Manufacturing Commons^™

A Metrics-Based Sustainability Assessment Of Cryogenic Machining Using Modeling And Optimization Of Process Performance, Tao Lu

Theses and Dissertations--Mechanical and Aerospace Engineering

The development of a sustainable manufacturing process requires a comprehensive evaluation method and fundamental understanding of the processes. Coolant application is a critical sustainability concern in the widely used machining process. Cryogenic machining is considered a candidate for sustainable coolant application. However, the lack of comprehensive evaluation methods leaves significant uncertainties about the overall sustainability performance of cryogenic machining. Also, the lack of practical application guidelines based on scientific understanding of the heat transfer mechanism in cryogenic machining limits the process optimization from achieving the most sustainable performance.

In this dissertation, based on a proposed Process Sustainability Index (ProcSI …

Lean Fire Management: A Focused Analysis Of The Incident Command System Based On Toyota Production System Principles, Jeremiah S. Fugate

Theses and Dissertations--Mechanical and Aerospace Engineering

A primary role of the Incident Command System is to learn from past incidents, as illustrated by its origins in the wildland firefighting community. Successful emergency response operations under the Incident Command System has prompted its nationwide spread, this promulgation critically relies on the system’s capability to stabilize and continuously improve various aspects of emergency response through effective organizational learning. The objective of this study is to evaluate the potential to apply fundamental principles of the Toyota Production System (Lean manufacturing) to improve learning effectiveness within the Incident Command System. An in-depth review of literature and training documents regarding both …

A Novel Microgrid Demand-Side Management System For Manufacturing Facilities, Terance J. Harper, William J. Hutzel, James C. Foreman, Aaron L. Adams, Athula Kulatunga

Purdue Polytechnic Masters Theses

Thirty-one percent of annual energy consumption in the United States occurs within the industrial sector, where manufacturing processes account for the largest amount of energy consumption and carbon emissions. For this reason, energy efficiency in manufacturing facilities is increasingly important for reducing operating costs and improving profits. Using microgrids to generate local sustainable power should reduce energy consumption from the main utility grid along with energy costs and carbon emissions. Also, microgrids have the potential to serve as reliable energy generators in international locations where the utility grid is often unstable.

For this research, a manufacturing process that had approximately …

Modelling Of Directed Energy Deposition Processes, Xueyang Chen

Masters Theses

"The laser additive manufacturing technique of laser deposition allows quick fabrication of fully-dense metallic components directly from Computer Aided Design (CAD) solid models. The applications of laser deposition include rapid prototyping, rapid tooling and part refurbishment. The development of an accurate predictive model for laser deposition is extremely complicated due to the multitude of process parameters and materials properties involved. In this work, a heat transfer and fluid flow model is developed.

In the heat transfer and fluid flow model, the governing equations for solid, liquid and gas phases in the calculation domain have been formulated using the continuum model. …

Performance Analysis Of Cutting Graphite-Epoxy Composite Using A 90,000 Psi Abrasive Waterjet, Aiswarya Choppali

Masters Theses

"Graphite-epoxy composites are being widely used in many aerospace and structural applications because of their properties: which include lighter weight, higher strength to weight ratio and a greater flexibility in design. However, the inherent anisotropy of these composites makes it difficult to machine them using conventional methods. To overcome the major issues that develop with conventional machining such as fiber pull out, delamination, heat generation and high tooling costs, an effort is herein made to study abrasive waterjet machining of composites. An abrasive waterjet is used to cut 1" thick graphite epoxy composites based on baseline data obtained from the …

Numerical Analysis Of Thermal Stress And Deformation In Multi-Layer Laser Metal Deposition Process, Heng Liu

Masters Theses

"Direct metal deposition (DMD) has gained increasing attention in the area of rapid manufacturing and repair. It has demonstrated the ability to produce fully dense metal parts with complex internal structures that could not be achieved by traditional manufacturing methods. However, this process involves extremely high thermal gradients and heating and cooling rates, resulting in residual stresses and distortion, which may greatly affect the product integrity. The purpose of this thesis is to study the features of thermal stress and deformation involved in the DMD process. Utilizing commercial finite element analysis (FEA) software ABAQUS, a 3-D, sequentially coupled, thermo-mechanical model …

An Interactive Product Development Model In Remanufacturing Environment: A Chaos-Based Artificial Bee Colony Approach, Vishwa V. Kumar

Masters Theses

"This research presents an interactive product development model in re-manufacturing environment. The product development model defined a quantitative value model considering product design and development tasks and their value attributes responsible to describe functions of the product. At the last stage of the product development process, re-manufacturing feasibility of used components is incorporated. The consummate feature of this consideration lies in considering variability in cost, weight, and size of the constituted components depending on its types and physical states.

Further, this research focuses on reverse logistics paradigm to drive environmental management and economic concerns of the manufacturing industry after the …

Additive Manufacturing Laser Deposition Of Ti-6al-4v For Aerospace Repair Application, Nanda Kumar Dey

Masters Theses

"Parts or products machined from high performance metals are very expensive, partly due to the processing complexities during manufacturing. Therefore, many high performance metal parts users, such as the aerospace industry, mold/die casting industry, heavy machinery consumers etc., extend the service of these damaged parts by employing repair or remanufacturing technology. The research objective is to use laser deposition and machining processes to repair titanium parts.

This thesis discusses a new way of approach for developing a repair process for Ti-6Al-4V for the aerospace industry using Laser Metal Deposition (LMD). The repairs were conducted in a multi-axis hybrid manufacturing systems …

Characterization Of 304l Stainless Steel By Means Of Minimum Input Energy On The Selective Laser Melting Platform, Ben Brown

Masters Theses

"Developing parameter sets for new materials on the Selective Laser Melting (SLM) platform has traditionally been done through the use of single line processing windows and a basic design of experiments (DOE) which would include varying machine parameters to maximize density. This study expands the traditional method by determining the main effects statistically for density, allowing for a more in depth analysis wherein the experimental results are statistically correlated to the variable machine parameters used. With this analysis, parameter optimization with respect to achieving near full density, while also considering build rates, can be performed. New parameters for 304L stainless …

S1nn Gmbh & Co. Kg (Automobile Connectivity Module 1.1), Tyler Alexander Ball

Industrial and Manufacturing Engineering

The results of this report show how when diagnostics were run on the Connectivity Module 1.1, the problems discovered such as potential short-circuiting, 90-degree copper tracing angles, and components overheating/tombstoning were addressed. By using the method of “DMAIC,” which stands for Design, Measure, Analyze, Implement, Control, successful corrections were made. In the first design of the Printed Circuit Board (PCB), 1454 critical issues were found. With the newly designed PCB’s modifications being implemented, only 12 critical issues remained, which were later addressed and corrected. The results from this report are a functional Automobile Connectivity Module 1.1.

Project Management Of High School Shadow And Building An Engineer Day, Andrea M. Carroll

Industrial and Manufacturing Engineering

Building an Engineer Day and High School Shadow are semi-annual outreach events hosted by Cal Poly’s Society of Women Engineers section during fall and spring quarters. The events focus on encouraging women and minorities to take an interest in engineering. These events are the two largest outreach events hosted by The Society of Women Engineers and need to run smoothly in order to provide student attendees with a meaningful experience.

Building an Engineer Day and High School Shadow are currently un-organized and un-planned, which leads to problems with officer retention, increase in expediting process and a low attendance rate at …

Equipment Maintenance And Replacement Decision Making Processes, Michael W. Gage

Industrial and Manufacturing Engineering

This project contains recommendations for the decision making processes for support and production equipment maintenance and replacement for a large defense contractor. Recent literature has been reviewed to provide perspective on current trends in the field. A complete evaluation of their current processes and systems is included with recommendations on areas for improvement. A decision support system is also proposed to supplement their existing decision making.

Fixture For Carbon Fiber Spar Of Human Powered Helicopter, David John Ikeda, Luis Gonzalez

Industrial and Manufacturing Engineering

The following report describes our contribution to Cal Poly Human Powered Helicopter for the 2012 competition for the Sikorsky Prize offered by the American Helicopter Society. In order to win this prize the team needs to build and fly a human powered helicopter for more than 60 seconds reaching and altitude of 3 meters while staying in a 10 meter square box. Our team was created to support the integration of Carbon Fiber parts, specifically the carbon fiber spars with rotor and landing gears. Precise cutting and accurate drilling was needed and our team was tasked with creating a fixture …

The Collapsible Trailer: Design And Manufacture, Robert Hobson

Biomedical Engineering

No abstract provided.

Design Of An Automatic Wood Trimming Machine, Van Ho, Nicholas Maskal, Andrew Rutland

Mechanical Engineering

This final design report, prepared for Sunrise Arts by the Cal Poly design team Mahogany Automation, details the year-long process in which the team of three engineering students designed and built an automated wooden -plank edge trimming machine that incorporates anti-jamming and continuous loading features. The team has examined current woodworking machines and features available on the industrial and commercial market, and used these as guides along with device requirements set by the project sponsor, Bruce Palmer. The focus has been on designing the simplest and most cost effective device that allows operators to make production runs of wooden slats …

Investigation Of Thermal Cycle And Hardness Distribution In The Laser Cladding Of Aisi H13 Tool Steel Produced By A High Power Direct Diode Laser, Parisa Farahmand, Prabu Balu, Fanrong Kong, Radovan Kovacevic

Mechanical Engineering Research

Laser cladding (LC) of tool steel has significant application in rapid tooling, and surface coating for worn-out components in different industries. During the LC process, several phase transformations influence the microstructural and mechanical properties of the deposited layer. In order to successfully implement the LC process, it is essential to understand the relationship between the thermal cycle (heating and cooling), phase transformations, and the output quantities of the deposited layer. In this study a direct diode laser with a power of up to 8 kW was used to deposit AISI H13 tool steel on mild steel grade A36 substrate to …

Nasa Msfc Summer Internship 2013 5.5m Composite Cryotank Sump Door Fabrication, Markus Murdy

Von Braun Symposium Student Posters

No abstract provided.

Effects Of Bit Type On Maximum Torque And Axial Force Using Manual Screwdrivers, Mark Hickok

Master's Theses (2009 -)

The screwdriver is a tool that has been among the most widely used hand tools for decades and continues to be used in the workplace to perform a variety of fastening tasks. Advancements in fastener technology have been complemented by the development of new types of screwdriver bits. While designs may vary, so do the force application requirements placed on the tool user. The primary objective of this experiment is to analyze the relationship between user torque and screwdriver bit design. A further objective is to utilize the results to develop an effort metric by which bits of different designs …

Theory Of Constraints Project Management In A Manufacturing Environment, Shihching Kraft

Mechanical & Aerospace Engineering Theses & Dissertations

The following thesis covers the concepts of Theory of Constraints (TOC) Project Management. Introduced by Eliyahu M. Goldratt in I 984, TOC is a management philosophy that focuses on the use of critical chain project management to prioritize everyday tasks in a company. In TOC Project Management, there is always at least one resource constraint that limits the speed at which projects are completed. TOC management philosophy also recognizes that most projects in the manufacturing industry face unknown schedule delays that could cause projects to be completed late or over the planned budget. During project plan creation, plans are developed …

Merging Creative Design And Cad Learning Activities In A Product Design Programme, Pearl O'Rourke, Colm O'Kane, Leslie Smith, Michael Ring

Conference Papers

Traditional learning and teaching methods for creativity differ from those used in a scientific context. Although the creative process can benefit from a certain level of prescription and structural constraint - with time allocated to research, problem definition, conceptualisation and idea development - flexibility and fluidity are necessary for creative innovation. In contrast, the more linear and rigid pedagogies associated with science and engineering education facilitate efficient learning of subjects such as those based on software packages, manufacturing and materials theory or mechanics. This paper describes the development of a project which aims to establish constructive links between the learning …