature as well as those used by leading companies fall short of comprehensively assessing suppliers from a Triple Bottom Line (TBL) perspective. TBL defined as holistically looking at the economic, environmental, and societal aspects of an entity. This paper presents a ...

Mitigation Of Pore Generation In Laser Welding Of Magnesium Alloy Az31b In Lap Joint Configuration, Masoud Harooni, Fanrong Kong, Blair Carlson, Radovan Kovacevic

Mechanical Engineering Research

Magnesium, as the lightest structural metal, has been widely used in the automotive and aerospace industries. Porosity is the main issue in the welding of magnesium alloys and can be caused by surface coatings, hydrogen gas, pre-existing porosity, the collapse of an unstable keyhole and vaporization of alloying elements. In this study, the effect of the oxide layer on pore generation in the welding of AZ31B-H24 magnesium alloy is investigated. A fiber laser with a power of up to 4 kW is used to weld samples in a lap joint configuration. Two groups of samples are studied: as received (AR ...

Studying The Effect Of Laser Welding Parameters On The Quality Of Zek100 Magnesium Alloy Sheets In Lap Joint Configuration, Masoud Harooni, Fanrong Kong, Blair Carlson, Radovan Kovacevic

Mechanical Engineering Research

Magnesium, as the lightest structural metal, has been widely used in the automotive and aerospace industries. Porosity is the main issue in the welding of magnesium alloys and can be caused by surface coatings, hydrogen gas, pre-existing porosity, the collapse of an unstable keyhole and vaporization of alloying elements. In this study, the effect of the oxide layer on pore generation in the welding of AZ31B-H24 magnesium alloy is investigated. A fiber laser with a power of up to 4 kW is used to weld samples in a lap joint configuration. Two groups of samples are studied: as received (AR ...

Wolfpack Gear Inc. Composite Frame Firefighter Backpack, Gabriel Mountjoy, Blair Ridings, Carl Drummond Buchenroth

Mechanical Engineering

No abstract provided.

Sustainability For Die Manufacturing: Comparative Study Of Wedm And Milling, Matthew S. Kalus

Mechanical (and Materials) Engineering -- Dissertations, Theses, and Student Research

Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society. Concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries are the most well known industries that machine harder materials using mills and WEDM. The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute ...

Tribometer-Based Quantifying Of Friction In Metal Cutting, Jeremy Boyd

Open Access Dissertations and Theses

The objective of this research was the further development and characterization of a heavy load, high temperature pin on disc tribometer. The goal of performing this testing on the tribometer is to simulate realistic machining conditions experienced between a tool and workpiece ‘offline’ in order to reduce the number of real machining trials used to select a tool coating and subsequently optimize cutting parameters. This approach is based on the understanding that a change in the cutting speed can alter the tool-chip interface temperature profile, which can change the coefficient of friction (COF) between the tool and workpiece and impact ...

Fea Modeling Of A Tribometer’S Pin And Disk Interaction, Haoyu Li

Open Access Dissertations and Theses

A bench scale tribometer, developed at the McMaster Manufacturing Research Institute (MMRI) was designed for mimicking the friction and wear conditions on the rake face of a metal cutting tool. It provides insight into the performance of cutting tools operating under high stress and high temperature machining conditions. It saves test material costs, reduces machine downtime for testing, increases the number of test replicates and effectively adds a reliable testing tool to characterize metal cutting operations.

A detailed investigation into the stress distribution, temperature profile and indentation pattern has been performed in order to verify the ability of the device ...

Process Optimization In Machining: An Applied Research Approach, Simon M. Oomen-Hurst

Open Access Dissertations and Theses

The objective of this research was to work with industrial partners to develop and apply innovative and intelligent improvement to their production processes in order to achieve a higher level of productivity and quality while lowering cost.

Two projects were completed and are discussed in this work. The first project was focused on improving tooling in a milling process of high value parts by varying coatings and geometries of the tooling. The second project involved implementing statistical process control (SPC) using control charts and process capability metrics through customized software.

In the first project, the industrial partner was experiencing rapid ...

Design, Construction, And Evaluation Of An Automated Chicken Coop Door, Kyle Inks

BioResource and Agricultural Engineering

This senior project takes a look into the design, construction, and evaluation of an automated chicken coop door. The idea and need for such a door came from my mother Jan Inks. The parameters for the project include, low production cost, easy installation on existing coops, sleek design, automatically open at a set time in the morning, and automatically close at a set time in the evening.

Recreational Nordic Sit Ski, Mathew Bissonnette, Johnathon Gorski, Kevin Izumiya

Mechanical Engineering

The purpose of this project was to design, build, and test a recreational Nordic sit ski for use by Disabled Sports Eastern Sierra. The goal was to improve adjustability and reduce weight compared to previous sit ski designs. The project was completed by Cal Poly Mechanical Engineering seniors Mathew Bissonnette, Johnathon Gorski, and Kevin Izumiya. Kinesiology seniors Harpreet Saini and Carl Anderson provided discipline support and disability etiquette training.

The project was sponsored by the National Science Foundation Research to Aid Persons with Disabilities (RAPD) grant. The grant was proposed by and awarded to Dr. Brian Self and Dr. James ...

Vibration And Buckling Of Cross-Ply Composite Beams Using Refined Shear Deformation Theory, Thuc Vo, Fawad Inam

Aeronautical Engineering

Vibration and buckling analysis of cross-ply composite beams using refined shear deformation theory is presented. The theory accounts for the parabolical variation of shear strains through the depth of beam. Three governing equations of motion are derived from the Hamilton’s principle. The resulting coupling is referred to as triply coupled vibration and buckling. A two-noded C1 beam element with five degree-of-freedom per node is developed to solve the problem. Numerical results are obtained for composite beams to investigate modulus ratio on the natural frequencies, critical buckling loads and load-frequency interaction curves.

Large Eddy Simulation (Les) Of Glass Fibre Dispersion In An Internally Spout-Fluidised Bed For Thermoplastic Composite Processing, Xiaogang Yang, Xiaobing Huang, Yuan Zong, Grance Dai

Aeronautical Engineering

Large eddy simulation (LES) has been conducted to investigate glass fibre dispersion in an internally spout-fluidised bed with draft tube and disk-baffle, which was used in the manufacture of long glass fibre reinforced thermoplastic composites. The LES results have demonstrated that the internally spout-fluidised bed with draft tube and disk-baffle can remarkably improve its hydrody-namic behaviour, which can effectively disperse fibre bundles and promote pre-impregnation with resin powder in manufacturing fibre reinforced thermoplastics. The hydrodynamics of the spout-fluidised bed has been investigated and reported in a previous paper (Hosseini et al., 2009). This study attempts to reveal important features of ...

Human Powered Helicopter: Rotor Structure, Joseph Ram, Juan Carlos Olvera

Mechanical Engineering

The following report encompasses the Human Powered Helicopter Rotor Team’s conceptual models and ideas based on research and modeling analysis. The following gives an overview of material researched, concept generation, analyzation, manufacturing, and testing for a rotor structure to be installed in a Human Powered Helicopter.

Formula Hybrid Drivetrain Design, Zachary (Zak) Mcfarland, Alex Pruitt, William Domhart

Mechanical Engineering

The Formula Hybrid senior project group was tasked with designing and building a drivetrain system for the Cal Poly Society of Automotive Engineers (SAE) Formula Hybrid (FHSAE) team. FHSAE gave customer requirements for performance and geometry for the drivetrain and the FHSAE rulebook has guidelines regarding safety requirements. The team chose to compete in the electric category of the 2012 FHSAE competition. After getting feedback from previous car performance and researching different powertrain options, the senior project team arrived at three conceptual ideas. Using a quality function deployment method, the senior project team chose the concept where two motors independently ...

The Hovering Ball Exhibit, Matthew Bauzon, Will Lennox, Michelle Swan

Mechanical Engineering

No abstract provided.

Design Of An Independent Star-Clip Organizer (Iso), Christopher Gonzales, Greg Lovasik, Daniel Silveira

Mechanical Engineering

Discussed below is a new concept to sort and deliver star clips for flight deck safety net manufacturing. Multiple methods were generated, along with the necessary research, and were narrowed down to a single concept: the tray-loading preprocess design, named ISO (Independent Star-Clip Organizer). The overall design has been finalized and designed. Due to budget constraints, an actual prototype was not built. However, the design of such a prototype is described by this report, backed with calculations and experimental testing.