Mechanical Engineering Commons^™

Experimental Investigation Of The Manufacture Of Tunable Graphene Oxide Filter Membranes Using Intense Pulse Light, Joshua H Kotter

Electronic Theses and Dissertations

Reduced graphene oxide is a thin, strong, and inexpensive material with a channel and pore structure that make it a promising candidate for a filtration material. Reduced graphene oxide has been produced and tested in the laboratory, but a lack of scalable manufacturing techniques have limited its commercial use.

This thesis has shown that graphene oxide can be rapidly manufactured with an industrially scalable flash reduction process. The flash reduction process uses 0.58 millisecond pulses from a xenon lamp to reduce the graphene oxide film in less than a minute. Results for partially reduced graphene oxide membranes tuned by the …

(Poster) Pneumatically Assisted Autocutter: Providing A Safe Workplace Environment For People With Disabilities, Ryan Kallenberger, Brian Galliher, Laura Johnson, Melanie Moore, Joseph Herzog, Renny Fernandez, Najmus Saqib

ASEE IL-IN Section Conference

We present a pneumatic autocutter to help workers with disabilities for reduced operator fatigue, increased efficiency, thereby giving enhanced capabilities when working on a production line without worrying about their ability to effectively do their jobs. We are students in a sophomore level six sigma based course through the R.B. Annis School of Engineering at the University of Indianapolis. The specific process of production being discussed involves cutting bulky cardboard frames with a metallic wire-mesh covering. The current process requires a considerable amount of physical labor from the operator; prolonged work results in gradial operator debility and injury. For Gateway …

Fracture Toughness And Fatigue Crack Growth Rate Characterization Of Inconel 718 Formed By Laser Powder Bed Fusion, Charles C. Hohnbaum

Theses and Dissertations

Continuing improvement in the field of AM of metals provides the opportunity for direct fabrication of aerospace parts. AM was once used in large part for rapid prototyping but improvements in technology and increases in the knowledge base of AM materials has provided the opportunity for manufacture of AM parts for operational use. The ability to create low numbers of unique parts without having to invest in expensive tooling provides great economic incentive to utilize this technique. IN718 is the most common high temperature alloy used in the aerospace industry and lends itself readily to formation by LPBF. The superior …

Providing A Meaningful Lab Experience For A Manufacturing Processes Course, Kevin Molyet

ASEE IL-IN Section Conference

No abstract provided.

Process Parameter Development Of Additively Manufactured Af9628 Weapons Steel, Erin M. Hager

Theses and Dissertations

The manufacture of components in Additive Manufacturing processes is limited by the range of materials available. Qualification of materials for Additive Manufacturing is time intensive, and is often specific to a single type of machine. In this study, an approach to selecting power, speed, and hatch spacing values for a newly powderized material, AF9628 weapons steel, is described that results in highly dense (>99.9%) parts on an MLab 200R Cusing. Initial power and speed values used in a weld track study were selected based on a survey of parameters used on similar materials, with a focus on the energy …

Microscale Metal Forming: Mesoscopic Size Effect, Extrusion And Molding, Bin Zhang

LSU Doctoral Dissertations

The continuing trend of metallic device and product miniaturization has motivated studies on microscale metal forming technologies. A better understanding of materials’ mechanical response and deformation behavior is of importance for the design and operation of micro metal forming processes. In this dissertation, uniaxial compression testing was conducted on Al ring and pillar specimens with characteristic dimensions at meso to micro scales. The experimental data reveal inadequacies of the existing surface layer model and provides a baseline for delineating deformation mechanisms in micro metal forming operations. Microscale reverse extrusion experiment was carried out on Cu and Al rod specimens with …

Investigation Of Design, Manufacture, Analysis, And Test Of A Composite Connecting Rod Under Compression, Thomas Juhl Rohrbach

Master's Theses

Composite materials hold great potential for the replacement of traditional materials in machines utilized on a daily basis. One such example is within an engine block assembly where massive components inherently reduce the efficiency of the system they constitute. By replacing metal elements such as connecting rods, cylinder caps, or a crank shaft with composite alternatives, a significant increase in performance may be achieved with respect to mechanical strength, thermal stability, and durability, while also reducing mass. Exploration of this technology applied to a connecting rod geometry was investigated through a combination of process development, manufacturing, numerical analysis and testing. …

Torsional Stiffness Of A Race Car, Reiley A. Schraeger, Cameron Kao, Raymond Deng, Omar Roman

Mechanical Engineering

Torsional stiffness plays a major role in any road vehicle. To understand torsional stiffness of a vehicle and make future iterations and improvements, a proper torsional stiffness jig is required to prove accurate and useful data. This report encompasses the new and improved testing jig and potential improvement ideas for more accurate results. With real data result relating to FEA calculations, designers can be confident in the FEA changes to torsional stiffness is accurate and will yield the probably results they desired. This report shows the methodology, manufacturing process and testing procedure to use on any Baja or SAE vehicle …

Application Of Metamaterials For Multifunctional Satellite Bus Enabled Via Additive Manufacturing, Michael A. Macchia

Theses and Dissertations

Space systems require materials with superior stiffness to weight ratios to provide structural integrity while minimizing mass. Additive manufacturing processes enable the design of metamaterials that exceed the performance of naturally occurring materials in addition to allowing the integration of non-structural functions. This research explored the use of a high stiffness, high density, small melt pool track width AM material, Inconel 718, to enable the production of metamaterials with finer features possible than can possibly be created using a lower density aluminum alloy material. Various metamaterials were designed utilizing thin wall triply periodic minimal surface infilled sandwich structures. The performance …

Carbon Fiber Recycler : Fiber Reclaimer, Alexander Edwards

All Undergraduate Projects

Boeing uses composite components for the 777x aircraft. The production of composite parts results in flashing (excess material) that must be trimmed and "thrown away" as scrap. Boeing is investigating means of recycling these scraps. The method proposed for this project is to delaminate and shred the composite material. The delamination process uses a ram to press two claw shaped devices together that bends and deforms the material in opposite directions. The chipper process uses counter rotating saw blades spaced 1/8” apart to produce small shredded material. This shredding material is pyrolyzed (heated) to decay the resin leaving the carbon …

Medallion Manufacturing, Luis Perez

All Undergraduate Projects

A more efficient manufacturing process is needed to create the approximately 30 MET medallions, given to the graduating class. The process must be repeatable, consistent, and efficient. The objective is to create a method that can remain the same year to year, save time, and be repeated by anybody. Two approaches were developed: a casting method, and a machining method involving a computer numerically controlled (CNC) mill. The casting method began with a match plate was developed by attaching 3D printed models and runners to plywood. The design was evaluated before the pour using SolidCast software. Special attention was directed …

Custom Designed Wall Mounted Shop Crane, Bradley Lewis

All Undergraduate Projects

The objective of this project was to design and fabricate a custom wall mounted jib crane to specific, non-standard dimensions. The crane was designed to be industry rated for 2000 pounds, rotate at least 180 degrees, and be designed to have a maximum boom length tailored to the specific installation site. Two potential installation sites and purposes were selected for construction: inside the bay doors of a fabrication shop, intended to transfer large pieces of material to and from a plasma table, and inside a car maintenance garage, intended to lift and remove engines and transmissions from cars.

Design of …

Stair Climbing Hand Truck, James Mcpherson

All Undergraduate Projects

Abstract

Getting a heavy object up a flight of stairs usually requires a team of two or more people. Even with a team of people, the task is often still difficult, dangerous, and possibly insurmountable by one person. This problem is especially prevalent in for those who are moving into apartment complexes. Most apartment complexes have many buildings with two or more floors of living quarters, and elevators are often missing. This project sought to offer a solution to this problem. The solution in question; a motorized hand-truck with 2, trigonal planar pinwheels in place of the stock wheels. The …

Composite Recycler: Delamination, Nathan Sauer

All Undergraduate Projects

A great deal of composite waste is generated in the construction of wings for the Boeing 777. These carbon fiber “wing trimmings” are currently being disposed of in a landfill. These carbon fiber boards are made of several layers laminated together, making them very rigid and hard to recycle. This report proposes a method to delaminate the layers of these composite wing trimmings using a hydraulic press and a V-shaped steel die so that they may be more easily shredded and thus recycled. A top, “male” die with two points is pressed into a bottom, “female” die with three points …

The Bracket, Ryan Jerome Skerbeck

All Undergraduate Projects

• Abstract
• Bracket, casting, aluminum; if any of these for mentioned words interest you in anyway this is a document that you should read.
• There is a need for a compressor to be mounted to the front of a Cummins engine so that compressed air would be available on a work truck. The York compressor and the engine were known quantities, so what this project covered was the bracket that mounted the compressor to the engine and the manufacturing processes. The process chosen to make the bracket was aluminum casting; casting was chosen because of the ease of making many parts …

Process Sustainability Evaluation For Manufacturing Of A Component With The 6r Application, Ana E. Bonilla Hernández, Tao Lu, Tomas Beno, Claes Fredriksson, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Sustainability in manufacturing can be evaluated at product, process and system levels. The 6R methodology for sustainability enhancement in manufacturing processes includes: reduced use of materials, energy, water and other resources; reusing of products/components; recovery and recycling of materials/components; remanufacturing of products; and redesigning of products to utilize recovered materials/resources. Although manufacturing processes can be evaluated by their productivity, quality and cost, process sustainability assessment makes it a complete evaluation. This paper presents a 6R-based evaluation method for sustainable manufacturing in terms of specific metrics within six major metrics clusters: environmental impact, energy consumption, waste management, cost, resource utilization and …

Autojack - Hydraulic Powertrain System, Tyce Vu

All Undergraduate Projects

A primary problem for mechanics and automotive enthusiasts is the risk associated with lifting and securing a vehicle with conventional jack stands. Often times, improper jack-stand installation results in the vehicle collapsing unexpectedly, causing injury and/or death. This problem can be minimized through the application of a newly re-designed vehicle lifting system. The conventional method for lifting cars is time consuming and can be unsafe in many circumstances. A better, safer, and more efficient lift design was needed; the AutoJack. The approach of the AutoJack design was entirely focused on the safety of lifting a vehicle. Safety was improved by …

Ua66/1/5 Ogden College Of Science & Engineering Dean's Office Centers, Wku Archives

WKU Archives Collection Inventories

Records created by and about centers associated with the Dean's office in the Ogden College of Science & Engineering.

Custom Foot Prosthetic: Diabetic Care, Chandler Streuli

All Undergraduate Projects

Across the United States there are people every day who lose their toes to diabetes or to loss of circulation within their legs. The problem becomes building a more cost effective and efficient prosthetic for these individuals. The prosthetics that are used for medical purposes are often costly, especially without the help of insurance. The new prosthetic was designed to be taken in and out of shoes so that it is fast and easy for the user to move the device from shoe to shoe. The manufacturing method for this project was using a 3D printer to build the initial …

Electrathon: Body, Ryan Shiner

All Undergraduate Projects

• The Electrathon Vehicle project is an ongoing project that dates back to 2012. This vehicle will be raced at events to see how many laps it can complete on a single battery charge. The existing body for the Central Washington University Electrathon vehicle required modifications to fit over the current frame. These modifications were required because the rear suspension design had changed. The rear panel of the body interfered with the rear suspension. Using a rotary cutting wheel, the panel was slotted so the body could slide over the suspension and drive chain. Additionally, spacers for various sizes were needed …

3d Textile Preforms And Composites For Aircraft Strcutures: A Review, Abbasali Saboktakin

International Journal of Aviation, Aeronautics, and Aerospace

Over the last decades, the development of 3D textile composites has been driven the structures developed to overcome disadvantages of 2D laminates such as the needs of reducing fabrication cost, increasing through-thickness mechanical properties, and improving impact damage tolerance. 3D woven, stitched, knitted and braided preforms have been used as composites reinforcement for these types of composites. In this paper, advantages and disadvantages of each of them have been comprehensively discussed. The fabric architects and their specification in particular stitched preforms and their deformation mode for aerospace applications have been reviewed. Exact insight into various types of damage in textile …

Ares Cleaning System, Andy Sagers, John Cunningham, Peter Greig, Jack Glynn

Mechanical Engineering

In this Final Design Review, the team outlines the general scope of the ARES Cleaning System project and the final design direction chosen and built. This team consists of a group of four mechanical engineering students who have been tasked with designing and manufacturing an autonomous ARES cleaning system to help their sponsor, Fracsun, better track soiling losses measured at large solar arrays. They designed, conceptualized, manufactured, and tested throughout the project as they looked to create a final, functioning product. In creating this Final Design Review, they have identified how the product will perform the desired functions and what …

A Total Life Cycle Approach For Developing Predictive Design Methodologies To Optimize Product Performance, Buddhika M. Hapuwatte, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Sustainable products must be designed by considering how design decisions impact their total life cycle (TLC) sustainability content. Even more so important when designing products to incorporate the technological elements of sustainable manufacturing, the 6Rs (Reduce, Reuse, Recycle, Recover, Redesign and Remanufacture), to achieve Circular Economy (CE). This paper presents the preliminary work of an ongoing research project on developing a novel framework incorporating predictive models with TLC considerations. This unique approach develops and integrates models with associated risks, and optimizes for maximizing the sustainability benefits due to design decisions. Such predictive capability is extremely useful for process planning, where …

Designing And Redesigning Products, Processes, And Systems For A Helical Economy, Ryan Bradley, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

The Circular Economy (CE) concept has promised to unlock trillions of dollars in business value while driving a significant reduction in the world’s resource consumption and anthropogenic emissions. However, CE mainly lives in ambiguity in the manufacturing domain because CE does not address the changes needed across all of the fundamental elements of manufacturing: products, processes, and systems. Conceptually, CE is grounded in the concept of closed-loop material flows that fit within ecological limits. This grounding translates into a steady state economy, a result that is not an option for the significant portion of the world living in poverty. Therefore, …

Rotary Friction Welding Versus Fusion Butt Welding Of Plastic Pipes – Feasibility And Energy Perspective, Ramsey F. Hamade, Tarek R. Andari, Ali H. Ammouri, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

According to the Plastics Pipe Institute, butt fusion is the most widely used method for joining lengths of PE pipe and pipe to PE fittings “by heat fusion” (https://plasticpipe.org/pdf/chapter09.pdf). However, butt-welding is not energy-cognizant from the point of view of a phase-change fabrication method. This is because the source of heating is external (heater plate). The initial heating and subsequent maintenance at relatively high temperature (above 200 C for welding of high-density polyethylene pipe) is energy intensive. Rotary friction welding, on the other hand focuses the energy where and when as needed because it uses electric motor to generate mechanical …

The Effects Of 3d Printing Parameters And Surface Treatments On Convective Heat Transfer Performance, Lucas N. Pereira

Electronic Theses and Dissertations

Additive manufacturing technology and applications have quickly expanded in many industries over the last five years. As additive manufacturing is studied and refined, improvements in resolution and strength have helped propel further growth of the industry. This study focuses on an additive manufacturing technology called fused filament fabrication (FFF). FFF involves the extrusion and layer-by-layer deposition of a molten thermoplastic material to create the desired part. One potential new application of fused filament fabrication is the manufacture of heat exchangers and heat sinks. This study focuses on developing baseline experimental data related to convective heat transfer coefficients over surfaces of …

An Analysis Of Resistance Spot Weld Quality Based On Acoustic And Electrical Signatures, Ivan Charles Butler

Theses and Dissertations--Manufacturing Systems Engineering

The union of a set of materials by way of Resistance Spot Welding is designed so that once fused together, a substantial amount of intentional, external force must be applied to separate the contents. Therefore, Resistance Spot Welding is often the preferred fusion method in high-volume manufacturing processes. The result of Resistance Spot Welding however is the formation of a weld nugget which is not visible to the naked eye. Destructive and/or ultrasonic methods applied off-line must be used to determine the quality of each weld; both inefficient and expensive processes. The following research analyzes the data fed back during …

Implementation And Analysis Of True Lean In A Startup Company By Using Pdca Model, A Case Study In A Manufacturing Venture, Ankit Jangid

Theses and Dissertations--Manufacturing Systems Engineering

The purpose of this research is to implement and analyze the true lean transformation in a manufacturing start-up organization. Often, lean transformations are observed in developed manufacturing organizations having sophisticated production lines and numerous employees, where lean tools are utilized to reduce waste while increasing profit. However, this type of transformation is narrowly focused on quantifiable process results and falls short of the ultimate goal, establishing a true lean culture within the organization. As a result, it is recommended that true lean principles, philosophies, culture, operations environment and tools be applied at the very beginning stages of an organization, or …

Investigation Of Chip-Form And Tool-Wear In Turning Of Hardened Af9628 Alloy Under Various Cooling And Lubrication Conditions, Jason Wolf

Theses and Dissertations--Manufacturing Systems Engineering

Next generation defense and commercial applications for structural steels require new alloys that eliminate or reduce critical elements from their composition to lower cost and improve manufacturability, while maintaining or exceeding high strength and toughness requirements. A new alloy, denoted as AF9628, has recently been developed for this purpose and its manufacturing characteristics and the material response in component manufacturing must be fully understood.

In the present study, hardened AF9628 alloy was turned with a coated carbide cutting tool under fixed cutting speed, feed rate, and depth of cut parameters. This work focuses on chip-form and tool-wear analysis to understand, …

Étude Exploratoire Sur Les Pratiques Des Fabricants De Machines Au Québec En Lien Avec L’Intégration De La Sécurité Des Machines Dès Leur Conception, Yuvin Chinniah, François Gauthier, George Abdul-Nour, Sabrina Jocelyn, Barthélemy Aucourt, Guy Bordeleau

Rapports de recherche scientifique

Le présent rapport est destiné principalement à tout organisme québécois œuvrant en matière de prévention des lésions professionnelles (ex. : la Commission des normes, de l’équité, de la santé et de la sécurité du travail (CNESST), les associations sectorielles paritaires (ASP)), pour un ou plusieurs secteurs industriels donnés. Il porte sur une étude exploratoire concernant l’intégration de la sécurité dès la conception des machines et qui a été réalisée auprès de fabricants. Ce rapport intéressera également les concepteurs et fabricants désireux de se renseigner sur la manière dont la sécurité est prise en compte dans la mise en œuvre de …