Manufacturing Commons^™

A Literary Survey On The Challenges Of Adopting Lean In Aerospace Production And Aviation Maintenance, Seanan C. Lee

Journal of Aviation Technology and Engineering

Lean production began as a new method for creating value through the elimination of waste, continuous process improvement by workers, and fostering respect for people. Despite its success in other industries, the significantly lower production volume, the substantially higher complexity, and the service-oriented nature of aviation maintenance demand significant adaptation of Lean principles to be effective. The lack of a holistic study on Lean adoption for aerospace production and aviation maintenance organizations hinders transformation as the two industries are intertwined in product and characteristics. Lean adoption in aerospace production is hindered by the lingering notion that it is an ‘‘automotive …

Electromagnetically Actuated Modular Robots With Controlled Self-Assembly And On-Demand Disassembly, Anuruddha Bhattacharjee

Mechanical Engineering Research Theses and Dissertations

Modular reconfigurable robots, with on-demand assembly and disassembly, offer the possibility of mesoscale (milli- and microscale) manufacturing. However, most of the existing modular robotic platforms currently being designed and functionalized rely on complex actuation and assembly mechanisms and so lack further scalability and transformability required for mesoscale applications. Therefore, this dissertation seeks to develop a novel scalable modular robotic platform with controlled self-assembly, disassembly, and reconfiguration techniques using an external electromagnetic field. While current cutting-edge research in this area uses a single magnet to move one module at a time into the target position, this dissertation explores processes to move …

Crafting Comfort: The Design And Production Of A High-End Poolside Lounge Chair, John Hollis Tackett, Robert Griffis

Honors Theses

This report focuses on the development, design, and manufacturing of the Adjustable Lounge Chair, a high-end poolside lounge chair created to address un-met customer demand in the market. The investigation began with a market analysis to identify sought-after features not currently offered by competitors' products. This analysis drove the design of the chair, which was developed using CAD software, followed by the construction of a physical prototype to validate the concept.

The chair's innovative features include adjustable lumbar support and chair height, as well as a removable face-piece that enables users to comfortably lie prone without straining their necks. These …

The Engineering Challenges Of Designing And Manufacturing A Tensegrity Cup Stand, Yaniv Goulet, Daniel Ferro

Honors Theses

Progressing from a simple idea into a fully developed product is one of the main goals of any engineer. Through Haley Barbour Center for Manufacturing Excellence’s capstone program, the team was tasked with realizing a tensegrity cup stand. The tensegrity structure consists of a top and a bottom of some form only supporting itself by tension. The team had to research the concept, create an initial design, create a prototype of the product, improve the design after the prototype’s mistakes, apply lean principles to improve the manufacturing efficiency, and analyze all the economic impacts of the engineering decisions. In the …

Exploring Methods For Recycling Filament Waste In 3d Printing, Max Rios Carballo

Publications and Research

The goal of the current study is to investigate cutting-edge techniques for recycling filament waste from 3D printing procedures. Appropriate waste management techniques are required to reduce this trash's harmful environmental consequences. The goal of the project is to look at new methods for recycling filament waste in order to minimize disposal and encourage reuse. To acquire data from pertinent papers and research, a thorough literature review methodology was used. The findings show that this issue may be resolved utilizing a variety of recycling techniques, including shredding, melting, and re-extrusion. The type of filament waste and the intended goal will …

A Proof-Of-Concept Study For An Elastohydrodynamic Seal Design, Cameron M. Stuart

Honors College Theses

Supercritical CO₂ (sCO₂) power cycles are superior to traditional water based, air-breathing, direct-fired, open Brayton cycles or indirect-fired, closed Rankine cycles in terms of efficiency and equipment size. They hold great potential in fossil fuel power plants, nuclear power production, solar power, geothermal power, and ship propulsion. To unlock the potential of sCO₂ power cycles, utilized technology must withstand 10–600 MWe and at sCO₂ temperatures and pressures of 350–700℃ and 20–35 MPa for nuclear industries. Amongst many challenges at the component level, the lack of suitable shaft seals for sCO₂ operating conditions needs to …

Engineering 3d Architected Metamaterials For Enhanced Mechanical Properties And Functionalities., Huan Jiang

Electronic Theses and Dissertations

Compared with conventional materials, architected metamaterials have shown unprecedented mechanical properties and functionalities applications. Featured with controlled introduction of porosity and different composition, architected metamaterials have demonstrated unprecedent properties not found in natural materials. Such design strategies enable researchers to tailor materials and structures with multifunctionalies and satisfy conflicting design requirements, such as high stiffness and toughness; high strength with vibration mitigation properties, etc. Furthermore, with the booming advancement of 3D printing technologies, architected materials with precisely defined complex topologies can be fabricated effortlessly, which in turn promotes the research significantly. The research objectives of this dissertation are to achieve …

Developing Executable Digital Models With Model-Based Systems Engineering – An Unmanned Aerial Vehicle Surveillance Scenario Example, Viviana Guadalupe Lopez

Theses and Dissertations

There is an increase in complexity in modern systems that causes inconsistencies in the iterative exchange loops of the system design process and in turn, demands greater quality of system organization and optimization techniques. A recent transition from document-centric systems engineering to Model-Based Systems Engineering (MBSE) is being documented in literature from various industries to address these issues. This study aims to investigate how MBSE can be used as a starting point in developing digital twins (DT). Specifically, the adoption of MBSE for realizing DT has been investigated, resulting in various literature reviews that indicate the most prevalent methodologies and …

Cycle Time Reduction In Additive Manufacturing Using Peltier Thermoelectric Cooling Devices, Trevor Carlton

Honors College Theses

Thermoelectric cooling and the Peltier effect were discovered in 1834, over 188 years ago. Additionally, the first iterations of additive manufacturing (i.e., 3D printing) began in the early 1980s, more than 40 years ago. Despite these technologies’ age and years of advancements, the application of Peltier cooling-based devices in additive manufacturing has not yet been realized. These devices can be used for the active thermal management of print beds in 3D printers. Developing a mechanism to heat and cool a print bed can reduce the cycle time to manufacture a part. In 3D printing, waiting for the heated bed to …

Performance Of A Solar Seawater Distillation With A Triangle Prism Cover And A Fin-Type Absorber, Risse Entikaria Rachmanita, Miftah Khoirul Umam

Makara Journal of Technology

Solar-powered distillation is a seawater distillation method that utilizes solar heat as its main energy source for the purpose producing freshwater and a by-product of the distillation process in the form of salt. This study aims to determine the performance of a solar seawater distillation design with a semi-batch system by combining a fin-type absorber plate and a triangular prism cover. This design is equipped with a reflector and absorber plate, which has a surface area of 0.3969 m2 with a volume capacity of seawater that can be accommodated in a basin of ±24 liters. It uses a knockdown system …

Structural Design And Fabrication Of A Test Chamber To Test Ppes For Effective Particle Filtration, Matthew G. Adharsingh

Honors College Theses

This research project aims to design and fabricate a test chamber for testing Personal Protective Equipment (PPE) to ensure effective particle filtration. The chamber has a special purpose, which is to measure ultrafine and submicron particles concentration in the air and test the ergonomic design of PPE based on its effective filtration. The project also considers the environmental aspects of the chamber such as the level of noise and vibration. The chamber will be designed to measure upstream and downstream particle count. Initially, the chamber was going to be made from wood, but the research team encountered difficulties in the …

Effects Of Tempering Temperature On Gas Turbine Fan Cases, Seth Utter

Honors Scholar Theses

The project aimed to investigate the effects of tempering temperature on metals used for gas turbine engine fan cases as a major relevant concern is containing blades in during blade-out events. There are three ways to accomplish this: using a thicker metal, incorporating different materials into the case, or heat treating the metal. This project focused on the third solution: reviewing the impact toughness and hardness of fractured samples and their equivalent ductile-to-brittle transition shear faces. Given its availability, 1045 steel, as opposed to aerospace grade metals, was used for in-house testing. The data obtained from these experiments were then …

Pla-S-Tech: Pla Sustainable Technology, Sean Sapper, Ryan Decarlo, Elle Whitney, Samantha Dombrowski, Dalton Prokop, Dominic Zaio, Tyler Stokes, David Deese, Blake Hengel, Yi Guo

Mechanical and Civil Engineering Student Publications

To recycle waste material produced by fused deposition modeling (FDM) 3D printers, a recycler was designed and manufactured to convert plastic scraps into usable filament. The device does so by breaking down plastic material to a uniform size with the shredder, melting and compressing these pieces into a cylindrical strand with the extruder, and wrapping this strand around a filament spool with the spooler. As the device is mostly made from commercially-available components, it is easily maintainable and user-serviceable, while also costing less than similar devices on the market.

Naphtha Characterization (Piona, Density, Distillation Curve And Sulfur Content): An Origin Comparison, Aline Pioli Silva, Juliana Otavia Bahú, Renato Soccol Jr., Leonardo Rodriguez-Urrego, William Stive Fajardo-Moreno, Hiram Moya, Jeffrey Leon-Pulido, Víktor Oswaldo Cárdenas Concha

Manufacturing & Industrial Engineering Faculty Publications

Naphtha is an important distillation product of crude oil, and is used as a raw material for first-generation products such as ethylene, propylene, gasoline, xylene (BTX), and others. However, due to the different sources of crude oil, differences in naphtha composition impact the quality of conversion processes. Parameters such as pressure, charge flow, and temperature need to be adjusted for conversion efficiency. This work aims to compare naphtha samples from different origins, through the analysis of distillation curve (ASTM D86), density (ASTM D4052), total sulfur (ASTM D4294), and n-paraffins, iso-paraffins, olefins, naphthene, and aromatics (PIONA, ASTM D5134). Among these parameters …

Mechanical Characterization Of Additively Manufactured Alloys Compared To Their Wrought Counterparts, Laith A. Alqawasmi

Mechanical Engineering ETDs

Additive manufacturing is a method of manufacturing based on building parts layer by layer, allowing for more control over shape of the product, therefore reducing machining costs, reducing material waste, faster production times and the ability to build complex engineering design that other manufacturing technologies won’t be able to produce. This research is on the tensile and indentation testing (following ASME standards) of 3D printed Ti-6Al-4V and Inconel 718 built by powder-based direct energy deposition technology. Ti-6Al-4V is an attractive material for the aerospace and aviation industry, and Inconel 718, a nickel-chromium based superalloy, is an attractive material for usage …

A High-Strength Precipitation Hardened Cobalt-Free High-Entropy Alloy, Matthew Luebbe, Jiaqi Duan, Fan Zhang, Jonathan Poplawsky, Hans Pommeranke, Maalavan Arivu, Andrew Hoffman, Mario Buchely, Haiming Wen

Materials Science and Engineering Faculty Research & Creative Works

Recent studies on precipitation-hardened high-entropy alloys (HEAs) demonstrate their high strength and thermal stability, making them promising materials for high-temperature structural applications such as nuclear reactors. However, many existing HEAs contain cobalt (Co), which is unsuitable for nuclear applications because of the long-term activation issue of Co. Co is also expensive and considered a critical material for other applications. Therefore, it is desired to exclude Co from the composition. a Co-free (Fe0.3Ni0.3Mn0.3Cr0.1)88Ti4Al8 HEA was developed and studied in this work. in contrast to previous Co-free HEAs, this alloy is close to Equi atomic in its composition and promises a more …

A Molecular Dynamics Study Of Atomic Diffusion Effects On Thermomechanical Properties Applying Laser Additive Alloying Process For The Cantor High Entropy Alloy, Mathew Farias, Han Hu, Shanshan Zhang, Jianzhi Li, Ben Xu

Manufacturing & Industrial Engineering Faculty Publications

High entropy alloys (HEAs) can be manufactured in many conventional ways, but it becomes difficult to fabricate heterogeneous materials and structures. The Selective Laser Melting (SLM) method generally melts pure elemental powders or prefabricated alloy powders without an alloying process. In-situ alloying in SLM, which is also called Laser Additive Alloying (LAA), using pure elemental powders becomes a promising method for creating HEA with heterogeneous structures. However, the effect of the diffusion of elements in the molten pool on the formation of HEA remains unclear. In this paper, the well-discussed Cantor HEA was studied in an in-situ alloying situation, where …

Portable Drinking Water Cooler And Dispenser, Gustavo Hernandez-Lerena, Erik Torres, Caleb Francis Parham, Terry Leung

Mechanical Engineering

This document serves as the comprehensive report for the testing and building for the Portable Water-Cooling System by team AquaCool. Team AquaCool is comprised of four mechanical engineers with a passion to help the agricultural industry in their efforts to keep the health of the workers at their peak. The four engineers who partook in helping the farm workers are as follows: Caleb F. Parham, Erik Torres, Gustavo Hernandez-Lerena, and Terry Leung. To reduce the risk of heatstroke and other unwanted effects from the harsh working conditions during summer, a small and portable system was built to help in the …

Fast-, Light-Cured Scintillating Plastic For 3d-Printing Applications, Brian G. Frandsen, Michael Febbraro, Thomas Ruland, Theodore W. Stephens, Paul A. Hausladen, Juan J. Manfredi, James E. Bevins

Faculty Publications

Additive manufacturing techniques enable a wide range of possibilities for novel radiation detectors spanning simple to highly complex geometries, multi-material composites, and metamaterials that are either impossible or cost prohibitive to produce using conventional methods. The present work identifies a set of promising formulations of photocurable scintillator resins capable of neutron-gamma pulse shape discrimination (PSD) to support the additive manufacturing of fast neutron detectors. The development of these resins utilizes a step-by-step, trial-and-error approach to identify different monomer and cross-linker combinations that meet the requirements for 3D printing followed by a 2-level factorial parameter study to optimize the radiation detection …

Material Property Dependence Of Nanoparticle Silicon Carbide Alloying In Additively Manufactured Molybdenum, Andrew P. Mason

Theses and Dissertations

The structural performance of additively manufactured Mo printed by LPBF can be significantly improved by nanoparticle alloying. Previous AFIT studies of SiC nanoparticle addition conducted by Ellsworth (2022) et al. demonstrated increased powder consolidation, leading to reduced porosity, increased microhardness, and a shift in atomic defect concentrations. The addition of defected SiC particles is proposed to reduce in situ oxidation by acting as a sacrificial oxidizing agent and contributing to the formation of Mo disilicide secondary phases. This study investigated the relationship between laser powder bed fusion Mo microscale and nanoscale properties with varying SiC particle size while maintaining a …