Engineering Commons^™

A Two-Diameter Helical Endmill Beam Model For Tool Tip Dynamics Prediction With Application To Milling, Emma D. Betters

Doctoral Dissertations

The aim of this dissertation is to describe the dynamic response of helical endmill geometries to enable the use of receptance coupling substructure analysis (RCSA) to predict the tool tip vibration response of arbitrary tool-holder-spindle-machine combinations. The tool tip vibration response, or receptance, is a key input for milling stability prediction. Currently, a measurement is required to determine the tool tip receptance for each tool-holder-spindle-machine combination, which may not be possible in production environments. In the RCSA approach, the spindle receptances are measured once and archived, while the tool and holder are modeled. Tool tip receptances are predicted by analytically …

Additively Manufactured Nature Inspired Morphology For Redesign: Advancing Next Generation Energy Systems, Vanshika Singh

Doctoral Dissertations

To meet cleaner energy goals and increasing demand, energy systems such as gas turbines and power plants are required to be operated under harsh loading conditions like higher temperatures and pressures, fluctuating loads, and corrosive environments. Advanced manufacturing techniques such as additive manufacturing (AM) have put us on the trajectory for next-generation system designs, allowing complex geometries and high-temperature alloys with tailored material properties. We need new and systematic design philosophies to use AM's unique characteristics prudently. For a given functionality, nature tends to provide similar solutions in animate and inanimate structures. We propose to take inspiration from nature's repetitive …

Modular Composite Sandwich Structures For Thermal And Structural Retrofitting Of Existing Buildings, Marc Al Ghazal

Masters Theses

Around 40% of global energy consumption and 30% of worldwide carbon dioxide (CO2) emissions are attributed to buildings. Most of this consumption is dedicated to ensuring thermal comfort. The goal of this research was to develop and field validate retrofit solutions to improve the energy efficiency of buildings. Exterior cladding panels were designed and tested to ensure adequate thermal and structural performance. Sandwich panels (glass fibers reinforced polymer (GFRP) skins and polymeric foam cores) were fabricated using the vacuum assisted resin transfer molding (VARTM) process. Extruded polystyrene (XPS) and polyurethane (PU) foams were compared as core materials through a series …

Spall Characteristics Of Additively Manufactured Stainless Steel, Kevin Lamb

Doctoral Dissertations

Additive manufacturing (AM) has rapidly transformed from a novelty prototyping technology into a growing sector of production across a wide range of industries. Much work has been documented in literature to demonstrate the behavior of AM products under static and quasi-static loading conditions. However, the behavior of AM materials under high strain rate loading is not as well understood. This research attempts to advance the fundamental knowledge of the relationship between the unique aspects of AM and the mechanical performance under high velocity impact loading conditions.

This project examines the behavior of AM 316L stainless steel (SS) exposed to high …

In Situ Process Monitoring And Machine Learning Based Modeling Of Defects And Anomalies In Wire-Arc Additive Manufacturing, Eduardo Miramontes

Masters Theses

Wire Arc Additive Manufacturing (WAAM) has made great strides in recent years however, there remain numerous persistent challenges still hindering more widespread adoption. Defects in the parts produced degrade their mechanical performance. Inconsistency in the geometry of the weld beads or undesirable anomalies such as waviness, or humps can lead to loss of geometric accuracy and in extreme cases, when anomalies propagate to subsequent layers, build failure. Such defects can be mitigated by a controls framework, which would require a model that maps undesirable outcomes to information about the process that can be obtained in real time. This thesis explores …

Design Of Machine Tool Cross Beam Using Metal Big Area Additive Manufacturing, Tyler Poon

Masters Theses

The modern world would not be what it is now without machine tools. Advances in materials and processes, such as carbon fiber and additive manufacturing (AM), enable the design space for machine tool components to expand. However, machine tool components require accurate geometry, which is not available from parts produced by metal Big Area Additive Manufacturing (mBAAM). This project outlines the process in which a traditionally manufactured machine tool component, a welded box structure on an existing machine tool, was redesigned to be made using mBAAM. The goal was to design a structure that was printable using the MedUSA system …

Correlating Large-Format Additive Manufacturing Processing Parameters To Fiber Length And The Mechanical Performance Of Reinforced Polymer Composites, Andrew Phillip Rhodes

Masters Theses

The Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory has been used to produce carbon fiber reinforced structures for several years, including vehicles, building constituents, composite tooling, etc. While the development of a large-format polymer additive manufacturing (AM) system has moved quickly, the impact of the BAAM’s extruder on the length of carbon fiber feedstock has not been systematically studied. Numerous studies in processing fiber reinforced thermoplastics in plasticizing and injection molding systems have shown that fibers are subjected to significant shear as they are processed, which can cause a drastic reduction in fiber length which negatively …

Comparative Analysis On Low Cost Continuous Carbon Fiber Polypropylene Composite Using Compression Molding And Automated Tape Placement, Benjamin U. Schwartz

Masters Theses

Carbon fiber reinforced plastics (CFRP) are widely used throughout the aerospace industry where a weight reduction remains the highest priority with less emphasis on cost. Textile grade carbon fiber (TCF) and other low cost carbon fiber (LCCF) alternatives have recently emerged for use in the automotive market where emissions regulations have pushed automotive manufacturers and research institutions to look for cost effective light weight materials. Fiber reinforced thermoplastics provide an effective solution that align with automotive design including low cost, high processing rates, high impact toughness, unlimited shelf life, and recyclability.

TCF and Zoltek_PX35 fibers are two LCCF aimed at …

Repeatability And Reproducibility Analyses For Structured Light Scanning, Leah Jacobs

Masters Theses

Structured light scanning is used to create a digital twin of a manufactured part. Features can be extracted from this digital twin to determine if the part meets the designer’s intent and required tolerances. This paper describes a repeatability and reproducibility study for a selected structured light scanning system and measurement artifact.

Path Planning For Additive Manufacturing Of Wire Arc Additive Manufacturing And Blue Light Fringe Projection Scanning, Tiffany Patricia Quigley

Masters Theses

Current methods of manufacturing large scale parts can take up to six months to generate the objective product. The objective of the wire arc additive manufacturing (WAAM) hybrid cell is to significantly reduce lead time associated with large scale parts. The WAAM process utilizes a 6 degree-of-freedom (DOF) robot manipulator in addition to a 2 DOF part positioner. 5 degrees of freedom are necessary for an effective WAAM process, leaving 3 DOF as redundant in this cell. This thesis serves to prove successful implementation of redundant kinematics on a WAAM robotic system. This is accomplished by maintaining a gravity aligned …

Optimized 3d-Printing Of Carbon Fiber-Reinforced Polyether-Ether-Ketone (Cfr-Peek) For Use In Overmolded Lattice Composite, Ryan C. Ogle

Masters Theses

Current orthopedic implants are overwhelmingly composed from metallic materials. These implants show superior mechanical properties, but this can additionally result in stress shielding due to a modulus mismatch between the bone tissue and implanted device. Polymeric implants reduce this stress shielding effect but have much lower mechanical properties, limiting their use. Polylactic acid (PLA) is a widely used biodegradable thermoplastic polymer, however, its use has been limited by the polymer’s mechanical properties and rapid loss of strength during degradation in vivo. Polyether-ether-ketone (PEEK) is another common biocompatible polymer , with chemical and mechanical properties which make it a popular alternative …

Aluminum-Based Material Fabrication By Friction Stir Processing: Microstructural Evolution And Mechanical Properties, Suhong Zhang

Doctoral Dissertations

Friction stir processing (FSP) is an energy efficient solid-state material processing technique for microstructure modification of commercial high-strength Al alloys. Many variant techniques were developed in recent years that enabled light-weight and high-strength structure fabrication. Identifying relationship among process conditions, microstructures, and mechanical properties is of critical importance to facilitate the practical implementation of these new techniques. The research in the dissertation focusses on developing two main techniques of the FSP: a) friction stir back extrusion (FSBE) of 6063 aluminum alloy for tube making and b) FSP of 7075 aluminum alloy from powder feedstock. FSBE fabricated Al 6063 alloy tubes …

Modelling, Sensing, And Control Of Weld Beads In Gravity Aligned And Non-Gravity Aligned Orientations For Wire Arc Additive Manufacturing, Joshua J. Penney

Doctoral Dissertations

Wire Arc Additive Manufacturing (WAAM) has recently developed into a viable manufacturing process for large, complex metal parts. The WAAM process uses a Gas Metal Arc Welding (GMAW) torch mounted to an automated motion platform to execute a predetermined path plan based on a desired CAD geometry. As the desired geometry becomes more complex, it is advantageous to utilize out-of-position welding techniques used by human welders to stabilize the weld pool during the deposition of large overhangs. To ensure part accuracy and quality, adding layers of real-time control to manage various aspects of the WAAM process is critical. First, a …

Trajectory Planning Of Non-Gravity Aligned (Nga) Segments In Arbitrary Directions For Large Scale Additive Manufacturing Of Metals (Lsamm), James Logan Mcneil

Doctoral Dissertations

Traditionally, slicing and path planning are done along the gravity-aligned direction of a part, causing more complex geometrical shapes to have unsupported overhangs. Wire Arc Additive Manufacturing (WAAM) has typically handled overhangs with a robotic part positioner; but, to extend the current capabilities of LSAMM, a new framework for slicing and building parts out of gravity alignment has been developed. The proposed framework focuses on segmenting more complex geometrical parts into gravity-aligned (GA), non-gravity aligned (NGA), and transition zones to support tool-path generation. GA and NGA segments can be planned with traditional slicing techniques, but the NGA tool-paths must be …

Sensor Comparison For Low-Cost Dynamic Force Measurement In Milling, Zachary Mason

Masters Theses

Machine cutting forces are commonly measured using piezoelectric dynamometers. Such dynamometers can be prohibitively expensive and may still require extensive post processing. Previous work used a low-cost single degree of freedom constrained motion dynamometer (CMD) in conjunction with a knife edge sensor to determine the cutting forces through inverse force filtering. In that approach, the measured displacement of the CMD was transformed into the frequency domain by the fast Fourier transform (FFT) and convolved with the inverted receptance frequency response function (FRF) to yield force in the frequency domain. The force was then converted to the time domain using the …

Eastman Guide Rail Project, Camryn J. Hurley, Jace Lyon, Isaiah Wallace, Cole Thomas, Erin Bennett

Chancellor’s Honors Program Projects

No abstract provided.

Processing Of Preceramic Polymers For Direct-Ink Writing, James W. Kemp

Doctoral Dissertations

Preceramic polymers are organosilicon polymers that, when pyrolyzed to above 1000°C, convert from a polymer to an amorphous ceramic. These polymers have been used for fiber spinning, polymer infiltration, and casting of materials but have recently gained interest for use as the feedstock material for additive manufacturing techniques. This work explores preceramic polymers being used for direct-ink writing (an additive manufacturing method) and many of the issues that occur with the polymers during curing and pyrolysis.

The first chapter of this dissertation provides a review of preceramic polymers, while the second and third chapters focus on the development of inks …

Structural Stability Of Thermosets During Material Extrusion Additive Manufacturing, Stian K. Romberg

Doctoral Dissertations

Over the past decade, the scale of polymer additive manufacturing has been revolutionized with machines that print massive thermoplastic parts with greater geometric complexity than can be achieved by traditional manufacturing methods. However, the heat required to print thermoplastics consumes energy and induces thermal gradients that can reduce manufacturing flexibility and final mechanical properties. With the ability to be extruded at room temperature and excellent compatibility with fibers and fillers, thermoset resins show promise to decrease the energy consumption, expand the manufacturing flexibility, and broaden the material palette offered by large-scale polymer additive manufacturing. However, structural instability in the uncured …

Innovations In Aligned And Overmolded Long Fiber Thermoplastic Composites, Shailesh P. Alwekar

Doctoral Dissertations

Long fiber thermoplastic (LFT) composite materials are increasingly used in high performance lightweight automotive, sporting, and industrial applications. LFT composites are processed with extrusion-compression molding (ECM) and/or injection molding (IM). Melt extrusion offers unique opportunities to align long fibers in a thermoplastic polymer melt. The properties of LFT materials are highly influenced by processing techniques which leads to different porosity content, fiber length distribution, and fiber orientation distribution. Hence, it is important to understand the various LFT processing techniques and their effect on mechanical, thermal, and microscopic properties.

The fundamental process-property relationships in LFT composites are investigated in this dissertation. …

Assessing Mechanical Performance Of Dissimilar Steel Systems Made Via Wire-Arc Additive Manufacturing, Obed Daniel Acevedo

Masters Theses

Hot stamping is part of a specific type of metalworking procedure widely used in the automotive industry. This research seeks to help make hot stamp tooling component production more cost-effective by using large-scale additive manufacturing. Additive manufacturing can produce dissimilar steel components that can be more cost-effective and time-efficient and allow for complex geometries to be made. A dissimilar steel system consisting of 410 martensitic stainless steel and AWS ER70S-6 mild steel is proposed to make hot stamps, making them more cost-efficient. However, the material interface's mechanical behavior in 410SS-mild steel additively manufactured material systems is not well understood. This …

Digital Cutting Force Modeling For Milling Operations, Timothy T. No

Doctoral Dissertations

Process improvement in milling through improved understanding of machining dynamics is an on-going research endeavor. The objective of this project is to advance digital modeling of the milling process by incorporating tool-specific geometry in the machining analysis. Structured light scanning will be used to perform tool geometry measurements and produce a 3D model. The 3D model data will include the spatial location of the cutting edges, as well as the rake and relief profiles from the tool cross section. The rake and relief profiles will be imported, together with the work material flow stress model, into a finite element analysis …

Transients In Plastic Instabilities During Thermo-Mechanical Reversals In An Additively Manufactured Ti6al4v, Sabina C. Kumar

Doctoral Dissertations

A complex interaction of process variables in an evolving geometry during Additive Manufacturing (AM), can bring about spatial and temporal transients of temperature and stress within each layer in a part. Although AM shares commonalities with conventional processing techniques such as casting, welding, and thermo-mechanical process, published literature has shown that the steady-state conditions are not strictly valid during AM process. Macro-scale fluctuations of thermal gradients (dT/dx: 10³ to 10⁷ K/m) combined with local changes in thermal expansion coefficients, crystallographic strains and localized stress-strain constitutive properties in conjunction with thermal cycles, can bring about a plastic strain gradient …

3d Printing Of Hybrid Architectures Via Core-Shell Material Extrusion Additive Manufacturing, Robert Cody Pack

Doctoral Dissertations

Biological materials often employ hybrid architectures, such as the core-shell motif present in porcupine quills and plant stems, to achieve unique properties and performance. Drawing inspiration from these natural materials, a new method to fabricate lightweight and stiff core-shell architected filaments is reported. Specifically, a core-shell printhead conducive to printing highly loaded fiber-filled inks, as well as a new low-density syntactic foam ink, are utilized to 3D-print core-shell architectures consisting of a syntactic epoxy foam core surrounded by a stiff carbon fiber-reinforced epoxy composite shell. Effective printing of test specimens and structures with controlled geometry, composition, and architecture is demonstrated …

Process-Structure-Property Relationships In 3d-Printed Epoxy Composites Produced Via Material Extrusion Additive Manufacturing, Nadim S. Hmeidat

Doctoral Dissertations

Extrusion-based additive manufacturing (AM) technologies, such as direct ink writing (DIW), offer unique opportunities to create composite materials and novel multi-material architectures that are not feasible using other AM technologies. DIW is a novel 3D-printing approach in which viscoelastic inks, with favorable rheological properties, are extruded through fine nozzles and patterned in a filament form at room temperature.

Recent developments in DIW of polymer composites have led to expanding the range of materials used for printing, as well as introducing novel deposition strategies to control filler orientation and create improved functional/structural composite materials. Despite these substantial advancements, the successful and …

Displacement-Based Dynamometer For Milling Force Measurement, Michael F. Gomez

Doctoral Dissertations

This project will study the design and testing of a low-cost dynamometer for milling dynamic force measurement. The monolithic design is based on constrained-motion/flexure-based kinematics, where force is inferred from displacement measured using a low-cost optical interrupter (i.e., a knife edge that partially interrupts the light beam in an emitter-detector pair). The time-dependent displacement of the dynamometer’s moving platform caused by the milling force is converted to the frequency domain, multiplied by the inverse of the dynamometer’s ideally single degree of freedom (SDOF) frequency response function (FRF), and converted back into the time-domain to obtain the time-dependent cutting force. The …

Design And Fabrication Of Invar Layup Tool Molds Using Additive And Subtractive Manufacturing, Matthew Lamsey

Masters Theses

The development of novel additive manufacturing technologies, such as Wire Arc Additive Manufacturing (WAAM), has opened the door for the fabrication of complex part geometries that could not be achieved with traditional manufacturing methods. Best practices for designing parts for fabrication with WAAM are still in their infancy. This thesis presents a novel design and fabrication framework for parts created using WAAM, which was realized through the fabrication of two demonstration composite layup tool molds. The framework includes design principles for WAAM, finite element simulation of part performance, metrological analysis of printed preforms, and considerations for closely integrating the WAAM …

Design Of A Cable-Driven Manipulator For Large-Scale Additive Manufacturing, Phillip Chesser

Masters Theses

Additive manufacturing of concrete is a growing field of research, yet current motion platforms do not offer viable routes towards large scale deployable systems. This thesis presents the design and analysis of a novel cable-driven robot for use in large scale additive manufacturing. The system developed, termed SkyBAAM, is designed to be easily deployable to a construction site for on-site additive manufacturing of buildings and other large structures. The design philosophy behind this system is presented. Analysis of this system first explores the kinematics, and stiffness as a function of cable tension. Analysis of the workspace and singularities is also …

Development Of Data Science Tools For Part Qualification In Additive Manufacturing, Sujana Chandrasekar

Doctoral Dissertations

In recent years, metal additive manufacturing processes have become popular choices for part production especially for low volume, high complexity parts. To enable widespread adoption of these methods, it is essential to understand the link between process parameters and part properties. This is particularly because additive manufacturing processes cause inherently complex thermo-mechanical cycles and drastically different local process conditions within a part, compared to conventional manufacturing processes like casting and forging. Additionally, properties of feedstock material like metal powder impact final part properties. The focus of this dissertation is on development of data-driven methods using in situ monitoring, as a …

Mechanics Of The Solid-State Bonding Under Severe Thermomechanical Processes, Xue Wang

Doctoral Dissertations

Friction stir welding (FSW) has found increased applications in automotive and aerospace industries due to its advantages of solid-state bonding, no fusion and melting, and versatility in various working conditions and material combinations. The extent and quality of the solid-state bonding between workpieces in FSW is the ultimate outcome of their industrial applications. However, the relationship among processing parameters, material properties, and bonding extent and fidelity remains largely empirical, primarily because of the lack of the mechanistic understanding of (1) tool-workpiece frictional behavior, and (2) bonding formation and evolution.

In this dissertation, to study the underlying mechanism of tool-workpiece frictional …

Vibration Behavior In Modulated Tool Path (Mtp) Turning, Ryan William Copenhaver

Doctoral Dissertations

This project studies the process dynamics and surface finish effects of modulated tool path (MTP) turning. In MTP turning, a small amplitude (typically less than 0.5 mm), low frequency oscillation (typically less than 10 Hz) is superimposed on the feed motion by the machine controller to intentionally segment the traditionally long, continuous chips. The basic science to be examined is the vibration behavior of this special case of interrupted cutting, which is not turning because the chip formation is intentionally discontinuous and is not milling because the time-dependent chip geometry is defined by the oscillatory feed motion, not the trochoidal …