Mechanical Engineering Commons^™

Hydrogen Fuel Cell Gasket Handling And Sorting With Machine Vision Integrated Dual Arm Robot, Devin C. Fowler

College of Graduate Studies: Theses & Dissertations

Recently demonstrated robotic assembling technologies for fuel cell stacks used fuel cell components manually pre-arranged in stacks (presenters), all oriented in the same position. Identifying the original orientation of fuel cell components and loading them in stacks for a subsequent automated assembly process is a difficult, repetitive work cycle which if done manually, deceives the advantages offered by automated fabrication technologies of fuel cell components and by robotic assembly processes. We present an innovative robotic technology which enables the integration of automated fabrication processes of fuel cell components with robotic assembly of fuel cell stacks into a fully automated fuel …

Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang

Doctoral Dissertations

"Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims …

Differential Mobility Classifiers In The Non-Ideal Assembly, Thamir Alsharifi

Theses and Dissertations

The differential mobility classifier (DMC) is one of the core components in electrical mobility particle sizers for sizing sub-micrometer particles. Designing the DMC requires knowledge of the geometrical and constructional imperfection (or tolerance). Studying the effects of geometrical imperfection on the performance of the DMC is necessary to provide manufacturing tolerance and it helps to predict the performance of geometrically imperfect classifiers, as well as providing a calibration curve for the DMC. This thesis was accomplished via studying the cylindrical classifier and the parallel plate classifier. The numerical model was built using the most recent versions of COMSOL Multiphysics^{® …}

Material Interactions And Self-Assembly In Inkjet Printing, Karam Nashwan Al-Milaji

Theses and Dissertations

Inkjet printing has attracted much attention in recent years as a versatile manufacturing tool, suitable for printing functional materials. This facile, low-cost printing technique with high throughput and accuracy is considered promising for a wide range of applications including but not limited to optical and electronic devices, sensors, solar cells, biochips, and displays. The performance of such functional devices is significantly influenced by the deposit morphology and printing resolution. Therefore, fabrication functional devices with precise footprints by inkjet printing requires deep understanding of ink properties, material interactions, and material self-assembly.

In conventional inkjet printing process, where sessile droplets are directly …

Remotely Controlled Industrial Robotic Arm And Simulation Of Automated Thermal Furnace, Prince Mehandi Ratta

Dissertations, Master's Theses and Master's Reports

The right execution of controllers ensures the correct analysis of information, generating efficient results and better optimizing the system. In this report, two controllers were designed. Firstly, a remotely controlled robotic arm, since there are no such type commercially available controllers. Moreover, robotic platforms are costly, so students and researchers are often unable to learn the concepts of programming industrial robots. This project makes a non-destructive, remotely-controlled robotic arm to better teach students and researchers about programming and control of robotic arms. Secondly, simulation of an automated thermal furnace for ArcelorMittal on SIMULINK, which is used for the annealing process …

3d Printing In Low Resource Healthcare Settings: Analysis Of Potential Implementations, Alenna Beroza

Dissertations, Master's Theses and Master's Reports

3D printing has gained significant momentum in the past ten years, and its unique advantages make it especially ideal for use in low resource healthcare settings, where many designs have already been successfully implemented. Yet, little has been studied on how 3D printing can be sustainably and functionally implemented in low resource healthcare systems as a manufacturing practice. In this report, three business models are proposed for this implementation: In-House Operator, Independent Operator, and Print Farm. These models were then tested over four months in Kisumu county, Kenya, at two workshops and seven public hospitals. I worked with local medical …

Development Of A Rapid Fatigue Life Testing Method For Reliability Assessment Of Flip-Chip Solder Interconnects, Cody Jackson Marbut

Graduate Theses and Dissertations

The underlying physics of failure are critical in assessing the long term reliability of power packages in their intended field applications, yet traditional reliability determination methods are largely inadequate when considering thermomechanical failures. With current reliability determination methods, long test durations, high costs, and a conglomerate of concurrent reliability degrading threat factors make effective understanding of device reliability difficult and expensive. In this work, an alternative reliability testing apparatus and associated protocol was developed to address these concerns; targeting rapid testing times with minimal cost while preserving fatigue life prediction accuracy. Two test stands were fabricated to evaluate device reliability …

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

All-Terrain Storage Surfboard Carts, Ben M. Kennedy, Danny Riedeman, Roberto Gonzalez

Mechanical Engineering

All Terrain Storage consists of three mechanical engineering students: Roberto Gonzalez, Ben Kennedy, and Danny Riedeman. The goal of All Terrain Storage is to design and create two portable storage devices for the non-profit organization AmpSurf. AmpSurf helps veterans, people with disabilities, and anyone else who could be helped through adaptive surfing and other outdoor activities. Their current method of storing and transporting equipment for events is carrying it from the trailer in the parking lot through the sand onto the beach. This document will provide: a more thorough introduction to AmpSurf and the project, the objectives, background information, the …

Daimscale — 1:14th Tractor-Trailer For Testing Driver Assistance Technology, Christopher Marrale, Jase Sasaki, Devin Bodmer

Mechanical Engineering

Active driver assistance systems are becoming increasingly wide-spread throughout the automotive industry due to their potential for safer roads and decreased costs of transportation, but testing these systems on real trucks can be time consuming, dangerous, and costly. Testing these systems on a small-scale tractor-trailer combination will lead to faster and more efficient development of driver assistance systems and can be used by both engineers and students, leading to a larger field of experienced developers to improve these systems.

Our goal will be to design, manufacture, and build a scale 6x2 model of the tractor portion of a Daimler semi-truck …

Optimization Of The Practice Of Slow Cooling Steel Bars: A Redesign And Modernization Of Materials, Eryn Johnston

Mechanical Engineering Undergraduate Honors Theses

Throughout the process of steel making, certain grades of steel are a higher risk for defects caused by the inability to quickly diffuse hydrogen through the steel when cooled to room temperature at a normal rate based on the ambient air temperature. To reduce the hydrogen flaking defects that are caused due to hydrogen entrapment in the steel, the process of slow cooling is utilized. This process reduces the cooling rate of steel bars by keeping them at a higher temperature for extended periods and in turn gives the hydrogen a chance to fully dissipate from the steel. In many …

Process-Property-Microstructure Relationships In Laser-Powder Bed Fusion Of 420 Stainless Steel., Subrata Deb Nath

Electronic Theses and Dissertations

Laser-powder bed fusion (L-PBF) is an additive manufacturing technique for fabricating metal components with complex design and customized features. However, only a limited number of materials have been widely studied using L-PBF. AISI 420 stainless steel, an alloy with a useful combination of high strength, hardness, and corrosion resistance, is an example of one such material where few L-PBF investigations have emerged to date. In this dissertation, L-PBF experiments were conducted using 420 stainless steel powders to understand the effects of chemical composition, particle size distribution and processing parameters on ensuing physical, mechanical and corrosion properties and microstructure in comparison …

A Systematic Approach To High Blood Pressure Risk Analysis And Healthcare Cost Reduction In Young Adults [Metodología Sistemática Para El Análisis De Riesgo Y Reducción De Costos De Servicios Médicos De Hipertensión En Adultos Jóvenes], Francisco Rafael Torres Diaz

Theses and Dissertations

The purpose of this research is to utilize publicly available data to estimate the current rate of occurrence of undiagnosed High Blood Pressure (HBP) in young adults (18 to 24 years old) and the out-of-pocket healthcare expenses associated with complications of HBP, to provide feasible alternatives to mitigate the effects on a region's economy. This has been done by building a Risk Factor Simulation Model that utilizes known HBP risk factors’ correlation to HBP, insurance coverage data, and rate of diagnosis to formulate the average Risk Factor Value for a region, which through an Annual Expected Cost Function estimates the …

Single Arm Recumbent Bicycle, Alexander Borsotti, Ryan Westermann, Sean Liston

Mechanical Engineering

The goal of this report is to outline and cover the scope of work for the Single Arm Recumbent Bicycle Senior Project. The report will give an introduction of the problem, a background of the existing research or products relating to our project, the objectives of our project, our project management plan, our final design, manufacturing, testing, our project management, and final recommendations for improving the final design. The team is being supported by the Quality of Life Program, a non-profit organization that works to improve the lives of those injured in duty while serving our nation.

Up until now, …

Photochemical Etching Of Nitrided Stainless Steel Piston Rings, Steven Sonntag

Mechanical Engineering Undergraduate Honors Theses

Piston rings are designed to provide a seal between the piston and the cylinder wall of internal combustion engines, keeping oil from the crankcase from getting into the combustion chamber. This means piston rings are the main point of contact between the piston and the cylinder wall, which causes the piston to experience high amounts of friction and wear. By texturing the surfaces of the cylinder wall and/or the piston ring, the amount of contact area can be reduced, allowing for less friction, slower wear, and better gas mileage. In this thesis experiments, photochemical etching processes were developed to etch …

A Scalable, Chunk-Based Slicer For Cooperative 3d Printing, Jace J. Mcpherson

Computer Science and Computer Engineering Undergraduate Honors Theses

Cooperative 3D printing is an emerging technology that aims to increase the 3D printing speed and to overcome the size limit of the printable object by having multiple mobile 3D printers (printhead-carrying mobile robots) work together on a single print job on a factory floor. It differs from traditional layer-by-layer 3D printing due to requiring multiple mobile printers to work simultaneously without interfering with each other. Therefore, a new approach for slicing a digital model and generating commands for the mobile printers is needed, which has not been discussed in literature before. We propose a chunk-by-chunk based slicer that divides …

Transcribing Braille Code: Learning Equations Across Platforms, Deegan Atha, Courtney Balogh

Purdue Journal of Service-Learning and International Engagement

Deegan Atha, a graduating senior in electrical engineering and a future engineer, is interested in human-centered design and developing technology that helps students engage and be successful in STEM.

Courtney Balogh, a junior in mechanical engineering, is interested in human-centered design and the importance it plays in product development. Deegan and Courtney are members of the Purdue EPICS project, Learning Equations Across Platforms (LEAP). They partnered with the Indiana School for the Blind and Visually Impaired (ISBVI) to develop a braille transcription device and web application that converts braille to print in real time.

Three-Dimensional Forming Of Multi-Layered Materials: Material Heat Response And Quality Aspects, Sami-Seppo Ovaska, Pavel Geydt, Ville Leminen, Johanna Lyytikäinen, Sami Matthews, Panu Tanninen, Malte Wallmeier, Marek Hauptmann, Kaj Backfolk

Journal of Applied Packaging Research

The micro- and macrostructural changes occurring in multi-layered substrates during three-dimensional forming were studied by atomic force microscopy (AFM), scanning electron microscopy (SEM) and optical analyses. Particular attention was paid to heat-induced deformations at the interface between of polymeric coating layer and the paperboard. With excessive heat transfer, occasional delamination of polyethylene terephthalate (PET) coating from the paperboard was observed. The mechanism behind delamination was studied in detail in-situ with an AFM at temperatures relevant to the converting process. Based on the analysis, the delamination could partially be linked to the widening of the initially-existing nano-scale cracks at the coating-paperboard …

Modular Crates – A Holistic Design Approach For Optimizing Cube Size In Industrial Packaging, Marshal Louie, Kumar B

Journal of Applied Packaging Research

Global market is a field where all industries strive to provide personalized product for every customer demand in order to compete with their competitors in the business battlefield. Product personalization varies with customer to customer which increases the product variety. When the product size variability is vast, producing packages for every individual product is not only difficult but also increases the design time, production time, total manufacturing cost and inventory cost. For the present scenario, Industrial packages does not opt customizability for variable product sizes. Customized package for personalized product is achievable only by redesigning the existing distribution package with …

The Influence Of Build Parameters On The Compressive Properties Of Selective Laser Melted 304l Stainless Steel, Okanmisope Fashanu, Mario F. Buchely, R. Hussein, S. Anandan, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, H. Misak, M. A. Walker

Materials Science and Engineering Faculty Research & Creative Works

Process parameters used during Selective Laser Melting (SLM) process have significant effects on the mechanical properties of the manufactured parts. In this study, the influence of two build parameters (build orientation and hatch angle) on the compressive properties of 304L stainless steel was evaluated. SLM 304L samples were manufactured using three hatch angles, 0°, 67°,105° and two orientations, z-direction and x-direction, and tested using a compression frame according to ASTM E9-09. Bulk density was measured according to ASTM C373-17 before compression. Properties evaluated were the bulk density, yield strength, strength at 15% plastic-strain and strength at 30% plastic-strain. Results showed …

General Rules For Pre-Process Planning In Powder Bed Fusion System -- A Review, Tan Pan, Sreekar Karnati, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Powder bed fusion (PBF) is one of the current additive manufacturing techniques that can fabricate almost fully dense functional metal components. Through a layer by layer fabrication methodology, complex geometries to meet the requirements of aerospace, automotive, biomedicine industries, etc. can be produced. The success of a build largely depends on having a flawless pre-process planning, including build orientation selection, support structure optimization, process parameter chosen, etc., which closely relates to the quality of the final products. Geometric inaccuracy and poor surface quality can occur due to a bad build plan. This review presents the crucial general planning rules for …

Additive Manufacturing Of Metal Functionally Graded Materials: A Review, Yitao Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Functionally graded materials (FGMs) have attracted a lot of research interest due to their gradual variation in material properties that result from the non-homogeneous composition or structure. Metal FGMs have been widely researched in recent years, and additive manufacturing has become one of the most important approaches to fabricate metal FGMs. The aim of this paper is to review the research progress in metal FGMs by additive manufacturing. It will first introduce the unique properties and the advantages of FGMs. Then, typical recent findings in research and development of two major types of metal additive manufacturing methods, namely laser metal …

Incorporation Of Automated Ball Indentation Methodology For Studying Powder Bed Fabricated 304l Stainless Steel, Sreekar Karnati, Jack L. Hoerchler, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Automated Ball Indentation (ABI) is a viable method for estimating the ductility, yield stress, and ultimate stress, among other metrics, in different metallic materials. Currently, ABI data analysis utilizes Holloman’s Power Law to model the plastic region of the true stress-true strain curve. While this formulation is accurate for some materials, its relevance for additively manufactured austenitic stainless steels, such as 304L, needed investigation. The deviation of the material’s plastic behavior from the Power Law was investigated. In order to better model this behavior, both the Voce and Ludwigson formulation were investigated. These formulations were tested for both wrought and …

Experimental Characterization Of A Direct Metal Deposited Cobalt-Based Alloy On Tool Steel For Component Repair, Xinchang Zhang, Tan Pan, Wei Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Die casting dies made of tool steel is subject to impact, abrasion and cyclic thermomechanical loading that delivers damage such as wear, corrosion, and cracking. To repair such defects, materials enveloping the damage need to be machined and refilled. In this study, V-shape defects with varied sidewall inclination angles were prepared on H13 tool steel substrates and refilled with cobalt-based alloy using direct metal deposition (DMD) for superior hardness and wear resistance. The microstructure of rebuild samples was characterized using an optical microscope (OM) and scanning electron microscope (SEM). Elemental distribution from the substrate to deposits was analyzed using energy …

Effects Of Thermal Camera Resolution On Feature Extraction In Selective Laser Melting, Xin Wang, Cody S. Lough, Douglas A. Bristow, Edward C. Kinzel, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective Laser Melting (SLM) is a common additive manufacturing process which uses a laser energy source to fuse metal powder layer by layer. Engineering properties and microstructure are related to the part’s thermal history. It is important to measure the thermal history in-situ to qualify parts and provide the sensing which is necessary for process control. A common measurement tool for this purpose is a thermal camera that records the thermal emission of the part’s surface.

This study investigates the effects of spatial sampling resolution of thermal cameras when monitoring the temperature in SLM processes. High-fidelity simulation of an SLM …

Development Of Pre-Repair Machining Strategies For Laser-Aided Metallic Component Remanufacturing, Xinchang Zhang, Wenyuan Cui, Leon Hill, Wei Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Remanufacturing worn metallic components can prolong the service life of parts that need frequent replacement but are extremely costly to manufacture, such as aircraft titanium components, casting dies. Additive manufacturing (AM) technology enables the repair of such valuable components by depositing filler materials at the worn area layer by layer to regenerate the missing geometry. In general, damaged parts would be inspected and pre-machined prior to material deposition to remove oil, residue, oxidized layers or defects located in inaccessible regions. Therefore, the motivation of this paper is to introduce pre-repair machining strategies for removing contaminated materials from damaged components and …

Recyclability Of 304l Stainless Steel In The Selective Laser Melting Process, Austin T. Sutton, Caitlin S. Kriewall, Ming-Chuan Leu, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

During part fabrication by selective laser melting (SLM), a powder-bed fusion process in Additive Manufacturing (AM), a large amount of energy is input from the laser into the melt pool, causing generation of spatter and condensate, both of which have the potential to settle in the surrounding powder-bed compromising its reusability. In this study, 304L stainless steel powder is subjected to five reuses in the SLM process to assess its recyclability through characterization of both powder and mechanical properties. Powder was characterized morphologically by particle size distribution measurements, oxygen content with inert gas fusion analysis, and phase identification by X-ray …

Additive Manufacturing Of Metal Bandpass Filters For Future Radar Receivers, Bradley Grothaus, Dane Huck, Austin T. Sutton, Ming-Chuan Leu, Ben Brown

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Selective laser melting (SLM) is a powder-bed fusion (PBF) process that bonds successive layers of powder with a laser to create components directly from computer-aided design (CAD) files. The additive nature of the SLM process in addition to the use of fine powders facilitates the construction of complex geometries, which has captured the attention of those involved in the design of bandpass filters for radar applications. However, a significant drawback of SLM is its difficulty in fabricating parts with overhangs necessitating the use of support structures, which, if not removed, can greatly impact the performance of bandpass filters. Therefore, in …

Mechanical Properties Of Zr-Based Bulk Metallic Glass Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Yingqi Li, Ming-Chuan Leu, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The application of bulk metallic glasses (BMGs) has been traditionally limited to parts with small dimensions and simple geometries, due to the requirement of fast cooling during the conventional process of casting. This research exemplifies a promising additive manufacturing method, i.e., laser-foil-printing (LFP), to fabricate high-quality BMG parts with large dimensions and complex geometries. In this study, Zr_52.5Ti₅Al₁₀Ni_14.6Cu_17.9 BMG parts were fabricated by LFP technology in which MG foils are laser welded layer-by- layer upon a substrate. The mechanical properties of the fabricated BMG parts were measured using micro-indentation, tensile test …

Effects Of Identical Parts On A Common Build Plate On The Modal Analysis Of Slm Created Metal, Tristan Cullom, Troy Hartwig, Ben Brown, Kevin Johnson, Jason Blough, Andrew Barnard, Robert G. Landers, Douglas A. Bristow, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The frequency response of parts created with Additive Manufacturing (AM) is a function of not only process parameters, powder quality, but also the geometry of the part. Modal analysis has the potential to evaluate parts by measuring the frequency response which are a function of the material response as well as the geometry. A Frequency Response Function (FRF) serves as a fingerprint of the part which can be validated against the FRF of a destructively tested part. A practical scenario encountered in Selective Laser Melting (SLM) involves multiple parts on a common build plate. Coupling between parts influences the FRF …