Manufacturing Commons^™

Analyzing The Effects Of Ultrafast Laser Processing On Mechanical Properties Of 3d-Printed Pla Parts, Darshan Pramodbhai Yadav

Theses and Dissertations

Recent advances in additive manufacturing technologies have already led to wide-scale adoption of 3D-printed parts in various industries. The expansion in choice of materials that can be processed, particularly using Fused Deposition Modeling (FDM), and the steady advancements in dimensional accuracy control have extended the range of applications far beyond rapid prototyping. However, additive manufacturing still has considerable limitations compared to traditional and subtractive manufacturing processes. This work addresses limitations associated with the as-deposited surface roughness of 3D-printed parts. The effects of roughness-induced stress concentrations were studied on ultimate tensile strength and fatigue life. The samples were manufactured using a …

Kwad - Ksu All Weather Autonomous Drone, Nick Farinacci, Sebastian Gomez, Stewart Baker, Ed Sheridan

Symposium of Student Scholars

"KWAD" or "KSU all-Weather Autonomous Drone" project was sponsored by Ultool, LLC to the KSU Research and Service Foundation to create a lightweight drone capable of capturing HD video during all-weather operations. The conditions of all-weather operation include rainfall of one inch per hour and wind speeds of up to twenty miles per hour. In addition, a global minimum structural safety factor of two is required to ensure the system's integrity in extreme weather conditions. Potential mission profiles include autonomous aerial delivery, topological mapping in high moisture areas, security surveillance, search and rescue operations, emergency transportation of medical supplies, and …

Wire Electrical Discharge Machining Of Aisi304 And Aisi316 Alloys: A Comparative Assessment Of Machining Responses, Empirical Modeling And Multi-Objective Optimization, Mona Aboueleaz, Noha Naeim, Islam Abdelgaliel, Mohamed Aly, Ahmed Elkaseer

Mechanical Engineering

This research investigates the multi-response of both material removal rate (MRR) and surface roughness (Ra) for the wire electrical discharge machining (WEDM) of two stainless steel alloys: AISI 304 and AISI 316. Experimental results are utilized to compare the machining responses obtained for AISI 316 with those obtained for AISI 304, as previously reported in the literature. The experimental work is conducted through a full factorial experimental design of five running parameters with different levels: applied voltage, transverse feed, pulse-on/pulse-off times and current intensity. The machined workpieces are analyzed using an image processing technique in order to evaluate the size …

Implementation Of Experimental Static Recrystallization Of High Strength Steel Into Computational Simulation Of Multi-Pass Slab Hot Rolling, S. K. Dasari, S. Ganguly, A. Abutunis, K. Chandrashekhara, M. F. Buchely, S. N. Lekakh, R. J. O'Malley, T. Natarajan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Microstructural changes and softening due to static recrystallization have a critical influence on thermo-mechanical behavior of high strength steels during industrial multi-pass hot rolling. Numerical simulation using finite element analysis (FEA) can be used to accurately predict the softening behavior during the hot rolling process. Therefore, the implementation of an experimentally defined static recrystallization model into FEA is necessary to get realistic simulation prediction. in this study, the extent of softening during static recrystallization in Si and Mn alloyed high strength steel was measured using double hit tests. a Gleeble™ thermo-mechanical simulator was used to perform the double hit tests …

An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding

LSU Doctoral Dissertations

Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.

Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …

Influence Of Technological Parameters On Chip Formation And Chip Control In Precision Hard Turning Of Ti-6al-4v, Elshaimaa Abdelnasser, Samar El-Sanabary, Ahmed Nassef, Azza Barakat, Ahmed Elkaseer

Mechanical Engineering

This article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the macro level by varying the process parameters, namely, feed rate, cutting speed and depth of cut during turning tests. A scanning electron microscope (SEM) was used to examine the chips produced for a better understanding of chip curling mechanisms at the micro level. Surface roughness of the machined specimens was measured to …

Additive Manufacturing And Characterization Of Auxetic Structures, Jayesh P. Moore, Stephanie R. Ruzicka

College of Engineering Summer Undergraduate Research Program

An auxetic structure is an arrangement of unit cells that under a uniaxial load experiences expansion in both the longitudinal and transverse directions, resulting in a negative Poisson’s ratio (NPR). Research in auxetics has led to new insights into how non-linear mechanical reactions can be applied to various engineering fields. This project utilized stereolithography (SLA) 3D printing to manufacture auxetic test specimens to analyze of geometry-driven NPRs. With the distinctive mechanical properties of auxetic structures and vast applications, the future of product development of these geometries seems promising.

Additive Manufacturing For Medical Education, Michael Noon

College of Engineering Summer Undergraduate Research Program

A growing body of evidence is suggesting that anatomical knowledge, the keystone of many medical specialties, is suffering among new graduates. While a host of reasons are provided, one common thread that many point to is the decline of cadaver dissections in the classroom. Many virtual audio-visual tools are used to address this gap, yet evidence has shown their ineffectiveness. Given this gap, the high degree of flexibility found in additive manufacturing (AM), and the many uses AM has already found in the medical field, we propose its use to fill this gap, allowing for students to learn with touch …

Numerical Study Of Solar Receiver Tube With Modified Surface Roughness For Enhanced And Selective Absorptivity In Concentrated Solar Power Tower, Shawn Hatcher, Mathew Z. Farias, Jianzhi Li, Peiwen Li, Ben Xu

Manufacturing & Industrial Engineering Faculty Publications

Concentrated solar power (CSP) is a reliable renewable energy source that is progressively lowering its cost of energy. However, the heat loss due to reflected and emitted radiation hinders the maximum achievable thermal efficiency for solar receiver tubes on the solar tower. Current solar selective coatings cannot withstand the high temperatures that come with state-of-the-art CSP towers often needing to be recoated soon after initial operation. We intend to use Inconel 718 with different additive manufacturing (AM) practices to construct surfaces that allow for more light-trapping to occur. By adjusting printing parameters, we can tailor a surface to allow for …

Wire Deflection Investigation During Wedm Of Aisi 304 Stainless Steel: An Experimental And Numerical Study, Sara A. El-Bahloul, Mohamed G. Elkhateeb

Mansoura Engineering Journal

Wire electrical discharge machining (WEDM) is a specific form of electrical discharge machining that employs a small diameter wire electrode to cut a narrow kerf in the workpiece. Since the wire deflection has a negative effect on the performed cutting, this research seeks to study the resultant wire deflection during WEDM of AISI 304 stainless steel. This study is performed with the help of three types of modeling; namely, mathematical modeling, experimental modeling, and thermo-mechanical finite element modeling. The mathematical modeling is performed to analyze the stresses and the wire lag, while the experimental modeling is achieved to observe the …

Laboratory Glovebox, Jackson T. Tenne, Noah Fitzgerald, Scott Stirling, Danny Ho

Mechanical Engineering

The Laboratory Glovebox project aimed to create an affordable, functional, ready to use, airtight workstation enabling Dr. Ramanan Sritharan to continue his research of the mechanical properties of nanomaterials. When airborne, nanomaterials are a health risk if inhaled, so the design requires a hermetic seal to protect the user. The design was meant to emulate features of the glovebox used by Dr. Sritharan during his PhD research, but was optimized to meet a budget of $3000, much cheaper than comparable alternatives. Key design features included acrylic panels, a transfer chamber, glove mounts, and a main access door, all sealed to …

Optimizing Mn-Al Permanent Magnet Performance Through Control Of The Phase Transformation, Ternary Element Addition, And Advanced Processing, Thomas R. Keller

Dartmouth College Ph.D Dissertations

The growing need for electrical power in machines and vehicles brings with it a growing need for critical materials. The current high-performance permanent magnets (PMs) based on rare-earth (RE) elements Nd and Sm cannot escape the problem of raw material cost, geographic scarcity in the earth’s crust, and lack of circular global supply chains. This poses a problem of industrial ecology: can PMs be made from inexpensive, more abundant materials while still meeting sufficient performance criteria? PMs based on the magnetic τ phase of Mn-Al offer a possible alternative to REPMs. However, years of innovation have not yet achieved real-world …

Effects Of Machining Parameters Of C45 Steel Applying Vegetable Lubricant With Minimum Quantity Cooling Lubrication (Mqcl), Mayur A. Makhesana, Prashant J. Bagga, Kaushik M. Patel, Jaime Taha-Tijerina

Informatics and Engineering Systems Faculty Publications

One of the most significant performance indicators for measuring the machinability of materials is tool wear and surface roughness. Choosing the best combination of cutting parameters can help reduce production costs, which is what the manufacturing industry is interested in. At the same time, industries are always looking for an alternative to conventional flood cooling since its use creates an environmental burden and health concerns for the operators. Therefore, vegetable oil-based minimum quantity cooling lubrication (MQCL) is considered a cutting environment. Sunflower oil is utilized as base fluid in MQCL and applied to the cutting zone through a nozzle. The …

Explainable Ai (Xai)-Driven Vibration Sensing Scheme For Surface Quality Monitoring In A Smart Surface Grinding Process, Abhishek Hanchate, Satish T.S. Bukkapatnam, Kye Hwan Lee, Anil K. Srivastava, Soundar Kumara

Manufacturing & Industrial Engineering Faculty Publications

Local Interpretable and Model-agnostic Explanation (LIME), an explainable artificial intelligence (XAI) approach is adapted to identify the globally important time-frequency bands for predicting average surface roughness (Ra) in a smart grinding process. The smart grinding setup consisted of a Supertech CNC precision surface grinding machine, instrumented with a Dytran piezoelectric accelerometer attached to the tailstock quill along the tangential direction (Y-axis). For every grinding pass, vibration signatures were captured, and the ground truth surface roughness values were recorded using a Mahr Marsurf M300C portable surface roughness profilometer. The roughness values ranged from 0.06 to 0.14 microns over the complete set …

Fatigue And Fracture Of Electron Beam Melting Ti-6al-4v, William A. Grell

Electronic Theses and Dissertations

For applications in the aerospace field, selection of materials for a given design requires an understanding of critical properties, like fatigue and fracture, in addition to static mechanical and physical properties. With the ongoing advancements in metallic additive manufacturing techniques and the interest in applying the process to aerospace applications, there is a clear need to fully characterize properties. Arguably, the most attractive alloy for applications in aerospace is the Ti-6Al-4V alloy. The current dissertation examines the mechanical properties of the alloy, made by the Electron Beam Melting (EBM) Powder Bed Fusion (PBF) method. As illustrated in this work, the …

The Influence Of Diversity Dimensions On Student’S Collaboration Success: What It Means For Workforce Development In Manufacturing, Oyinkansola Adeite

All Theses

Manufacturing productivity is measured by labor productivity which is the hourly output of the manufacturing economy. The recent reduction in productivity numbers by the United States Bureau of Labor Statistics emphasizes the need for workforce development. With globalization and technological advancements, diversity has emerged as a critical aspect for the workplace. By encompassing dimensions such as education, race, and age, diversity creates a tapestry of unique perspectives and experiences. This study’s aim is to figure out the effect of a diversity dimension on team performance using intelligent systems, and in addition, if extra dimensions of diversity further impact team performance. …

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

All Theses

Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

Characterization Of Mechanically Recycled Polylactic Acid (Pla) Filament For 3d-Printing By Evaluating Mechanical, Thermal, And Chemical Properties And Process Performance, Mahsa Shabani Samghabady

All Theses

Polylactic acid (PLA) is a biopolymer made from renewable resources such as sugar and corn. PLA filament is a popular material used in Fused Deposition Modeling (FDM) 3D-printing. While this material has many advantages, all the failed parts, support structures, rafts, nozzle tests, and the many prototype iterations during the 3D-printing process contribute to the plastic pollution and release of greenhouse gases. Although PLA is biodegradable, it can take years to degrade in landfills. Instead of throwing away PLA waste and buying new filaments, PLA can be recycled. Amongst the different recycling technologies, mechanical recycling is the most environmentally friendly. …

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

Laser-Induced Forward Transfer (Lift) Based Bioprinting Of The Collagen I With Retina Photoreceptor Cells, Md Shakil Arman, Ben Xu, Andrew Tsin, Jianzhi Li

Manufacturing & Industrial Engineering Faculty Publications

This study focuses on the 3D bioprinting of retina photoreceptor cells using a laser-induced forward transfer (LIFT) based bioprinting system. Bioprinting has a great potential to mimic and regenerate the human organoid system, and the LIFT technique has emerged as an efficient method for high-resolution micropatterning and microfabrication of biomaterials and cells due to its capability of creating precise, controlled microdroplets. In this study, the parameters for an effective femtosecond laser-based LIFT process for 3D bioprinting of collagen biomaterial were studied. Different concentrations of collagen I solutions were tested and 0.75 mg/ml to 1 mg/ml collagen Ⅰ was identified as …