Mechanical Engineering Commons^™

Ultrasonic Nondestructive Evaluation Of Metal Additive Manufacturing., Venkata Karthik Nadimpalli

Electronic Theses and Dissertations

Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of process-structure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the …

Phase Field Model Of Thermally Induced Phase Separation (Tips) For The Formation Of Porous Polymer Membranes, Ashley Green, Aria Green

Mechanical Engineering Undergraduate Honors Theses

Most membrane research and development has been done through experimental work, which can be costly and time consuming. An accurate computational model would greatly reduce the need for these experiments. The focus of the research presented in this paper is to create an accurate computational model for membrane formation using thermally induced phase separation (TIPS). A phase field model is employed to create this model including the Cahn Hilliard Equation and Flory Huggins Theory. This model produced computational results that correspond well with theoretical and experimental results. The model was then adapted to correspond to the PVDF/DPC polymer-solvent system by …

Influence Of Impact Conditions On Feedstock Deposition Behavior Of Cold-Sprayed Fe-Based Metallic Glass, Constance Ziemian, Wendelin Wright, David E. Cipoletti

Faculty Journal Articles

Cold spray is a promising method by which to deposit dense Fe-based metallic glass coatings on conventional metal substrates. Relatively low process temperatures offer the potential to prevent the crystallization of amorphous feedstock powders while still providing adequate particle softening for bonding and coating formation. In this study, Fe48 Mo14 Cr15 Y2 C15 B6 powder was sprayed onto a mild steel substrate, using a variety of process conditions, to investigate the feasibility of forming well-bonded amorphous Fe-based coatings. Particle splat adhesion was examined relative to impact conditions, and the limiting values of temperature and velocity associated with successful softening and …

Design And Implementation Of A Virtual Reality Laboratory For Mechanical Maintenance, Adolfo Enrique Samudio Cano

Morehead State Theses and Dissertations

A thesis presented to the faculty of the College of the College of Business and Technology at Morehead State University in partial fulfillment of the requirements for the Degree Master of Science by Adolfo Enrique Samudio Cano on April 27, 2018.

Novelis Teaching Table, Phillip Laplante, Robert Hemker, Taylor Mcgriff, Juan Restrepo, Shelly Abraham

KSU Journey Honors College Capstones and Theses

Novelis is a company that specializes in metal casting, recycling, and rolling. They primarily focus on aluminum rolling for cans and car bodies but are an industry leader in numerous related areas. As the rolling process is not taught in most general engineering courses, Novelis periodically teaches new engineers and technicians about the specifics of this relatively mathematically complex process. Most of the current teaching methods are through PowerPoint presentations and group exercises, with minimal hands-on involvement. One of the most useful tools for teaching the rolling process is an actual jeweler’s rolling mill, which Novelis currently possesses, but is …

Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one …

Effect Of Shot Peening On Stress Corrosion Behavior Of Biodegradable Magnesium We43, Tejaswita Patil

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Conventionally used metals for orthopedic devices made of titanium, stainless steel, and Co-Cr alloys are designed to be permanently implanted. However, long-term complications arise and a secondary implant removal surgery is often necessary. A mismatch in stiffness between the bone and implant results in stress shielding that negatively affects bone density. To overcome these problems, magnesium alloys (e.g., WE34) are favored due to a lower Young’s modulus (45 GPa) and biodegradability. The critical technical barrier with magnesium alloys is their high corrosion rate in physiological (salt-based) environments. One solution is to use surface treatments, such as shot peening (SP), to …

Reducing Stress In 3d Printed Parts Made With Laser Engineered Net Shaping, Shaun Ross Whetten

Mechanical Engineering ETDs

Thermal cycling and repeated melting/solidification cycles characteristic of 3D metal printing processes causes buildup of residual stress in 3D printed parts. Using laser engineered net shaping (LENS®), residual stresses are formed leading to deformation and possible cracking of the 3D printed metal components. The LENS process offers opportunities for rapid prototyping, alternative manufacturing processes, and repair of worn/broken components so it is important to be able to minimize the effects of residual stress. Work was performed to understand the benefit of substrate heating on reducing residual stress in metal parts made using the LENS process. Substrate deformation, and destructive methods …

Developing Nanopore Electromechanical Sensors With Transverse Electrodes For The Study Of Nanoparticles/Biomolecules, Mohammadsadegh Beheshti

LSU Doctoral Dissertations

This study concerns development of a technology of utilizing metallic nanowires for a sensing element in nanofluidic single molecular (nanoparticle) sensors formed in plastic substrates to detect the translocation of single molecules through the nanochannel. We aimed to develop nanofluidic single molecular sensors in plastic substrates due to their scalability towards high through and low cost manufacturing for point-of-care applications. Despite significant research efforts recently on the technologies and applications of nanowires, using individual nanowires as electric sensing element in nanofluidic bioanalytic devices has not been realized yet. This dissertation work tackles several technical challenges involved in this development, which …

Manufacturing Process Simulation – On Its Way To Industrial Application, Dennis Otten, Tobias A. Weber, Jan-Christoph Arent

International Journal of Aviation, Aeronautics, and Aerospace

Manufacturing process simulation (MPS) has become more and more important for aviation and the automobile industry. A highly competitive market requires the use of high performance metals and composite materials in combination with reduced manufacturing cost and time as well as a minimization of the time to market for a new product. However, the use of such materials is expensive and requires sophisticated manufacturing processes. An experience based process and tooling design followed by a lengthy trial-and-error optimization is just not contemporary anymore. Instead, a tooling design process aided by simulation is used more often. This paper provides an overview …

Sensel Morph: Product Communication Improvement Initiative, Kasper W. Lui-Delange, Samuel Distler, Rafael Paroli

Industrial and Manufacturing Engineering

Sensel is a startup company that recently launched their first product. The Morph is a multi-functional touch interface that interacts with a wide range of software through touching enabled silicon overlays. The support documentation was believed to cause confusion, which is leading to limited sales and increased returns. We focused on the structures of its website and product documentation, which were initially developed without end user testing. Our team explored Sensel’s current state to develop two multiphase design alternatives. These designs provide multiple user-facing testing frameworks as well as determine the root-cause of the Morph’s current communication issues. The designs …

Improving Warehouse Capacity For Synergy Manufacturing, Brian Garcia

Industrial and Manufacturing Engineering

This report aims to aid Synergy Manufacturing (a well-recognized producer of high-performance components for off-roading vehicles) to improve in-house production capacity in wake of an expanded facility space and substantial increase in the number of current available products over the span of a few years. Current warehouse issues include struggling to meet demand, high inventory, and an unsafe overcrowding of WIP on the floor space. The steps taken to resolve these issues are to collect setup times, operational times, total process times, machine tool usage, and flow process from a selected group of five high-demand items from Synergy Manufacturing’s current …

Building A Database For A Startup: Boltabout, Danielle Tran

Industrial and Manufacturing Engineering

BoltAbout is a young start-up based out of San Luis Obispo, CA. Their primary business is renting out bikes via monthly-subscription with the opportunity to lease to own. BoltAbout has seen great success over the past 2 years and is looking to expand. The company currently has 200 bikes, but the demand is far outweighing the supply. The CEO of BoltAbout hopes to grow to grow the company’s inventory to 500 bikes by the end of 2017 and 1500 by the end of the school year. As the company continues to expand, it will need to be able to accurately …

Crystal Engineering Manufacturing Facility Analysis, Maximiliano Cortes, Eric Dustin Kornrumpf, Sthefano Alvarado

Industrial and Manufacturing Engineering

This report will encompass a two-quarter long senior project effort to provide a recommendation for the client, Crystal Engineering. Crystal Engineering is currently in the process of introducing three new products, one now and two within the next six months. However, their existing lines already occupy the available production space and as a result, they are unable to determine how to effectively incorporate new production lines within the facility. Therefore, the main objectives of this project were to deliver several facility redesign layouts backed by a holistic justification for each. The formulation of the facility redesign layouts incorporated several industrial …

Cal Poly Rose Float Overheight Mechanism, Ali A. Harake, Breanna H. Tran, Morgan K. Montalvo, Sergio B. Gutierrez

Mechanical Engineering

The Cal Poly Universities jointly build and enter a floral entry, commonly known as a float, into the Pasadena Tournament of Roses Rose Parade. At the end of this parade route, there is a 16’6” bridge all floats must drive under. The scope of our project is to design and build a mechanism roughly described as an “overheight” mechanism, as its function is to raise and lower large heavy structures so the float is able to pass under the bridge. This hydraulic mechanism is powered via the float animation system.

Manufacturing Of A Carbon Fiber Part With Complex Geometry, Caitlyn Pellemeier, Eric Rodan, Alex King, Nicolas Carlucci

Mechanical Engineering

The purpose of this study is to determine the best method for manufacturing a part with precision tolerances and a small deflection requirement. The desired tolerances include a flatness of 0.002in, parallelism of 0.005in, heat tolerance of 60℃, and a max deflection at the loaded end of the part of 0.28mm. To accomplish this, our team uses carbon fiber as the part material because compared to traditional metals it is stiffer and lighter. Carbon fiber molding processes are explored and narrowed down to Liquid Composite Molding (LCM) and Resin Transfer Molding (RTM). These processes use dry fiber combined with epoxy …

Student Shop Access And Inventory Control In The College Of Architecture And Environmental Design Shops, Ryan Raj Mattel, Chris Steven Chen, Kevin Michael Gallagher

Industrial and Manufacturing Engineering

The Cal Poly College of Architecture and Environmental Design shops, directed by David Kempken, give the opportunity for thousands of students to use the “Learn By Doing” philosophy and operate various machinery, tooling, and devices to complete projects inside and outside of the classroom. These students are able to check out tools and machinery to complete these projects on a weekly basis. This report will discuss the complexities and shortcomings of the current database system, FileMaker Pro, that is used for these transactions. The report will furthermore discuss the design and methodology of replacing this system with an improved integrated …

Reducing Same Day Missed Appointments, Lucas Madison, Tyler Moore, Jolani Chun-Moy

Industrial and Manufacturing Engineering

Radiology Associates (RA) is a diagnostic imaging center that offers high-quality, digital medical imaging and interventional radiology services for patients, physicians and healthcare organizations across the Central Coast. They are an ongoing problem that involves a considerable portion of their patients not showing up for their appointments Our project aims to reduce same day missed appointments at Radiology Associates. Radiology Associates currently has a no-show rate of 13.48%. They lose approximately $240 for every same day missed appointment. Our goal was to find new ways to reduce their no-show rate to 8%. Based on our calculations, Radiology Associates could save …

Toward A Production Ready Fbj Process For Joining Dissimilar Combinations Of Gadp 1180 Steel And Aa 7085-T76, Kevin Alexander Shirley

Theses and Dissertations

Friction Bit Joining (FBJ) is a new technology that can be used to join dissimilar materials together. This ability makes it a good candidate for creating light weight structures for the automotive industry by combining lightweight materials such as aluminum to stronger materials like advanced high-strength steels. The automotive industry and many other industries have great interest in reducing structure weight to increase fuel efficiency. The purpose of this research is to make FBJ of GADP 1180 to AA 7085-T76 a production ready process by (1) better understanding the effects of process parameters, bit design and tool design on joint …

Manufacture Of Complex Geometry Component For Advanced Material Stiffness, David Russell Bydalek

Master's Theses

The manufacture, laminate design, and modeling of a part with complex geometry are explored. The ultimate goal of the research is to produce a model that accurately predicts part stiffness. This is validated with experimental results of composite parts, which refine material properties for use in a final prototype part model. The secondary goal of this project is to explore manufacturing methods for improved manufacturability of the complex part. The manufacturing portion of the thesis and feedback into material model has incorporated a senior project team to perform research on manufacturing and create composite part to be used for experimental …

Microfluidic Technology And Application In Urinal Analysis, Jiwen Xiang

LSU Doctoral Dissertations

Microfluidic technology offers numerous advantages in minimizing and integrating the traditional assays. However, the lack of efficient control components of the microfluidic systems has been hindering the widely commercialization of the technology. The research work in this dissertation focused on the development of effective control components for microfluidic applications.

A linear peristaltic pump was firstly designed, fabricated, and tested for conventional microfluidics by synchronously compressing the microfluidic channel with a miniature cam-follower system in Chapter 2. The miniature cam-follower system and microfluidic chip was prototyped using three-dimensional (3D) printing technology and soft lithography technology. Results from experimental test showed that …

A 2-D Finite Element Modeling And Simulation Of 3-Roll Forming, Wenbo Zhao

LSU Master's Theses

Medium to large diameter carbon steel pipes are widely used in various applications such as gas and fluid transportation, tunnels construction and building construction. Based on manufacturing techniques and characteristics, they are mainly categorized into three categories: Seamless pipe, Butt-welded pipe and Spiral pipe. The forming of butt-welded and spiral pipe is often performed by a technique called 3-roller bending. While traditional trial-and-error method is costly, the geometry complexity, along with material nonlinearity makes exact theoretical analysis difficult unless heavy simplified assumptions are made. While the forming parameters in the 3-roller forming process of butt-welded pipe has been studied in …

Industrial Conveyors’ Taxonomy And Its Applications, A. Hoshimov, A. Rustamov, J. Rozzokov

Acta of Turin Polytechnic University in Tashkent

In any manufacturing processes includes a material handling equipment that can transport raw material or semi-finished products from the one workstation to another. Material handling equipment are designed based on the type of manufacturing product or the process. Therefore, engineers can easily make decision anaylsis while the selection of the most preferred type of industrial conveyors among others. This paper focuses on the industrial conveyors that classifies all available conveyor types. In this work is defined a review that covers most of the currently available literatures and conveyors types that describes industrial conveyors, types, characteristics and applications. A taxonomy is …

Rc Baja Car Suspension, Tyler Martin

All Undergraduate Projects

This year the Mechanical Engineering Technology Department at CWU is holding an R/C Baja car competition using the same rules as the ASME competition. The designed car must compete in three separate events: the slalom course, drag race, and obstacle course. By not only completing, but also being competitive in each of the events, the car will be deemed a success. Suspension and steering are two essential components of any R/C car, and was the main focus for this report. The suspension must be able to support the car in the event of impacts. In addition, the steering must be …

Slab Tipper, Thomas C. Durand

All Undergraduate Projects

Stone countertops are very heavy and fragile. When installing a finished countertop, up to six workers are required to lift the stone onto the countertop, risking their safety and possibly breaking the stone. The safety of both the workers and the stone are very important, so there needs to be a better way. NSI Solutions came up with an idea for a mechanism to aid in the insulation process while limiting the number of workers required, and keeping the workers safer while adequately supporting the stone to prevent it from breaking. Designing methods and calculations were done to ensure the …

Exercise Machine Generator, Duane Harbick

All Undergraduate Projects

Exercise “spinning bikes” and bicycle training stands are common ways to maintain fitness and train for cycling. This exercise necessitates the user putting work into the machine by means of pedaling. In many instances the work put into exercise bikes and training stands is not taken advantage of. The objective of this project is an attempt to make use of some of the energy that a person would usually expend during exercise by building a generator that interfaces with multiple spinning bikes and training stands. It uses a synchronous pulley system to interface with the exercise machine and spin a …

Asme Rc Baja Challenge: Suspension And Steering, Hunter W. Jacobson

All Undergraduate Projects

The American Society of Mechanical Engineers (ASME) usually hosts an RC Baja challenge each year, testing a RC car in three events: slalom, acceleration and Baja. Although ASME will not be holding an event this year, CWU will be holding a similar event with three RC Baja car teams from CWU. The RC car that is tested in these events is designed and manufactured typically in teams of two. The RC car that each team submits must be able to complete these events while also remaining competitive. One part of great importance for the RC car is the suspension and …

Cwu Bottle Opener Manufacturing, Austin Sanford

All Undergraduate Projects

Previous students from the Mechanical Engineering Technology program came up with a method to help raise funds and awareness for the program. The idea was to manufacture and sell CWU bottle openers. However, a more efficient manufacturing method was needed. The aspect of the process that would have the most impact on the manufacturing time and material efficiency was the CNC machining of the parts. There were many potential variables to change to improve the process, but the main changes were to the cutter speeds and stock material size. Consequently, the changes made to stock material size reduced the number …

Asme R/C Baja Car, Torrie Large

All Undergraduate Projects

How does one build a car? Do they start with the tires and build inward or do they develop separate aspects at the same time? This remote-controlled car was designed and built with the intention of competing in the annual Baja Competition. There are three competitions: sprinting, slalom, and an obstacle course. The suspension system of this car must be designed to support the car for both the physical build and the competitiveness. It must do this without interfering with the drive train and steering mechanism designed by Doug Erickson. The suspension system employs suspension arms attached to the chassis …

Cassette Lockring Removal Tool, Kyle Wright

All Undergraduate Projects

Removal of a bicycle cassette requires additional tools to hold the cassette in place while loosening the cassette lockring. Typically a tool called a chain whip is used to stabilize the cassette, but is difficult to quickly and correctly apply to the cassette. Due to the need for an additional tool to hold the cassette, the user is faced with utilizing both hands while still needing to somehow hold the wheel in place. The lockring is torqued relatively tight and the overall combination of force, ergonomics, and number of tools required makes the task difficult to perform quickly. The objective …