Manufacturing Commons^™

Perspectives On Quality Coordination And Assurance In Global Supply Chains, Ling Li, John N. Warfield

Information Technology & Decision Sciences Faculty Publications

The 2007 recall of Berko Electric Toe-Space Heaters made in the US, the recall of backpack blowers made in Japan, the recalls of toys and pet food produced in China have exposed the potential of global supply chain disruptions. This product recall storm leads to the issue of quality assurance in global supply chain management. Product recalls indicate that manufacturing companies are particularly vulnerable to ensure quality when they source via a global supply chain with poor visibility. Obviously, a supply chain cannot afford this kind of sourcing and supply structure that threatens the supply-chain integrity. This special issue on …

Self Assembly In Additive Manufacturing: Opportunities And Obstacles, Nathan B. Crane, J. Tuckerman, G. N. Nielson

Faculty Publications

Purpose

Additive manufacturing offers substantial flexibility in shape, but much less flexibility in materials and functionality—particularly at small size scales. A system for automatically incorporating microscale components would enable the fabrication of objects with more functionality. This paper considers the potential of self assembly to serve as an automated programmable integration method. In particular, it addresses the ability of random self assembly processes to successfully assemble objects with high performance despite the possibility of assembly errors.

Methodology

A self-assembled thermoelectric system is taken as a sample system. The performance expectations for these systems are then predicted using modified one-dimensional models …

Asme Human Powered Vehicle, Benjamin Knaus, Philip Basmadjian, Nick Supat

Mechanical Engineering

Speed Solutions has been contracted to design and build a Human Powered Vehicle (HPV) frame and drivetrain for the Cal Poly HPV club to use in their 2011 race season. This project is being funded by the Cal Poly HPV club and their sponsors. The goal is to design, test and build a bicycle frame that the HPV club can attach to a fairing of their design. Primary design considerations will include speed, weight, cost, rider ergonomics, reliability and ease of repair. This vehicle will be used to compete in ASME’s Human Powered Vehicle Challenge (HPVC) series of races.

Adapted Recumbent Bike, Kurtis Mundell, Dane Tiemeier, Laura Yakuma, Darius Yu

Mechanical Engineering

The adapted recumbent project was to redesign a disabled veteran’s recumbent bicycle. The main areas of concern were the crank pedal, chain tension, braking and steering system, and ergonomics. Since the customer is an avid biker, this bike will be used often, so the design is based on the ease of repair and replacement. The crank system was redesigned to a lightweight, adjustable part with chain clearance and high strength. The chain tension was improved by replacing the existing single idler wheel/chain tube system with a dual idler wheel system. The dual idler has a titanium sprocket in one of …

Piedras Blancas Clock Works, Andrew James, Andrew Jupin, Matt Weber

Mechanical Engineering

In 1875, the Piedras Blancas Lighthouse was built to warn ships sailing the California coast of the hazards of the rocky shore. In 1949 a fierce storm damaged the top portion of the lighthouse and the eight ton cast iron and brass assembly had to be replaced by a much lighter piece that still served the purpose of warning oncoming vessels. The former top portion came to rest in downtown Cambria and is still there today, enclosed in a glass room to be observed by visitors and townspeople. Today, the Piedras Blancas Light station is cared for by the Bureau …

An Analysis Of The Manufacturing Process As Related To The Camber Requirement For Brake Pads, Daniel Patrick Midden

Morehead State Theses and Dissertations

A thesis presented to the faculty of the College of Science and Technology at Morehead State University in partial fulfillment of the requirements for the Degree of Master of Science by Daniel Patrick Midden on November 30, 2010.

Lean Manufacturing As A Source Of Competitive Advantage, Ryan Scott Williams

Theses and Dissertations

The productivity advances generated from lean manufacturing are self-evident. Plants that adopt lean are more capable of achieving high levels of quality, shorter lead times, and less waste in the system. While it seems logical that higher levels of productivity and quality, as is common in lean companies, should result in positive financial performance, the research community has failed to establish the financial profitability of lean. Those researchers who have studied the financial returns issue report varying results. The goal of this research was to determine if a connection exists between lean and financial success and to discover why so …

Gas Turbine, Vijaya Krushna Varma Mr

VIJAYA KRUSHNA VARMA Mr

Varma designed ultra modern and high efficiency turbines which can use gas, steam or fuels as feed to produce electricity or mechanical work for wide range of usages and applications in industries or at work sites. Varma turbine engines can be used in all types of vehicles. These turbines can also be used in aircraft, ships, battle tanks, dredgers, mining equipment, earth moving machines etc, Salient features of Varma Turbines. 1. Varma turbines are simple in design, easy to manufacture, easy to operate and maintain. 2. Varma turbines are less expensive. 3. Varma turbines have a great power to weight …

Water Turbine, Vijaya Krushna Varma Mr

VIJAYA KRUSHNA VARMA Mr

Varma designed ultra modern and high efficiency turbines which can use gas, steam or fuels as feed to produce electricity or mechanical work for wide range of usages and applications in industries or at work sites. Varma turbine engines can be used in all types of vehicles. These turbines can also be used in aircraft, ships, battle tanks, dredgers, mining equipment, earth moving machines etc, Salient features of Varma Turbines. 1. Varma turbines are simple in design, easy to manufacture, easy to operate and maintain. 2. Varma turbines are less expensive. 3. Varma turbines have a great power to weight …

Lunar Wormbot--A Robotic Tunneling Worm For Operation In Harsh Environments, Josh Johnson

Von Braun Symposium Student Posters

No abstract provided.

Comparative Corrosive Characteristics Of Petroleum Diesel And Palm Biodiesel For Automotive Materials, Haseeb Asma

Haseeb ASMA

Corrosive characteristics of biodiesel are important for long term durability of engine parts. The present study aims to compare the corrosion behavior of aluminum, copper and stainless steel in both petroleum diesel and palm biodiesel. Immersion tests in biodiesel (B100) and diesel (B0) were carried out at 80 degrees C for 1200 h. At the end of the test, corrosion characteristic was investigated by weight loss measurements and changes on the exposed metal surface. Surface morphology was examined by optical microscope and scanning electron microscopy with energy dispersive X-ray analysis (SEM/EDS). Fuels were analyzed by using TAN analyzer. FTIR, GCMS …

Use Of A Porous Membrane For Gas Bubble Removal In Microfluidic Channels: Physical Mechanisms And Design Criteria, Jie Xu, Regis Vaillant, Daniel Attinger

Daniel Attinger

We demonstrate and explain a simple and efficient way to remove gas bubbles from liquid-filled microchannels, by integrating a hydrophobic porous membrane on top of the microchannel. A prototype chip is manufactured in hard, transparent polymer with the ability to completely filter gas plugs out of a segmented flow at rates up to 7.4 μl/s/mm2 of membrane area. The device involves a bubble generation section and a gas removal section. In the bubble generation section, a T-junction is used to generate a train of gas plugs into a water stream. These gas plugs are then transported toward the gas removal …

Sae Baja: Final Drive Gearbox, Michael Mccausland, Michael Watkins, Ian Masterson, Andrew Sommer

Mechanical Engineering

This paper presents the results of a manual transmission project for SAE Baja. A full engineering process is documented, including problem definition, scheduling, conceptualization, decision theory, synthesis, analysis, manufacturing, and testing. A comparison is made between existing and potential mechanical power train solutions. The final design is analyzed in dynamic simulations, AGMA stress, predicted FFT spectrums, and shifting rod buckling. A number of complicated parts are manufactured through investment casting and direct CNC machining. Issues in the final assembly have prevented the project from being fully realized, recommendations are made for future SAE Baja teams.

Computer Aided Contour Profiling Of High Strength Deposits, Sriram Praneeth Isanaka, Amar Bala Sridhar, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufacturing processes suffer from the effect of ripples, edge rounding and surface variations. To reduce their effect, ideal process parameters for the laser deposition process were investigated. Also, a new method was identified to analyze deposits by accurately plotting their contours. This was achieved through point cloud data of the deposits generated using coordinate measurement and 3D scanning. Curve fitting was performed on the data in Matlab to generate the contours of the deposit. The intercept values, heights, and contact angle of the curves give an indication of the uniformity of deposits and aid in reducing defects.

Optimization Of Selective Laser Sintering Process For Fabrication Of Zirconium Diboride Parts, Ming-Chuan Leu, Shashwatashish Pattnaik, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective Laser Sintering (SLS) was investigated to fabricate Zirconium Diboride (ZrB₂) parts for ultra-high temperature applications. Experiments were conducted to determine values of SLS process parameters (laser power, scan speed, line spacing, and layer thickness) that can be used to build ZrB₂ parts with high integrity and sharp geometrical features. A sacrificial plate with a proper number of layers (determined from experimentation) separated from the main part was built in order to reduce thermal gradients when building the main part. The sacrificial plate was found to assist in eliminating cracks in the bottom of the main part. …

Selective Laser Sintering Of 13-93 Bioactive Glass, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Mariano Garcia Velez

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Bioactive glasses are more promising than biopolymers in fabricating scaffolds for bone tissue repair because they convert to hydroxyapatite, when implanted in vivo. Both direct and indirect selective laser sintering (SLS) methods of 13-93 bioactive glass were considered in this research to study the feasibility of fabricating scaffolds for bone repair applications. Stearic acid was used as the binder in the indirect method to fabricate the scaffolds. The green scaffolds underwent binder burnout and sintering at various soaking conditions between 675⁰C and 700⁰C, achieving a maximum compressive strength of 23.6 MPa, which is higher than that of the human cancellous …

Development Of A Low Cost Imaging System For A Laser Metal Deposition Process, Shyam Barua, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The size of the melt pool created by the laser is one of the most important quality characteristic in a laser metal deposition process. This paper discusses the development of a low-cost vision system to automatically determine the size of the melt pool for in-process control. To cope with the intense infrared signal from the laser and melt pool, external ultraviolet illumination is paired with narrow bandpass filters on a usb microscope to achieve a clear image of the melt pool. The sensitivity of the melt pool to changes in system parameters and various substrate materials are also evaluated.

Effect Of Different Graphite Materials On Electrical Conductivity And Flexural Strength Of Bipolar Plates Fabricated By Selective Laser Sintering, Nannan Guo, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Graphite is an excellent material for bipolar plates used in Proton Exchange Membrane (PEM) fuel cell due to its great chemical resistance, but the brittle nature makes it difficult to manufacture. Selective Laser Sintering (SLS) based on layer-by-layer manufacturing technology can fabricate graphite bipolar plates with complex gas flow channels. To improve the performance of bipolar plates including electrical conductivity and flexural strength, different graphite materials (natural graphite, synthetic graphite, carbon black, and carbon fiber) were investigated to fabricate test samples. These samples then went through post processing including carbonization and infiltration. The results show that bipolar plates with electrical …

Multi-Axis Planning System (Maps) For Hybrid Laser Metal Deposition Processes, Frank W. Liou, Jianzhong Ruan, Todd E. Sparks

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper summarizes the research and development of a Multi-Axis Planning System (MAPS) for hybrid laser metal deposition processes. The project goal is to enable the current direct metal deposition systems to fully control and utilize multi-axis capability to make complex parts. MAPS allows fully automated process planning for multi-axis layered manufacturing to control direct metal deposition machines for automated fabrication. Such a capability will lead to dramatic reductions in lead time and manufacturing costs for high-value, low-volume components with high performance material. The overall approach, slicing algorithm, machine simulation for planning validation, and the planning results will be presented.

Uncertainty Analysis In Laser Deposition Finish Machining Operations, Jomy Francis, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Laser Aided Manufacturing Process (LAMP) from Missouri S&T is a laser based metals rapid manufacturing process that uses machining to improve the final part's surface finish. When free-form machining, the absence of enough deposited material results in inconsistent scallop heights which result in poor surface finish or incorrect geometry in the final part. This paper investigates a probabilistic approach to various uncertainties involved in the deposition and subsequent machining of an arbitrary part. Furthermore, this paper analyses the machine errors which makes the response of Scallop Height to exceed the predefined maximum scallop height when traveling along the tool …