Mechanical Engineering Commons^™

Analysis Of Approximations In Flash Thermal Diffusivity Measurements Using High‑Fidelity Simulations, Tage T. Burnett, Jakob G. Bates, Matthew R. Jones, Christopher R. Dillon, John Tencer

Faculty Publications

Thermal diffusivity is an important material property for understanding and characterizing transient behavior in many heat transfer applications. This study investigates the accuracy and approximations of inverse mathematical models for measuring thermal diffusivity of materials via the widely used Flash Method. High-fidelity simulations of the Flash Method in copper, silicon carbide, silicon, and glass were performed as numerical experiments and included physics such as in-depth absorption, radial conduction, and surface convection. Data from those numerical experiments were used to estimate material thermal diffusivity using seven traditional and new inverse models. Parker’s original model had relative errors 𝜖< 5% when the approximations it makes were enforced in numerical experiments. Newer models performed well even when experimental restrictions were relaxed. Models that include radial heat conduction were capable of accurately measuring thermal diffusivity (𝜖< 1%) when a Gaussian energy source was used. Models with radial conduction and in-depth material absorption of the laser source could calculate thermal diffusivity for semi-transparent materials such as silicon (𝜖< 1%) and even transparent materials like glass (𝜖< 10%). Convective losses from the material’s front surface had a negligible impact on measurements except for very low thermal diffusivity materials. Using temperatures from many locations of the test material’s surface increased resilience to noise, reducing the distribution of thermal diffusivity measurements by more than an order of magnitude. The models developed in this study could enable a more relaxed Flash Method experimental setup that maintains thermal diffusivity accuracy and extend the utility of the Flash Method to semitransparent materials.

Aquaculture Ecosystem Modeling Aeration Efficiency Optimization Using Cfd, Gabriela Reyes Gomez

Electronic Theses and Dissertations 2020 - Present

The Harbor Branch Oceanographic Institute (HBOI) is developing the Intelligent and Resource Efficient Pond Aquaculture (IREPA) project, which aims to improve aquaculture management through the integration of predictive models and automated technologies. This approach seeks to transition traditional practices toward data-driven systems capable of supporting informed decision-making for aeration management.

This study investigates the effectiveness of different aerator configurations on hydrodynamic circulation and dissolved oxygen (DO) distribution in aquaculture ponds using computational fluid dynamics (CFD). A model was developed in ANSYS Fluent, where the aerator was represented using a power-based formulation and implemented as a moving wall boundary condition. Dissolved …

Aerodynamic Performance Of Grid Fins As High Lift Devices, Luke Jeffrey Krick

Senior Honors Theses

Flaps are used in almost all aircraft to increase the amount of lift the wings can produce at low speeds. However, the flaps also increase the amount of drag experienced by the aircraft. The drag induced by the flaps causes energy loss and is unfavorable for aircraft effectiveness. In recent years, grid fins have become a popular choice for aircraft and armaments to control their orientation. First developed for launch escape towers, grid fins are made up of lines that cut the fin into many quadrants, leaving the fin with multiple rectangular shaped open areas. The aim of this study …

Engineering Design And Analysis Using Creo® Cad, Cae, And Manufacturing Applications, Swapnil Moon

Open and Affordable Textbooks

This textbook presents a structured approach to computer-aided design using Creo, integrating CAD, CAE, and CAM workflows within a unified engineering framework. The material emphasizes parametric modeling, design intent, and feature-based modeling as foundations for creating robust and adaptable engineering models. Through progressively structured tutorials, students develop skills in part modeling, assemblies, engineering drawings, mechanism design, simulation, and manufacturing. The text incorporates real-world engineering components and workflows, including structural and thermal analysis, motion simulation, and toolpath generation, reflecting modern engineering practice. Designed for upper-division undergraduate and graduate students, this open educational resource supports hands-on learning and prepares students for industry-relevant …

Introduction To Computer-Aided Design Using Solidworks® : A Structured Approach To Parametric Modeling And Design Intent, Swapnil Moon

Open and Affordable Textbooks

This textbook introduces computer-aided design (CAD) using SOLIDWORKS® through a structured, design-centered approach that emphasizes parametric modeling and engineering reasoning. Rather than focusing solely on software commands, the material develops foundational skills in design intent, constraint-based modeling, and feature relationships to create robust, adaptable models.

The content is organized progressively, beginning with basic sketching and feature creation and advancing to complex part modeling, assemblies, motion studies, and engineering drawings. Each chapter builds upon prior concepts, reinforcing systematic modeling practices and promoting the development of system-level thinking required in real-world engineering design workflows.

Designed for undergraduate students with little or no …

Design Of Air-Entrained Concrete For Airport Pavements Through Local Aggregate Utilization: Performance Optimization And Economic Analysis, Li Wentao, Rizwan Qadir, Arslan Mushtaq, Hilal Khan, Kamran Jillani

Journal of Sustainable Construction Materials and Technologies

Airport pavement construction in developing countries faces critical challenges balancing international performance standards with economic constraints, while limited research exists on optimizing air-entrained concrete mixes using locally sourced materials for cost-effective solutions. This study investigated the development of economical air-entrained concrete mix designs for airport pavements utilizing Pakistani aggregates and systematic cement content optimization. Comprehensive experimental evaluation included material characterization through petrographic analysis, alkali-aggregate reactivity assessment via accelerated mortar bar testing, and mechanical property development across cement contents from 360-450 kg/m3. Air entrainment was achieved through controlled admixture dosing while maintaining target slump of 50mm. Results demonstrated that locally sourced …

Niu Fsae Brake Rotor Design & Flywheel-Based Test Stand Development, Cody J. Marko, Austin Coyne, Alexander Boyden

Honors Capstones

This project addresses the need for a reliable and validated brake rotor for the Northern Illinois University Formula SAE vehicle following a prior catastrophic rotor failure within the team. Brake rotors in high-performance applications are subjected to significant thermal and mechanical loads, and inadequate design can lead to failure, posing serious safety risks and limiting vehicle performance. To solve this issue, a new brake rotor was designed alongside a dedicated test stand to both improve braking performance and enable experimental validation. The rotor was evaluated using finite element analysis (FEA), including transient thermal and structural simulations, to predict maximum temperature, …

Portable Humidity Chamber, Calvin Wright, Ian Heilers, Sam Taylor

Honors Capstones

This engineering project, sponsored by Crandall Stats and Sensors, focuses on improving the ability to test product performance under controlled environmental conditions by designing a portable humidity chamber capable of maintaining a stable relative humidity between 20 and 80 percent with a tolerance of ±0.5 percent. Consistent humidity is crucial for evaluating how moisture influences material properties, product reliability, and long-term durability in real production environments. Because Crandall conducts testing across multiple facility locations, the chamber must also be lightweight, transportable, and easy for operators to use without specialized training. Developing such a system provides the company with a valuable …

Tribological Evaluation Of A Graphite Coating Using A Custom Miniature Conveyor, Shae Threlfall

Mechanical Engineering Undergraduate Honors Theses

Reducing friction in conveyor systems has significant economic and environmental implications, as a substantial portion of energy losses originates at the belt-bed interface. This thesis outlines the design, construction, and validation of a miniature conveyor tribological test system. Unlike conventional tribometers, which impose concentrated point contacts, the miniature conveyor replicates the distributed load consistent with industrial conveyor systems. It can measure real-time mechanical responses of steel samples coated in a low friction coating.

The mini conveyor was validated by evaluating three materials: uncoated mild steel, PDA/graphite coated steel, and Polytetrafluoroethylene (PTFE). Electrical power, temperature, sound, and acceleration were recorded. Electrical …

Automating Building Feature Recognition In Digital Twin Models Using Computer Vision, Jaron Harbison

Undergraduate Honors Capstone Projects

Standard 3D scans treat all surfaces as generic geometry, but Wi-Fi signals don't. A signal drops by a different magnitude through a wooden door than a concrete wall. Without labeling these materials, Internet Service Providers (ISPs) cannot accurately predict "dead zones". This project addresses that gap by creating a machine learning model that identifies structural and architectural features. This includes features such as walls, doors, windows, and columns directly from RGB-D (Red, Green, Blue, Depth) point cloud data. 

I constructed the model on a custom U-Net architecture featuring a symmetric encoder-decoder structure with skip connections, trained on the StructScan3D dataset …

Ngc - Torch Test Ablation Stand Improvements And Upgrades, Sarah Nelson

Undergraduate Honors Capstone Projects

This capstone project is sponsored by Northrop Grumman (NGC). The goal of the project is to redesign an ablation torch testing system to improve usability, safety, and versatility. Northrop Grumman relies on their ablation torch testing system to conduct quantitative evaluations of materials and high stress and high temperature conditions. The system provides essential data that supports product development, safety validation, and compliance with performance standards. By improving usability, safety, and versatility, NGC will be able to streamline testing operations, increase accuracy of results, and reduce operator risk. The system must allow testing using both a bent and straight torch …

Development Of A Novel Method For Simultaneously Testing Multiple Specimens To Evaluate Tension-Tension Fatigue Life, Mehedi Hasan Mahfuz

All Graduate Theses and Dissertations, Fall 2023 to Present

The aim of this study is to develop a novel method for rapidly evaluating the tension–tension fatigue life of metals. Fatigue failure, which occurs when materials gradually weaken and fracture under repeated loading, is a critical concern in designing safe and reliable structures such as airplanes, cars, and bridges. Traditional fatigue testing methods are slow, costly, and typically limited to one specimen at a time. To address this, a high-throughput testing method was developed that allows multiple small-scale specimens to be tested simultaneously while following international testing standards. Using stainless steel sub-sized specimens scaled at 1:5 relative to the ASTM …

The Expectation Of Pain: Effects On Threshold, Tolerance, And Perception, Emma Paulus

Mechanical Engineering Undergraduate Honors Theses

Brain activity in pain-related regions of the cortex is thought to be influenced by interactions between expectations and incoming sensory information. However, the subjective experience of pain based on expectation has not been thoroughly explored. By changing visual and auditory cues to set expectation levels, a relationship between unconscious expectation of pain and actual sensory pain experienced was characterized. With IRB approval, volunteers were randomly and blindly grouped into low and high pain expectancy groups. Each group completed a survey about initial pain expectations before the muscle stimulation tolerance test, followed by a survey about actual pain perception after the …

Harness: Hybrid Architecture For Resilience In Networked Engineering System Simulations, Daniel Scott

Graduate Theses and Dissertations

This dissertation presents the development of HARNESS, a unified, domain-agnostic framework for the modeling, optimization, and evaluation of complex systems under conditions of degradation and uncertainty. The research addresses a persistent challenge in systems engineering: the lack of a generalizable, behaviorally grounded approach for quantifying resilience and robustness across diverse domains. HARNESS integrates graph-theoretic dependency modeling, GPU-accelerated evolutionary optimization, and agent-based simulation into a modular architecture that enables both system design and diagnostic analysis. The framework models system interdependencies through user-defined components, parameters, and constraints, allowing architectures to evolve dynamically while maintaining structural validity. A mutation-only genetic algorithm with a …

Aerodynamic Parameter Estimation For A Scaled F-16: A Simulation-Based Sensitivity Analysis, Kathle C. Tischner

All Graduate Theses and Dissertations, Fall 2023 to Present

The physical motion of an aircraft is determined by the resulting forces and moments acting on the aircraft. These forces and moments can be defined as a mathematical equation where the control deflections, rotation rates, and orientation of the aircraft are multiplied by individual constants and summed together to define the entire force or moment. This method results in a highly accurate model that defines the motion of the aircraft at low angles of attack and sideslip. Initial calculations of the aerodynamic model are created based on analytical estimations based on the physical properties of the aircraft. Additional refinement of …

Developing And Improving Digital Image Correlation (Dic) Techniques For Challenging Environments, Prasenjit Dewanjee

All Graduate Theses and Dissertations, Fall 2023 to Present

Understanding how materials and parts deform during testing is crucial for creating safer and more reliable engineering systems. Engineers need to measure not only how much a part deforms, but also where deformation concentrates before any damage or failure happens. Digital image correlation (DIC) is a camera-based, non-contact measurement method that tracks surface motion and deformation across a whole area. It is particularly useful when traditional contact-based measurement techniques cannot withstand harsh conditions or capture enough detail. This dissertation develops optical methods to improve DIC in three challenging measurement situations. First, a shortwave ultraviolet lighting technique is developed to reduce …

Electric Charging Arm Mechanism - Echarm, Jacob A. Lewis, Gabriel A. Greer

Mechanical Engineering Student Research

As demand for electric and hybrid vehicles continues to rise, many EV owners rely on home charging in their garages. Gabriel Greer and I’s Senior Design Project, the Electric Charging Arm Mechanism (ECHARM), addresses this by creating a robotic system that autonomously detects a vehicle’s charging port, connects to it, and returns to a rest position when charging is complete. ECHARM is designed as a six-axis robotic arm with wrist and shoulder joints driven by stepper motors through custom cycloidal drive gearboxes. A closed-loop control system using rotary potentiometers ensures precise motion control. At the end of the arm is …

Stakeholder Perspective-Taking In Engineering Design: A Neurocognitive Approach, Megan C. Taylor

Mechanical Engineering Undergraduate Honors Theses

Stakeholder engagement is a critically important yet overlooked phase of engineering design. While addressing stakeholders is known to lead to more thoughtful design outcomes, little work has been done regarding how stakeholder personas influence brain activity while designing. This study asks if the introduction of stakeholder personas- short overviews of people affected by a design problem- affects brain activation in undergraduate students during three design tasks: stakeholder identification, stakeholder needs generation, and stakeholder needs prioritization. To test this, 18 undergraduate mechanical engineering students were given a stormwater management design vignette; one group was given four stakeholder personas, while the control …

Enhancing The Leaning Control And Braking Sensation Of A Virtual Reality Vespa Simulator, Joseph Boccuzzi, Wesley Bleck, Jacob Hannebaum

Honors Capstones

The 71 North Partnership Studio located in Northern Illinois University’s Founders Memorial Library has developed a prototype Vespa simulator featuring an interactive Virtual Reality (VR) game and reactive elements. A previous Mechanical Engineering Senior Design team developed the system and improvements after its original development were sought after over the course of the current school year. The system consists of a stationary bike that allows the rider to lean left and right, which in turn causes their in-game character to turn left and right accordingly, simulating the effect of riding a Vespa scooter within a VR environment. Improvements were made …

Optimization Of Stamped Tool Geometry Using Regression-Based Cost Models And Structural Constraints, Matthew J. Teague

Mechanical Engineering Undergraduate Honors Theses

Stamped steel paint can openers are simple tools but still require sufficient strength for the end user and low material consumption for the manufacturer. The goal of this project is to optimize the stamped design of a paint can opener by reducing material cost while maintaining structural rigidity and device performance. This was achieved in part by simplifying the tool’s geometry so that an equation for the mass could be developed analytically and checked against the simulation’s outputs. First, a 25-run design of experiments was created that varied the shaft length and the endloop diameter. Next, a CAD model for …