Engineering Commons^™

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 …

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

Characterization Of Mechanically Recycled Polylactic Acid (Pla) Filament For 3d-Printing By Evaluating Mechanical, Thermal, And Chemical Properties And Process Performance, Mahsa Shabani Samghabady

All Theses

Polylactic acid (PLA) is a biopolymer made from renewable resources such as sugar and corn. PLA filament is a popular material used in Fused Deposition Modeling (FDM) 3D-printing. While this material has many advantages, all the failed parts, support structures, rafts, nozzle tests, and the many prototype iterations during the 3D-printing process contribute to the plastic pollution and release of greenhouse gases. Although PLA is biodegradable, it can take years to degrade in landfills. Instead of throwing away PLA waste and buying new filaments, PLA can be recycled. Amongst the different recycling technologies, mechanical recycling is the most environmentally friendly. …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

All Theses

Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

Laser-Induced Forward Transfer (Lift) Based Bioprinting Of The Collagen I With Retina Photoreceptor Cells, Md Shakil Arman, Ben Xu, Andrew Tsin, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications and Presentations

This study focuses on the 3D bioprinting of retina photoreceptor cells using a laser-induced forward transfer (LIFT) based bioprinting system. Bioprinting has a great potential to mimic and regenerate the human organoid system, and the LIFT technique has emerged as an efficient method for high-resolution micropatterning and microfabrication of biomaterials and cells due to its capability of creating precise, controlled microdroplets. In this study, the parameters for an effective femtosecond laser-based LIFT process for 3D bioprinting of collagen biomaterial were studied. Different concentrations of collagen I solutions were tested and 0.75 mg/ml to 1 mg/ml collagen Ⅰ was identified as …

The Influence Of Diversity Dimensions On Student’S Collaboration Success: What It Means For Workforce Development In Manufacturing, Oyinkansola Adeite

All Theses

Manufacturing productivity is measured by labor productivity which is the hourly output of the manufacturing economy. The recent reduction in productivity numbers by the United States Bureau of Labor Statistics emphasizes the need for workforce development. With globalization and technological advancements, diversity has emerged as a critical aspect for the workplace. By encompassing dimensions such as education, race, and age, diversity creates a tapestry of unique perspectives and experiences. This study’s aim is to figure out the effect of a diversity dimension on team performance using intelligent systems, and in addition, if extra dimensions of diversity further impact team performance. …

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 …

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 …

Estudio Termoquímico Asistido Por Computadora De Los Polifenoles Presentes En La Fresa [Thermochemical Computer Assisted Study Of Polyphenols Presented In Strawberry], Federico Lopez, Jeimmy Rocio Bonilla Méndez, Luis Ricárdez Sandoval, Hiram Moya, Daniela Mainardi, Arturo González Quiroga, Jeffrey Leon-Pulido

Manufacturing & Industrial Engineering Faculty Publications and Presentations

Las fresas son un alimento importante en Latinoamérica debido a sus componentes químicos, puesto que son una considerable fuente de calorías y polifenoles. Estos elementos son útiles por su capacidad antioxidante y otras propiedades beneficiosas para la salud. Sin embargo, la presión y la temperatura pueden llegar a afectar la integridad molecular de estos componentes, por lo tanto, en el proceso de producción de diferentes productos basados en fresas, se requiere estudiar las propiedades termoquímicas de los diferentes polifenoles presentes en esta fruta. Para ello, se extrajeron datos de las principales familias de polifenoles, antocianinas, flavanoles, flavonoles, ácidos hidroxibenzoicos y …

Optimization Of Alti Pld Coating By Increasing Ti Content, N2 And Annealing Which Used For Skd61 Pins In Aluminum Die Casting, Rusman Kosasih, Maria Margaretha Suliyanti Prof, Dedi Priadi, Wisnu Usni

Journal of Materials Exploration and Findings

The Alumunium Titanium Nitrogen (AlTiN) coating is known as one of the best coating materials for protective coating, while Pulsed Laser Deposition (PLD) is a laser coating process used for electric layer and superconductor applications, producing thin films up to 20 µm in thickness. The combination of these two matters has already been researched and is still in progress. One major challenge in the aluminium casting industry is to minimize the damage caused to tool steel pins made from SKD61, when aluminium material sticks to the pin, and halting production. Therefore, research on effective coatings for tool steels and testing …

The Effect Of Current Density And Hard Chrome Coating Duration On The Mechanical And Tribological Properties Of Aisi D2 Steel, Indah Uswatun Hasanah, Dedi Priadi, Donanta Dhaneswara

Journal of Materials Exploration and Findings

The effect of hard chromium coating on AISI D2's mechanical properties and wear resistance has been investigated using the electrolysis technique with varying current and coating duration. The variations of current used are 0.8 A, 1.2 A, and 1.6 A, while the coating duration used are 300, 600 and 900 seconds. Characterization of the films was conducted using SEM-EDS, and XRD. It can be observed from SEM characterization that the chrome grains resulted from the electroplating process are fine. The XRD identify chrome compund on the surface coating. The highest hardness value was 520.6 HV on a sample with a …

Enhancement Of Interlaminar Shear Strength Of Carbon Fiber Reinforced Polymer Composites With Freeform 3d Printing Using Magnetic Compaction & Zt-Cfrp Technologies, Mohammad Rakibul Islam

<strong> Theses and Dissertations </strong>

Carbon Fiber Reinforced Polymer (CFRP) laminates often exhibit matrix-sensitive weaknesses and flaws when produced via conventional additive manufacturing (AM) techniques due to the introduction of voids and defects during the AM process. This thesis employs a new approach called Magnetic Compaction Force Assisted-Additive Manufacturing (MCFA-AM) to fabricate Carbon Nanofibers (CNF)Z-threaded CFRP (i.e., ZR-CFRP) composite laminates. This novel method utilized a magnetic force to simultaneously levitate, deposit, and compact Continuous Carbon Fiber Reinforced Polymer (C-CFRP) composites in free space and rapidly solidifies the CFRP part without any mold; and effectively reduces the voids. Previous studies have demonstrated that the incorporation of …

Image Segmentation With Human-In-The-Loop In Automated De-Caking Process For Powder Bed Additive Manufacturing, Vincent Opare Addo Asare-Manu

Theses and Dissertations

Additive manufacturing (AM) becomes a critical technology that increases the speed and flexibility of production and reduces the lead time for high-mix, low-volume manufacturing. One of the major bottlenecks in further increasing its productivity lies around its post-processing procedures. This work focuses on tackling a critical and inevitable step in powder-bed additive manufacturing processes, i.e., powder cleaning or de-caking. Pressing concerns can be raised with human involvement when performing this task manually. Therefore, a robot-driven automatic powder cleaning system could be an alternative to reducing time consumption and increasing safety for AM operators. However, since the color and surface texture …

Modeling, Control, And Hardware Development Of A Thrust-Vector Coaxial Uav, Andrew North

Doctoral Dissertations and Master's Theses

This thesis introduces a unique thrust vector coaxial unmanned aerial vehicle (UAV) configuration and presents a comprehensive investigation encompassing dynamics modeling, hardware design, and controller development. Using the Newton-Euler method, a dynamic model for the UAV is derived to gain in-depth insights into its fundamental flight characteristics. A simple thrust model is formulated and modified by comparing it with data obtained from vehicle testing. The feasibility of manufacturing such a vehicle is assessed through the development of a hardware prototype. Finally, a linear state feedback controller is designed and evaluated using the non-linear dynamics model. The results demonstrate successful validation …

The Potential Of The Implementation Of Offline Robotic Programming Into Automation-Related Pedagogy, Max Rios Carballo, Xavier Brown

Publications and Research

In this study, the offline programming tool RoboDK is used to program industrial robots for the automation sector. The study explores the feasibility of using this non-disruptive robot programming software for classroom use; assesses how well RoboDK can be used to program various robots used in the industry; creates and tests various applications; and pinpoints technical obstacles that prevent a smooth link between offline programming and actual robots. Initial results indicate that RoboDK is an effective tool for deploying its offline programming code to a Universal Robot, UR3e. There are many potential for advanced applications. The goal of the project …

Empowering Student Success: Unlocking The Potential Of Project-Based Steel Design Education, Aly Mousaad Aly

Faculty Publications

In the pursuit of student success, it is essential to acknowledge that a singular teaching style does not universally cater to all students. The educator's crucial role lies in creating an optimal learning environment that fosters students' endeavors to excel. This endeavor transcends mere classroom success or employment prospects, encompassing a broader impact on societal well-being. An experiential learning approach, where students actively engage in practical tasks, emerges as the most effective mode of instruction. Integrating project-based learning activities into the curriculum holds immense potential for enhancing student learning. Additionally, the utilization of analysis software tools like FTool and STAAD …

Consumer 3d Printing For Remote Control Aircraft Wings: Development Of Novel Wingbox Structure, Ian Clark

University Honors Theses

Remote control aircraft construction and can be a very expensive and time-consuming hobby. With 3D printer consumer adoption rates skyrocketing, there is a gap between demand for RC aircraft and suitable well-designed models available to creators and hobbyists. By creating and testing two iterations of wingbox geometries, this research aims to help close that gap by producing an easily printable wing structure. While there are improvements that can be made on this work, this research has been effective in generating a novel wingbox structure for FFF 3D printing that has distinct advantages over other designs currently available.

Additive Manufacturing Of Stretchable Strain Sensors: Fabrication, Optimization And Application, John Nady Shihat Bastawrous

Theses and Dissertations

In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a change in resistivity as the distances among the conductive carbon particles change according to the strain applied.

Sensor fabrication consists of two parts: spring manufacturing and development of nanocomposite encapsulation The nanocomposite matrix is developed through the dispersion of Graphene and Carbon nanotubes in Thermoplastic Polyurethane through sonication and magnetic hotplate stirring. While the spring itself is manufactured …

Comparative Cutting Fluid Study On Optimum Grinding Parameters Of Ti-6al-4v Alloy Using Flood, Minimum Quantity Lubrication (Mql), And Nanofluid Mql (Nmql), Jaime Taha-Tijerina, Immanuel A. Edinbarough

Informatics and Engineering Systems Faculty Publications and Presentations

Titanium alloys have been of paramount interest to the aerospace industry due to their attractive characteristics. However, these alloys are difficult to machine and require grinding post-processes for quality assurance of the products. Conventional grinding takes a long time and uses a flood coolant-lubrication technique, which is not cost effective nor environmentally friendly. Several studies have been performed to prove the viability and benefit of using Minimum Quantity Lubrication (MQL) with vegetable or synthetic-ester fluids. This work aims to find the optimum grinding parameters of creep feed grinding Ti-6Al-4V with a green silicon carbide wheel, using a flood lubrication system …

Fungi In Flux | Designing Regenerative Materials And Products With Mycelium, Arvind Bhallamudi

Masters Theses

As the world grapples with the escalating crisis of climate threats and environmental degradation, this research delves into the synergistic potential of design and biology, developing safe and sustainable materials for applications in prototyping, furniture and interior design. Harnessing the power of a unique organism - fungi, the study proposes an accessible, efficient, and resilient material resource system. It utilizes local waste streams and mycelium (the vegetative part of fungi) to grow functional structures. An experimental and small-scale protocol is modeled by testing bio-fabrication and bio-printing methods. The composites' performance qualities and characteristics are evaluated through mechanical testing and a …

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Recor-Diy, Maxwell W. Ferrer

Industrial and Manufacturing Engineering

RecorDIY is an affordable alternative to ordering Vinyl Records from a manufacturer in the form of an at-home record-cutting lathe. This report will cover the record cutting process from audio to physical, at home record lathes that are currently available, and the possible improvements that I plan to implement in order to make these devices a more viable alternative for small artists. Current models can only create low fidelity records, specifically they struggle with lots of “noise”, extra sounds such as static that make it harder to hear the actual audio. Another issue is record size, as current models can …

Prove Primary Battery Structure, John D. Burkhart, Andy Mccormick, Ryan Yu, Soren Barclay

Mechanical Engineering

In conjunction with Prototype Vehicle (PROVE) Laboratory, our group designed, manufactured, and tested a prototype structure to house the battery boxes for PROVE’s endurance vehicle. Our structure was designed to support the batteries during normal use, and in the event of a front crash. Our design is comprised of a secondary composite box to house the battery boxes, a bottom plate to affix the secondary box to the chassis floor, a horizontal plate fastened to the chassis, and a brace structure welded to the chassis. From the outset, we chose to use a secondary box, the primary battery boxes must …

Headlamp/Bike Light Damping System, Ethan Reece Clark, Alec Stonehouse, Omeed Ostry, Mitchel Anderson

Mechanical Engineering

The task for this project is to design a headlamp and/or bike light that absorbs the impact shocks from the user’s actions. The user that the system is being designed for may be riding a bike or running on a trail in the evening or early in the morning where the light needs to be stabilized and their path must be illuminated. This report presents the final design chosen after months of prototyping and design iteration. It encompasses the system design, design verification through testing, implementation, future recommendations, and lessons learned throughout the process. The chosen design utilizes a fully …

Parametric Bicycle Yoke, Colin Reay, Walter Minehart, Robby Harrigan, Jordan Olson

Mechanical Engineering

This report outlines the entire design, fabrication, and validation process of a parametric yoke design that addresses the packaging problem of the bottom-bracket chainstay junction in modern bicycle frames. The goal was to create an elegant, space-efficient solution that is accessible to the Cal Poly Bike Builders Club. The report includes documentation of the three-part fixture system, manufacturing process, and testing results for the yoke.

Our yoke design outperforms traditional round-tube weldments in torsional and vertical stiffness. Additionally, all manufacturing fixtures and machining operations function as intended, resulting in a finished yoke that meets all required tolerances in under an …

In-Situ Mechanical Tester, Andrrew Murach, Gustavo Marquez, Kosimo Tonn, Jake Vormbaum

Mechanical Engineering

Over the course of the 2022-23 Cal Poly SLO school year, a small tensile tester device was developed specifically for Dr. Long Wang to test thin film materials under a microscope and generate accurate force versus displacement graphs. A tensile tester was manufactured using purchased and machined components, electronics were consolidated in a separate box and connected, and a program and user interface were written to control the motion, provide custom inputs, and organize useful data for the researcher. Tests were conducted to compare the performance of the device to universal tensile testers available in the Composites lab. The device …

Disc Golf Throwing Robot, Nevada S. Schultz, Sydney M. Lewis, Erick Edmundo Daza, Rachel Alysse Greenberg, Peter M. Kean

Mechanical Engineering

Disc golf companies need better methods to test disc flight. The scope of this project is to create a disc throwing robot that can throw a disc golf driver 450-500 feet, with control over the speed, spin, and release angle. Research shows that multiple disc-throwing products exist; however, none meet the full requirements of this project. The Cal Poly senior project design team created a proof-of-concept machine. This prototype started as a two-wheel mechanism. Eventually, a third wheel was added, allowing for complete control over disc spin. The three-wheel prototype reached 62 mph when perfectly calibrated. The prototype is accurate, …

Programmable Vibration Table Retrofit With Eagle Medical, Jonathan Ilagan, Madhav Asok, Max Lewter

Biomedical Engineering

This project aimed to repair and upgrade a vibration table used for package testing for the sponsor, Eagle Medical - a medical packaging and sterilization company based in Paso Robles, California. The current vibration table is not programmable and lacks circuit diagrams, making it difficult to repair. In addition, it is not functional due to internal circuitry issues and power requirements. To address these issues, the team will implement several upgrades to improve the product and allow for better random cyclic vibration testing. A full assessment of the existing vibration table will be conducted to ensure the viability of these …

The Center For Centering Dome, Olek Piechaczek, Ryan M. Scharf

Architectural Engineering

The Center for Centering seeks to create a large-scale healing center, conducive to individual centering of the mind and body. This mobile installation provides a relaxing, enclosed space while still maintaining a connection to the outdoors. The clients liked the idea of having a pop-up installation that could be easily set up as a touring display. With a deadline for installation looming in June 2022, a team of students had five months to design and manufacture the structure.

In winter 2022, the students developed custom geometry to minimize the number of individual parts and built a ¼ scale model of …