Engineering Commons^™

Effect Of Build Parameters On Mechanical Properties Of Ultem 9085 Parts By Fused Deposition Modeling, Krishna Prasanth Motaparti

Masters Theses

"Additive manufacturing is a fabrication technique that is used to build components by depositing material in a layer-by-layer manner. Fused Deposition Modeling (FDM) is one of the additive manufacturing techniques which is widely used for prototyping and production applications of thermoplastic components. In load bearing applications, the flexural and compression forces often coexist. In order to avoid failure under these loads, it is essential to study the mechanical properties of the components fabricated by FDM. The main focus of this research is to study the mechanical properties of the fabricated components and to comprehend their dependence on various build parameters. …

Prediction Of Surface Roughness In Abrasive Waterjet Cutting Of Graphite Composite Using Response Surface Methodology, Prabhakar Bala

Masters Theses

"In the present work, surface roughness after machining of composite material was the main focus of study. Response surface methodology with Box- Behnken experimental design was applied in predicting the surface roughness (R_a) of abrasive waterjet cut 1-inch-thick graphite/epoxy composite. Second order response equations for R_a were generated with minitab, a statistical software as a function of pressure, traverse speed and isolated abrasive mesh size. Influence of each of these factors on the response were analyzed with 3D response surface plots. Abrasive mesh size was also found be a factor influencing Ra along with traverse speed and …

Engine Sound Simulation And Generation In Driving Simulator, Shuang Wu

Masters Theses

"Simulating a driving environment that provides engine sound as auditory feedback to the driver is a challenging task due to the complexity of engine sound, a wide range of operating speeds, and repeated sound clicking during playback. This thesis describes a method of engine sound simulation and generation for a driving simulator. By analyzing sample sounds, spectral modeling synthesis was used to decompose the sound samples into deterministic and stochastic components. Then, the modeled deterministic and stochastic signals were employed to resynthesize the sounds. To represent engine sounds not available in the recorded database, sound interpolation was applied to two …

Design And Analysis Of An Axisymmetric Aerospike Supersonic Micro-Nozzle For A Refrigerant-Based Cold-Gas Propulsion System For Small Satellites, Abdalla Ali Bani

Masters Theses

"The cold-gas propulsion system being developed by M-SAT requires improvements to its original nozzle design. This study documents the research, design, and analysis of a supersonic plug nozzle concept that could be integrated to the refrigerant-based cold-gas propulsion system to possibly improve its performance. As documented in this thesis, CFD analysis showed that the outlined nozzle design method resulted in a feasible nozzle concept that has the ability to out-perform a conventional nozzle of the same area ratio. The flow-fields and thrust of the aerospike nozzle, for the full and truncated nozzles, were investigated. The purpose of this study is …

Addressing The Influence Of Carbon Monoxide On The Behavior Of An Hcci Engine, Allen Charles Ernst

Masters Theses

"Homogeneous Charge Compression Ignition (HCCI) may be the next leap of improvement to internal combustion engines due to its decreased emissions and improved engine efficiencies. However, such a jump possesses challenges owing to its strict reliance on the inherent physics that dictate start of combustion and limit the reach of stable operation. This work investigates the role and fundamental influence of carbon monoxide on the cycle-to-cycle combustion dynamics present in the region of incomplete combustion that frames the limited HCCI operating region. An improved understanding will open doors to enhanced control methodologies and an expanded stable operating envelope. A constant …

Design Of An Adaptive Force And Stiffness Controlled Compliant Device For Robotic Polishing, Mohammad Masud Parvez

Masters Theses

"Polishing is a repetitive task done in an unhealthy environment. Often more than half of the manufacturing time is required to polish a die. The manual polishing process is a tedious work actively rely on a skilled human worker. Industrial Robot has replaced the human in performing these tasks. For robotic polishing to control the polishing force, an active compliant device is used. Due to the compressibility of air, a pneumatic system is preferred as the actuator of the device. The force of the actuator is controlled by regulating air pressure in both chambers of the cylinder. However, to improve …

Design And Fabrication Of A System For The Additive Manufacturing Of Transparent Glass, Luke John Gilbert

Masters Theses

"Despite glass' prevalence in the scientific and engineering community, very little research has been conducted attempting to additively manufacture (AM) glass. Even less research has been done on optically transparent glass. Glass’ material properties make it ineligible for most AM processes if the end result is to be transparent. Even small gas inclusions can cause large amounts of scattering. Additively manufacturing transparent glass brings the advantages found in other AM processes with the added benefit of having optical properties better than those found in polymers. Additively manufacturing glass also allows the optical properties of transparent parts to vary arbitrarily. This …

Multifunctional Wearable Epidermal Device For Physiological Signal Monitoring In Sleep Study, J V M S Avinash Kankipati

Masters Theses

"Sleep is the essential part of life. Thousands of people are suffering from different kinds sleep disorders. Clinical diagnosing and treating for such disorders are costly, painful and quite sluggish. To reach the demand many commercial products are into the market to encourage home based sleep studies using portable devices. These portable devices are limited in use, cannot be handled easily and quite costly. Advancements in technology miniaturized these portable devices to wearable devices to make them convenient and economical. Elastic, soft and thin silicon membrane with physical properties well matched with that of the epidermis provides conformal and robust …

Laser Sintering And Aerosol Printing Of Conductive Nanoparticles, Mahati Guntupalli

Masters Theses

"Fabrication and printing of nanoparticles is an essential step in the manufacturing of low cost- high efficiency electronic devices. High material costs of noble metal particles necessitates the investigation for a potential substituent. Conventional methods of manufacturing are time consuming and uneconomical, thus intense research is being done to employ new methods for cost, time and space effective manufacturing process.

The first part of the thesis presents the fabrication of Copper nanoparticles. As an economical substituent for noble metal nanoparticles, Copper nanoparticles satisfy various properties as conductive inks, simultaneously suffering from the vital problem of oxidation. The acceleration effects of …

Synthesis And Photonic Sintering Of Bioresorbable Zinc Nanoparticle Ink For Transient Electronics Manufacturing, Bikram K. Mahajan

Masters Theses

"Zinc is an essential 'trace element' that supports immune systems, and is required for DNA synthesis, cell division, and protein synthesis. Zinc nanoparticles (Zn NP) has antibacterial properties and potential to be used in biodegradable printed electronics devices. The research presented here is about the synthesis of Zn NP and their potential use in transient electronics devices. In Paper 1, a technique of room temperature synthesis of Zn NP is reported using ball milling. Controlled amount of PVP was mixed in the solvent to stabilize the Zn particles and minimize cold welding during milling. The size of the produced Zn …

Electronic Musical Instrument To Generate Musical Tones To Imitate A Stringed Instrument, Mizuki Nakagawa, Ikuo Tanaka, Shun Takai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Provided are an electronic musical instrument, computer storage device, and method for generating tone. A sound source in an electronic musical instrument generates a first tone at a first pitch in response to a first tone generation instruction received by an input device of the electronic musical instrument. A second tone generation instruction is received to generate a second tone at a second pitch while generating the first tone at the sound source. A determination is made of a pitch difference of the first and the second pitches. The sound source is controlled to generate the second tone and to …

Coalescence-Induced Jumping Of Nanoscale Droplets On Super-Hydrophobic Surfaces, Zhi Liang, Pawel Keblinski

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Coalescence-Induced Jumping of Tens of Microns Size Droplets on Super-Hydrophobic Surfaces Has Been Observed in Both Experiments and Simulations. However, Whether the Coalescence-Induced Jumping Would Occur for Smaller, Particularly Nanoscale Droplets, is an Open Question. using Molecular Dynamics Simulations, We Demonstrate that in Spite of the Large Internal Viscous Dissipation, Coalescence of Two Nanoscale Droplets on a Super-Hydrophobic Surface Can Result in a Jumping of the Coalesced Droplet from the Surface with a Speed of a Few M/s. Similar to the Coalescence-Induced Jumping of Microscale Droplets, We Observe that the Bridge between the Coalescing Nano-Droplets Expands and Impacts the …

Molecular Simulations And Lattice Dynamics Determination Of Stillinger-Weber Gan Thermal Conductivity, Zhi Liang, Ankit Jain, Alan J.H. Mcgaughey, Pawel Keblinski

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Bulk Thermal Conductivity of Stillinger-Weber (SW) Wurtzite GaN in the [0001] Direction at a Temperature of 300 K is Calculated using Equilibrium Molecular Dynamics (EMD), Non-Equilibrium MD (NEMD), and Lattice Dynamics (LD) Methods. While the NEMD Method Predicts a Thermal Conductivity of 166 ± 11 W/m·K, Both the EMD and LD Methods Predict Thermal Conductivities that Are an Order of Magnitude Greater. We Attribute the Discrepancy to Significant Contributions to Thermal Conductivity from Long-Mean Free Path Phonons. We Propose that the Grüneisen Parameter for Low-Frequency Phonons is a Good Predictor of the Severity of the Size Effects in NEMD …

Near Field Transducer For Heat Assisted Magnetic Recording, Xianfan Xu, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An antenna for heat assisted magnetic recording is disclosed. The antenna includes an optically opaque material and an optically transparent material positioned on the optically opaque material, the optically transparent material includes a half bowtie shape which includes a first half-wing substantially shaped in form of a right angle trapezoid, having a height substantially equal to the overall height of the half bowtie, a second half-wing Substantially shaped in form of a mirror image of the first half-wing and formed proximate and coupled to the first half-wing by a Substantially rectangular aperture having an aperture width and an aperture height. …

Enhanced Structural Color Generation In Aluminum Metamaterials Coated With A Thin Polymer Layer, F. Cheng, Xiaodong Yang, D. Rosenmann, L. Stan, D. Czaplewski, Jie Gao

Mechanical and Aerospace Engineering Faculty Research & Creative Works

No abstract provided.

Shear Lag Sutures: Improved Suture Repair Through The Use Of Adhesives, S. W. Linderman, I. Kormpakis, R. H. Gelberman, Victor Birman, U. G. K. Wegst, G. M. Genin, S. Thomopoulos

Mechanical and Aerospace Engineering Faculty Research & Creative Works

No abstract provided.

Ultrasensitive Detection And Characterization Of Molecules With Infrared Plasmonic Metamaterials, F. Cheng, Xiaodong Yang, Jie Gao

Mechanical and Aerospace Engineering Faculty Research & Creative Works

No abstract provided.

Dc-Gain Layer-To-Layer Stability Criterion In Laser Metal Deposition Processes, Patrick M. Sammons, Douglas A. Bristow, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In Laser Metal Deposition (LMD), a blown powder metal additive manufacturing process, functional metal parts are fabricated in a layer-by-layer fashion. In addition to the in-layer dynamics, which describe how the process evolves within a given layer, the additive-fabrication property of LMD creates a second set of dynamics which describe how the process evolves from layer-to-layer. While these dynamics, termed layer-to-layer dynamics, are coupled with both the in-layer dynamics and the process operating conditions, they are not widely considered in the modeling, process planning, or process control of LMD operations. Because of this, seemingly valid choices for process parameters can …

Freeform Extrusion Fabrication Of Titanium Fiber Reinforced Bioactive Glass Scaffolds, Albin Thomas, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Although implants made with bioactive glass have shown promising results for bone repair, their application in repairing load-bearing long bones is limited due to their low fracture toughness and fairly fast degradation response in vivo. In this paper, we describe our investigation of freeform extrusion fabrication of silicate based 13-93 bioactive glass scaffolds reinforced with titanium fibers. A composite paste was prepared with 13-93 bioactive glass filled with titanium fibers (~16 µm in diameter and aspect ratio of ~250) having a volume fraction of 0.4 vol. %. This paste was then extruded to fabricate scaffolds with an extrudate diameter …

Planning Freeform Extrusion Fabrication Processes With Consideration Of Horizontal Staircase Effect, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An algorithm has been developed to estimate the “horizontal” staircase effect and a technique is proposed to reduce this type of geometrical error for freeform extrusion fabrication processes of 3D “solid” parts. The adaptive rastering technique, proposed in this paper, analyzes the geometry of each layer and changes the width of each line of the raster adaptively in order to reduce the staircase error and increase the productivity simultaneously. For each line, the maximum width that results in a staircase error smaller than a predefined threshold is determined for decreasing the fabrication time or increasing the dimensional accuracy, or both. …

Direct Laser Deposition Of Ti-6al-4v From Elemental Powder Blends, Lei Yan, Xueyang Chen, Wei Li, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A thin-wall structure composed of Ti-6Al-4V has been deposited using direct laser deposition (DLD) from blended Ti, Al, and V elemental powders. The microstructure and composition distribution along the build height direction were intensively investigated using optical microscopy, scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDS), and Vickers hardness testing. The microstructures of the as-deposited Ti-xAl-yV were studied using EDS to determine appropriate weight percentage for Al and V in the blended powders before mixing. The effects of laser power and laser transverse speed on the microstructure were investigated and optimized laser processing parameters were concluded.

Parameter Determination And Experimental Validation Of A Wire Feed Additive Manufacturing Model, Kannan Suresh Kumar, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser metal deposition with wire feed is one of the additive manufacturing methods with great scope and robustness. Process parameters plays an important role in controlling the process and obtaining an ideal manufactured part. Simulations tools are highly essential in determining the ideal parameters and melt pool conditions. The current work is a transient 3D model of wire feed additive manufacturing which realizes the heat transfer and fluid flow behavior of the process with varying laser power and power density. The model was programmed in Python and a 1 KW Gaussian beam fiber laser was used to conduct experiments. The …

Laser Metal Deposition Of Functionally Gradient Materials From Elemental Copper And Nickel Powders, Sreekar Karnati, Todd E. Sparks, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, William J. Seufzer

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work deals with the planning and fabrication of a functionally gradient copper-nickel composition via Laser Metal Deposition (LMD). Various compositions of copper and nickel were made by blending different weight percentages which were then sequentially deposited to fabricate functionally gradient copper-nickel thin-wall structures. Analyses were performed by sectioning the thin-wall samples for metallographic, hardness, X-ray diffraction (XRD) and Energy Dispersive X-ray Spectroscopy (EDS) studies. The fabrication was studied for identifying and corroborating the deposited compositions and their corresponding gradients. XRD analyses were performed to identify the crystal structure of the deposit. EDS analysis was instrumental in identifying the variation …

Depth Of Cut Monitoring For Hybrid Manufacturing Using Acoustic Emission Sensor, Haythem Gaja, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Metal Deposition LMD is a hybrid manufacturing process consist of a laser deposition system combined with a 5-axis CNC milling system. During laser deposition many parameters and their interaction affect the dimensional accuracy of the part produced, powder flow rate, laser power and travel speed are some of these parameters. Sensing the acoustic emission during milling marching gives feedback information regarding depth of metal being cut subsequent part dimensions, if an error in dimensions is found certain actions, such as remaching, close loop control, or laser remelting can be carried out to correct it. Thus a reliable hybrid manufacturing …

Effects Of Temperature On Aqueous Freeform Extrusion Fabrication, Jie Li, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An experimental study was conducted to investigate the effect of temperature on ceramic parts produced by paste extrusion based additive manufacturing followed by sintering. A computer-controlled gantry system equipped with a piston extruder was used to extrude aqueous alumina paste. The system includes a temperature control subsystem that allows for freeform extrusion fabrication inside a low-temperature (<0°C) chamber. It can also be used for fabricating parts on a hot plate at ambient or higher temperatures (≥20°C). Test specimens were fabricated from aqueous aluminum pastes at -20°C in the low-temperature chamber and also on the hot plate at 40°C. The minimum angles achievable by these two processes for part fabrication, without use of support material, were compared. Also compared were the relative density and mechanical properties of the parts obtained after sintering. Microstructures were examined via scanning electron microscopy in order to obtain a deeper understanding of the effect of fabrication temperature.

Optimal Rastering Orientation In Freeform Extrusion Fabrication Processes, Amir Ghazanfari, Wenbin Li, Ming-Chuan Leu, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Many researchers have tried to optimize the build direction of additively manufactured parts to minimize the vertical staircase effect. However, the horizontal staircase effect should also be considered when fully dense parts are to be fabricated. In this paper, part inaccuracy due to the horizontal staircase effect is considered in order to determine the optimal rastering orientation in building the part. An algorithm is developed to estimate this inaccuracy and a technique is proposed to minimize it. The effect of rastering orientation on staircase errors is examined, and the particle swarm optimization method is used to determine the optimum rastering …

A Framework For Large Scale Fused Pellet Modeling (Fpm) By An Industry Robot, Zhiyuan Wang, Renwei Liu, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Fused pellet modeling (FPM) is an important method in additive manufacturing technology, where granular material is used instead of filaments. In FPM, prototypes are constructed by the sequential deposition of material layers. As the size of the part increases, the problem of long build times and part deformation becomes critical. In this paper, methods for eliminating the void density during deposition and accuracy control principles for large scale FPM processes are studied. By analyzing the ab initio principles of this process, a mini extruder with variable pitch and progressive diameter screw for the large scale fused deposition is proposed. Based …

Performance Metric For Powder Feeder Systems In Additive Manufacturing, Venkata Sivaram Bitragunta, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In blown powder Direct Metal Deposition (DMD) process, parts are built by adding metal powder on the melt pool created by the laser system. At low feed rates powder feeder systems have perturbations. The study focused on relationship between the perturbation frequencies by inherent powder feeder designs and its impact on deposition quality. Performance metric determine the relation between perturbations in the powder flow and quality of the deposit. To determine performance metric, various powder feeder designs were analyzed. Perturbation frequencies were introduced to the disk feeder design. The quality of the deposit was determined by the surface roughness of …

Modeling Of Powder Bed Processing -- A Review, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Many models have been developed to model powder beds and these methods can be implemented to model a powder bed for Selective Laser Sintering, Selective Laser Melting and any other technique of additive manufacturing which uses powder beds. Two of the main systems are the Discrete Element Method (DEM) and the Geometric Method. The purpose of this paper is to analyze each of the methods. It will first highlight how each of the models creates the powder bed. The next aspect reviewed is the computational time and its causes. And lastly, each of the methods will be examined for their …

Solid Freeform Fabrication Of Transparent Fused Quartz Using A Filament Fed Process, J. Luo, L. J. Gilbert, C. Qu, B. Morrow, Douglas A. Bristow, Robert G. Landers, J. Goldstein, A. Urbas, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Glass is a critical material for many scientific and engineering applications including optics, communications, electronics, and hermetic seals. Despite this technological relevance, there has been minimal research toward Additive Manufacturing (AM) of glass, particularly optically transparent glass. Additive Manufacturing of transparent glass offers potential advantages for lower processing costs for small production volumes, increased design freedom, and the ability to locally vary the optical properties of the part. Compared to common soda lime glass, fused quartz is better for AM since it has lower thermal expansion and higher index homogeneity. This paper presents a study of additive manufacturing of transparent …