Mechanical Engineering Commons^™

Feasibility And Uncertainty Evaluation Of Sequential Hybrid Manufacturing Using Optical Coordinate Metrology, Jake Dvorak

Doctoral Dissertations

Hybrid manufacturing has been suggested as a solution to global manufacturing challenges including stock availability, manufacturing costs, and difficulty in production of complex parts. However, feasibility and validation of hybrid manufacturing remain open research opportunities.

This research evaluates measurement uncertainty for optical coordinate metrology (OCM) within a sequential hybrid manufacturing (SHM) framework where a primary manufacturing process, a part geometry measurement, and a secondary manufacturing process are performed sequentially on optionally separate machine tools. In this work, an additively manufactured preform is produced, the part geometry is measured using structured light optical coordinate metrology, and the final geometry is obtained …

Milling Stability Map Identification And Machining Parameter Optimization Using Bayesian Inference, Aaron William Cornelius

Doctoral Dissertations

This dissertation describes a physics-guided Bayesian learning approach for statistically modelling and optimizing machining processes under a state of uncertainty. This approach uses a series of automatically-selected cutting tests to refine uncertainties about the machining system's dynamics and cutting force and identify higher productivity cutting parameters. The algorithm is evaluated experimentally and compared to the cutting tool manufacturer’s recommendations, both in laboratory conditions and in an industrial setting to optimize the machining process for a large aluminum component. These results show that the proposed Bayesian model can quickly identify both highly-productive machining parameters and accurate information about the underlying system …

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 …

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 …