Manufacturing Commons^™

A Methodology Towards Comprehensive Evaluation Of Shape Memory Alloy Actuators For Prosthetic Finger Design, Kevin O'Toole

Doctoral

Presently, DC motors are the actuator of choice within intelligent upper limb prostheses. However, the weight and dimensions associated with suitable DC motors are not always compatible with the geometric restrictions of a prosthetic hand; reducing available degrees of freedom and ultimately rendering the prosthesis uncomfortable for the end-user. As a result, the search is on-going to find a more appropriate actuation solution that is lightweight, noiseless, strong and cheap. Shape memory alloy (SMA) actuators offer the potential to meet these requirements. To date, no viable upper limb prosthesis using SMA actuators has been developed. The primary reasons lie in …

Modeling And Optimization To Evaluate Sustainability Performance Of Customizable Product Service Systems, Ken Harsha Tilakaratne Wijekoon

University of Kentucky Master's Theses

The aim of this thesis is to present a new methodology to evaluate and optimize sustainability of customizable product-service systems while ensuring economic, environmental and societal constraints are also satisfied. Activities across the total product lifecycle are considered to develop a model that evaluates closed-loop flow, while being monitored through the growth, maturity and decline stages of the product to provide a comprehensive analysis. A novel method to evaluate the customer satisfaction is also presented. The research considers a modular product where customization can be achieved by selecting from alternatives while ensuring the compatibility between these alternatives. A manufacturer will …

Mechanical Characterization Of Polymer Electrolyte Membrane With Optical Methods, Xinyu Huang, Luis Alva, Jay Neutzler

Faculty Publications

Mechanical properties of polymer electrolyte membrane have important implications in the endurance of many electrochemical energy conversion devices [1]. Mechanical experiments are effective method to reveal discrete damage developed in the membrane by quantifying the change of mechanical strength and toughness. Regular strain measurement methods are overly intrusive to the thin and relatively fragile polymer electrolyte membrane; hence optical-based minimal invasive stress/strain measurement methods are studied.

A Shock Tube Technique For Blast Wave Simulation And Studies Of Flow Structure Interactions In Shock Tube Blast Experiments, Nicholas N. Kleinschmit

Department of Engineering Mechanics: Dissertations, Theses, and Student Research

Improvised explosive devices (IED’s) are widely used against US and allied forces fighting in Iraq and Afghanistan. Exposure to IED blast may cause blast-induced traumatic brain injury (bTBI). The injury mechanisms are however not well understood. A critical need in bTBI-related research is the ability to replicate the loading conditions of IED blast waves in a laboratory environment. In this work, experimental studies have been carried out to explore the use of the shock tube technique for generating air shock waves that mimic the temporal and spatial characteristics of free-field blast waves and to investigate the blast wave-test sample interactions …

Use Of Collaborative Learning Technology To Support Cross-Faculty Group Learning, Colm O'Kane, Jennifer Mcdonnell

Conference Papers

The scope of applications of computer supported collaborative learning (CSCL) has grown exponentially in recent years. This group of techniques has been found to be extremely effective as a collaborative tool to inspire scaffolding between students. It is also useful when several academic supervisors wish to view the same project work.

This paper describes the process and the motivation behind the first implementation of a campus pack-based project in Year 3 of Technological University Dublin's (DIT) BSc. in Product Design programme. Issues have been encountered in previous years with this cross-faculty managed project, but this work shows the potential that …

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 …

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

Von Braun Symposium Student Posters

No abstract provided.

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.

Freeze Extrusion Fabrication Of 13-93 Bioactive Glass Scaffolds For Bone Repair, Tieshu Huang, Nikhil D. Doiphode, M. N. Rahaman, Ming-Chuan Leu, B. Sonny Bal, D. E. Day

Materials Science and Engineering Faculty Research & Creative Works

There is an increasing demand for synthetic scaffolds with the requisite biocompatibility, internal architecture, and mechanical properties for the bone repair and regeneration. In this work, scaffolds of a silicate bioactive glass (13-93) were prepared by a freeze extrusion fabrication (FEF) method and evaluated in vitro for potential applications in bone repair and regeneration. The process parameters for FEF production of scaffolds with the requisite microstructural characteristics, as well as the mechanical and cell culture response of the scaffolds were evaluated. After binder burnout and sintering (60 min at 700°C), the scaffolds consisted of a dense glass network with interpenetrating …

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 …

Laser Based Rapid Manufacturing Of Metallic Gas Diffusion Layers For Pem Fuel Cells, Gargi Tandra, Todd E. Sparks, Shyam Barua, Nikhil P. Kulkarni, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Gas Diffusion layers (GDL’s) are an essential component of Polymer Electrolyte Membrane Fuel cells (PEMFC’s) which aid in thermal & electrical conductivities, water management and act as backup layers for the membrane electrode assemblies. This paper summarizes the effort to prototype metallic GDL designs using a miniature laser deposition system developed at Missouri University of Science & Technology. The pore sizes are controlled by masking the diverging laser beam using stainless steel masks of varying sizes and shapes. The through pore feature and further treatment of the GDL’s for hydrophobicity reduces the water management issue and thereby increases the performance …

Mea Manufacturing Using An Additive Manufacturing Process To Deposit A Catalyst Pattern In An Mea And Its Impact On Cost Reduction, Nikhil P. Kulkarni, Todd E. Sparks, Gargi Tandra, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The manufacturing of a fuel cell Membrane Electrode Assembly (MEA) is a significant cost driver in polymer-electrolyte membrane (PEM) fuel cell technologies, primarily due to the inclusion of expensive materials in the catalyst layer. The selective deposition of a catalyst on the MEA of a fuel cell can drastically reduce the costs depending upon the catalyst, method used for deposition, and production volume. In this paper, testing and analysis of a novel catalyst iridium oxide is discussed. The performance of the catalyst will be compared with the conventional catalysts which will give us an estimate of its effectiveness however, in …

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.

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. …