Manufacturing Commons^™

Durability Of Vacuum Infusion Tooling Produced From Fused Granular Fabrication Additive Manufacturing, Nathan Northrup, Jason Weaver, Andy R. George

Faculty Publications

Large area additive manufacturing (LAAM) has the capability to create tooling that is lower cost than conventionally manufactured tooling and still has sufficient properties for many applications. A vacuum infusion mold was printed from fiberglass-ABS and evaluated for wear and suitability for small vacuum infusion runs. The mold was designed to accentuate high wear as a “worst case” scenario. The mold was able to produce 10 parts successfully before any noticeable change occurred to the surface finish. By 14 parts, the surface finish had roughened sufficiently that demolding was difficult and resulted in damage to the part. Profilometry measurements showed …

The Toyota Production System (Tps) In A Non-Traditional Manufacturing Environment: The Role Of Standardization In The Fast-Food Industry, Kevin Mccracken

Theses and Dissertations--Manufacturing Systems Engineering

The Toyota Production System (TPS), also known as Lean Manufacturing (LM), was founded in the automotive industry and has contributed to Toyota’s decades of success. This has brought much attention to TPS and how this system may be implemented in other industries. Focusing on the TPS foundational element of standardization, this study examines the impact of target cycle time (TCT) on process fluctuation in a fast-food environment. In order to observe the effects of TCT, team members within 3 production lines were timed. Times were measured before and after the addition of a TCT to the Standardized Work (STW) in …

Airflow Impact Upon Remote Laser Welding Quality, Baixuan Yang

Mechanical Engineering Research Theses and Dissertations

Laser induced plasma-plume and condensed particles attenuate the laser beam energy, resulting in keyhole instability and lacking penetration. There are various airflow devices that are currently used in both industrial and laboratory laser welding settings to suppress the detrimental effect of plasma plume and hot spatters. A systematic experimental and numerical study is presented in this dissertation that investigates different external airflow effects on the remote laser welding process used in automotive manufacturing applications.

The vertical airflow impact on the remote laser welding was first studied experimentally. The airflow velocity profiles of a coaxial vertical flow device were measured using …

Prediction And Validation Of Residual Stresses In Additively Manufactured Metal Parts, Jose Mayi Rivas

Electronic Theses and Dissertations, 2020-2023

Selective Laser Melted (SLM) Additively Manufactured (AM) metal parts are of special interest to many industries because their designs can be made arbitrarily complex while still maintaining bulk type mechanical properties. However, the large thermal gradients inherent to the SLM process generate residual stresses (RS) and distortions that are detrimental to the fit, functionality and integrity of parts. Predicting the state of stresses in as-built 3D printed parts is a difficult problem that currently has only been approached with the use of transient thermomechanical Finite Element Models (FEMs). The nonlinearities associated with AM processes are difficult to capture in these …

Laptop Recycling Case Study: Estimating The Contained Value And Value Recovery Process Feasibility Of End-Of-Life Consumer Electronics, Zebulon Hart

Theses and Dissertations--Mining Engineering

Work has been done to establish, through the development and use of novel assay techniques and analysis metrics, the contained value of a sampling of laptop computers (as an analog for myriad e-waste sources). This work has conceptualized e-waste as an alternative to geologic-origin complex metallic ores and has likewise evaluated the feasibility of value recovery from e-waste sources in a similar manner to an ore. The application of conventional and novel mineral separation techniques to e-waste recycling processes has been evaluated and positive results are demonstrated. Further, this work has demonstrated the ability to identify the presence of base …

Energy And Economic Modeling Of Stillage Dewatering Processes In Kentucky Bourbon Distilleries, William Brennan

Theses and Dissertations--Mechanical and Aerospace Engineering

Stillage is a byproduct of alcohol distillation and must be managed in all distilleries to sustain operations. In the United States, fuel ethanol plants typically convert all stillage into Dried Distillers’ Grains with Solubles (DDGS). This process and its variations are well known. Typical stillage management approaches are not well known, however, for the Kentucky bourbon industry. A survey of stillage management approaches in operational bourbon distilleries was conducted. Process modeling was performed to evaluate the energy and economic considerations of the available stillage dewatering methods for a 7 Million Original Proof Gallon (MMOPG) distillery. Monte Carlo simulations were performed …

Quantitative Methods For Total Lifecycle Risk Likelihood And Impact Assessment In Sustainable Product Design Decision Making, Christian Enyoghasi

Theses and Dissertations--Mechanical and Aerospace Engineering

Sustainable products promise significant economic, environmental, and societal benefits. Numerous methods are available for use during the new product development process to identify alternate product designs that optimize sustainability performance. Once any such design is selected and the product is launched, many uncertainties are likely to affect its performance over the total lifecycle. Such uncertainties give rise to risks that can influence the overall product sustainability performance. However, comprehensive quantitative methods to evaluate the likelihood or the impact of different risks to enable sustainable product design decision making are lacking.

This research aims to address this gap by developing a …

In-Situ Characterization Of Surface Quality In Γ-Tial Aerospace Alloy Machining, David Adeniji

Theses and Dissertations--Mechanical and Aerospace Engineering

The functional performance of critical aerospace components such as low-pressure turbine blades is highly dependent on both the material property and machining induced surface integrity. Many resources have been invested in developing novel metallic, ceramic, and composite materials, such as gamma-titanium aluminide (γ-TiAl), capable of improved product and process performance. However, while γ-TiAl is known for its excellent performance in high-temperature operating environments, it lacks the manufacturing science necessary to process them efficiently under manufacturing-specific thermomechanical regimes. Current finish machining efforts have resulted in poor surface integrity of the machined component with defects such as surface cracks, …

In-Situ Characterization Of Burr Formation In Finish Machining Of Inconel 718, Hamzah M. Zannoun

Theses and Dissertations--Mechanical and Aerospace Engineering

One of the undesirable byproducts that occur during the machining process is the development of burrs, which are defined as rough excess material that forms around the geometric discontinuities of a part. Burrs are especially problematic because they have negative impacts across the triple bottom line: economic, environmental, societal. For one, they are expensive to remove because the deburring process is entirely manual and requires skill. Further, burr material is typically discarded which is adding to the already mounting waste generated from machining such as in coolant and chip disposal. Lastly, there are many societal implications, such as operator injury …

Industry 4.0 Remanufacturing: A Novel Approach Towards Smart Remanufacturing, Prashansa Ragampeta

Masters Theses

“Smart remanufacturing has become more popular in recent years as a result of its multiple benefits and the growing need for society to encourage a circular economy that leads to sustainability. One of the most common end-of-life (EoL) choices that can lead to a circular economy is remanufacturing. As a result, at the end-of-life stage of a product, it is critical to prioritize this choice over other accessible options because it is the only recovery option that retains the same quality as a new product. This work focuses on the numerous technologies that can aid in the improvement of smart …

A Convolutional Neural Network (Cnn) For Defect Detection Of Additively Manufactured Parts, Musarrat Farzana Rahman

Masters Theses

“Additive manufacturing (AM) is a layer-by-layer deposition process to fabricate parts with complex geometries. The formation of defects within AM components is a major concern for critical structural and cyclic loading applications. Understanding the mechanisms of defect formation and identifying the defects play an important role in improving the product lifecycle. The convolutional neural network (CNN) has been demonstrated to be an effective deep learning tool for automated detection of defects for both conventional and AM processes. A network with optimized parameters including proper data processing and sampling can improve the performance of the architecture. In this study, for the …

Quickcut Waterjet Cutter, Kennedy Dunn, Jacob Storrow, Benjamin Laughrey

Williams Honors College, Honors Research Projects

The QuickCut Waterjet Cutter was created in 2019 as a senior design project. This is the third iteration of the waterjet cutter. The goal of this project was to create an operable CNC waterjet cutter that is able to cut 1/16” tensile specimens consisting of nonferrous metal or plastic. This machine will be utilized in the Manufacturing Laboratory at the University of Akron to provide education to interested students on the waterjet cutting process, how it operates, and industrial application of the technology. Waterjet cutting is a subtractive manufacturing process which is recognized for its specialized applications such as cutting …

Ballistic Impact Mitigation Pad, Adam Pianalto, Nathan Mayer, Wyatt Smith, Nick Green, Douglas Wild

Williams Honors College, Honors Research Projects

In our senior design project we have decided to work under Dr. Jon Gerhardt on creating a gel pad to mitigate blunt force behind bulletproof vests. Extensive research on injury, materials, manufacturing methods, and NIJ standards was completed during this project. Through the use of advanced modeling software and additive manufacturing, we prototyped a functioning pad to test and compare to a pad that is currently available in today's market. The results proved to be very successful, but there are many areas to improve upon down the road.

Dupont Seal Mold Assembly Machine, Brett Biederman, Craig Hanchett, Matthew Chilton

Williams Honors College, Honors Research Projects

The Seal Assembly Machine is a custom-built device that is designed to seat a thin polymer part between two mating pieces of metal tooling. To meet the specifications of the sponsor, the Seal Assembly machine must perform its function more quickly and accurately than manual labor at the same task. At the time of compiling this report, the machine is not yet functional due to time constraints.

Sintering Of 3-D Printed Metals, Adam Shuppe, John Griffiths

Williams Honors College, Honors Research Projects

There is a 3-D printer which prints metals such as 17-4 PH. In this project, we will learn how to use the machine to print samples, create a sintering graph for the material, and compare the properties with materials sintered using the machine. We will try to get as close as possible to the properties of the samples sintered using the machine. There will be a lot of samples made and tested, and we will learn how to use a testing machine and all other testing equipment in the department.

Adjust-A-Ramp, Taylor Sharrits, Courtney Banks, Emily Beck, Jazmin Buenrostro

Williams Honors College, Honors Research Projects

Adjust-A-Ramp is a portable ramp designed to ensure the safety of consumers and prevention of damage to cars, specifically towards low profile cars. A low-profile vehicle includes any vehicle that has a clearance off the ground of 6.5 inches or less. Advantages of low-profile vehicles include improved handling, better braking, increased fuel efficiency, increased stability, and an overall luxury aesthetic. The reduced tire size increases grip on smooth surfaces with better wheel response, creating a fast, more efficient ride. The simple tire tread patterns and the stiff sidewalls allow for lower rolling resistance which increases fuel economy. The Adjust-A-Ramp can …

Human Powered Vehicle Team Challenge, Sydney Nedlik, Spencer Brodie, Maria Griffin, William Schell, Ryan Serraglio

Williams Honors College, Honors Research Projects

Design and build a Human Powered Vehicle in a team of five. Compete at the ASME HPVC competition in March of 2022. Re-establish the Human Powered Vehicle Team at the University of Akron.

Workforce Development Strategies In Additive Manufacturing, Mel Cossette, Ismail Fidan, Gaffar Gailani, Angran Xiao

Publications and Research

Additive Manufacturing (AM), also known as 3D Printing (3DP), is one of the newest manufacturing technologies with growing utilization in our daily life. Parallel to this growth, new materials, machines, and specific processes are being developed to produce parts in better-finished quality, at lower cost, and with shorter production time. However, workforce education in this evolving field has not advanced at the same pace as the technology, lacking proven curriculums, high-quality/accredited degree programs, and specialized advanced degrees. In this paper, some best practices established by the authors are introduced. The list is far from exhaustive but is proven to be …

Chemical Clean Automated Loader, Jordyn Bryner

Williams Honors College, Honors Research Projects

TTM Technologies (TTM) is a global printed circuit board (PCB) manufacturer. The work described in this report was completed in the TTM North Jackson, Ohio location. This plant focuses primarily on the manufacturing of rigid and rigid-flex PCBs for the aerospace and defense industry. TTM North Jackson has an ongoing labor dependency issue due to the shortage of workers the nation is facing. To solve this problem, TTM has focused the efforts of their new engineers and interns on automating processes that are labor dependent. The goal is to provide design guidance to be used later by TTM to automate …

Npt Test Machine, Lauren Cash

Williams Honors College, Honors Research Projects

Located at the Research facility at The Goodyear Tire & Rubber Company, the Non-Pneumatic Tire (NPT) Program is currently in the prototype phase. However, airless tire structures are quickly gaining popularity as an alternative to a traditional pneumatic tire. The NPT Test Machine is a measurement fixture that will perform a series of evaluations to determine the stiffness of an NPT; this will allow the program to expand and evolve more rapidly into a manufacturing phase. In this Senior Design Project, a complete test solution was researched, designed, built, programmed, and validated so that data can be collected, and tires …