Mechanical Engineering Commons^™

Nondestructive Evaluation (Nde) Of Additively Manufactured Metal (Amm) Parts Using Ultrasonic Testing (Ut), Austin M. Thomas

Master's Theses

Additive manufacturing is a category of emerging manufacturing processes that have applications in creating metal components with high value and complexity. The adoption of these parts is limited by the lack of fully developed nondestructive techniques for identifying internal defects. The use of ultrasonic testing for detecting and measuring internal features in additively manufactured metal parts is investigated. A low-cost ultrasonic immersion testing system was designed, constructed, and validated for the inspection of an additively manufactured titanium specimen with artificial defects as well as other metal artifacts. An ultrasound calibration block was additively manufactured from stainless steel type 316L and …

Improvement Of Labyrinth Seal Leakage Rates Using Additive Manufacturing, Austin L. Gasbarra

Master's Theses

The growing popularity of additive manufacturing in commercial applications has al- lowed for new ideas and new ways of thinking when designing components. Further optimization at the component level is possible, though powder metallurgy is in its infancy. This study explores the possibility of using additive manufacturing to develop better labyrinth seals in turbomachinery. Labyrinth seals have a torturous fluid path with high losses, thus limiting the amount of fluid leakage. These types of seals can be non-rotating, allowing them to better take advantage of the additive manufacturing process due to the absence of rotating stresses. Labyrinth seal performance is …

Field Testing The Effects Of Low Reynolds Number On The Power Performance Of The Cal Poly Wind Power Research Center Small Wind Turbine, John B. Cunningham

Master's Theses

This thesis report investigates the effects of low Reynolds number on the power performance of a 3.74 m diameter horizontal axis wind turbine. The small wind turbine was field tested at the Cal Poly Wind Power Research Center to acquire its coefficient of performance, C­_p, vs. tip speed ratio, λ, characteristics. A description of both the wind turbine and test setup are provided. Data filtration and processing techniques were developed to ensure a valid method to analyze and characterize wind power measurements taken in a highly variable environment. The test results demonstrated a significant drop in the …

Understanding The Effects Of Long-Duration Spaceflight On Fracture Risk In The Human Femur Using Finite Element Analysis, Keyanna Brielle Henderson

Master's Theses

Long-duration spaceflight has been shown to have significant, lasting effects on the bone strength of astronauts and to contribute to age-related complications later in life. The microgravity environment of space causes a decrease in daily mechanical loading, which signals a state of disuse to bone cells. This affects the bone remodeling process, which is responsible for maintaining bone mass, causing an increase in damage and a decrease in density. This leads to bone fragility and decreases overall strength, posing a risk for fracture. However, there is little information pertaining to the timeline of bone loss and subsequent fracture risk.

This …

Finite Element Analysis Of Total Knee Arthroplasty, Sean Yueh

Master's Theses

The total knee arthroplasty (TKA) has become one of the most successful procedures in all of medicine, with an average of over 966,000 operations performed a year. Since its introduction in 1968, the TKA’s surgical process and implant designs have continuously been improved to increase survivability. However, the need for a revision TKA – due to aseptic loosening – continues to be a problematic aspect of the procedure. Stress shielding induced by different design parameters of the implant has generated controversy in the determination of an ideal configuration. The purpose of this study is to investigate how implant design parameters …

A Quantitative Approach For Tuning A Mountain Bike Suspension, Steven Robert Waal

Master's Theses

A method for tuning the spring rate and damping rate of a mountain bike suspension based on a data-driven procedure is presented. The design and development of a custom data acquisition system, known as the "MTB DAQ," capable of measuring acceleration data at the front and rear axles of a bike are discussed. These data are input into a model that is used to calculate the vertical acceleration and pitching angular acceleration response of the bike and rider. All geometric and dynamic properties of the bike and rider system are measured and built into the model. The model is tested …

Telescope Parallel Actuator Mount: Control And Testing, Samuel S. Artho-Bentz

Master's Theses

This thesis approaches the task of designing a control system for the Parallel Actuator Mount developed by Dr. John Ridgely and Mr. Garrett Gudgel. It aims to create a base framework that directly controls the telescope and can be expanded to accept external command. It incorporates lower priced components and develops more easily approachable software with great functionality. An open-loop method for velocity control is established. Developing repeatable tests is a major focus. Testing finds the control methods developed result in velocity error of less than 5% and position error of less than 1.5% despite several mechanical issues and inaccuracies. …

The Use Of Low-Cost Sensors And A Convolutional Neural Network To Detect And Classify Mini-Drones, Austin Florio

Master's Theses

The increasing commercial availability of mini-drones and quadrotors has led to their greater usage, highlighting the need for detection and classification systems to ensure safe operation. Instances of drones causing serious complications since 2019 alone include shutting down airports [1-2], spying on individuals [3-4], and smuggling drugs and prohibited items across borders and into prisons [5-6]. Some regulatory measures have been taken, such as registration of drones above a specific size and the establishment of no-fly zones in sensitive areas such as airports, military bases, and national parks. While commercial systems exist to detect drones [7-8], they are expensive, unreliable, …

Low-Cost Reaction Wheel Design For Cubesat Applications, Nicholas J. Bonafede Jr.

Master's Theses

As science instruments on CubeSats become more sensitive to the attitude of the spacecraft, better methods must be employed to provide the accuracy needed to complete the planned mission. While systems that provide the accuracy required are available commercially, these solutions are not cost-effective, do not allow the design to be tailored to a specific mission, and most importantly, do not give students hand-on experience with attitude control actuators. This thesis documents the design, modeling, and simulation of a low-cost, student-fabricated, reaction wheel system for use in 3U CubeSat satellites. The entire design process for the development of this reaction …

Data Acquisition, Analysis, And Modeling Of Rotordynamic Systems, Michael P. Mullen

Master's Theses

Data acquisition systems for rotordynamic analysis and machine vibration were explored for the purpose of replacing the obsolete Bently Nevada ADRE 208 and ADRE for Windows system. These included the development of Matlab based custom data acquisition systems and a user interface. A model of an anisotropic rotor response undergoing transient speed was developed for the rapid prototyping and testing of data acquisition systems. Several methods for the measurement of amplitudes and phase in both the time domain and frequency domain were developed and compared. An alternate data acquisition method which is more inline with industry practices was created for …

Pier Portal, Alec W. Hardy

Master's Theses

The Pier Portal marine monitoring system is an internet controlled underwater camera that will enable students, researchers, and the general public the ability to monitor underwater marine life and ocean conditions. Installed at Cal Poly’s Center for Coastal Marine Science pier at Avila Beach, California, the camera can be commanded in real-time to raise or lower to any position between the top of the pier and the bottom of the ocean floor, while providing a live-stream video to the operator and general public. This thesis effort focused on the integration of the various subsystem components through software, and the development …

Smartphone-Tape Method For Calculating Body Segment Inertial Parameters For Analysis Of Pitching Arm Kinetics, Jay Sterner

Master's Theses

The objectives of this study were to (1) develop a non-invasive method (referred to as Smart Photo-Tape) to calculate participant-specific upper arm, forearm, and hand segment inertial properties (SIPs) (e.g. mass, center of mass, and radii of gyration) and (2) use those Smart Photo-Tape properties in inverse dynamics (ID) analyses to calculate injury-related pitching arm kinetics. Five 20- to 23- year-old baseball pitchers were photographed holding a baseball and analyzed using the Smart Photo-Tape method to obtain 3-D inertial properties for their upper arm, forearm, and hand. The upper arm and forearm segments were modelled as stacked elliptic cylinders and …

Numerical Methods For Predicting The Dynamic Crushing Response And Energy Absorption Of Composite Aluminum Honeycomb Sandwich Structures, Cody R. Volk

Master's Theses

Edgewise crushing responses of composite aluminum honeycomb sandwich structures were predicted using finite element analysis (FEA) software LS-DYNA by modeling the honeycomb as a material with anisotropic properties. The goal of the project was to develop a process for modeling the sandwich structure to rapidly iterate possible solutions for a safer workstation train table. Current workstation tables are too rigid and may cause injury or death in a head-on collision. Experimental compression tests were used to calibrate the aluminum honeycomb core with material type 26 (MAT 26, honeycomb). A published composite tensile test was used to validate the use of …

Simulating Particle Packing During Powder Spreading For Selective Laser Melted Additive Manufacturing Using The Discrete Element Method In Abaqus, Priscilla Ng

Master's Theses

Metal additive manufacturing allows for the rapid production of complex parts that are otherwise impractical using conventional subtractive manufacturing techniques. Applications for additive manufacturing span across a broad array of industries including aerospace, automotive, and medical, among many others. One metric of printing success is material properties, including part density. While there has been extensive research completed for the density of printed parts, there is little published work concerning powder packing density on the build plate associated with powder spreading.

In this thesis, a Discrete Element Method (DEM) model was created in Abaqus to simulate the spreading behavior of particles …

The Effect Of Orientation On The Ignition Of Solids, David Morrisset

Master's Theses

The ignition of a solid is an inherently complex phenomenon influenced by heat and mass transport mechanisms that are, even to this day, not understood in entirety. In order to use ignition data in meaningful engineering application, significant simplifications have been made to the theory of ignition. The most common way to classify ignition is the use of material specific parameters such as such as ignition temperature (T_ig) and the critical heat flux for ignition (CHF). These parameters are determined through standardized testing of solid materials – however, the results of these tests are generally used in applications …

Design Of Structural Stand For High-Precision Optics Microscopy, Sara T. Novell

Master's Theses

Lawrence Livermore National Lab (LLNL) is home to the National Ignition Facility (NIF), the world’s largest and most energetic laser. Each of the 192 beamlines contains dozens of large optics, which require offline damage inspection using large, raster-scanning microscopes. The primary microscope used to measure and characterize the optical damage sites has a precision level of 1 µm. Mounted in a class 100 clean room with a raised tile floor, the microscope is supported by a steel stand that structurally connects the microscope to the concrete ground. Due to ambient vibrations experienced in the system, the microscope is only able …

Design Of A 5 Degree Of Freedom Kinematic Stage For The Dual Crystal Backlighter Imager Diagnostic, Nicholas Nguyen

Master's Theses

The National Ignition Facility (NIF) is home to the world’s most energetic laser. The facility is one of the leading centers in inertial confinement fusion (ICF) experiments to research and understand sustainable fusion energy. To fully document and understand the physics occurring during experiments, precise diagnostics are used for a wide range of purposes. One diagnostic, the crystal backlighter imager (CBI), allows for X-ray imaging of the target at late stages of its implosion.

The aim of this project was to increase the current capabilities of the CBI diagnostic with the addition of a second crystal. This thesis focuses on …

The Development And Evaluation Of A New Analytical Model For The Characterization Of Friction Induced Disc Brake Vibration, Michael Vladimirov

Master's Theses

This research proposes a new method of modeling vibration of disc brake systems. This modeling method treats the brake pads of a disc braking system as lumped spring-mass-damper subsystems and the disc as a continuous bar. This modeling concept increases both the ease of analytical expression and the insight provided into the behavior of the real-world systems. This paper describes the analytical expression of this model and its implementation in Matlab. A parameter variation study yielded results that agree with existing research, which serves to validate the fundamental principles of this proposed modeling method.

Design And Implementation Of Stewart Platform Robot For Robotics Course Laboratory, Trent R. Peterson

Master's Theses

A Stewart Platform robot was designed, constructed, and programmed for use in Cal Poly’s ME 423 Robotics: Fundamentals and Applications laboratory section. A Stewart Platform is a parallel manipulator robot with six prismatic joints that has six degrees of freedom, able to be defined in both position and orientation. Its purpose is to supplement parallel robot material covered in lecture. Learning objectives include applying and verifying the Stewart Platform inverse kinematics and investigating the Stewart Platform’s operation, range of motion, and limitations. The Stewart Platform geometry and inverse kinematics were modeled and animated using MATLAB. The platform was then built …

Use Of Body Composition Imaging To Calculate 3-D Inertial Parameters For Inverse Dynamic Analysis Of Youth Pitching Arm Kinetics, Dalton James Jennings

Master's Theses

The objectives of this study were to 1) calculate participant-specific segment inertial parameters using dual energy X-ray absorptiometry (DXA) data (referred to as full DXA-driven parameters) and compare the pitching arm kinetic predictions using full DXA-driven inverse dynamics vs scaled, DXA mass-driven (using DXA masses but scaled centers of mass and radii of gyration), and DXA scaled inverse dynamics(ID) (using the full DXA-driven inertial parameters averaged across all participants), 2) examine associations between full DXA-driven kinetics and body mass index (BMI) and 3) examine associations between full DXA-driven kinetics and segment mass index (SMI). Eighteen 10- to 11- year-olds pitched …

The Optimum Design Of A Vacuum-Compatible Manipulator To Calibrate Space Based Ultraviolet Imagers, Jason L. Grillo

Master's Theses

Recent discoveries in geospace science have necessitated the design of compact UV imaging instruments to make space-based observations from multiple vantage points. The miniaturized ultraviolet imager (MUVI) instrument from the Space Sciences Laboratory (SSL) at UC Berkeley is under development to facilitate such discoveries on a wider scale. This thesis documents the design, integration, and characterization of a vacuum compatible manipulator to calibrate the MUVI instrument inside the UV thermal vacuum chamber at SSL. Precision linear and rotation stages were implemented with custom mounting plates to achieve four degrees of freedom. Optical components were installed to imitate the MUVI instrument …