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Through-Thickness Reinforcement And Repair Of Carbon Fiber Based Honeycomb Structures Under Flexure And Tension Of Adhesively Bonded Joints, Aleric Alden Sanders

Mechanical & Aerospace Engineering Theses & Dissertations

Repair and reinforcement of composite honeycomb structures is an area of concern as higher demands are being placed on high strength, lightweight structural materials, such as carbon fiber reinforced plastics and corresponding honeycomb structures. A common issue with these structures is when a delamination in the facesheet may form and spread, leading to a failure scenario. An investigation of adding a through thickness reinforcement (TTR) to these structures at the sample level that undergo four-point-bending, tension, and joining methods is conducted throughout this thesis. The embedding of pultruded carbon fiber rods is found to be an ideal addition to composite …

Novel Methods For Composites Recycling Via Pyrolysis, Matt Jacobs

Undergraduate Honors Theses

Composites are unique materials in many respects. When fabric woven from carbon fibers is joined with a thermoset resin in a controlled environment, it results in a very strong material, especially evaluated on a pound-for-pound basis against metals and ceramics. One aspect of this construction that provides great strength lies in the fiber-matrix adhesion which facilitates load transfer to the reinforcement of the composite. This fiber-matrix adhesion is promoted by the polarity of the usual thermoset matrices, and properly designed sizing materials coating the fibers. It’s a two-edged sword, though. Although the resin and the fibers are quite strong together, …

Peridynamic Approaches For Damage Prediction In Carbon Fiber And Carbon Nanotube Yarn Reinforced Polymer Composites, Forrest E. Baber

Theses and Dissertations

Aerospace structures are increasingly utilizing advanced composites because of their high specific modulus and specific strength. While the introduction of these material systems can dramatically decrease weight, they pose unique certification challenges, often requiring extensive experimental testing in each stage of the design cycle. The expensive and time-consuming nature of experimental testing necessitates the advancement of simulation methodologies to both aid in the certification process and assist in the exploration of the microstructure design space.

Peridynamic (PD) theory, originating from Sandia National Lab’s in the early 2000’s, is a nonlocal continuum-based method that reformulates the equation of motion into an …

Computational Modeling Of Shock Wave Propagation In A Layered Composites, Nicholas Ryan Scott

Electronic Theses and Dissertations

Modeling and simulation of a metallic flyer plate impacting a woven glass-fiber reinforced plastic (GRP) plate at different velocities was performed using the ALE3D© finite element code. The one-dimensional strain-based shock wave propagation experimental data in terms of time history of GRP’s back surface material particle velocity, available in open literature [1], were utilized in the calibration of a continuum damage mechanics (CDM) model. The experimental data included D7 Tool Steel and 7075-T6 aluminum flyer plates and two different GRP thicknesses (6.8 mm or 13.6 mm) with varying impact velocities in the range of about 8.5 m/s to 418 m/s. …

Assessment Of Material State In Composites Using Global Dielectric State Variable, Vamsee Vadlamundi

Mechanical and Aerospace Engineering Dissertations

Composites are heterogeneous in nature and a fundamental understanding of the material response to applied mechanical, thermal, electrical and other multi-physical fields is required to efficiently design and synthesize the material system and demands attention to long-term behavior in particular. Unlike metals, composites are designed to develop distributed damage and initiation of a single microscopic crack does not individually affect the strength/life of these materials. Therefore, the primary interest is not in single local events but in the process of interaction of multiple events that have a collective global effect on the material behavior. The interaction of these local events …

Structural Health Monitoring Of Composite Parts: A Review, Jacob Pessin

Honors Theses

Structural health monitoring has the potential to allow composite structures to be more reliable and safer, then by using more traditional damage assessment techniques. Structural health monitoring (SHM) utilizes individual sensor units that are placed throughout the load bearing sections of a structure and gather data that is used for stress analysis and damage detection. Statistical time based algorithms are used to analyze collected data and determine both damage size and probable location from within the structure. While traditional calculations and life span analysis can be done for structures made of isotropic materials such as steel or other metals, composites …

Adaptive Paddle Board, Alexander Holthaus, Alexander Holthaus, Garrett Holmes, Garett Jones

Mechanical Engineering

This Final Design Review (FDR) document outlines the Adaptive Paddle Board senior project, done by four Mechanical Engineering Students at California Polytechnic State University and provides detail on the project and what the team has accomplished. The goal was to create a universally adaptive paddle board that can be used by the Central California Adaptive Sports Center for a wide range of persons with disabilities. This document highlights current research from patents and existing products, details regarding customer specifications, results from concept generation, the manufacturing and testing that went into the final design, and the process taken to get there. …

C6 Wheels, Samuel L. Pizot, Luke Martin, Josh Warner, Jonah Levis

Mechanical Engineering

This document details the C6 Wheels project being undertaken for senior design. The objective is to design and manufacture carbon fiber reinforced polymer wheels for the Cal Poly Formula Society of Automotive Engineers (FSAE) team. The wheel shells will be used on FSAE’s competition vehicles. FSAE requested the wheels to improve the handling characteristics of their vehicles by reducing the unsprung and rotational mass. They have attempted carbon fiber wheels previously but have not yet run any on their vehicles. FSAE specifically proposed the design of carbon fiber shells with an aluminum center as opposed to full carbon fiber wheels …

Micromechanics-Enriched Finite Element Modeling Of Composites With Manufacturing Or Service-Induced Defects, Alden S. Hyde

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Composite materials are increasingly used in many industries due to the high strength and low weight properties that they exhibit. Since composites are becoming more popular, they are being used in applications such as aircraft, boats, wind turbine blades, and even sports equipment. Composite behavior is complicated since they are made up of two completely different materials such as strong thin fibers and a relatively weaker resin material that hold the fibers together. It is becoming more important to understand how composites behave in different situations so that equipment designers have reliable material information in order to design safe products …

Characterization Of 3d Printed Pla With The Help Of Mechanical, Di-Electric And X-Ray Diffraction Techniques, Sai Sri Nidhi Munaganuru

Mechanical and Aerospace Engineering Theses

Additive manufacturing (AM) revolutionized many industries, i.e., Automotive, Biomedical, Aerospace and Defense. As opposed to traditional manufacturing methods, a part is manufactured layer by layer from 3D CAD models in AM. Though the vision of AM is impressive, there are many challenges that are hindering the widespread use of these complex parts. One of the main challenges is its strength that varies with different manufacturing parameters. We are going to investigate the effect of build parameters on the mechanical, electrical and crystalline properties of the additively manufactured heterogeneous material system. The goal of the thesis is to find a correlation …

Investigation Of Design, Manufacture, Analysis, And Test Of A Composite Connecting Rod Under Compression, Thomas Juhl Rohrbach

Master's Theses

Composite materials hold great potential for the replacement of traditional materials in machines utilized on a daily basis. One such example is within an engine block assembly where massive components inherently reduce the efficiency of the system they constitute. By replacing metal elements such as connecting rods, cylinder caps, or a crank shaft with composite alternatives, a significant increase in performance may be achieved with respect to mechanical strength, thermal stability, and durability, while also reducing mass. Exploration of this technology applied to a connecting rod geometry was investigated through a combination of process development, manufacturing, numerical analysis and testing. …

Freeform Extrusion Fabrication Of Advanced Ceramics And Ceramic-Based Composites, Wenbin Li

Doctoral Dissertations

"Ceramic On-Demand Extrusion (CODE) is a recently developed freeform extrusion fabrication process for producing dense ceramic components from single and multiple constituents. In this process, aqueous paste of ceramic particles with a very low binder content ( < 1 vol%) is extruded through a moving nozzle to print each layer sequentially. Once one layer is printed, it is surrounded by oil to prevent undesirable water evaporation from the perimeters of the part. The oil level is regulated just below the topmost layer of the part being fabricated. Infrared radiation is then applied to uniformly and partially dry the top layer so that the yield stress of the paste increases to avoid part deformation. By repeating the above steps, the part is printed in a layer-wise fashion, followed by post-processing. Paste extrusion precision of different extrusion mechanisms was compared and analyzed, with an auger extruder determined to be the most suitable paste extruder for the CODE system. A novel fabrication system was developed based on a motion gantry, auger extruders, and peripheral devices. Sample specimens were then produced from 3 mol% yttria stabilized zirconia using this fabrication system, and their properties, including density, flexural strength, Young's modulus, Weibull modulus, fracture toughness, and hardness were measured. The results indicated that superior mechanical properties were achieved by the CODE process among all the additive manufacturing processes. Further development was made on the CODE process to fabricate ceramic components that have external/internal features such as overhangs by using fugitive support material. Finally, ceramic composites with functionally graded materials (FGMs) were fabricated by the CODE process using a dynamic mixing device"--Abstract, page iv.

Prove Endurance Car Front Suspension, Lauren A. Williams, Logan Simon, Justine G. Kwan

Mechanical Engineering

This document details the collaborative Mechanical Engineering Senior Project with Cal Poly PROVE Lab on PROVE Lab’s Project 2; an electric vehicle designed to travel 1000 miles on a single charge. Logan Simon, Justine Kwan, and Lauren Williams are given the challenge of designing an innovative proof of concept front suspension suspension for this vehicle.

After detailed research of new suspension systems, it was determined that the innovative nature could be in the form of unique manufacturing methods, materials use, or mechanical design. At this point in time, this vehicle is a purely conceptual design with no concrete requirements. Therefore …

Investigation On Effective Modulus And Stress Concentration Factor Of 3d Reinforced Composite By Finite Element Analysis Method, Chandra Bhaskar Reddy Pittu

Mechanical and Aerospace Engineering Theses

Micromechanics of Composites aims to analyze the localized stresses inside any given constituents of the composite structure. This Thesis is focused on Calculating the effective modulus and the Stress concentration factor of the 3D straight Fiber Composite using Finite Element(FE). The compressive and a Shear response of a 3D Straight fiber composite comprising three directional E Glass Fibers reinforced in an epoxy matrix is analysed. This result is the 10% of overall Composite Ductility and a 10% of overall Shear displacement load in the orthogonal directions. FE calculations are reported to analyse the response of 3d reinforcement as of with …

Fea Of Carbon Composite As A Substitute For Steel (A992) In Case Of Square Or Rectangular Hollow Cross-Sections As Beams And Columns, Pradeep Ganesh Pai

Mechanical and Aerospace Engineering Theses

Improvement to an existing design is an ongoing and never-ending process in every field. The improvement can be in a myriad of areas like an increase in strength, reduction in weight, stiffness to a loading condition and so on. The way it is achieved can range from changing the properties of the material used by incorporating various manufacturing processes or by using an alternative material which can sustain the same loading conditions or for that matter, work better than the existing material. Composite materials like Carbon Fiber, Glass Fiber or Kevlar Fiber reinforced plastics, to name few, are being used …

Comparison Of Cross-Sectional Profiles For Side Impact Crash Structure In Passenger Vehicle, Nitish Sharma

Mechanical and Aerospace Engineering Theses

Car’s safety is most important structural criteria while designing an automotive chassis. To protect the occupants from a direct impact, the passenger cabin and the structure of the vehicle should have an appropriate stiffness so that the it absorbs any kind of impact and keeps the passenger safe. Design standards are set by various vehicle safety association around the world based on different crash situations i.e. front crash, side impact, roll over etc. Among these standards, side impact crash account for over all 40% crashes all around the world and is one of the most fatal crash scenarios. This research …

Finite Element Analysis Of Composite Reactor Pressure Vessel, Tejas Vasant Mhetre

Mechanical and Aerospace Engineering Theses

Reactor Pressure Vessel is the container designed to hold gases or liquids above atmospheric pressure. The focus of this study is to develop Finite Element Model to predict the performance of composite reactor pressure vessel subjected to extreme pressure and temperature and compare with pressure vessel manufactured using conventional materials. In the first part of the study, a pressure vessel system with Carbon steel material under design pressure and temperature have been analyzed for stresses, deformation and Safety Factor. Various loading cases have been discussed during the analysis of pressure vessel. Composite materials have been a suitable replacement to the …

Finite Element Analysis And Design Improvement Of Aerospace Composite Hinges, Gaurang Girish Sonpal

Mechanical and Aerospace Engineering Theses

Hinges are the most commonly used mechanical bearings to connect 2 objects for relative rotational motion. Modern day aerospace hinges are generally made using either Aluminum, Steel or bronze. The study analyzes the use of composite material as an alternative to traditional materials for manufacturing these hinges. The research is focused on the Finite element Analysis of a composite hinge as well as an aluminum hinge. The load capacity of both the types of hinges are compared. To improve the design of the composite hinge, a combination of composite material and aluminum is used to model a hybrid hinge design. …

Numerical Evaluation Of Energy Release Rate At Material Interfaces For Fatigue Life Predictions, Robert L. Hendrickson

All Graduate Theses and Dissertations, Spring 1920 to Summer 2023

Composite materials are becoming popular in almost all industries. Carbon-fiber and glass-fiber composites are used in aircraft, sports equipment, boats, prosthetics, and wind turbine blades. In all these applications, the composites are subjected to different loads. Loads can take the form of impact or cyclic/fatigue loading, both of which decrease the strength of composites as micro-cracks grow through the composite. Composite laminates are made up of fiber plies (thin layers of fiber) and the fibers are surrounded by a resin like epoxy. It is common for laminates to fail because of delamination growth (plies peeling apart). Small delaminations do not …

Development Of Waste-Based-Thermoplastic Composite Heat Insulators, Waseem Yousef Hittini

Mechanical Engineering Theses

The main scope of this research is to develop polymer-filler thermal insulators utilizing natural and industrial local waste such as date pit powder (DPP), devulcanized tire rubber (DVR), and buffing dust (BD). Recycling and reuse of these local wastes as fillers in insulation materials has significant benefits for the UAE environment. An objective of this work was to study the effect of the combination of these local wastes with polystyrene (PS) on the physical, mechanical, and thermal properties of the developed thermal insulators. PS was used as a matrix, mixed in different proportions with the waste fillers. Each mixture was …

High Temperature Polymer Composites Using Out-Of-Autoclave Processing, Sudharshan Anandan

Doctoral Dissertations

"High performance polymer composites possess high strength-to-weight ratio, corrosion resistance, and have design flexibility. Carbon/epoxy composites are commonly used aerospace materials. Bismaleimide based composites are used as a replacement for epoxy systems at higher service temperatures. Aerospace composites are usually manufactured, under high pressure, in an autoclave which requires high capital investments and operating costs. In contrast, out-of-autoclave manufacturing, specifically vacuum-bag-only prepreg process, is capable of producing low cost and high performance composites. In the current study, out-of-autoclave processing of high temperature carbon/bismaleimide composites was evaluated. The cure and process parameters were optimized. The properties of out-of-autoclave cured laminates compared …

Human-Robot Collaborative Force-Controlled Micro-Drilling For Advanced Manufacturing And Medical Applications, Parimal Mahesh Prajapati

Mechanical & Aerospace Engineering Theses & Dissertations

Robotic drilling finds applications in diverse fields ranging from advanced manufacturing to the medical industry. Recent advances in low-cost, and human-safe, collaborative robots (e.g., Sawyer) are enabling us to rethink the possibilities in which robots can be deployed for such tedious and time-consuming tasks. This thesis presents a robotic drilling methodology with features of force-control enabled micro-drilling and human-robot collaboration to reduce programming efforts and enhance drilling performance. A Sawyer robot from Rethink Robotics, which offers safe physical interactions with a human co-worker, kinesthetic teaching, and force control, is used as the test bed. The robot’s end-effector was equipped with …

A Micromechnics Approach To Predicting The Onset Yielding Envelope Of Particulate Composite Materials, Behrooz Karimi

Mechanical and Aerospace Engineering Dissertations

Composite materials fail for various reasons and extensive research has been conducted both experimentally and theoretically. However, theoretical prediction of composite failure by yielding seems scarce. Adding reinforcing elements to matrix significantly affects the structural behavior of composite materials. The inserted particles on one hand obstruct the progress of cracks and on the other hand cause stress concentration on the interface of the particle-matrix and eventually influence the ultimate strength of the material. In this research, we study the interface stresses and strength in particulate reinforced composites under uniform mechanical and thermal loading. We theoretically obtain failure envelopes for particulate …

Strength And Damage Prognosis Of Adhesive Bond And Inter-Ply Hybrid Composites Based On Dielectric Properties, Priyanshu K. Banerjee

Mechanical and Aerospace Engineering Theses

Composite materials have found their applications in a wide range of industries particularly in the aerospace and automotive sectors. This is because they are comparatively light-weight and provide a much better corrosion and wear resistance as compared to other ceramics and metals. Adhesive bonding can be used to improve the stress distribution between these composite materials. Moreover, adhesive bond decreases the weight and concentration of stresses in the structure. Broadband Dielectric Spectroscopy, BbDS is a robust tool used for analyzing the dielectric properties of a polymer composite. This method can be used to monitor the curing process of the specimen. …

Investigation On Metal-Composite Hybrid Flywheels Using Finite Element Method, Ching Huai Wang

Mechanical and Aerospace Engineering Theses

This research is aimed to investigate the kinetic energy storage of a hybrid metal-composite flywheel rotating at high speeds. The upper limit of energy, which flywheel can supply, is restricted by the strength of material because both energy and stress are proportional to the density of the material and the square of the velocity. Metal flywheels operate at lower rotational speed and supply less energy than the composite flywheels. Composite flywheels have a very high density per unit mass, but lower energy density per unit of the design volume. The ultra-high speed of composite flywheels creates some engineering challenges such …

Analysis Of Composite Structures With Curvature Under Temperature Environment, Muthu Ram Prabhu Elenchezhian

Mechanical and Aerospace Engineering Theses

Composite structures are frequently exposed to environments with change in temperatures during their service life. The thermal behaviours of the laminated composite structures are more pronounced than that of the structures made of isotropic materials. For the structures under thermal environment, extensive studies have been conducted to investigate the induced thermal stresses and deformation of composite laminated plates by linear/non-linear analysis and composite structures by finite element analysis. The main focus of this study is concentrated on development of an analytical method for analyzing composite thin shells and/or moderate curved beam structures under temperature environment. This includes the derivation of …

Advanced Methods Of Nondestructive Inspection Of Composite Structures Based On Limited Angle X-Ray Computed Tomography, Ekaterina Bostaph

Mechanical and Aerospace Engineering Dissertations

This research aimed to study the potential for breaking through object size limitations of current X-ray computed tomography (CT) systems by implementing a limited angle scanning technique. CT stands out among other industrial nondestructive inspection (NDI) methods due to its unique ability to perform 3D volumetric inspection, unmatched micro-focus resolution, and objectivity that allows for automated result interpretation. This work attempts to advance NDI technique to enable microstructural material characterization and structural diagnostics of composite structures, where object sizes often prohibit the application of full 360o CT. Even in situations where the objects can be accommodated within existing micro-CT configuration, …

Drawing And Twisting Of Graphene Fibers, Gregory T. Lane, Robert J. Sekerak, Isaias Diaz

Mechanical Engineering

The aim of this project was to develop a more automated process for drawing and twisting of graphene fibers than was currently in place. This was implemented by having two chemical baths with variable speed rollers at either end, and intermediate roller to spool fiber between stages, and a twisting cylinder with integral spool to twist the fiber as it is collected. The goal was to have this first iteration deliver a working prototype, however due to manufacturing delays and timing constraints, that will be missed. A second follow-on project would be able to continue the work presented here and …

Finite Element Analysis Of Composite Aircraft Fuselage Frame, Aditya Milind Dandekar

Mechanical and Aerospace Engineering Theses

Composites have been introduced in aircraft industries, for their stronger, stiffer, and lighter properties than their metal-alloys counterparts. The general purpose of an aircraft is to transport commercial or military payload. Aircraft frames primarily maintains the shape of fuselage and prevent instability of the structure. Fuselage is similar as wing in construction which consist of longitudinal elements (longerons and stringers), transverse elements (frames and bulkheads) and its external skin. The fuselage is subjected to forces such as the wing reactions, landing gear reaction, empennage reaction, inertia forces subjected due to size and weight, internal pressure forces due to high altitude. …

Load Carrying Capacity Management Of Compound Anisotropic Composite Rings Under External Pressure, Salman Bakhrayba

Mechanical and Aerospace Engineering Theses

Composites have much higher strength than conventional materials such as steel. This makes it attractive to replace heavy loaded structural elements, made traditionally from steel, by elements made from composites. However, it is not a trivial task for statically indeterminate structures due to anisotropy of elastic and strength properties of composites. Present investigation is done for a ring subjected to external load. Such rings are used as bulkheads in many applications. Dependence of ultimate external pressure on thickness of the ring is nonlinear one. It is related to non-uniformity of distribution of circumferential stresses, with anisotropy of material, with set …