Engineering Science and Materials Commons^™

Theoretical And Experimental Study Of Active Magnetic Bearing Control Integrated On Bently's Rotor Kit, Arturo Mario Flores

Master's Theses

This thesis focuses on the comprehensive study of controlling a customized Active Magnetic Bearing (AMB) installed on Bently Nevada’s RK4 rotor kit in Cal Poly’s Vibrations and Rotordynamics Lab. The AMB was uniquely designed and manufactured by a Cal Poly senior project team to fit Bently’s rotor kit and the results of this research are distinctive to the custom system. To achieve practical functionality of the AMB system, we designed a controller a Virtual Instrument (VI) using the National Instrument software, LabVIEW. From the experimental study, we calibrated the programming to find unknown parameters of the AMB system and validated …

In-Situ Defect Detection Using Acoustic Vibration Monitoring For Additive Manufacturing Processes, Ali Harake

Master's Theses

The world of additive manufacturing revolves around speed and repeatability. Inherently, the process of 3D printing is plagued with variability that fluctuates with every material and parameter modification. Without proper qualification standards, processes can never become stable enough to produce parts that may be used in aerospace, medical, and construction industries. These industries rely on high quality metrics in order to protect the lives of those who may benefit from them. To establish trust in a process, all points of variation must be controlled and accounted for every part produced. In instances where even the best process controls are enacted, …

A Single-Stage Passive Vibration Isolation System For Scanning Tunneling Microscopy, Toan T. Le

Master's Theses

Scanning Tunneling Microscopy (STM) uses quantum tunneling effect to study the surfaces of materials on an atomic scale. Since the probe of the microscope is on the order of nanometers away from the surface, the device is prone to noises due to vibrations from the surroundings. To minimize the random noises and floor vibrations, passive vibration isolation is a commonly used technique due to its low cost and simpler design compared to active vibration isolation, especially when the entire vibration isolation system (VIS) stays inside an Ultra High Vacuum (UHV) environment. This research aims to analyze and build a single-stage …

Design, Modeling And Control Of A Two-Wheel Balancing Robot Driven By Bldc Motors, Charles T. Refvem

Master's Theses

The focus of this document is on the design, modeling, and control of a self-balancing two wheel robot, hereafter referred to as the balance bot, driven by independent brushless DC (BLDC) motors. The balance bot frame is composed of stacked layers allowing a lightweight, modular, and rigid mechanical design. The robot is actuated by a pair of brushless DC motors equipped with Hall effect sensors and encoders allowing determination of the angle and angular velocity of each wheel. Absolute orientation measurement is accomplished using a full 9-axis IMU consisting of a 3-axis gyroscope, a 3-axis accelerometer, and a 3-axis magnetometer. …

Metal Segregation During The Solidification Of Titanium-Aluminum Alloys For 3d Printing Applications, Jwala Parajuli

Master's Theses

Titanium-Aluminum alloys are one of the widely used alloys in multiple engineering applications. They are highly preferred in Selective Laser Melting (SLM) processes due to their low density, high melting temperature, and good strength. Segregation occurs during the solidification of most alloys and produces a non-uniform distribution of atoms. In SLM, segregation may depict the type of adhesion between the two deposited interfacial layers and the strength between the interphase between an already solidified layer and a new one, and overall, the quality of the printed part. In order to avoid segregation, the understanding of the segregation behavior at atomistic …

The Role Of Soil Stiffness In Reverse Fault Rupture Propagation, Moises I. Buelna

Master's Theses

A nonlinear Mohr-Coulomb constitutive model with a strain dependent yield surface and non-associated flow was employed to study the plastic soil properties which affect the rate of surface fault rupture propagation in reverse events. These numerical simulations show a trend for soils with higher stiffness to have a higher rate of rupture propagation. Additionally the study shows the effects of strain softening and hardening on the rate of rupture propagation. Soils which strain harden exhibiting ductile behavior typically require more basal offset to rupture to the surface than soils which strain soften exhibiting brittle behavior. These results agree with our …

A Comparison Study Of Composite Laminated Plates With Holes Under Tension, Joun S. Kim

Master's Theses

A Comparison Study of Composite Laminated Plates with Holes under Tension

A study was conducted to quantify the accuracy of numerical approximations to deem sufficiency in validating structural composite design, thus minimizing, or even eliminating the need for experimental test. Error values for stress and strain were compared between Finite Element Analysis (FEA) and analytical (Classical Laminated Plate Theory), and FEA and experimental tensile test for two composite plate designs under tension: a cross-ply composite plate design of [(0/90)4]s, and a quasi-isotropic layup design of [02/+45/-45/902]s, each with a single, centered hole of 1/8” diameter, and 1/4" diameter (four sets …

Structure-Property Relationships Of Polyisobutylene-Block-Polyamide Thermoplastic Elastomers, Morgan Dunn Heskett

Master's Theses

Thermoplastic elastomers (TPEs) are a class of polymer fit for a wide variety of applications due to their customizability. In the synthesis of these types of materials, an elastically-performing polymer, deemed the “soft block,” is combined with a stiffer “hard block” polymer, each of which can be selected based on their own specific properties in order to achieve desired material behavior in the final copolymer. Recently, the use of polyisobutylene as a soft block in combination with a polyamide hard block has been investigated for use in TPE synthesis. While the material showed some promising behavior, many properties were still …

Process Development For Compression Molding Of Hybrid Continuous And Chopped Carbon Fiber Prepreg For Production Of Functionally Graded Composite Structures, Corinne Marie Warnock

Master's Theses

Composite materials offer a high strength-to-weight ratio and directional load bearing capabilities. Compression molding of composite materials yields a superior surface finish and good dimensional stability between component lots with faster processing compared to traditional manufacturing methods. This experimental compression molding capability was developed for the ME composites lab using unidirectional carbon fiber prepreg composites. A direct comparison was drawn between autoclave and compression molding methods to validate compression molding as an alternative manufacturing method in that lab. A method of manufacturing chopped fiber from existing unidirectional prepreg materials was developed and evaluated using destructive testing methods. The results from …

Analysis Of A Carbon Fiber Reinforced Polymer Impact Attenuator For A Formula Sae Vehicle Using Finite Element Analysis, John T. Rappolt

Master's Theses

The Hashin failure criteria and damage evolution model for laminated fiber reinforced polymers are explored. A series of tensile coupon finite element analyses are run to characterize the variables in the physical model as well as modeling techniques for using an explicit dynamic solver for a quasi-static problem. An attempt to validate the model on an axial tube crush is presented. It was found that fiber buckling was not occurring at the impactor-tube interface. Results and speculation as to why the failure initiation is incorrect are discussed. Lessons learned from the tube crush are applied successfully to the quasi-static Formula …

Mode I Fracture Toughness Of Eight-Harness-Satin Carbon Cloth Weaves For Co-Cured And Post-Bonded Laminates, Josh E. Smith

Master's Theses

Mode I interlaminar fracture of 3k 8-Harness-Satin Carbon cloth, with identical fill and weft yarns, pre-impregnated with Newport 307 resin was investigated through the DCB test (ASTM D5528). Crack propagations along both the fill and weft yarns were considered for both post-bonded (co-bonded) and co-cured laminates. A patent-pending delamination insertion method was compared to the standard Teflon film option to assess its applicability to mode I fracture testing. The Modified Beam Theory, Compliance Calibration method, and Modified Compliance Calibration method were used for comparative purposes for these investigations and to evaluate the validity of the proposed Equivalent Stiffness (EQS) method. …

Quantum Dot Deposition Into Pdms And Application Onto A Solar Cell, Christopher Marcus Botros, Richard N. Savage

Master's Theses

Research to increase the efficiency of conventional solar cells is constantly underway. The goal of this work is to increase the efficiency of conventional solar cells by incorporating quantum dot (QD) nanoparticles in the absorption mechanism. The strategy is to have the QDs absorb UV and fluoresce photons in the visible region that are more readily absorbed by the cells. The outcome is that the cells have more visible photons to absorb and have increased power output. The QDs, having a CdSe core and a ZnS shell, were applied to the solar cells as follows. First, the QDs were synthesized …

A Resistance Based Structural Health Monitoring System For Composite Structure Applications, Dennis N. Boettcher

Master's Theses

This research effort explored the possibility of using interwoven conductive and nonconductive fibers in a composite laminate for structural health monitoring (SHM). Traditional SHM systems utilize fiber optics, piezoelectrics, or detect defects by nondestructive test methods by use of sonar graphs or x-rays. However, these approaches are often expensive, time consuming and complicated.

The primary objective of this research was to apply a resistance based method of structural health monitoring to a composite structure to determine structural integrity and presence of defects.

The conductive properties of fiber such as carbon, copper, or constantan - a copper-nickel alloy - can be …

Finite Element Modeling Of Ballistic Impact On A Glass Fiber Composite Armor, Dan M. Davis

Master's Theses

Finite Element Modeling of Ballistic Impact on a Glass Fiber Composite Armor

Dan Davis

Experiments measuring the ballistic performance of a commercially available fiberglass armor plate were used to guide the development of constitutive laws for a finite element model of the impact. The test samples are commercially available armor panels, made from E-glass fiber reinforced polyester rated to NIJ level III. Quasi-static tensile tests were used to establish material properties of the test panels. These properties were then used to create models in the explicit finite element code LSDYNA.

Ballistic impact testing of the panels was conducted using a …

Laboratory And Field Evaluation Of Two Warm-Mix Additives In Connecticut And Validation Of An Alternative Moisture Susceptibility Test, Alexander K. Bernier

Master's Theses

The first official state Warm-Mix Asphalt (WMA) pavement project in Connecticut was constructed between July 20th and 22nd, 2010 and it involved three experimental sections, i.e. one section with a conventional HMA (control section) and two WMA sections with different technologies, wax and foamed asphalt. All three sections are located on Route 70 in central Connecticut. The materials were collected in loose form and reheated and compacted in laboratory conditions (laboratory fabricated specimens). This paper discusses the effect of mix type on the results from several tests conducted in the laboratory, such as Semi-Circular Bending, Hamburg Wheel Tracking, Indirect Tensile, …

Vibration-Based Health Monitoring Of Multiple-Stage Gear Train And Differential Planetary Transmission Involving Teeth Damage And Backlash Nonlinearity, Andrew Patrick Sommer

Master's Theses

The objective of this thesis is to develop vibration-based fault detection strategies for on-line condition monitoring of gear transmission systems. The study divides the thesis into three sections. First of all, the local stresses created by a root fatigue crack on a pinion spur gear are analyzed using a quasi-static finite element model and non-linear contact mechanics simulation. Backlash between gear teeth which is essential to provide better lubrication on tooth surfaces and to eliminate interference is included as a defect and a necessary part of transmission design. The second section is dedicated to fixed axis power trains. Torsional vibration …

Characterization Of A Viscoelastic Response From Thin Metal Films Deposited On Silicon For Microsystem Applications, Steven L. Meredith

Master's Theses

Understanding the mechanisms that control the mechanical behavior of microscale actuators is necessary to design an actuator that responds to an applied actuation force with the desired behavior. Micro actuators which employ a diaphragm supported by torsional hinges which deform during actuation are used in many applications where device stability and reliability are critical. The material response to the stress developed within the hinge during actuation controls how the actuator will respond to the actuating force. A fully recoverable non-linear viscoelastic response has been observed in electrostatically driven micro actuators employing torsional hinges of silicon covered with thin metal films. …