Mechanical Engineering Commons^™

Cp Check Valve Design, Alec B. Der Matoian, Jessica M. Dent, Skylar M. Tusting

Mechanical Engineering

This report is to serve as a final design review and update to the project sponsors at Zurn Wilkins for the Check Valve Design Senior Project. The senior project team was tasked with improving upon the design of Zurn Wilkins’ backflow prevention assembly for small diameter pipes by reducing the pressure loss created by the check valves within the double check backflow assembly. The information contained in this report builds off the information contained in the Critical Design Report (CDR), as well as feedback and further investigation suggested during an Intermediary Design Review. Based on conclusions from the CDR, our …

Composite Lattice Tooling, Rachel Greene, Isaiah De Leon, Patrick O'Donnell, Alec Fuoti

Mechanical Engineering

Composite lattice structures allow for a high strength to weight ratio which is favorable in the aerospace industry where mass is a driving design consideration. Maxar Technologies has tasked the senior project team with creating a process and subsequent tooling to effectively manufacture their patented composite lattice structure as shown in United States patent #10326209B2. The only current industry solution to manufacture similar structures is Isotruss’s utilization of filament winding. The project team was asked to deliver a two-cube-by-four-cube lattice structure manufactured for properties testing and proof of a working manufacturing process. They also required that the process is well …

Safran Seat Attachment System, Craig John Kimball, Tyler Bragg, Lynette Cox

Mechanical Engineering

This final design review (FDR) document outlines the senior design project being carried out by a team of mechanical engineering undergraduate students attending California Polytechnic State University, San Luis Obispo for Safran Seats in Santa Maria, CA. The project originally was to design, build, and test a universal attachment to secure a widebody business class seat to seven aircraft models with different seat track geometry. The goal was to design, document, and create a finished product that fits design, weight, and manufacturing requirements, as well as passes static 9G FWD testing. Structural analysis, manufacturing analysis, FEA, and CAD assemblies will …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

Fox Factory Bearing Assembly Rundown And Torque Automation Project, David Ethan Daley, Eric Michael Forrester, Christopher Enrique Hansen, Riley Jacob O'Connor

Mechanical Engineering

A machine design was created to partially automate the rundown and torque of a Fox Factory shock bearing housing. This machine is needed at the factory to keep line associates safe by reducing ergonomic strains associated with this stage in the shock assembly process. Due to the lack of applicable torque drivers for this operation, an open ended, geared drivetrain was designed to allow for engagement of the bearing housing while allowing clearance for the shock shaft that the bearing rides on. This open drivetrain is held by a structure of linear rails and bearings to allow the line associate …

Prosthetic Foot Shell, Ql+, Kathryn Victoria Versteeg, Jackson A. Tucker, Ethan William Frey

Mechanical Engineering

This final design review includes an overview of our project and the steps we have taken to create our final product. We discuss the background research conducted, including various products like the foot shell we are trying to design and its related patents, along with similar past senior projects. As our product is considered a medical device, there are also certain standards that we must comply with. After determining our problem statement, we established what we believe to be the wants and needs of our user. These wants and needs were converted into specifications for our design, with durability as …

Effects Of New And Recycle Flux On The Mechanical Properties Of Submerged Arc Welded (Saw) Line Pipe Grade X52m And X65m, Taib Meor Mohd Adli

Student Works (2020-2029)

Two line pipe grade X52M and X65M were manufactured using submerged arc welding process. For each grade, two different welding flux condition were simulated, i.e. 100% new flux and 100% recycle flux. The flux used was aluminate basic type trade name OP 132. The outside diameter and wall thickness for X52M was 610mm x 12.7mm and for X65M was 762mm x 14.3mm. Lower weld re-entrant angle and higher weld bead height were observed in recycle flux condition. Lower weld manganese content recorded in recycle flux condition. And lower mechanical tests (i.e. tensile, impact, and hardness) value reported for recycle flux …

Fly Ash Based Geopolymer For High Temperature And High Compressive Strength Applications In Aggressive Environment, Aaryan Manoj Nair, Akm S. Rahman

Publications and Research

Geopolymers are the results of geosynthetic reactions between aluminosilicates and strong bases. This results in chemical bonds between aluminum (Al), Silicon (Si)and oxygen (O) composing polymer rings in tetrahedral coordination. These bonds give them widespread useful applications such as high heat bearing ceramics, and base construction material whilst being far more environmentally conscious. The purpose of the experiment is to examine the effect of Silicon Carbide whisker and inorganic glass particles on thermal and mechanical properties of Geopolymers. This study will help understand the effect of various compositions and concentrations of SiO₂ in mechanical strength. In this experiment, the …

Design Of Versatile Feedback Control System Components For Selective Laser Sintering, Thomas Chessman

University Scholar Projects

Selective laser sintering (SLS) is an additive manufacturing technique that involves using a laser to fuse powdered material together, layer by layer, in order to create a 3-D product. Despite its numerous benefits over traditional methods of manufacturing, including higher efficiency, versatility, and the ability to process many materials, selective laser sintering suffers from its propensity to generate structural errors during operation.

Feedback control has been shown to improve fabrication quality in other laser-based additive manufacturing techniques when implemented properly. Widespread exploration of applying feedback control in SLS might lead to significant performance improvements in this form of manufacturing.

This …

Hollow-Core Photonic Crystal Fiber Mach–Zehnder Interferometer For Gas Sensing, Kaveh Nazeri, Farid Ahmed, Vahid Ahsani, Hang-Eun Joe, Colin Bradley, Ehsan Toyserkani, Martin B. G. Jun

Manufacturing & Industrial Engineering Faculty Publications

A novel and compact interferometric refractive index (RI) point sensor is developed using hollow-core photonic crystal fiber (HC-PCF) and experimentally demonstrated for high sensitivity detection and measurement of pure gases. To construct the device, the sensing element fiber (HC-PCF) was placed between two single-mode fibers with airgaps at each side. Great measurement repeatability was shown in the cyclic test for the detection of various gases. The RI sensitivity of 4629 nm/RIU was demonstrated in the RI range of 1.0000347–1.000436 for the sensor with an HC-PCF length of 3.3 mm. The sensitivity of the proposed Mach–Zehnder interferometer (MZI) sensor increases when …

Comparative Analysis And Dynamic Response Of Garolites Under Temperature Spectrum Using Low Velocity Impact Test, Birendra Chaudhary

Honors Theses

The purpose of this study was to examine the dynamic response of three different grades of garolites under the temperature spectrum. High-Temperature G-11 Sheet (HTG), Impact Resistance Garolite E-glass (HIG), and Economical Garolite (EG) were tested using an Instron Dynatup 8250 impact tester. Three specimens were used for all three composites and were tested at 6 different temperatures, -10^oC, 25^oC, 50^oC, 100^oC, 150^oC and 200^oC using the Low-Velocity Impact Machine with 20 Kip punch shear load cell. The results showed that HIG had the highest resistance to punch …

A Study Of The Marketing Analysis Concerning Mind The Gap: A Wall-Bed Space Saving Platform, Brenna Johnson

Honors Theses

The purpose of this thesis is to conduct a marketing analysis on the capstone project concerning the product titled Mind the Gap. The thesis will explore the potential industries that could be entered and marketing strategies that would be implemented if the Mind the Gap product was mass produced and either sold online or through brick and mortar locations. Outlined in this research is an analysis of the competitive landscape, potential target markets, situational aspects concerning this product, and the resulting recommended marketing mix. The Mind the Gap is centered around a practical and efficient process which has a goal …

Product Realization Capstone: Using Project Management To Optimize Manufacturing Of Charcuterie Boards, Megan Staffieri

Honors Theses

The purpose of this project was to successfully create 36 charcuterie boards with varying designs during a two-week production period using principles of project management and manufacturing. In the initiation phase, the needs and requirements were assessed according to the project definition. During the planning phase, a work breakdown structure was created, material was researched, a budget was developed, and an initial risk assessment was performed. During the executing phase, the initial designs were prototyped before production began. The controlling phase was done in conjunction with the executing phase. The controlling phase monitored the project management plan and recorded the …

Utilizing The Product Development Process To Bring An Idea From Concept To Production, Sydney Ferguson, Jackson Sneed

Honors Theses

The purpose of this thesis is to document and discuss the five-stage product development process starting with defining a problem and resulting in manufacturing a final product for sale as it was implemented in the Portable Fire Pit Center for Manufacturing Excellence Senior Capstone Project. This project was carried out over the course of the Fall 2019 and Spring 2020 semesters by a team consisting of three Undergraduate Mechanical Engineering majors and two Undergraduate Accountancy majors. The ultimate goal of the project was to carry out a full production run of the Portable Fire Pit outputting fifteen units meeting retail …

Experimental And Numerical Study Of Process Parameters Effects Towards Part Quality And Porosity During Powder Bed Additive Manufacturing Processes., Subin Shrestha

Electronic Theses and Dissertations

Powder bed additive manufacturing (PB-AM) process utilizes an electron beam or a laser as a heat source to melt the metallic powder particles. These processes have the capability of freeform fabrication, however certain defects such as porosity, high surface roughness, etc. would hinder its application. It is important to understand the effect of the process parameters and the underlying physical phenomena, which lead to the formation of such defects. In this regard, a three-dimensional (3D) thermo-fluid model is developed to study the effect of beam speed on the surface morphology during powder bed electron beam additive fabrication (PB-EBAF). Besides, the …

Utilization Of Recycled Filament For 3d Printing For Consumer Goods, Alexa Peterson

Apparel Merchandising and Product Development Undergraduate Honors Theses

The 3D printing market has been used in a wide variety of manufacturing industries including textile and apparel. Many consumers can now own a personal 3D printer at home for recreational printing. There are even websites dedicated to 3D printing patterns made by consumers. However, the materials used in the 3D printing process pose a problem for the environment due to their plastic-based nature. 3D printing is a layered process with each layer being printed depending on the layer below it for strength and stability. During the 3D printing process, great amounts of waste are produced as a result of …

Materials-Processing Relationships For Metal Fused Filament Fabrication Of Ti-6al-4v Alloy., Paramjot Singh

Electronic Theses and Dissertations

Additive manufacturing (AM) is at the mainstream to cater the needs for rapid tooling and small-scale part production. The metal AM of complex geometries is widely accepted and promoted in the industry. While several metal AM technologies exist and are matured to a level where expectation in terms of design and properties are possible to realize. But the metal AM suffers from the heavy expense to acquire equipment, isotropic property challenges, and potential hazards to work with loose reactive metal powder. With this motivation, the dissertation aims to develop the fundamental aspects to print metal parts with bound Ti-6Al-4V powder …

Selective Laser Melting 17-4 Ph Stainless Steel And The Effect Of Varied Thermal Treatments On Fatigue Behavior., Sean Daniel Dobson

Electronic Theses and Dissertations

Fatigue failure is the leading source of loss in industry. In order for new means of manufacturing to move towards mainstream use a complete understanding of material and mechanical behavior must be gained. This endeavor seeks to aide in that task by observing the fatigue behavior of selective laser melting (SLM) additive manufacturing (AM) specimens and the effect of differing thermal treatment conditions for an optimized AM process. Stainless steel 17-4 PH specimens were fabricated using SLM AM and thermally treated to three conditions: as-built, solutionized and hardened, and direct hardened. These specimens were characterized for material (powder quality, density, …

Design And Demonstration Of Automated Technologies For The Fabrication And Testing Of Pem Fuel Cell Systems, Vladimir Gurau, Daniel Cox, Devin C. Fowler, Matthew Carter, Adedayo Ogunleke

Manufacturing Engineering: Faculty Publications (2015-2023)

This paper describes the research efforts at Georgia Southern University to develop robotic technologies for the fabrication of fuel cell components and stacks, as well as the design and fabrication of a High Temperature Proton Exchange Membrane Fuel Cell (HT-PEMFC) power system to be used as motive power and auxiliary power unit (APU) for a long range, unmanned, fully autonomous forest rover. The paper describes a manufacturing workcell consisting of a Yaskawa Motoman SDA5F dual arm robot with machine vision used for sorting, reorientation and stacking fuel cell components in presenters in preparation for their subsequent robotic assembly in fuel …

Spherical Cavity Expansion Approach For The Study Of Rigid-Penetrator’S Impact Problems, Mario Buchely, Alejandro Marañon

Materials Science and Engineering Faculty Research & Creative Works

In recent years, Spherical Cavity Expansion (SCE) theory has been extensively utilized to model dynamic deformation processes related to indentation and penetration problems in many fields. In this review, the SCE theory is introduced by explaining the different mathematical features of this theory, its solution, and a potential application to model the penetration of a rigid penetrator into a deformable target. First, a chronologically literature review of the most common models used to study this kind of penetration problems is introduced, focusing on the SCE theory. Then, the engineering model of penetration is presented using the SCE approach. The model …

Impact Of Magnetocaloric Material Properties On Performance Of A Magnetocaloric Heat Pump., Michael G. Schroeder

Electronic Theses and Dissertations

In the field of magnetocaloric heat pumps much research has been performed around machine design and theoretical machines, but little has been researched around practical problems such as variability in material properties. The present work defines a simulation tool that has been proven with experimental data. Magnetocaloric material cascades were statistically analyzed and parameterized, such that they could be recreated parametrically using a split Lorentz function with normally distributed parameters. Correlated curve-defining values with standard deviations were used as input into the simulation tool to determine the effect of variation on cooling heat pump performance for a household refrigerator application. …

Service Dog Ramp, Matthew Lundgren, Ariel Tolentino, Dallas Rocha, Adam Mayeda

Mechanical Engineering

This project involves designing a device to help a service dog easily get into and out of a truck. It details the design and manufacturing process. The project was interrupted due to the COVID-19 pandemic, so detailed instructions are provided for whoever takes on the project in the future.

Impact Of Part Thickness And Drying Conditions On Saturation Limits In Binder Jet Additive Manufacturing, Nathan B. Crane

Faculty Publications

Binder jetting (BJ) is a high build-rate additive manufacturing process with growing commercial interest. Growth in BJ applications is driven by the use of finer powders and improved post-processing methods that can produce dense, homogenous final parts. However, understanding of the basic droplet/powder interaction is relatively limited. This paper considers the impact of in-process drying, part geometry, and droplet size on a key printing parameter: binder saturation. Parts of varying thicknesses are printed with a range of saturation levels under various heating conditions. The ratio of the printed part mass to the theoretical part mass is used to detect bleeding. …

Investigating The Production Of Cores By Using Reclaimed Foundry Green Sand, Kristopher Lee Boss

Dissertations and Theses @ UNI

Increasing environmental regulations, transportation cost, delivery interruptions leading to production concerns, disposal cost, and demand from other industries have influenced the way foundry’s view used sand. The purpose of this research was to determine a beneficial reuse of overflow-green sand that would normally be disposed. The reclamation process used is a combination of mechanical and wet reclamation. The focus was on the production of foundry cold box cores and if using this reclamation process could create a core with a similar quality performance compared to new sand. Research in reclamation could pave the way for a closed loop sand system, …

3d-Printed Biomimetic Bioactive Glass Scaffolds For Bone Regeneration In Rat Calvarial Defects, Krishna C. R. Kolan, Yue-Wern Huang, Julie A. Semon, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

The pore geometry of scaffold intended for the use in the bone repair or replacement is one of the most important parameters in bone tissue engineering. It affects not only the mechanical properties of the scaffold but also the amount of bone regeneration after implantation. Scaffolds with five different architectures (cubic, spherical, x, gyroid, and diamond) at different porosities were fabricated with bioactive borate glass using the selective laser sintering (SLS) process. The compressive strength of scaffolds with porosities ranging from 60% to 30% varied from 1.7 to 15.5 MPa. The scaffold's compressive strength decreased significantly (up to 90%) after …

A Study Of The Design And Manufacturing Of An Elevated Dog Feeder, Lena Turner

Honors Theses

ABSTRACT

The senior capstone which students in the Center for Manufacturing Excellence program partake in was the basis for project. The Dog Box is an elevated dog feeder with an internal food storage compartment. It was designed for medium to large dogs, and can hold over 40 lbs of dog food. The internal storage compartment has drawer access and contains a plastic tote that will hold the food. The purpose of the design was to create an aesthetically pleasing elevated dog feeder that would double as a storage device, and elevated feeding can help prevent health issues in large dog …

Faculty Instruction Face Shield Project, David Holden, John Schneiderhan

Michigan Tech 3D Designs

Early in the spring of 2020 project contributors David Holden and John Schneiderhan began test printing a variety of open source Personal Protective Equipment (PPE)/Covid related items that could help protect or prevent the spread of the emerging virus. With assistance from Pete Baril of the Western Upper Peninsula Health Department (WUPHD) approval was obtained for the face shields to be used in the health care and nursing homes in the area. With the support and approval from university and library administration efforts were coordinated with Dr. Joshua Pearce and the students from the MOST lab to concentrate on the …

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

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

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

Advanced Mechatronics, Hao Su

Open Educational Resources

Project-based course on the design of mechatronic devices to address needs identified by hospital-based clinicians and industry. Students work in teams to develop a mechatronic prototype. The lectures will cover the design of medical devices and robotics including sensors, actuators, and robots. The students will communicate with customers to understand design needs, then conduct study on prior art, intellectual property, due diligence, and idea conceptualization. Students will present ideas in class and to a broad audience from local industry. Students will also write a publication-quality final report, which they will be encouraged for publication submission.

Development Of A Finite Element Model Of The Stamping Process To Predict The Natural Frequencies Of Dimpled Beams, Varad Vasudeo Pendse

Masters Theses

Creating dimples on beams has been proven to be an effective way of altering their vibrational behavior. The objective of this research is to simulate the process of stamping using the finite element (FE) method to create a model of a dimpled beam. This dimple has non-uniform thickness, so it shows close agreement with its real-life counterpart.

ANSYS® Parametric Design Language (APDL) is used to build a three-dimensional (3-D) finite element model and simulate the process of stamping used to create the dimple. The structural simulation is validated by calculating the thickness and width of the deformed geometry of the …