Manufacturing Commons^™

Ranking Of Non-Destructive Testing Methods For Ductile Iron Castings For Industry 4.0, Michael W. Jones

College of Graduate Studies: Theses & Dissertations

Non-destructive testing techniques provide a unique solution to provide quality assurance of parts rapidly and efficiently without altering the functional properties of the workpiece. The metal casting industry requires an elevated level of quality assurance, as castings are critical components to several industries. The wrong selection of non-destructive testing methods could increase production costs, quality costs, and potentially permit non-conforming castings to enter the market. The aim of this research is to develop a ranking model for non-destructive testing techniques for ductile iron castings within the context of the fourth industrial revolution. The ranking model analyzes the effectiveness of the …

Effect Of Build Orientation On Tensile Properties And Fractography Of Additive Manufactured Inconel 718 Alloy, Ajay Kumar Maurya, Amit Kumar, Swarnambuj Suman

ASEAN Journal on Science and Technology for Development

The additive manufacturing (AM) technique “Direct Metal Laser Sintering (DMLS)” is used to create 3D objects directly from 3D design data. A lightweight and complexity-free part without any expensive tooling can be fabricated easily using this method, but it is still challenging to achieve the desired mechanical strength from AM parts, as the mechanical properties of AM-produced parts vary with orientation, scan strategy, and process parameters. Inconel 718 alloy is most commonly utilized in the aerospace and automotive industries, because of its high resistance to corrosion and excellent mechanical qualities. This work presents a study to investigate the orientation-based mechanical …

Fabrication And Characterization Of Cast Copper Heatsinks For Computer Chip Cooling, John James Recktenwald

Graduate Theses, Dissertations, and Problem Reports (ETD)

Humanity has worked copper for millennia, from primitive tools in prehistory to the wires and cooling solutions facilitating the modern digital age. While high performance fin style heatsinks are commonplace, more complex heatsink geometries in high performance applications are rare due to manufacturing challenges. In this study a casting process was developed to fabricate copper pin fin heatsinks. To assess the performance of heatsinks fabricated using the process three pin fin heatsinks were fabricated, one machined from a commercially manufactured billet, one machined from a cast block, and one cast directly to final shape. Each of the three heatsinks were …

Characterization Of Properties And Defects Of Alternative Matrix Materials For 3d Printed Continuous Carbon Fiber Reinforced Composites, Noah Darren Osborne

Graduate Theses, Dissertations, and Problem Reports (ETD)

Additive manufacturing, commonly known as 3D printing, has the potential to transform the production of end-use parts by facilitating the creation of complex shaped, low-volume components that are expensive to manufacture using traditional methods. However, thermoplastic polymer matrices currently utilized in 3D printing of carbon fiber composites, often lack the mechanical properties needed for aerospace applications. To address this issue, researchers have developed fiber-reinforced 3D-printed composites using an innovative two-step process which involves printing 3D preforms using fused deposition modeling, followed by compression molding. However, most previous work involves the use of nylon-based polymer matrices while there are a number …

Exploration Of The Iterative Design Process: Integrating A Requirements Matrix And Hazard Analysis Toolsexploration Of The Iterative Design Process: Integrating A Requirements Matrix And Hazard Analysis Tools, Blaine Edlefsen

Theses

The iterative design process is applied to multiple industry sectors from software development to product manufacturing. The cyclical approach integrates the steps of design, prototyping, and testing toward the realization of a user's specified needs. The use of a requirements traceability matrix and hazard analysis documentation that supports the definition of the iterative design process is explored. These design project management tools are applied to a case study involving workholding design for a Wire Electrical Discharge Machining (Wire-EDM) manufacturing process. This industry-relevant case study is conducted in collaboration with New Jersey Precision Technologies, Incorporated (NJPT). The design requirements involve both …

Nano-Second Pulsed Laser Ablation Of Inconel 718 And Mmpcd For Simultaneous Optimal Ablation Rate And Surface Quality, Ahmed Elkaseer, Islam Abdelgaliel, Jon Lambarri, Iban Quintana, Steffen Scholz, Mohamed Aly

Mechanical Engineering

This study investigates the ablation performance of Inconel 718, a nickel-based superalloy, and metalmatrix polycrystalline diamond (MMPCD), a super composite, using a nano-second (ns) pulsed laseracross a range of ablation conditions. Single trenches varying in energy fluence and scanning speedswere created, analyzing the experimental responses in terms of ablation rate and surface roughness.Using regression techniques, models were developed to understand these relationships. Four multi-objective optimization algorithms, weighted value grey wolf optimizer (WVGWO), multi-objectivePareto search (MOPS), multi-objective genetic algorithm (MOGA), and multi-objective sunfloweroptimization (MOSFO), were employed to optimize these models. Key findings include MMPCDachieving the highest ablation rates at maximum fluence …

Using Additive Manufacturing To Characterize Effects Of Sparse Infill Density And Sparse Infill Pattern On The Compressive Properties Of Short Strand Carbon Fiber Infused Petg, Luke C. Salisbury

Honors Theses

The advent of additive manufacturing has revolutionized the prototyping, design, and manufacturing of new and innovative products. Through the use of Fused Deposition Modeling (FDM), parts can be manufactured using different sparse infill percentages (the percentage of void space within a printed object) and sparse infill patterns (the lattice structure of material within the object). Through the manipulation of these variables, the same material and part can have different compressive and flexural properties. In addition to sparse infill, the thermoplastics used in fused deposition modeling can be reinforced with carbon fiber strands to create a printable composite material capable of …

Fpga-Based Sensors For Distributed Digital Manufacturing Systems: A State-Of-The-Art Review, Laraib Khan, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The combination of distributed digital factories (D2Fs) with sustainable practices has been proposed as a revolutionary technique in modern manufacturing. This review paper explores the convergence of D2F with innovative sensor technology, concentrating on the role of Field Programmable Gate Arrays (FPGAs) in promoting this paradigm. A D2F is defined as an integrated framework where digital twins (DTs), sensors, laser additive manufacturing (laser-AM), and subtractive manufacturing (SM) work in synchronization. Here, DTs serve as a virtual replica of physical machines, allowing accurate monitoring and control of a given manufacturing process. These DTs are supplemented by sensors, providing near-real-time data to …

Hitch Cart “Landing Gear”, Rebekah White, Jose Raygoza, Randy Hernandez, Brandon Leon

Mechanical Engineering

This report aims to allow our sponsor, to review our design process of the Hitch Cart Landing Gear Prototype. In the design overview section of this report, we discuss the primary design modifications we made to the wheel mechanism of the existing hitch cart prototype, including the addition of the ACME screws and the folding brackets. This allows our sponsor to see the intended improvements made to the past prototype and understand the primary goal of our project. Then, in the implementation section, we cover the entire manufacturing process to allow our sponsor to understand what manufacturing steps must be …

Expandable And Retractable Wheel Design, Ethan Fortenberry, Emily Cottrell, Keegan Martin, Benjamin Mcconnell

Mechanical Engineering

Our sponsor, Jeremy Goren, wants to see his patented expandable wheel design come to life. He requires a functional final product actuated by linear actuators and with a continuous, circular outer shell. The overall design can be broken up into 2 parts: the inner hub and outer shell. The wheel's shell will consist of a 12-piece outer shell that guides the 6 inner shell pieces. The outer shell pieces will be connected via a UBracket. The hub will consist of 3 identical parts that will hold 2 linear actuators each. The pieces will be bolted together to create 1 singular …

The Waterbug: Adaptive Paddle Board Frame, Remy James Elio Lacchia, Katie Kellum, Madeline Evenson, Shelbi Sullaway

Mechanical Engineering

People with disabilities, particularly wheelchair users, face limitations in participating in outdoor activities like paddleboarding. Central Cal Adaptive, a nonprofit organization, aims to bridge this gap by offering adapted paddleboarding experiences. However, their current paddleboard presents challenges such as portability, range of motion, stability, and safety. Our team, comprising Madeline Evenson, Remy Lacchia, Katie Kellum, and Shelbi Sullaway, has collaborated with Central Cal Adaptive to refine the existing paddleboard design. The team’s goal is to enhance the paddleboard's functionality to better cater to wheelchair users' needs, ensuring lightweight, portable, and safe features for an improved outdoor experience.

Our paddleboard concept …

Development Of A Manifold Microchannel Heat Sink For The Electrification Of Aircraft, Joshua Mora Sanchez

Mechanical Engineering Undergraduate Honors Theses

The miniaturization of microprocessors and power electronics is leading to critical thermal management challenges. For instance, the heat flux generated in modern computer chips is at the order of 100W/cm², which is well beyond the limit of air cooling. This high heat generation can cause a variety of thermal or mechanical failures in electronic devices. As such, there is a pressing need to devise effective cooling strategies for these microelectronic devices. Liquid cooling with microchannel heat sinks is a promising technology for high power loads. Nevertheless, traditional heat sinks with straight microchannels suffer from two critical challenges: high pressure drop …

Neural Operator And Physics-Informed Deep Learning Approaches For Inverse Design Of Composites And Manufacturing Processes, Minglei Lu

All Dissertations

In this dissertation, artificial intelligence (AI) models are designed and used to accelerate inverse design of composites and manufacturing processes. The critical bottlenecks in machine learning (ML) including data availability, data quality, model generalization and adaptation, interpretability, physical consistency, and the ’black box’ nature of models for the inverse design are addressed. And the proposed AI models are tested under different engineering scenarios. Firstly, a fast deep neural operator (DNO) structure was developed to significantly reduce training time. This model was tested in the context of additive manufacturing, a transformative industrial technology that allows for the creation of materials with …

Sensitive Grip Mounting Surfaces For Physical Human-Robot Interaction., Branden Shay

Electronic Theses and Dissertations

As the development of robotics becomes ever increasingly present in our society, the need for studying how humans and robots interact with each other becomes more of a necessity to be properly integrated in the changing world around us. In this thesis, we undertake the study and development of how to create a tactile human-robot operator interface to guide a robot perform a physical task. The implementation of tactile interfaces such as SkinCell sensor arrays emulating skin, and of a robotic handlebar fitted with tactile sensors are critical examples of the challenges that come with mounting and packaging such sensors …

Fabrication And Performance Of Scalable Bio-Engineered Porous Layers For Efficient Co2 Capture, Mary Sharon Rose Bondugula

Theses and Dissertations

This dissertation addresses the critical challenge of mitigating climate change by advancing CO2 capture technologies. As global CO2 emissions continue to rise, effective methods for capturing and separating CO2 from industrial processes are essential to combat climate change. Existing CO2 capture systems, such as Pressure Swing Adsorption (PSA) and Temperature Swing Adsorption (TSA), often rely on packed bed designs that face limitations, including poor heat and mass transfer, slow gas diffusion, and low thermal conductivity, reducing their efficiency. To overcome these challenges, this dissertation explores innovative solutions by developing advanced adsorbent coatings and scalable bed configurations.

This research begins by …

Greek Key-Inspired Fractal Metamaterials With Enhanced Flexibility And Energy Absorption., Zhennan Zhang

Electronic Theses and Dissertations

Architected materials with intricate three-dimensional (3D) geometries offer unique properties and functionalities but face challenges in manufacturing costs and complexity. This research explores the integration of simple 2D Greek Key-inspired lattices into fractal designs to achieve exceptional mechanical performance. Using 3D printing and kerfing, these fractal structures demonstrate enhanced flexibility and energy absorption capabilities. Through three-point bending and in-plane tensile tests, the 2D fractal lattices exhibited a 600-fold reduction in bending force and a tensile stretch capacity of up to 520%, significantly outperforming brittle parent materials. Out-of-plane compression tests revealed a five-fold increase in energy absorption compared to honeycomb structures, …

Modeling And Understanding Of Additive Manufacturing Periodic Cellular Structures With Heterogeneity: Property, Quality And Design Strategy., Naresh Koju

Electronic Theses and Dissertations

Lightweight cellular structures with their higher per mass performance capability, multifunctional designability and property tolerability are gaining much wider adaptation in many engineering applications ranging from aerospace, defense, biomedical, automotive to sports. However, to achieve the desired performance levels careful design must be carried out. The experimental-based empirical design often involves high manufacturing cost, and there are also certain information/knowledges about the cellular deigns that could not be easily obtained experimentally, such as the deformation local fracture initiation. Similarly, numerical modeling-based design approach commonly suffers from high computation cost and the lack of inverse designability. In addition, numerical models often …

An Efficient Computational Frameworks For Design And Analysis Of Metamaterials, Raj Pradip Khawale

All Dissertations

Advancement in additive manufacturing helps in building artificial lattice structures with unique properties that are not available in naturally occurring materials or in continuum structures. Specifically, beam-based lattices are well known for producing lightweight structures with very high strength, auxetic behavior, and energy absorption capabilities. In recent years, numerous research studies have been conducted on generating algorithms and frameworks to obtain unusual properties based on the variation in the cell geometry and material properties. However, the exploration of the full design space is hampered in practice primarily due to restrictions on cell tiling variation. Additionally, the lattices are very intricate, …

Mitigation Of The Environmental Impacts Of Lithium Extraction And Lithium Battery Manufacturing, Dominick R. Strollo

Sustainability Conference

Lithium extraction and the production methods utilized for lithium-ion batteries can have a large impact on the areas directly surrounding them, and if not mitigated properly, the rest of the world as well. For these batteries to be produced, lithium must be mined and refined from sources all around the world. The main concern of lithium mines is their impact on the water cycle and the surrounding water tables due to the heavy metals involved in the process and the sheer amount of water required. Production of the batteries themselves using the lithium slurry is far less impactful on the …

A Study Of Fit And Friction Force As A Function Of The Printing Process For Fff 3d-Printed Piston–Cylinder Assembly, Philippe A. Passeraub, Quentin Allen, Elizabeth Clark, Michael Miles, Siddartha Berns, Maija Pearson, Sterling Allred, Jonah Brooks, Sylvain Hugon

ScholarsArchive Data

Dataset DOI: https://doi.org/10.26067/hjm6-3d45

The shared data comprises the experimental measurements performed presented in the figures 5, 6, 7, 9, 10, 11, 12, and in the tables for the following article:

Passeraub, P.A.; Allen, Q.; Clark, E.; Miles, M.; Berns, S.; Pearson, M.; Allred, S.; Brooks, J.; Hugon, S. A Study of Fit and Friction Force as a Function of the Printing Process for FFF 3D-Printed Piston–Cylinder Assembly. J. Manuf. Mater. Process. 2024, 8, 249. https://doi.org/10.3390/jmmp8060249