Manufacturing Commons^™

Selective Laser Sintering; A Design Of Experiments, Philip David Hopkins, Victor Castillo Phd

STAR Program Research Presentations

Additive Manufacturing (AM), also commonly known as 3D Printing or Rapid Prototyping, is a method of manufacturing that provides for the ability to make intricate internal features and easily customizable parts. The concept is to break a Computer Aided Design (CAD) file into a series of thin layers that are sent to the machine and laid down one layer at a time. Just like any other form of processing, material properties can alter by undergoing this process. Manipulating various parameters of the AM process can allow for different properties to be achieved. For this reason, an in depth study will …

A Case Study For Financial Feasibility Of Automated Costing Support In A Small Machine Shop, Benito A. Gonzalez

Theses and Dissertations - UTB/UTPA

A knowledge-based cost estimating expert system is chosen by a Mexican machine shop. Differences between the traditional experience-based system employed and the automated system are studied. Data is gathered to analyze time effectiveness, accuracy and payback of the software. Data from seventy part models is recorded to study the time experiment, and data from fifty part models is used to study the accuracy and consistency. Data is analyzed by calculating mean, standard deviation, and test of hypothesis. The results indicate that the software is faster than the traditional quoting system; however, the payback point is high. Also, results show the …

Remanufacturing Cleaning Process Evaluation, Comparison And Planning, Ozan Yagar

Theses and Dissertations - UTB/UTPA

This thesis aims to combine previous research on remanufacturing cleaning processes and applications into a single decision-making tool, in the form of software, which a remanufacturer can use to find a cleaning system that matches their specific demands. This thesis will provide an in-depth review of each cleaning process, the chemicals used in those processes, and the contamination types for which they were developed. This research also provides evaluation and comparison that assists remanufacturers in designing their cleaning systems. Finally, there will be a description and demonstration of the software. The ultimate goal is to find correct cleaning process to …

A Comparative Study Of Strength And Stiffness Of Thin-Walled Specimens Fabricated By Fdm And 3d Printing Technologies, Miranda Rodrigo

Theses and Dissertations

Rapid Prototyped part failure constitutes a major issue for both RP providers and customers. When parts fail the reputation of the vendor is heavily deteriorated, customer dissatisfaction increase and replacement of the broken parts is often necessary to avoid the loss of future business. Product design teams often run into situations where Rapid Prototyped parts are not able to withstand shipping and handling and delivered broken or while demonstrating and examining the parts. When done in the face of customers this builds a perception of poor quality and lack of aptitude on the design group as well as the RP …

Design, Construction, And Evaluation Of An Automated Chicken Coop Door, Kyle Inks

BioResource and Agricultural Engineering

This senior project takes a look into the design, construction, and evaluation of an automated chicken coop door. The idea and need for such a door came from my mother Jan Inks. The parameters for the project include, low production cost, easy installation on existing coops, sleek design, automatically open at a set time in the morning, and automatically close at a set time in the evening.

The Hovering Ball Exhibit, Matthew Bauzon, Will Lennox, Michelle Swan

Mechanical Engineering

No abstract provided.

Formula Hybrid Drivetrain Design, Zachary (Zak) Mcfarland, Alex Pruitt, William Domhart

Mechanical Engineering

The Formula Hybrid senior project group was tasked with designing and building a drivetrain system for the Cal Poly Society of Automotive Engineers (SAE) Formula Hybrid (FHSAE) team. FHSAE gave customer requirements for performance and geometry for the drivetrain and the FHSAE rulebook has guidelines regarding safety requirements. The team chose to compete in the electric category of the 2012 FHSAE competition. After getting feedback from previous car performance and researching different powertrain options, the senior project team arrived at three conceptual ideas. Using a quality function deployment method, the senior project team chose the concept where two motors independently …

Recreational Nordic Sit Ski, Mathew Bissonnette, Johnathon Gorski, Kevin Izumiya

Mechanical Engineering

The purpose of this project was to design, build, and test a recreational Nordic sit ski for use by Disabled Sports Eastern Sierra. The goal was to improve adjustability and reduce weight compared to previous sit ski designs. The project was completed by Cal Poly Mechanical Engineering seniors Mathew Bissonnette, Johnathon Gorski, and Kevin Izumiya. Kinesiology seniors Harpreet Saini and Carl Anderson provided discipline support and disability etiquette training.

The project was sponsored by the National Science Foundation Research to Aid Persons with Disabilities (RAPD) grant. The grant was proposed by and awarded to Dr. Brian Self and Dr. James …

Design Of An Independent Star-Clip Organizer (Iso), Christopher Gonzales, Greg Lovasik, Daniel Silveira

Mechanical Engineering

Discussed below is a new concept to sort and deliver star clips for flight deck safety net manufacturing. Multiple methods were generated, along with the necessary research, and were narrowed down to a single concept: the tray-loading preprocess design, named ISO (Independent Star-Clip Organizer). The overall design has been finalized and designed. Due to budget constraints, an actual prototype was not built. However, the design of such a prototype is described by this report, backed with calculations and experimental testing.

Human Powered Helicopter: Rotor Structure, Joseph Ram, Juan Carlos Olvera

Mechanical Engineering

The following report encompasses the Human Powered Helicopter Rotor Team’s conceptual models and ideas based on research and modeling analysis. The following gives an overview of material researched, concept generation, analyzation, manufacturing, and testing for a rotor structure to be installed in a Human Powered Helicopter.

Advanced Design Optimization For Composite Structure: Stress Reduction, Weight Decrease And Manufacturing Cost Savings, Shayan Ahmadian

Master's Theses

An injection moldable chopped fiber composite actuator with detailed drawing and tolerances was designed within one year. A vendor was selected and a quote for injection molding tooling cost for production was obtained and the first prototype was built in addition of six months. The risks are identified and material characterization tests are proposed.

The objective of this project was redesigning an aluminum made actuator with a continuous fiber composite for weight saving purposes. After searching the literature and consulting with experts in the field it was concluded that manufacturing costs associated with continuous fiber composite are 3 times as …

Study Of Grinding Burn Using Design Of Experiments Approach And Advanced Kaizen Methodology, Kiruthika Devi Sundarrajan

Department of Industrial and Management Systems Engineering: Dissertations, Theses, and Student Research

Grinding burn has been one of the re-occurring issues at a leading automotive manufacturer. Historically when grinding burn occurred, trial and error was used to delicately find a set up process settings that provided good-enough-to-get-by results, but not optimal. Some changes include changing the coolant manifold to improve the coolant flow and rate, changing the grinding wheel, changing the type of coolant. The experiments have proved to introduce some improvements, however the occurrence of grinding burns have not been reduced or quantified and the cause of the grinding burn has not been identified or quantified. Grinding is a complex phenomenon …

Integrating Courses Through Project Based Learning, Lizabeth Schlemer, Sema E. Alptekin, Karen R. Bangs

Industrial and Manufacturing Engineering

Integrating three courses (one sophomore level, two senior level) through Project Based Learning (PBL) within the Industrial Engineering curriculum at the California Polytechnic State University, San Luis Obispo is presented. Three courses (IME 443 Facilities Planning and Design - senior level; IME 420 Simulation - senior level; and IME 223 Process Improvement Fundamentals - sophomore level) were linked by various mechanisms: Common industry projects, common students in two of the three courses; senior students having access to sophomores in their teams to carry out time consuming tasks such as time studies, and sophomores having access to seniors as team members, …

Improving Manufacturing Processes Through Energy Monitoring, Andrew Grzelak

Purdue Polytechnic Masters Theses

Energy efficiency and sustainability are very popular topics in the current field of manufacturing. With the increase in use of automation technology as well as the recent growth in the area of energy management, there is much focus on the overall improvement of manufacturing processes. For this research a project was completed to create a system that could improve both process efficiency as well as decrease energy consumption. By taking a look at the machine level energy consumption of an automated piece of manufacturing equipment, by eliminating waste in process, both energy efficiency and operational efficiency can be improved.

Using …

Acoustic Emission Detection Of Metals And Alloys During Machining Operations, Jameson K. Nelson

Purdue Polytechnic Masters Theses

Nelson, Jameson K. M.S., Purdue University, May 2012. Acoustic Emission Detection of Metals and Alloys During Machining Operations. Major Professor: Rodney G. Handy.

Practical correlation between material deformation attributes and theoretical concepts of machining has proven difficult to attain. The purpose of this study was to further explore trends and relationships using acoustic emission detection of materials undergoing single-point lathe turning machine processes. The majority of machining experiments that incorporate acoustic emissions focuses on tool degradation for the purposes of optimizing consumables required to manufacture mechanical devices. Experiments were implemented varying recording location, mechanical barrier condition, and machine parameters. The …

High Speed Friction Stir Spot Welding On Dp 980 Steel:Joint Properties And Tool Wear, Nathan David Saunders

Theses and Dissertations

With the desire to improve passenger safety and fuel efficiency, Ultra High Strength Steels (UHSS) have been developed for use in the automotive industry. UHSS are high strength steels with high ductility and strength. DP 980 is one of these UHSS being applied in automobile manufacturing. DP 980 is difficult to join with Resistance Spot Welding (RSW) because of the high carbon content and alloying in this material. The weld becomes brittle when it solidifies during the welding process. With the desire and motivation of widely using UHSS, new welding processes are needed to be developed in order to effectively …

Effect Of Gold Content On The Microstructural Evolution Of Sac305 Solder Joints Under Isothermal Aging, Mike Powers, Jianbiao Pan, Julie Silk, Patrick Hyland

Industrial and Manufacturing Engineering

Au over Ni on Cu is a widely used printed circuit board (PCB) surface finish, under bump metallization (UBM), and component lead metallization. It is generally accepted that less than 3 wt.% Au in Sn-Pb solder joints inhibits formation of detrimental intermetallic compounds (IMC). However, the critical limit for Au content in Pb-free solder joints is not well established. Three surface-mount package platforms, one with a matte Sn surface finish and the others with Ni/Au finish, were soldered to Ni/Au-finished PCB using Sn-3.0Ag- 0.5Cu (SAC305) solder, in a realistic manufacturing setting. The assembled boards were divided into three groups: one …

Feasibility Analysis For Electrically-Powered Hoverboard, Cameron Chan, Jason Cortez, Jay Lopez

Aerospace Engineering

Composite materials are engineered by combining two or more constituent materials with significantly different physical or chemical properties in such a way that the constituents are still distinguishable, and not fully blended. Due to today’s high rising prices of gasoline and aviation fuel costs, many manufacturers have turned to the use of lightweight composites in their designs due to the advantages of the composite material, which include outstanding strength, excellent durability, high heat resistance, and significant weight reduction that the composite material properties hold. The purpose of this project is to design and construct a composite structure for an electrically-powered …

Lunalight Project: Solar-Rechargeable Led Lantern And Cell Phone Charger, Sean C. Dawson, Michael E. Deagen, Francisco N. Dye, Brian S. Mircheff, Ryan O. Ramelb

Materials Engineering

Today, 1.6 billion people in the world do not have access to grid electricity. Villagers living off the grid in developing nations resort to kerosene lanterns to light their homes. The fumes from burning kerosene are toxic and lead to respiratory illnesses over time. Our sponsor, OneMillionLights, plans to help people to escape poverty by providing them with a clean source of light at night. Children that must work in the fields during the day can use a solar-rechargeable lantern at night to read or study, and street vendors can use the lanterns at night to improve their businesses.

The …

The Morphology Evolution And Voiding Of Solder Joints On Qfn Central Pads With A Ni/Au Finish, Julie Silk, Jianbiao Pan, Mike Powers

Industrial and Manufacturing Engineering

In this paper, we report on a comprehensive study regarding the morphology evolution and voiding of SnAgCu solder joints on the central pad of two different packages – QFN and an Agilent package called TOPS – on PCBs with a Ni/Au surface finish. Samples were isothermally aged at the equivalent of 0, 2, 7 and 14 years service life. Representative solder joints were cross-sectioned and analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) in order to investigate the evolution of the solder joint morphology as a function of Au content and isothermal aging. IMC thickness was …