Mechanical Engineering Commons^™

New Product Launch Decisions Under Competition And Uncertainty: A Real Options And Game-Theoretic Approach To New Product Development, James O. Ostler

Theses and Dissertations

New product development is central to many firms' future success. Not only as a means to continue to maintain their piece of the market, but product development can also be a strategic means for a company to diversify, and/or alter focus to adapt to changing market conditions.

Most of the research in new product development has been on how to do it cheaper and faster than the next guy. However, early commercialization does not guarantee a position of strength in the market. Failures of EMI in CT scanners and Xerox in personal computers illustrate that being first to market does …

Dynamic Stability And Handling Qualities Of Small Unmanned-Aerial-Vehicles Unmanned-Aerial-Vehicles, Tyler Michael Foster

Theses and Dissertations

General aircraft dynamic stability theory was used to predict the natural frequencies, damping ratios and time constants of the dynamic modes for three specific small UAVs with wingspans on the scale from 0.6 meters to 1.2 meters. Using USAF DatCom methods, a spreadsheet program for predicting the dynamic stability and handling qualities of small UAVs was created for use in the design stage of new small UAV concept development. This program was verified by inputting data for a Cessna-182, and by then comparing the program output with that of a similar program developed by DAR Corporation. Predictions with acceptable errors …

A Finite Element Simulation Of Temperature And Material Flow In Fricton Stir Welding, Mark J. Lasley

Theses and Dissertations

The purpose of this research was to use the Transvalor S.A. product, Forge3, to develop a finite element simulation of the friction stir welding process that improves the predictability of temperature evolution and material flow within the plunge portion of the process. Previous modeling created more heating within the billet than experimental results, probably due to the simplification of the simulation with adiabatic boundary conditions. More realistic tooling temperatures were included in this model as these affect heat evolution which is a determining factor in microcrystalline growth. These results were validated by experimental efforts using a billet and tooling instrumented …

A Method For Winding Advanced Composites Of Unconventional Shapes Using Continuous And Aligned Fibers, Abraham K. Allen

Theses and Dissertations

Advanced composites are extremely strong, rigid, and light, even when compared with advanced metals. Advanced composites are replacing high-tech metals as the material of choice for aerospace engineering. However, the processes used to manufacture advanced composites generally lose some of the properties of the materials by their process limitations.

One process that keeps the theoretically awesome qualities of the composite materials in tact is filament winding. Filament wound parts are used as rocket shells, bicycle frame tubes, drive shafts, pressure vessels, etc. Filament winding is an automated process and makes reliable parts to close tolerances. If a straight tube were …

Development Of Pole Impact Testing At Multiple Vehicle Side Locations As Applied To The Ford Taurus Structural Platform, Mark Halford Warner

Theses and Dissertations

A test method was developed whereby repeated pole impacts could be performed at multiple locations per test vehicle, allowing a comparison of energy and crush relationships. Testing was performed on vehicles moving laterally into a 12.75 inch diameter rigid pole barrier. Crush energy absorption characteristics at the different locations were analyzed, and the results compared to test data from broad moving barrier crashes and available crash tests with similar pole impacts. The research documents the crush stiffness characteristics for narrow impacts at various points on the side of the Taurus vehicle platform. Factors encountered during the research include the importance …

The Effectiveness Of Computer-Based Tutorials In Learning Computer-Aided Design Methods For Tool Design Procedures, Andrew Moroni Hall

Theses and Dissertations

Throughout the past twenty-five years the process of designing and manufacturing a product has been revolutionized by the integration of Computer Aided Design (CAD). Although three-dimensional solid modeling, or 3-D CAD offers a better representation of the product in a virtual environment, it can be complicated and difficult to learn. Tutorials have been developed to assist manufacturing tool design student in the learning of 3-D CAD principles as they apply to tool design. This study seeks to test the effectiveness of those tutorials. A BYU tool design class was divided into two groups according to their assigned laboratory time. The …

Compliant Mechanisms To Perform Bearing And Spring Function In High Precision Applications, Jesse R. Cannon

Theses and Dissertations

An increasing number of mechanical systems are being designed on the micro and meso scales. Assembly and maintenance become increasingly difficult as the size of mechanisms decrease, and the minimum size of traditional elements such as bearings and springs is limited. The backlash of bearings also limits their usefulness in applications where high precision and repeatability are needed. At small scales and for high precision applications, alternative, non-traditional elements are needed.

The objective of this thesis is to develop reliable and scalable compliant components to replace bearings and helical springs. Components replacing springs must be able to produce specified torque/motion …

Thermally Developing Electro-Osmotic Convection In Circular Microchannels, Spencer L. Broderick

Theses and Dissertations

Thermally developing, electro-osmotically generated flow has been analyzed for a circular microtube under imposed constant wall temperature (CWT) and constant wall heat flux (CHF) boundary conditions. Established by a voltage potential gradient along the length of the microtube, the hydrodynamics of such a flow dictate either a slug flow velocity profile (under conditions of large tube radius-to-Debye length ratio, a/lambda_d) or a family of electro-osmotic flow (EOF) velocity profiles that depend on a/lambda_d. The imposed voltage gradient results in Joule heating in the fluid with an associated volumetric source of energy. For this scenario coupled with a slug flow velocity …

Quantifying The Effects Of Aging On The Mechanical Properties Of Medical Grade Polycarbonate And Uv Cured Adhesives, Christopher James Lewis

Theses and Dissertations

Advances in engineering polymer technology have created a generation of high strength-to-weight materials for medical applications, with virtually no adverse interactions with body fluids. Polycarbonate is a widely used engineering polymer, and is often used in connection with ultra-violet light (UV) cured adhesives. Because of the chemical complexity of polymers, little is known about their actual aging characteristics. By characterizing the effects of aging, storage environment, and sterilization on medical grade polycarbonate/adhesive system properties, more accurate failure predictions can be made. In this thesis, efforts to better understand the effects of accelerated aging on a medical grade polycarbonate and UV …

A Cad-Centric Approach To Cfd Analysis With Discrete Features, Matthew Lee King

Theses and Dissertations

During the conceptual design stage several concepts are generated, and a few are selected for detailed analyses. CAD models from conceptual design often follow the "over-the-wall" approach for downstream analyses such as FEA, CFD, heat transfer, and vibrations. A CAD-centric approach will be applied to the CAD-to-CFD process to help industry in an ongoing quest to shorten the design cycle time. The CAD-centric approach consists of using the CAD model as a source of data for downstream applications such as mesh generation, and CFD setup. The CAD model used in the CAD-centric approach contains the geometry to be analyzed and …

Development Of A Virtually Calibrated Projection Moire Interferometry Technique Capable Of Inaccessible Surface Measurements, Mark Lee Kimber

Theses and Dissertations

Optical-based techniques have found merit in measuring displacement and strain for decades. These techniques are commonly used in numerous applications ranging from large displacements in wind tunnel experiments to displacement measurements on the submicron scale. Projection Moiré Interferometry (PMI) is an out-of-plane displacement measurement technique, and consists of capturing reference and deformed images of a grid pattern projected on the test object. By differencing the reference and deformed images of the projected grid pattern, a fringe pattern is generated from which the displacement field can be extracted. This computation requires calibration procedures that analyze a number of fringe patterns from …

Variation Simulation Of Fixtured Assembly Processes For Compliant Structures Using Piecewise-Linear Analysis, Michael L. Stewart

Theses and Dissertations

While variation analysis methods for compliant assemblies are not new, little has been done to include the effects of multi-step, fixtured assembly processes. This thesis introduces a new method to statistically analyze compliant part assembly processes using fixtures. This method, consistent with the FASTA method developed at BYU, yields both a mean and a variant solution. The method, called Piecewise-Linear Elastic Analysis, or PLEA, is developed for predicting the residual stress, deformation and springback variation in compliant assemblies. A comprehensive, step-by-step analysis map is provided. PLEA is validated on a simple, laboratory assembly and a more complex, production assembly. Significant …

The Benefit Of Using Simulation To Improve The Implementation Of Lean Manufacturing Case Study: Quick Changeovers To Allow Level Loading Of The Assembly Line, Jack J. Mcclellan

Theses and Dissertations

In today's competitive manufacturing environment, companies are constantly looking for ways to improve. Because of this, many companies are striving to become "lean" by implementing lean manufacturing, which is a difficult process. To aid in the implementation of lean manufacturing, simulation was used to reduce the trial-and-error period of lean manufacturing and find to optimum approach to implement the lean manufacturing principle. In this research, a case study of implementing level loading of the production schedule for BullFrog International, L.C. will be examined. To make it possible to implement level loading, the thermo-former machine at the beginning of the operations …

A Review Of Setup Practices And Procedures For Creating Ieee 802.11 Wireless Community Networks, Jae M. Theobald

Theses and Dissertations

IEEE 802.11 wireless networking equipment has made it possible to bridge the last mile for new broadband internet service providers. Inexpensive wireless networking equipment and high gain antennas enable high speed internet delivery at a fraction of the cost of installing or upgrading land lines for cable or DSL services. Based on this research, a guide of general practices and procedures is proposed for designing, installing, and maintaining a reliable wireless community area network. Included tests have provided performance results for several types of wireless antennas (including wire grid parabolic dishes, Yagi and Vagi styles, and echo backfire), wireless bridges, …

Numerical Simulations In Electro-Osmotic Flow, Joseph S. Tenny

Theses and Dissertations

The developing flow field in a parallel plate microchannel, induced by wall motion, has been modeled numerically. This type of flow simulates the physical driving mechanism that exists in electro-osmotically generated flow with large channel diameter-to-Debye length ratios (Z). The physics of the flow field were compared between the moving wall model (MWM) and electro-osmotic flow (EOF) at Reynolds numbers of 1 and 1800, and Z > 2500. Also, Z-values between 50 and 500 were studied to investigate the accuracy of the MWM. Results show that for Z-values greater than 100 the MWM shows good agreement with EOF.

The dynamics of …

An Open Architecture For Versatile Machine And Actuator Control, Michael Scott Baxter

Theses and Dissertations

Automatic control technology increases usability, reliability and productivity in manufacturing, transportation, and climate control. There are many additional areas of modern life that could benefit through automatic control; however, current automation components are too expensive or aren't sufficiently flexible. For example, the cost of current commercial motion control components precludes their use in an average home. This thesis describes an automatic control methodology that is low cost and is flexible enough for a wide variety of control applications. Typical applications could include:

- Home lighting, security and appliances

- Commercial building heating, ventilation and air conditioning

- Industrial machine tool …

Electrostatic Radio Frequency (Rf) Microelectromechanical Systems (Mems) Switches With Metal Alloy Electric Contacts, Ronald A. Coutu Jr.

Theses and Dissertations

RF MEMS switches are paramount in importance for improving current and enabling future USAF RF systems. Electrostatic micro-switches are ideal for RF applications because of their superior performance and low power consumption. The primary failure mechanisms for micro-switches with gold contacts are becoming stuck closed and increased contact resistance with increasing switch cycles. This dissertation reports on the design, fabrication, and testing of micro-switches with sputtered bi-metallic (i.e., gold (Au)-on-Au-(6.3at%)platinum (Pt)), binary alloy (i.e., Au-(3.7at%)palladium (Pd) and Au-(6.3at%)Pt), and ternary alloy (i.e., Au-(5at%)Pt-(0.5at%)copper (Cu)) contact metals. Performance was evaluated, in-part, using measured contact resistance and lifetime results. The micro-switches with …

A Tightly-Coupled Ins/Gps Integration Using A Mems Imu, Jonathan M. Neu

Theses and Dissertations

Micro-Electro-Mechanical Systems (MEMS) technology holds great promise for future navigation systems because of the reduced size and cost of MEMS inertial sensors relative to conventional devices. Current MEMS devices are much less accurate than standard inertial sensors, but they can still be useful. In this thesis, data was recorded from an inexpensive MEMS inertial measurement unit and integrated with GPS measurements using a tightly-coupled Kalman filter. The overall goal of this research is to investigate the usefulness of MEMS sensors for a small, real-time, low-cost INS/GPS integration. A golf cart was used to collect dynamic data, along with a commercial …

Fully Compliant Tensural Bistable Mechanisms (Ftbm) With On-Chip Thermal Actuation, Daniel L. Wilcox

Theses and Dissertations

The Fully compliant Tensural Bistable Mechanism (FTBM) class is introduced. The class consists of fully compliant linear bistable mechanisms that achieve much of their displacement and bistable behavior through tension loading of compliant segments. Multiple topologies of designs arising from the FTBM class were designed using a finite element analysis (FEA) model with optimization. In a coupled design approach, thermal actuators were optimized to the force and displacement requirements of the bistable mech-anisms, and selected FTBM devices were combined in switching systems with the result-ing Thermomechanical In-plane Microactuators (TIMs) and Amplified Thermomechanical In-plane Microactuators (ATIMs). Successful on-chip actuation was demonstrated. …

Flexible Machine Tool Control For Direct, In-Process Dimensional Part Inspection, Tyler Addison Davis

Theses and Dissertations

For some time now coordinate measuring machines have been an integral part of the shop floor. The goal has been to make coordinate measuring machines (CMMs) into tools that can easily be used by machinists to improve their manufacturing capabilities. The value of a CMM as a quality control tool is undisputed. Now efforts are being made to further reduce the time and cost of measurement by reducing the physical distance between machining and measuring processes. The ability to reduce that distance to zero and measure a part directly on the chip-making machine has been a goal for many years. …

The Development Of An Accelerated Testing Facility For The Study Of Deposits In Land-Based Gas Turbine Engines, Jared Wilfred Jensen

Theses and Dissertations

Turbine engine efficiency modeling depends on many parameters related to fluid dynamics and heat transfer. Many of these parameters change dynamically once the engine enters service and begins to experience surface degradation. This thesis presents a validation of the design and operation of an accelerated testing facility for the study of foreign deposit layers typical to the operation of land-based gas turbines. It also reports on the use of this facility in an effort to characterize the change in thermal resistance on the surface of turbine blades as deposits accumulate. The facility was designed to produce turbine deposits in a …

Effects Of Friction Stir Processing On The Microstructure And Mechanical Properties Of Fusion Welded 304l Stainless Steel, Colin J. Sterling

Theses and Dissertations

Friction stir processing (FSP) has been utilized to locally process regions of arc weldments in 304L stainless steel to improve the microstructure and mechanical performance. The cast microstructure and coarse delta-ferrite has been replaced with a fine-grained wrought microstructure. Furthermore, twins were introduced throughout the friction stir processed region. Although sub-surface sigma and carbides were introduced during FSP, their presence is not expected to adversely affect the resulting mechanical or corrosion properties of friction stir processed 304L arc welds. The resulting mechanical properties of FS processed weldments were also an improvement over as-welded arc welds. FSP resulted in an increase …

Modeling And Control Of Surface Micromachined Thermal Actuators, Robert K. Messenger

Theses and Dissertations

A model that accurately describes the transient and steady-state response of thermal microactuators is desirable to provide guidance for design and operation. However, modeling the full response of thermal actuators is challenging due to the temperature-dependent material properties and nonlinear deformations that must be included to obtain accurate results. To meet these challenges a three-dimensional multi-physics nonlinear finite-element model was developed using commercial code. The Thermomechanical Inplane Microactuator (TIM) was chosen as a candidate application to validate the model. TIMs were fabricated using the SUMMiT V™ process and their response was measured using a high-speed camera. The TIMs were modeled …

Numerical Modeling Of Friction Stir Welding: A Comparison Of Alegra And Forge3, Alma H. Oliphant

Theses and Dissertations

The objective of this research was to evaluate the capabilities of ALEGRA, a Sandia National Labs hydrocode, and Forge3, a Transvalor S.A. product, to accurately model the Friction Stir Welding Process. ALEGRA and Forge3 are discussed in light of the inherent challenges of modeling Friction Stir Welding, and a rotational boundary condition is added to ALEGRA. Results are presented from Friction Stir Welding modeling outputs from both ALEGRA and Forge3. ALEGRA is shown to be incapable of modeling the Friction Stir Welding process, in large part due to its focus on shock propagation, which causes extremely small time steps. Forge3 …

Coordinated Uav Target Assignment Using Distributed Calculation Of Target-Task Tours, David H. Walker

Theses and Dissertations

This thesis addresses the improvement of cooperative task allocation to vehicles in multiple-vehicle, multiple-target scenarios through the use of more effective preplanned tours. Effective allocation of vehicles to targets requires knowledge of both the team objectives and the contributions that individual vehicles can make toward accomplishing team goals. This is primarily an issue of individual vehicle path planning --- determining the path the vehicles will follow to accomplish individual and team goals. Conventional methods plan optimal point-to-point path segments that often result in lengthy and suboptimal tours because the trajectory neither considers future tasks nor the overall path. However, cooperation …

A Comprehensive Model For Technology Push Product Development, Gregory Loren Bishop

Theses and Dissertations

Successful product development has been a fundamental part of many of today's companies and their continued prosperity depends on continuing to develop new products in the future. There are many models of product development. The two most common classes of development are market pull (MP) and technology push (TP). TP product development differs from MP in that the development begins with a specified technology rather than a specified customer. Because TP development is generally considered more difficult and challenging, most of the product development research has focused on MP development and many researchers and practitioners favor MP development over TP …

The Contextable: Building And Testing An Intelligent, Context-Aware Kitchen Table, Daniel Matthew Hoopes

Theses and Dissertations

The purpose of this thesis was to design and evaluate The ContexTable, a context-aware system built into a kitchen table. After establishing the current status of the field of context-aware systems and the hurdles and problems being faced, a functioning prototype system was designed and built. The prototype makes it possible to explore established, untested theory and novel solutions to problems faced in the field.

High-Torque Capacity Compliant Centrifugal Clutches, Ryan G. Weight

Theses and Dissertations

This thesis developed high-torque-capacity floating opposing arm clutches that are manufactured with standard economical manufacturing processes, while maintaining critical performance characteristics. Contact engagement speed and torque capacity models were created for the Hoffco-Comet, floating-opposing-arm (FOA), and floating 1 (F1) clutches. Sensitivity analyses were performed to identify key design parameters. A robust compliant FOA clutch was designed by minimizing the tolerance for both contact engagement speed and torque capacity. The robust design insures that the clutch will operate within the prescribed application constraints. Additional modeling showed that using a layered clutch would significantly tighten the contact engagement speed and torque performance …

Percolation Paths Of Three-Dimensions In Sensitized Stainless Steel, Alisa Jean Henrie

Theses and Dissertations

The study of three-dimensional percolation paths through materials is important in its contribution to understanding defect sensitive properties of materials. This work shows the importance of grain boundary character in modeling defect sensitive boundaries. Also presented are trends of percolation of sensitized grain boundaries in 304 stainless steel (304SS). Of particular interest is how open paths form in a three-dimensional model created through serial sectioning. Evidence is presented that triple or quadruple points that contain typically two boundaries with special character that intersect the percolation path break up the path. Some grains with no known special qualities (i.e., CSL) have …

Demonstrating Optothermal Actuators For An Autonomous Mems Microrobot, Francis R. Szabo

Theses and Dissertations

There are numerous applications for microrobots which are beneficial to the Air Force. However, the microrobotics field is still in its infancy, and will require extensive basic research before these applications can be fielded. The biggest hurdle to be solved, in order to create autonomous microrobots, is generating power for their actuator engines. Most present actuators require orders of magnitude more power than is presently available from micropower sources. To enable smaller microrobots, this research proposed a simplified power concept that eliminates the need for on-board power supplies and control circuitry by using actuators powered wirelessly from the environment. This …