Manufacturing Commons^™

Fiber Length Attrition In Additive Manufacturing, Michael Chapiro

Materials Engineering

Chopped carbon fibers are used as reinforcements in thermoplastics, but the viscous shear forces that arise in melt-processing reduces the fiber length well below its critical length resulting in only moderate strength and stiffness gains compared to the neat resin. This research project aimed to experimentally determine the effect of the melt–flow portion of a single-screw- extrusion process on carbon fiber length attrition in isolation from the immediately preceding screw–plastication step that is responsible for most of the heat needed for melting. Carbon fibers with an initial length of 2 mm were stirred into 5,000 centipoise and 10,000 centipoise silicone …

Ultra-Light Bear Canister, Naveen Beasley, Eli Rogers, Cory Wilson, Donald Wood

Mechanical Engineering

A bear canister is the primary tool used by outdoor enthusiasts to protect their food from bears while camping or backpacking. There are many effective products currently on the market, however many are not designed with reduced weight in mind. Hardcore backpackers want to have the lightest gear possible to ease the strain of carrying a large pack for sometimes weeks at a time.

Current bear canisters exist that utilize carbon fiber for weight reduction, however they rely on stock carbon tubes and lack engineering analysis, and no competitor has a fully composite bear canister available. Our sponsor, Nick Hellewell, …

Metals Am Design For Manufacturing, Maren Cosens, Ben Wong, Kevin Hale

Mechanical Engineering

We are looking to improve upon the current post processing techniques for metal additive manufacturing (AM). This project, sponsored by Lawrence Livermore National Laboratory (LLNL), will investigate ways to improve the design of stainless steel 316 parts made by AM, and how these designs will help with post processing techniques. We hope that the findings regarding stainless steel will apply to to improve the AM and post processing handshake in general. In particular, the project will focus on including different features in different basic part design shapes to aid in fixturing and post-processing of the part made by AM. This …

Facility Redesign For Increased Throughput And Improved Product Flow Of Shark Rack Products Final Assembly At Paris Precision, Karina Hromyak, Julia Remnant

Industrial and Manufacturing Engineering

Paris Precision is a metal fabrication company that fabricates metal components for various companies, one of which is Shark Rack, which creates high end server racks. Shark Rack has plans for a dramatic increase in demand over the next two years. Paris Precision’s Final Assembly area is currently not conducive to produce such a large increase in demand. A redesign of the Final Assembly facility is needed to handle the increase in production and to improve product flow through the space. The project team’s objectives are to:

● Study current Final Assembly production process

● Analyze the production flow

● …

Ymca Operations Manual Development, Devlin Stewart

Industrial and Manufacturing Engineering

The San Luis Obispo YMCA sports department was losing money and overworking their employees due to lack of processes and organizational issues. To address this, a plan was made with the sports director to begin organizing the sports department. This would be done by creating an operations manual for them to organize and consolidate all of their relevant information.

The project was scoped to develop a plan for the YMCA to implement an operations manual. By delivering a work breakdown structure, a gantt chart, and a plan for continuous improvement, the YMCA could use these tools to develop their operations …

Zero Waste Campus Dining, Jenny Caudillo, Sarah Dahel, Youlen Ghazalian

Industrial and Manufacturing Engineering

Cal Poly Campus Dining has a goal of becoming a zero waste entity by providing their customers with alternative methods of disposing their trash. Their current operations produce waste, specifically their methods of packaging the food. Campus dining plans to be more sustainable by providing their customers with reusable containers. The objective of this implementation is to reduce waste produced from one-time use, disposable food containers. The success criteria for the desired system is based around the ability to track and measure the reusable containers to prevent further waste, while providing the user an accommodating environment to ensure they will …

Metals Additive Manufacturing Powder Aging Characterization, Thomas Russell Lovejoy, Nicholas Karl Muetterties, David Takeo Otsu

Mechanical Engineering

The metallic additive manufacturing process known as selective laser melting requires highly spherical, normally distributed powder with diameters in the range of 10 to 50 microns. Previous observations have shown a degradation in powder quality over time, resulting in unwanted characteristics in the final printed parts. 21-6-9 stainless steel powder was used to fabricate test parts, with leftover powder recycled back into the machine. Powder samples and test specimens were characterized to observe changes across build cycles. Few changes were observed in the physical and mechanical properties of the specimens, however, there were indications of chemical changes across cycles. Potential …

Design And Testing Of A Top Mask Projection Ceramic Stereolithography System For Ceramic Part Manufacturing, Dylan Robert De Caussin

Master's Theses

Ceramic manufacturing is an expensive process with long lead times between

the initial design and final manufactured part. This limits the use of ceramic as a viable material unless there is a large project budget or high production volume associated with the part. Ceramic stereolithography is an alternative to producing low cost parts through the mixing of a photo curable resin and ceramic particles. This is an additive manufacturing process in which each layer is built upon the previous to produce a green body that can be sintered for a fully dense ceramic part.

This thesis introduces a new approach …

Haul Truck Tires Recycling, Jessica N. Lizarazu

Chemical Engineering Undergraduate Honors Theses

The disposal of large Off-the-Road (OTR) tires is an increasingly important concern. These tires can weigh up to 8,450 pounds with an overall diameter and width of approximately 140.7 inches and 45.1 inches respectively. OTR tires are used for mining vehicles such as haul trucks, wheel loaders, backhoes, graders, and trenchers. These new tires cost between $38,000 and $50,000 each, depending on multiple factors including oil prices and the cyclical nature of the industry. Haul trucks contain six tires per vehicle, and mines replace these tires around every 9-12 months. Statistics regarding discarded OTR tires are not provided by the …

Low-Cost Inkjet Process For 3-D Printing, Christopher T. Schmitt

Mechanical Engineering Undergraduate Honors Theses

This paper presents a low-cost 3-D inkjet process design. Current commercially available 3-D inkjet printers (e.g., Objet Connex) that are capable of multi-material printing are expensive and out-of-reach of most consumers. While fused deposition modeling and other extrusion-based hybrid processes for multi-material printing are becoming available, these techniques are slow and relatively low-resolution. This research attempts to fill the gap by presenting a simple and low-cost solution to bring desktop 3-D inkjet to the community by utilizing components from an Epson inkjet printer. The mechanical system was designed with maximum utilization of the Epson carriage system with the addition of …

Droplet Generation At Megahertz Frequencies, John C. Miers

Mechanical Engineering Undergraduate Honors Theses

Droplet formation has been a fascinating subject to scientists for centuries due to its natural beauty and importance to both scientific and industrial applications, such as inkjet printing, reagent deposition, and spray cooling. However, the droplet generation frequency of common drop-on-demand jetting techniques is mostly limited to ~10 kHz. This paper presents an investigation of the possibility of jetting at megahertz frequencies in order to boost the productivity of drop-on-demand material deposition by ~100 times. The focus of this paper is to understand the limitations of generating droplets at a megahertz frequency and to explore possible solutions for overcoming these …

Mechanical Properties And Microstructure Evolution Of 17-4 Ph Stainless Steel Processed By Laser-Powered Bed Fusion., Harish Irrinki

Electronic Theses and Dissertations

Laser powder bed fusion (L-PBF) is a potential manufacturing route for the production of tooling using different steel materials. However, there is a limited understanding of how the mechanical properties and microstructures of the L-PBF produced parts vary with change in powder type and process conditions. The current research studied the influence of L-PBF process parameters on mechanical properties and microstructures of 17-4PH stainless steel using gas and water-atomized powders. The results demonstrate the feasibility of using water-atomized powders as starting raw materials instead of typically used gas-atomized powders to fabricate parts in the L-PBF process at high energy densities.

Computing Research In Academia: Classifications, Keywords, Perceptions, And Connections, Sung Han Kim

Theses and Dissertations

The Association for Computing Machinery (ACM) recognizes five computing disciplines: Computer Science (CS), Computer Engineering (CE), Information Technology (IT), Information Systems (IS), and Software Engineering (SE). Founded in 1947 the ACM is the world's largest society for computing educators, researchers, and professionals. While Computer Science has been a degree program since 1962, the other four are relatively new. This research focuses on understanding the graduate research in four of the five ACM disciplines (CS, CE, IT, and IS) using a large body of thesis and dissertation metadata. SE is not found in the metadata and graduate work in SE is …

Wire + Arc Additive Manufacturing, Micheal Santangelo

GS4 Student Scholars Symposium

Additive manufacturing is a rapidly developing technology which promises to drastically reduce the cost and waste associated with manufacturing parts. However, current systems of additive manufacturing used for creating metal parts which are suitable for use in the aerospace, automotive, and defense industries are complex, expensive, and not robust enough to produce a wide range of part features and geometries. A relatively new method, called wire arc additive manufacturing(WAAM) is a low cost option that can create parts which have a near-net shape, and only require a small amount of post processing before they are ready for use. This system, …

Densification Of W-Ni-Fe Powders Using Laser Sintering, Xuan Wang, Matthew Wraith, Stephen Burke, Howard Rathbun, Kyle Devlugt

Industrial and Manufacturing Engineering

In this paper, Laser Sintering (LS) of 90%W–7%Ni–3%Fe (wt.%) powders have been investigated, with the goal to understand the influence of final density by laser power, scanning speed, laser trace width, and the number of scanning passes. The results suggest that the laser power and scanning speed are the most important factors influencing density; the influence of trace width and number of scanning passes are not significant. With the increase of laser power and decrease of scanning speed, higher density can be achieved. The microstructure analysis indicated that the porosity changed from open porosity to closed porosity with higher laser …

A Study On The Sustainable Machining Of Titanium Alloy, Abdulhameed Alaa Dawood

Masters Theses & Specialist Projects

Titanium and its alloy (Ti-6Al-4V) are widely used in aerospace industries because of their light weight, high specific strength, and corrosion resistance. This study conducted a comparative experimental analysis of the machinability of Ti-6Al-4V for conventional flood coolant machining and sustainable dry machining. The effect of cutting speed, feed rate, and depth of cut on machining performance has been evaluated for both conditions. The machining time and surface roughness were found to be lower in dry machining compared to flood coolant machining. The tool wear was found to be unpredictable, and no significant difference was observed for dry and coolant …

Optimization Of Process Parameters In Micro Electrical Discharge Machining (Edm) Of Ti-6al-4v Alloy, Farshid Alavi

Masters Theses & Specialist Projects

Ti-6Al-4V has a wide range of applications such as in the automotive and aerospace industries. Nevertheless, titanium alloys are very difficult to machine by conventional methods. Micro-EDM is a non-conventional machining method that uses the thermal effect of precisely controlled sparks. Manufacturers are looking for the methods and optimal settings to increase the productivity of micro-EDM in terms of lessening machining time and tool wear. Moreover, surface integrity of the machined area is crucial for some products such as biomedical implants.

The objective of this study was to investigate the effects of the micro-EDM process parameters on response variables, in …

Development Of Distributed Off-Grid Renewable Energy System For Rural African Communities, Mateo Sebastian Guerrero, Menghong Feng

Engagement & Service-Learning Summit

Our Hybrid Energy System team is committed to develop low-cost renewable energy solutions to rural African communities where access to electricity from government grid is not available. According to a World Bank’s report, only 24% of sub-Saharan countries have access to electricity. Our team has been working with local partners to build renewable energy systems since 2008. From 2015 the team has been working on micro hydropower turbine and vertical-axis wind turbine with solar energy system combined. Our current efforts include a prototype design of a wind-solar system, using a new concept of vertical axis wind turbine to harvest wind …

Skycsr: Optimal Communication Methods For Coordinating Ground Support In A Private And General Aviation Setting, Jessica Burke

Industrial and Manufacturing Engineering

Delays due to miscommunication of between the pilot and ground service providers are increasing. The objective of this project is to develop a new method of communication between pilots, line service technicians and customer service agents. This will be achieved first through an investigation into current methods and state of the industry, followed by a survey conducted with a group of pilots and flight schools. This culminates in a web application that will take the deficiencies identified in the survey, to make sure ground service or fuel orders are explicitly clear and minimize the probability of a mis-fueling, overlooked fueling, …

Carbon Emission Awareness And Information Platform, Jose Ignacio Cordero, Paul Romero

Industrial and Manufacturing Engineering

Climate change due to global warming has become a worldwide concern.

Nowadays, people are starting to wake up and realize that changes need to be

made in their lifestyles in order to preserve this earth and provide a better planet

for future generations. Finding a concrete solution to global warming and climate

change has proven to be a very challenging task. Governments have tried

implementing solutions and as a result, corporations have been forced to absorb

or transfer the cost of unsuccessful environmental regulations. Meanwhile,

individuals remain frustrated, wishing they could find a way to help.

The motivation behind this …