Manufacturing Commons^™

Simulating Particle Packing During Powder Spreading For Selective Laser Melted Additive Manufacturing Using The Discrete Element Method In Abaqus, Priscilla Ng

Master's Theses

Metal additive manufacturing allows for the rapid production of complex parts that are otherwise impractical using conventional subtractive manufacturing techniques. Applications for additive manufacturing span across a broad array of industries including aerospace, automotive, and medical, among many others. One metric of printing success is material properties, including part density. While there has been extensive research completed for the density of printed parts, there is little published work concerning powder packing density on the build plate associated with powder spreading.

In this thesis, a Discrete Element Method (DEM) model was created in Abaqus to simulate the spreading behavior of particles …

Rapid Manufacturing Of Critical Industrial Parts: A Method Based On Reverse Engineering, Rapid Prototyping, And Coordinate Metrology, Immanuel Edinbarough, Aditya Akundi

Manufacturing & Industrial Engineering Faculty Publications

This paper presents a method of rapidly manufacturing industrial parts that are critical to the production. In order to assist the Advanced Manufacturing industry, a senior project team at the University of Texas Rio Grande Valley (UTRGV) applied Rapid Manufacturing (RM) to manufacture or fabricate critical machine parts used to maintain production machines. Failures of parts and tools in industrial settings cost money and hurt output. Usually, the problem arises when the tooling being used is one of a kind and repair or replacements come with long leadtimes. Other problems are encountered when original part or tool engineering drawing is …

Text Mining-Based Qualitative Student Assessment Of Interactive Simulation Learning Using Simio Tool – A Work In Progress, Aditya Akundi, Immanuel Edinbarough

Manufacturing & Industrial Engineering Faculty Publications

Computer simulations complement and extend the real-world components of industries and manufacturing organizations. Teaching simulation-based tools helps students in modeling and analyzing the behavior of real time systems. With the increased demand observed in products and technology consumption, manufacturing industries are evolving to embrace new technologies and initiatives. To keep the emerging workforce technically competent in current tools to understand and interpret manufacturing processes, this paper portrays an effort by the authors in introducing SIMIO i.e. a tool on Simulation of intelligent objects to undergraduate students at University of Texas Rio Grande Valley and in understanding the influence of using …

Expanding Engineering And Technology Opportunities To Students In The Border Region Through International Collaboration, Jesus A. Gonzalez-Rodriguez, Immanuel Edinbarough, Adriana Rios-Santiago, Anabel Pineda-Briseno

Manufacturing & Industrial Engineering Faculty Publications

Expanding Engineering and Technology Opportunities to Students in the Border Region through International Collaboration

For some years now, our Department of Engineering Technology of the XXXX, has collaborated with Universities across the southern border to carry out different activities such as undergraduate research, collaborative course-based projects, and senior design projects. We have observed how students benefit from being exposed to work in multidisciplinary and multicultural teams.

We now expand this form of work to a higher-level research collaboration where students and faculty from four different institutions participate. Two institutions of higher education in Mexico and a University and a Community …

Smart Environments For Assisted Living: A Multidisciplinary Collaboration In Engineering And Architecture Education, Adriana Rios-Santiago, Anabel Pineda-Briseno, Jesus A. Gonzalez-Rodriguez, Uriel Saul Huerta

Manufacturing & Industrial Engineering Faculty Publications

This paper presents a description of a collaborative project based on the integration of technology development in the built environment for assisted living. The multidisciplinary collaboration is developed as a cooperative commitment to provide support for cross-border, collective projects. It was initiated as a project-based learning setting between undergraduate engineering students, and four years later the program shifted to include undergraduate architecture students and engineering master’s students. The learning experience opens the gate to a completely new collaborative setting, yet to be established, independent from its predecessor setting of project-based learning, focusing now towards an interdisciplinarity setting in cross-border collaboration. …

Tmtt Chimera Valve Attachment Process, Paulina Nguyen, Devin Debouk, Tamar Kazazian, Noah Thompson

Biomedical Engineering

No abstract provided.

Spring Loaded Camming Device, Jared S. Christner, Kaitlin O. Deherrera, Ryan W. Edwards, John S. Hickey

Mechanical Engineering

Spring loaded camming devices or “cams” are used in traditional rock climbing as a means of active fall protection. Climbers place cams in cracks and fissures in the rock wall. The cam’s lobes press against the walls, locking it in place, anchoring the climber in case of a fall. Currently, there is a lack of large cams on the market. Only two small companies produce cams that are usable in cracks 6.5 inches wide and larger, however their designs are either too heavy and/or lack features to be comfortable. We are a group of mechanical engineering students at Cal Poly …

Modular Cable Buoy, James J. Marinas, Gabriela Vargas, Anthony Catello, Joseph Heald

Mechanical Engineering

Cable terminations are often the least reliable and most expensive components of a maritime system. These cables are suspended in water by a buoy to reduce wear at the terminations. The Naval Information Warfare Center requires a modular auxiliary float with tunable buoyancy that can be placed along such cable. Our system must be able to be deployed, adjusted, and retrieved quickly and easily during operational use. This report focuses on our team’s final design concept and includes all analysis to justify our design direction along with safety, maintenance, and repair considerations. The report further elaborates on cost analysis, manufacture …

Virginia Digital Shipbuilding Program (Vdsp): Building An Agile Modern Workforce To Improve Performance In The Shipbuilding And Ship Repair Industry, Joseph Peter Kosteczko, Katherine Smith, Jessica Johnson, Rafael Diaz

VMASC Publications

Industry 4.0 is the latest stage in the Industrial Revolution and is reflected in the digital transformation and use of emergent technologies including the Internet of Things, Big Data, Robotic automation of processes, 3D printing and additive manufacturing, drones and Artificial Intelligence (AI) in the manufacturing industry. The implementation of these technologies in the Shipbuilding and Ship Repair Industry is currently in a nascent stage. Considering this, there is huge potential to increase cost savings, decrease production timelines, and drive down inefficiencies in Lifecyle management of ships. However, the implementation of these Industry 4.0 technologies is hindered by a noticeable …

Effects Of Powder Recycling In Selective Laser Melting, Nina L. Menon

Industrial and Manufacturing Engineering

The following report analyzes 316L stainless steel powder characteristics of new powder and powder that has been used in the selective laser melting process for 40-50 builds. A literature review was done of powder characteristics, different ways flowability can be tested, and effects of recycling other types of metal powders in Additive Manufacturing. Flowability improved over 21 reuses of the titanium alloy Ti-6Al-4V and resulted in stronger printed parts. Flow of S17-4 PH steel powder was measured with a Hall flowmeter and increased significantly over the course of 10 reuses. Heavily recycled (estimated 50 reuses) 316L SS powder and brand …

Cp Check Valve Design, Alec B. Der Matoian, Jessica M. Dent, Skylar M. Tusting

Mechanical Engineering

This report is to serve as a final design review and update to the project sponsors at Zurn Wilkins for the Check Valve Design Senior Project. The senior project team was tasked with improving upon the design of Zurn Wilkins’ backflow prevention assembly for small diameter pipes by reducing the pressure loss created by the check valves within the double check backflow assembly. The information contained in this report builds off the information contained in the Critical Design Report (CDR), as well as feedback and further investigation suggested during an Intermediary Design Review. Based on conclusions from the CDR, our …

Composite Lattice Tooling, Rachel Greene, Isaiah De Leon, Patrick O'Donnell, Alec Fuoti

Mechanical Engineering

Composite lattice structures allow for a high strength to weight ratio which is favorable in the aerospace industry where mass is a driving design consideration. Maxar Technologies has tasked the senior project team with creating a process and subsequent tooling to effectively manufacture their patented composite lattice structure as shown in United States patent #10326209B2. The only current industry solution to manufacture similar structures is Isotruss’s utilization of filament winding. The project team was asked to deliver a two-cube-by-four-cube lattice structure manufactured for properties testing and proof of a working manufacturing process. They also required that the process is well …

Safran Seat Attachment System, Craig John Kimball, Tyler Bragg, Lynette Cox

Mechanical Engineering

This final design review (FDR) document outlines the senior design project being carried out by a team of mechanical engineering undergraduate students attending California Polytechnic State University, San Luis Obispo for Safran Seats in Santa Maria, CA. The project originally was to design, build, and test a universal attachment to secure a widebody business class seat to seven aircraft models with different seat track geometry. The goal was to design, document, and create a finished product that fits design, weight, and manufacturing requirements, as well as passes static 9G FWD testing. Structural analysis, manufacturing analysis, FEA, and CAD assemblies will …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

Fox Factory Bearing Assembly Rundown And Torque Automation Project, David Ethan Daley, Eric Michael Forrester, Christopher Enrique Hansen, Riley Jacob O'Connor

Mechanical Engineering

A machine design was created to partially automate the rundown and torque of a Fox Factory shock bearing housing. This machine is needed at the factory to keep line associates safe by reducing ergonomic strains associated with this stage in the shock assembly process. Due to the lack of applicable torque drivers for this operation, an open ended, geared drivetrain was designed to allow for engagement of the bearing housing while allowing clearance for the shock shaft that the bearing rides on. This open drivetrain is held by a structure of linear rails and bearings to allow the line associate …

Prosthetic Foot Shell, Ql+, Kathryn Victoria Versteeg, Jackson A. Tucker, Ethan William Frey

Mechanical Engineering

This final design review includes an overview of our project and the steps we have taken to create our final product. We discuss the background research conducted, including various products like the foot shell we are trying to design and its related patents, along with similar past senior projects. As our product is considered a medical device, there are also certain standards that we must comply with. After determining our problem statement, we established what we believe to be the wants and needs of our user. These wants and needs were converted into specifications for our design, with durability as …

Effects Of New And Recycle Flux On The Mechanical Properties Of Submerged Arc Welded (Saw) Line Pipe Grade X52m And X65m, Taib Meor Mohd Adli

Student Works (2020-2029)

Two line pipe grade X52M and X65M were manufactured using submerged arc welding process. For each grade, two different welding flux condition were simulated, i.e. 100% new flux and 100% recycle flux. The flux used was aluminate basic type trade name OP 132. The outside diameter and wall thickness for X52M was 610mm x 12.7mm and for X65M was 762mm x 14.3mm. Lower weld re-entrant angle and higher weld bead height were observed in recycle flux condition. Lower weld manganese content recorded in recycle flux condition. And lower mechanical tests (i.e. tensile, impact, and hardness) value reported for recycle flux …

Fly Ash Based Geopolymer For High Temperature And High Compressive Strength Applications In Aggressive Environment, Aaryan Manoj Nair, Akm S. Rahman

Publications and Research

Geopolymers are the results of geosynthetic reactions between aluminosilicates and strong bases. This results in chemical bonds between aluminum (Al), Silicon (Si)and oxygen (O) composing polymer rings in tetrahedral coordination. These bonds give them widespread useful applications such as high heat bearing ceramics, and base construction material whilst being far more environmentally conscious. The purpose of the experiment is to examine the effect of Silicon Carbide whisker and inorganic glass particles on thermal and mechanical properties of Geopolymers. This study will help understand the effect of various compositions and concentrations of SiO₂ in mechanical strength. In this experiment, the …

Design Of Versatile Feedback Control System Components For Selective Laser Sintering, Thomas Chessman

University Scholar Projects

Selective laser sintering (SLS) is an additive manufacturing technique that involves using a laser to fuse powdered material together, layer by layer, in order to create a 3-D product. Despite its numerous benefits over traditional methods of manufacturing, including higher efficiency, versatility, and the ability to process many materials, selective laser sintering suffers from its propensity to generate structural errors during operation.

Feedback control has been shown to improve fabrication quality in other laser-based additive manufacturing techniques when implemented properly. Widespread exploration of applying feedback control in SLS might lead to significant performance improvements in this form of manufacturing.

This …

Hollow-Core Photonic Crystal Fiber Mach–Zehnder Interferometer For Gas Sensing, Kaveh Nazeri, Farid Ahmed, Vahid Ahsani, Hang-Eun Joe, Colin Bradley, Ehsan Toyserkani, Martin B. G. Jun

Manufacturing & Industrial Engineering Faculty Publications

A novel and compact interferometric refractive index (RI) point sensor is developed using hollow-core photonic crystal fiber (HC-PCF) and experimentally demonstrated for high sensitivity detection and measurement of pure gases. To construct the device, the sensing element fiber (HC-PCF) was placed between two single-mode fibers with airgaps at each side. Great measurement repeatability was shown in the cyclic test for the detection of various gases. The RI sensitivity of 4629 nm/RIU was demonstrated in the RI range of 1.0000347–1.000436 for the sensor with an HC-PCF length of 3.3 mm. The sensitivity of the proposed Mach–Zehnder interferometer (MZI) sensor increases when …