Manufacturing Commons^™

Nfpa Fluid Power Vehicle Challenge, Ean H. Dickerhoof

Williams Honors College, Honors Research Projects

Every year the National Fluid Power Association hosts a Fluid Powered Vehicle Challenge, this exposes students from universities all around the United States to the power and possibilities of hydraulics. This year the University of Akron’s team of engineers set out to design a bicycle that would be competitive and innovative in all aspects of the competition. In order to accomplish this, the designed bicycle must excel in three categories of competition; a sprint race, an endurance race, and an efficiency challenge.

To accomplish this task the University of Akron’s team of engineers used a lightweight bicycle frame with many …

Instruction Pamphlet Insertion Machine, Jim Griggs, Scott Miller, Michael Kubala

Williams Honors College, Honors Research Projects

Weaver Industries in Akron, Ohio provided us with our senior design project. Weaver Industries seeks individuals with disabilities and provides them with job opportunities. One of their products is a “Kong” dog toy. As of now, the instruction pamphlet that comes with this dog toy is placed into each piece of packaging individually by hand. We are tasked with automating this process. Two years ago, a group of students worked on this project, but the reliability of their prototype was only around 60-70%. Then last year, another group of students worked on this project, but again, the reliability of their …

Trustworthiness Requirements For Manufacturing Cyber-Physical Systems, Radu F. Babiceanu, Remzi Seker

Publications

Distributed manufacturing operations include cyber-physical systems vulnerable to cyber-attacks. Long time not considered a priority, cybersecurity jumped to the forefront of manufacturing concerns due to the need to network together legacy, newer equipment, and entire operation centers. This paper proposes trustworthiness solutions for integrated manufacturing physical-cyber worlds, where trustworthiness is defined to complement system dependability requirements with cybersecurity requirements, such that the resulting manufacturing cyber-physical system delivers services that can justifiably be trusted. Acknowledging the inevitability of cyber-attacks, the paper models the cybersecurity component using the resilient systems framework, where system resilience is viewed as preservation of a required state …

Pore Formation In Aluminum Castings: Theoretical Calculations And The Extrinsic Effect Of Entrained Surface Oxide Films, Pedram Yousefian

UNF Graduate Theses and Dissertations

Aluminum alloy castings are being integrated increasingly into automotive and aerospace assemblies due to their extraordinary properties, especially high strength-to-density ratio. To produce high quality castings, it is necessary to understand the mechanisms of the formation of defects, specifically pores and inclusion, in aluminum. There have been numerous studies on pore formation during solidification which lead to hot tearing and/or reduction in mechanical properties. However, a comprehensive study that correlates pore formation theory with in situ observations and modeling assumptions from the literature as well as experimental observations in not available. The present study is motivated to fill this gap. …

Error Mapping Of Build Volume In Selective Laser Melting, Ninad Kulkarni

Masters Theses

“Selective laser melting is one of the commonly used additive manufacturing processes employed for production of functional part. Therefore, quality aspects such as dimensional accuracy have become a point of great interest. Like all of the other additive manufacturing processes selective laser melting process suffers from the issue if having wide range of process parameters making the process control a complex task. Additionally, issues specific to the selective laser melting process such as position dependency of accuracy of the part, makes it difficult to predict the resulting dimensional inconsistencies in the part manufactured by this processes. This research is an …

Mechanical Characterization Of Parts Produced By Ceramic On‐Demand Extrusion Process, Amir Ghazanfari, Wenbin Li, Ming Leu, Gregory Hilmas

Faculty Publications, Mechanical Engineering

Ceramic On‐Demand Extrusion (CODE) is an additive manufacturing process recently developed to produce dense three‐dimensional ceramic components. In this paper, the properties of parts produced using this freeform extrusion fabrication process are described. High solids loading (~60 vol%) alumina paste was prepared to fabricate parts and standard test methods were employed to examine their properties including the density, strength, Young's modulus, Weibull modulus, toughness, and hardness. Microstructural evaluation was also performed to measure the grain size and critical flaw size. The results indicate that the properties of parts surpass most other ceramic additive manufacturing processes and match conventional fabrication techniques.

Chocolate Bar Wrapping Machine, Austin M. Hoff, Daniel R. Trepke, Caleb B. Krichbuam

Williams Honors College, Honors Research Projects

Gilbert Chocolates has proposed to manufacture a machine to wrap chocolate bars. This machine is intended to replace two people wrapping the chocolate bars by hand, which is a time consuming method. This is especially apparent between October and January when the workers are working long hours in preparation for the Christmas rush of customers. Currently wrapping a bar takes about a minute and Gilbert Chocolates wants this time reduced down to 20-30 seconds. The budget for this project is set at $1000, and is being funded by the company. This machine needs to fit in a cubic foot of …

Precise Flow-Control Using Photo-Actuated Hydrogel Valves And Pid-Controlled Led Actuation, Colm Delaney, Peter Mccluskey, Simon Coleman, Jeff Whyte, Nigel Kent, Dermot Diamond

Conference Papers

Herein we demonstrate remarkable control of flow within fluidic channels using photo-actuated hydrogel valves. By polymerizing the valves in situ it has been possible to create highlyreproducible valves. Through the use of an LED platform and a PID algorithm we have generated extremely accurate flow control and created prototype devices to document their potential application within the microfluidics field.

Compact Humidity Sensor Based On A Multi-Layer Agarose Hydrogel Coated Silica Microsphere Resonator, Arun Mallik, Yuliya Semenova, Vishnu Kavungal, Dejun Liu

Conference Papers

In this paper we report on a novel approach to implementing a compact humidity sensor that utilizes whispering gallery mode (WGM) phenomena in a silica microsphere coated with Agarose hydrogel. The spectral positions of the WGM resonances for such a sensor depend strongly on the refractive index and thickness of the coating. The WGM’s spectral shift occurs due to adsorption/desorption of the water vapor in response to changes in ambient humidity and also due to the corresponding changes of the coating thickness. We experimentally investigated the WGMs spectral shift for a 100 μm diameter silica microsphere coated with Agarose hydrogel …

High Sensitivity Refractometer Based On Reflective Smf-Small Diameter No Core Fiber Structure, Guorui Zhou, Qiang Qu, Rahul Kumar, Wai Pang Ng, Hao Liu, Longfei Niu, Nageswara Lalam, Xiaodong Yuan, Yuliya Semenova

Conference Papers

A high sensitivity refractive index sensor based on a single mode-small diameter no core fiber structure is proposed. In this structure, a small diameter no core fiber (SDNCF) used as a sensor probe, was fusion spliced to the end face of a traditional single mode fiber (SMF) and the end face of the SDNCF was coated with a thin film of gold to provide reflective light. The influence of SDNCF diameter and length on the refractive index sensitivity of the sensor has been investigated by both simulations and experiments, where results show that the diameter of SDNCF has significant influence. …

Metal Cutting And Manufacturing Economics Project For Freshmen, Hüseyin Sarper, Nebojsa I. Jaksic, Linda Vahala

Electrical & Computer Engineering Faculty Publications

This paper describes a laboratory experiment and a team project to teach manufacturing concepts to new students. This project is one of two team projects of 1.5 credit portion of a two-credit course in exploration of engineering and technology. This course teaches students skills they need late and teamwork is a major skill that they acquire. They organize into a group with specialized responsibilities for the purpose of calculating the total production time and cost of a manufactured part using turning, drilling, and milling operations. Students also learn or improve spreadsheet skills while performing data entry and necessary machining calculations. …

Design And Implementation Of A Fixture For Robotic Welding, Isaac Nathaniel Williams

Industrial and Manufacturing Engineering

The Cal Poly IME department recently purchased a robotic welder. The faculty would like to see this robot incorporated into the welding class. The robot was capable of moving, but was not able to perform a weld prior to this project. This problem is addressed by creating a demonstration part for the welding class. The objectives that need to be complete for this to be possible is designing a part, designing a fixture, analyzing the cost of robotic welding, and implement welding the part in the class. The part is designed with specific requirements in mind. The fixture is designed …

Application Of Gearbox Drivetrains For Commuting Bicycles, Loren Sunding

Industrial and Manufacturing Engineering

People all over the world are beginning to ride their bicycles more often to destinations which include work, school, and local markets. Most bicycles being used for these activities have an external drivetrain exposed to the elements of the road including water, mud, dirt, and debris. External drivetrains are very fragile and when damaged, pedaling efficiency is greatly reduced and the overall riding experience diminishes.

One solution to this issue is a gearbox specifically designed for a bicycle frame. A gearbox has several mechanical mechanisms operating inside a protective housing. Since the housing is fully sealed, outside elements are not …

Assembly Line Kitting: Foam Mold Material Substitute, Samer Samy Saleh

Industrial and Manufacturing Engineering

Kitting is considered an incredibly innovative and effective solution intended to aid operators within a mixed model assembly line. However, it is a non-value added procedure and one that customers may not be willing to pay for. With this project, the goal is to examine opportunities to employ lean principles and provide a solution that further eliminates non-value added procedures, while also producing the potential for a flexible, mixed model assembly line.

To achieve the aforementioned purpose, the production of foam molds, located within industrial totes and sent to the assembly line, was found to be a major waste within …

Mri Upgrades At Radiology Associates, Patrick Cheung, Charlene Donlon

Industrial and Manufacturing Engineering

Problem Statement: The MRI machines at Radiology Associates are limiting the company’s ability to expand and compete within the local market. After discussing with technicians and managers at Radiology Associates, we decided to focus on hardware and software upgrades for the MRI machines. With 2 of the 3 locations purchasing new machines in the near future, our focus was on upgrades at the Santa Maria facility. The two machines at this location needed hardware and/or software upgrades to remain on par competitively both within the company and with local scanning options. Flexible coils are beneficial in terms of size, weight, …

Development Of A Process Monitoring Tool For The Manufacturing Process Of An Electric Vehicle Battery Enclosure, Ian Lamond

Industrial and Manufacturing Engineering

High volume manufacturing requires process control that is responsive to manufacturing related issues. It is critical that tools and resources are implemented that gauge manufacturing performance and identify root cause issues.

This project focuses on the design and manufacturing process of an electric vehicle aluminum battery enclosure and the implementation of a production measurement system. The current problem is a lack of process control communication and out of control alarms when uncontrolled events occur for manufacturing associates at the battery enclosure manufacturing work station.

This report examines the core principles of Quality Engineering, the economic advantages of implementing a vision …

Design And Prototyping Of An Adjustable Putter, Daulton Morgan

Industrial and Manufacturing Engineering

Being able to demo a golf putter is essential for a golfer since the feel of the putter is critical in determining what suits the golfer best. Due to the market being primarily dominated by right-handed players, it is difficult for left-handed players to demo high quality putters since the selection is sparse.

This report is about designing and integrating an interchangeable fastening system that allows a putter to be altered between a right and left-handed orientation, while still maintaining the traditional look of a putter. The report covers the necessary design steps, the prototyping of the putter, the projected …

Selective Resistive Sintering: A Novel Additive Manufacturing Process, Austin Bryan Van Horn

Graduate Theses and Dissertations

Selective laser sintering (SLS) is one of the most popular 3D printing methods that uses a laser to pattern energy and selectively sinter powder particles to build 3D geometries. However, this printing method is plagued by slow printing speeds, high power consumption, difficulty to scale, and high overhead expense. In this research, a new 3D printing method is proposed to overcome these limitations of SLS. Instead of using a laser to pattern energy, this new method, termed selective resistive sintering (SRS), uses an array of microheaters to pattern heat for selectively sintering materials. Using microheaters offers significant power savings, significantly …

Automated Machine Tender, Ryan A. Canfield, Samuel N. Adler, Louis S. Roseguo

Mechanical Engineering

The use of CNC (Computerized Numerical Control) machines automate production in factories through programs controlling manual operations such as milling or lathing. The manufacturing process can be automated beyond the use of CNC machines through the addition of a robotic tender capable of carrying out the same tasks as a human operator. A tender can be integrated into the CNC machine itself, or purchased separately and configured to autonomously operate a particular machine. Smaller companies making limited production runs may not find it economically feasible to purchase large scale integrated machine tenders, but would benefit from a versatile autonomous machine …

Final Design Report: Polymer Fatigue Characterization Test Method, Wyatt Ayling, Tyler Price, Brandon Stell, Michela Upson

Mechanical Engineering

Polylogix is a team dedicated to the design, build, and testing of a fatigue machine to simulate cyclic loading on a biomedical polymer. This project is sponsored by Endologix, Inc. to provide test data characterizing mechanical material properties of various formulations of polymer used in abdominal aortic aneurysm surgeries. With this project goal, the machine must be able to test the polymer at body conditions; these include a testing temperature of 37°C and a cycling frequency ranging from 1 Hz to 10 Hz. This report proposes the following solution to this design challenge: an AC motor-driven mechanism utilizing a planetary …