Manufacturing Commons^™

Loss On Ignition Using Infrared Heating, Benjamin J. Binoniemi

Masters Theses

The focus of this study is a proof of concept that infrared heating can be used to produce a reliable and rapid method of performing the loss on ignition test. The loss on ignition test is a foundry industry standard test that requires all moisture and volatile organic compounds be vaporized from a sample of foundry sand. The standard test as recommended by the American Foundry Society uses a muffle oven and requires nearly four hours to perform. This new concept performs the same test in approximately ten minutes. The biggest issues with the loss on ignition test are time …

Manipulating The Mass Distribution Of A Golf Putter, Paul J. Hessler Jr.

Senior Honors Projects

Putting may appear to be the easiest but is actually the most technically challenging part of the game of golf. The ideal putting stroke will remain parallel to its desired trajectory both in the reverse and forward direction when the putter head is within six inches of the ball. Deviation from this concept will cause a cut or sidespin on the ball that will affect the path the ball will travel.

Club design plays a large part in how well a player will be able to achieve a straight back and straight through club head path near impact; specifically the …

Parker Hannifin Chainless Challenge 2014-15 Senior Design Project, Matt Pallotta, Nathan Klammer, Kemper Whaley, Jack Rechtin

Mechanical Engineering

California Polytechnic State University has been invited to compete in the Parker Hannifin Chainless Challenge Competition in 2014-15. Cal Poly has chosen a team of mechanical engineering students to take part. We have named our team “Bike Under Pressure” and all references as such refer to the team.

The challenge is to build a bicycle which does not have a solid mechanical connection between the power input of the rider to the power output of the wheel(s). After conducting research into different previous designs and brainstorming designs of their own, Bike Under Pressure developed two conceptual designs. One design featured …

Mechatronics Design Process With Energy Optimization For Industrial Machines, Aderiano Medeiros Da Silva

Dissertations (1934 -)

The need for designing industrial machines with higher energy efficiency, reliability, flexibility, and accuracy has increased to satisfy market demand for higher productivity at reduced costs in a sustainable manner. As machines become more complex, model-based design is essential to overcome the challenges in mechatronic system design. However, a well-designed mechanical system with a well-designed and tuned control system are not sufficient for machines to operate at high-performance conditions; this also heavily depends on trajectory planning and the appropriate selection of the motors controlling the axes of the machine. In this work, a model-based design approach to properly select motors …

The Design For Manufacturing And Assembly Analysis And Redesign Of An Aircraft Refueling Door Hinge Utilizing Additive Manufacturing, Kurt A. Schwarz

Doctoral Dissertations and Master's Theses

In this thesis, an aircraft door hinge assembly provided by Gulfstream Aerospace was analyzed following an established process called DFMA. The hinge was then redesigned to be additively manufactured, which is uncommon currently in industry for load bearing components. It was shown that the Design for Manufacturing (DFM) guidelines were inadequate when applied to the new technology of additive manufacturing (AM). This was primarily due to AM's unique and unprecedented manufacturing capabilities.

A conservative redesign approach was followed due to a limitation in current AM material properties and time available for analysis. Despite this, a significant improvement in weight reduction …

Creating A User-Friendly Personal Wine Collection Inventory Management System, Peter Loddengaard

Industrial and Manufacturing Engineering

This project set out to create a user-friendly wine collection management software. Existing systems were reviewed and discussions with collectors took place to establish the user requirements for this type of inventory management system. This led to the scope of the project being narrowed to making a wine bottle entry form that was quick and easy to use. The programming language, Ruby on Rails, was used to design this system, and learning the software was a large part of the project itself. It was established that four forms would be designed using combinations of two ergonomic factors: an “F” shaped …

Wasco Environmental Chamber System Manifold, Steve Mark Yatco

Industrial and Manufacturing Engineering

This report details the process of designing and producing a manifold that connects ultra-high purity (UHP) pressure and vacuum switches to an air supply so that the parts may be tested in an environmental chamber. Using the DMAIC (define, measure, analyze, improve, and control) methodology of problem solving, progress on the project includes thorough research about the problem, preliminary design solutions, iterative prototyping, and testing specific functionalities. Manufacturing engineering topics of tooling, fixturing, metrology, quality, and machining with manual and computer numerical control (CNC) varieties of both mills and lathes are applied during the course of the project. The report …

Frito-Lay - Supply Chain Impact Analysis, Kerri Blosch, Vincent Phua, Jeffrey Silva

Industrial and Manufacturing Engineering

The snack food company Frito-Lay relies on Route Sales Representatives (RSRs) to stock and maintain shelves of snack foods in every store. Frito-Lay currently does not have a system which can accurately predict cannibalization, or the effects of a store opening or closing on other stores of the same chain in the area. The goal is to sort through 1900 stores in a given metropolitan area to see the effects of cannibalization. In order to tackle the problem, a Microsoft Access program was created to filter stores based on location or whether the store was open for the full three-year …

Process Testing And Improvement Of Tapping Machinery At Lisi Aerospace, Michael James Hester

Industrial and Manufacturing Engineering

This report documents my senior project for California Polytechnic State University San Luis Obispo. I have chosen to do a senior project with Lisi Aerospace. Lisi would like to compare the manufacturer rated cycle count of taps versus an experimental one based on our machines in house. My goal for this project would be to run an experiment on one tapping machine and report on the achievable cycle count for the taps. I plan to do this in several ways including:

• Running extra cycle counts above tap manufacturer recommendations

• Documenting machine failure modes

• Create a process document to be repeated …

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Improving Advertisement Recognition And User Interface Of Gameofwarrealtips.Com, Chad Kihm, Alexander Meyer

Industrial and Manufacturing Engineering

The purpose of this experiment was to determine which location of advertisement would be the most recognized on the Game of War Real Tips website and to improve the website’s user interface by using both quantitative and qualitative data. To accomplish this, two experiments were created. The first experiment was designed to determine which location of advertisement would be recognized most by users. A screen would flash for 0.5 seconds and the subjects would mark where they believed they recognized an advertisement. A statistical analysis was completed to determine whether the location of the advertisement had an effect on the …

Wine Club Shipment Package Redesign, Emily E. Prescott

Industrial and Manufacturing Engineering

This report shows the design, manufacturing, and testing process for the product development of a wine club shipment package for Niner Wine Estates. Niner has two different shipment sizes, 4 bottles and 6 bottles, and wishes to improve their current package by giving it a more “high-class” feel. After the new package was designed and prototyped, it went through standardized quality testing to be cleared for commercial use. This testing is intended to simulate the distribution cycle the package will experience and subject it to potential hazards such as being dropped and vehicle vibration during transportation.

After the package passed …

Methods Of Extrusion On Demand For High Solids Loading Ceramic Paste In Freeform Extrusion Fabrication, Wenbin Li, Amir Ghazanfari, Ming Leu, Robert Landers

Faculty Publications, Mechanical Engineering

Fabrication of highly dense parts with complex geometry by paste-extrusion-based solid freeform fabrication processes requires a precise control of the extrusion flow rate to dispense material on demand, which is often referred as Extrusion-On-Demand (EOD). The extrusion process for aqueous ceramic pastes is complex and difficult to control due to their non-Newtonian behavior, compressibility and inhomogeneity. In this study, three methods of EOD (based on ram extruder, needle valve, and auger valve) are introduced and investigated for the extrusion of high solids loading (i.e., >50%, volumetric) aqueous alumina paste. Optimal extrusion process parameters for these methods are determined through printing …

Optimal Rastering Orientation In Freeform Extrusion Fabrication Processes, Amir Ghazanfari, Wenbin Li, Ming Leu, Robert Landers

Faculty Publications, Mechanical Engineering

Many researchers have tried to optimize the build direction of additively manufactured parts to minimize the vertical staircase effect. However, the horizontal staircase effect should also be considered when fully dense parts are to be fabricated. In this paper, part inaccuracy due to the horizontal staircase effect is considered in order to determine the optimal rastering orientation in building the part. An algorithm is developed to estimate this inaccuracy and a technique is proposed to minimize it. The effect of rastering orientation on staircase errors is examined, and the particle swarm optimization method is used to determine the optimum rastering …

Stress-Limiting Test Structures For Rapid Low-Cost Strength And Stiffness Assessment, Andrew Katz, Craig P. Lusk, Nathan B. Crane

Faculty Publications

Purpose: Evaluate the use of a simple printed geometry to estimate mechanical properties (elastic modulus, yield strength) with inexpensive test equipment.

Design Methodology/Approach: Test geometry is presented that enables controlled strains with manual deformation and repeatable measurement of vibrational frequencies. This is tested with multiple FDM machines to assess measurement accuracy and repeatability. Printing orientation and some printing parameters are varied to assess the measurement sensitivity.

Findings: The test methods show good correlation with manufacturer material specifications in the X-Y plane and reported elastic strain limits. It is also sensitive to printing orientation and printing parameters.

Research Limitations/Implications: Further work …

Size Effects In Human Visual Inspection For Micro/Meso Scale Parts, Sri Harsha Kavuri

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Visual inspection has been a major method of quality control in conventional manufacturing processes for the last fifty years. Utilizing trained human inspectors to perform this visual inspection has been the most effective means of maintaining quality control. Extensive research has been performed to understand the factors that influence the human inspection process.

In the recent years, there has been a significant emphasis on manufacturing at the smaller end of the size-spectrum such as Micro and Meso scale manufacturing. Quality control at becomes a challenging task due to the extremely small sizes. Several automated visual inspection techniques have been proposed …

Binder Jet Additive Manufacturing Of Stainless Steel-Hydroxyapatite Bio-Composite, Don Suranga Dhanushka Uduwage

All Graduate Theses, Dissertations, and Other Capstone Projects

This study was conducted to create a bio-composite with a porous structure using the binder-jet printing additive manufacturing process. The samples were printed by changing the parameters such as layer thickness, roller speed, sintering time and sintering temperature of the X1-Lab binder jet additive manufacturing printer. The samples were printed 80% stainless steel 316 mixed with 20% Calcium Phosphate Tribasic by volume. Eight experiments were attempted to print according to the fractional factorial design of experiment. The effects of changing parameters on the mechanical properties of the new bio-composite was tested using ASTM E-09 compressive strength standards. The compression testing …

Parameter Determination And Experimental Validation Of A Wire Feed Additive Manufacturing Model, Kannan Suresh Kumar

Masters Theses

“Laser metal deposition is an additive manufacturing method with great scope and robustness. The wire fed additive manufacturing method has great opportunities in space applications and other zero gravity manufacturing processes. Process parameters play an important role in controlling the complex phenomenon and obtaining an ideal manufactured part. These parameters can be efficiently determined using simulation tools which are highly essential in visualizing real world experiments, therefore saving time and experimental costs. The objective of this study is to develop a transient 3D model of laser aided wire feed metal deposition which realizes the heat transfer and fluid flow behavior …

Performance Metrics For Powder Feeder Systems In Additive Manufacturing, Venkata Sivaram Bitragunta

Masters Theses

"In blown powder Direct Metal Deposition (DMD) process, parts are built by adding metal powder on the melt pool created by the laser system. At low feed rates powder feeder systems have perturbations. The study focused on relationship between the perturbation frequencies by inherent powder feeder designs and its impact on deposition quality. Performance metric determine the relation between perturbations in the powder flow and quality of the deposit. To determine performance metric, various powder feeder designs were analyzed. Perturbation frequencies were introduced to the disk feeder design. The quality of the deposit was determined by the surface roughness of …

Effect Of Heating And Ionization Of Four Atomizing Gases On The Spray Characteristics Of A High Volume Low Pressure Spray Atomizer, Anthony V. Adornato

Theses and Dissertations--Mechanical and Aerospace Engineering

The disintegration of a liquid jet emerging from a nozzle by a high speed gas stream has been under investigation of several decades. A result of the liquid jet disintegration is droplet formation. This process is referred to as atomization. Industrial applications use atomization as a method for applying coatings to substrates. It has been reported that the use of other atomizing gases instead of compressed plant air will positively affect paint droplet size distributions, spray patterns and finish qualities; furthermore, the ionization and heating of the atomizing gas was reported to positively affect finish qualities. Although ionization techniques have …

A Framework For Sustainable Material Selection For Multi-Generational Components, Ryan T. Bradley

Theses and Dissertations--Mechanical and Aerospace Engineering

The early stages of a product’s design are a critical time for decisions that impact the entire life-cycle cost. Product designers have mastered the first generation; however, they currently do not have the ability to know the impact of their decisions on the multi-generational view. This thesis aims at closing the gap between total life-cycle information and the traditional design process in order to harbor sustainable value creation among all stakeholders involved. A framework is presented that uses a combination of a life-cycle costing methodology and an evolutionary algorithm in order to achieve a sustainability assessment for a true multi-generational …