Mechanical Engineering Commons^™

Evaluation Of Direct Diode Laser Deposited Stainless Steel 316l On 4340 Steel Substrate For Aircraft Landing Gear Application, Tian Fu, Todd E. Sparks, Frank W. Liou, Joseph William Newkirk, Zhiqiang Fan, Syamala Rani Pulugurtha, Jianzhong Ruan, Hsin-Nan Chou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

300M steel is used extensively for aircraft landing gears because of its high strength, ductility and toughness. However, like other high-strength steels, 300M steel is vulnerable to corrosion fatigue and stress corrosion cracking, which can lead to catastrophic consequences in the landing gear. Stainless steels offer a combination of corrosion, wear, and fatigue properties. But for an aircraft landing gear application a higher surface hardness is required. A laser cladding process with fast heating and cooling rates can improve the surface hardness. AISI 4340 steel is used as a lower cost alternative to 300M due to its similar composition. In …

Increase Of Heat Transfer To Reduce Build Time In Rapid Freeze Prototyping, Ming-Chuan Leu, Sriram Praneeth Isanaka, Von Richards

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Reduction of part build time in the Rapid Freeze Prototyping (RFP) process, which fabricates a 3D ice part layer-by-layer by depositing and freezing water droplets, has been achieved by increase of heat transfer. Three mechanisms have been experimentally investigated: 1) cooling the substrate, 2) use of forced convection, and 3) use of a chilling plate. Cooling the substrate is effective for parts of small heights but becomes ineffective with increase in part height. Forced convection produced desirable reduction in part build time but with the undesirable formation of frost on the built ice part. The use of chilling plate to …

Functionally Graded Materials By Laser Metal Deposition, Syamala Rani Pulugurtha, Joseph William Newkirk, Frank W. Liou, Hsin-Nan Chou

Materials Science and Engineering Faculty Research & Creative Works

Fabrication of functionally graded materials (FGMs) by laser metal deposition (LMD) has the potential to offer solutions to key engineering problems over the traditional metal-working techniques. But the issues that need to be addressed while building FGMs are intermixing in the layers and cracking due to the residual stresses. This paper is to present the study of the effect of process parameters (laser power and travel speed) on the degree of dilution between the substrate (or, previous layer) and powder material for few metallurgical systems.

Development Of Extrusion-On-Demand For Ceramic Freeze-Form Extrusion Fabrication, Thomas Oakes, Parimal Kulkarni, Robert G. Landers, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In the Freeze-form Extrusion Fabrication (FEF) process, extrusion-on-demand (EOD) refers to the ability to control the start and stop of paste extrusion on demand and is vital to the fabrication of parts with complex geometries. This paper describes the development of EOD for ceramic FEF through modeling and control of extrusion force, selection of appropriate process parameters, and a dwell technique for start and stop of extrusion. A general tracking controller with integral action is used to allow tracking of a variety of reference forces while accounting for the variability in the paste properties. Experiments are conducted to model the …

Fuel Cell Development Using Additive Manufacturing Technologies -- A Review, Nikhil P. Kulkarni, Gargi Tandra, Frank W. Liou, Todd E. Sparks, Jianzhong Ruan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Fuel cells are being perceived as the future clean energy source by many developed countries in the world. The key today for clean power is the reliance of fuel cells not only to power automobiles but also for residential, small commercial, backup power etc. which calls for production on a large scale. Additive manufacturing is perceived as a way to develop cost effective fuel cells. It imparts flexibility to design different kinds of fuel cells along with reduction in material wastage. This paper deals with the review of additive manufacturing processes for research and development of fuel cell components, such …

A New State Observer And Flight Control Of Highly Maneuverable Aircraft, S. N. Balakrishnan, Ming Xin

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In this paper, a new nonlinear observer (θ-D observer) is proposed to estimate the feedback states for optimal control of a highly maneuverable aircraft. This observer is derived by constructing the dual of a recently developed nonlinear optimal control technique-known as the θ-D technique. The θ-D optimal control approach provides an approximate closed-form solution to the Hamilton-Jacobi-Bellman (HJB) equation. An optimal flight controller using this technique is designed for a highly maneuverable aircraft operating at high angle of attack where the θ-D observer is employed to estimate the states for feedback. The structure of this observer is similar to the …

Systematic Functional And Object-Oriented Product Design Frameworks, Jen-Chi Wu

Doctoral Dissertations

"The existing co-design methods of mechatronic products focus on co-design of mechanical and electronic components or co-design of computer hardware and software components. There exist no effective co-design methods for mechanical, electronic and software components at the concept design stage. The research objective of this dissertation work is to develop more effective systematic product design approaches for co-design of mechatronic products. Three innovative functional and object-oriented integrated design frameworks and one virtual prototyping application, which leverages on these three design frameworks, have been developed for co-design of mechatronic products. The three frameworks are: I) Hierarchical Object-Oriented Functional Modeling Framework, 2) …

Filtering, Modeling, And Control Of Axial Force Signals In Friction Stir Welding Processes, Thomas Michael Oakes

Masters Theses

"In Friction Stir Welding Processes, good contact between tool and work piece can be accomplished through control of the axial force signals. A method of stochastic modeling is introduced and used in conjunction with a Kalman filter to develop empirical static and dynamic models relating the axial force to input process parameters. The filtering method reduces signal variance by an order of magnitude. The models are experimentally validated and used to design and implement a general tracking controller with disturbance rejection for axial force control. Online control of the axial force is experimentally validated for bead-on-plate welds using a 6061 …

Shear-Driven Liquid Film In A Duct, Magesh Thiruvengadam, B. F. Armaly, J. A. Drallmeier

Mining Engineering Faculty Research & Creative Works

Two-dimensional flow simulations of shear-driven thin liquid film by turbulent air flow in a duct is performed using the Reynolds Averaged Navier Stokes and continuity equations along with the Volume of Fluid (VOF) model that is part of the FLUENT-CFD code. the purpose of this study is to determine the suitability of using this code/model for predicting reported measurements of shear driven liquid film in a duct. Both a laminar and a turbulent flow model were examined for the liquid film flow region to assess their impact on film thickness and velocity. the Low Reynolds number k-ε turbulence model is …

Thermal Converter Devices, Systems And Control Methods, Richard A. Flanagan, Rod E. Hosilyk, Rob Arlt, Kakkattukuzhy M. Isaac, Ronald E. Loving, David Alan Gordon

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A system is provided for reducing exhaust emissions. The system can comprise a series of chambers, an injector head, and a controller. The controller can maintain desired temperature zones and chemical environments inside the series of chambers, and the chambers and structures inside the system 10 can provide a desired travel path for the air, fuel, and untreated exhaust mixture inside.

Modeling Of Wear And Oxidation Behavior Of A Carbon/Carbon Multidisk Clutch, Shankar Nagaraj

Masters Theses

"Carbon/carbon composites are a family of advanced composite materials. They are the most advanced form of carbon and consist of a fiber, based on carbon precursors, embedded in a carbon matrix. They are extensively used in design of sliding contact systems such as clutches and brakes because of their low weight, excellent thermal and mechanical properties, chemical inertness and self lubricating capability. They retain their mechanical strength in inert atmospheres up to 2000° C. However, in oxidizing environments, C/C composites rapidly react with oxygen forming gaseous carbon oxides around 450° C.

In the present study a C/C composite clutch assembly …

Development Of An Electronic Governor System For A Small Spark Ignition Engine, Donald Ray Hibler

Masters Theses

"The use of electronic controls on engines has been widespread and has now reached the small utility engine. The evolution from carburetion to electronic fuel injection has presented opportunity to implement additional controls with the intent to improve engine control and performance. In this study, an electronic governor system is developed for use on a small twin cylinder utility engine. This system is to replace an existing mechanical governor system, and it should have the potential as a production based solution that integrates with an existing fuel injection system. It must improve the speed droop characteristics over the current mechanical …

Hydrogen Applications For Lambert - St. Louis International Airport, Mathew Thomas

Masters Theses

"Today, major airports are facing challenges related to pollution, energy efficiency, and safety and security. Hydrogen and fuel cell technologies, regarded as one of the key energy solutions of the 21st century are more energy efficient and reliable than conventional systems and have the potential to diminish these challenges. These technologies can also play a significant role in reducing the noise, air, and water pollution and enhancing energy security. This paper presents the design of a set of hydrogen technologies and systems that are commercially available and are ready for practical, real-world use. The hydrogen applications selected for Lambert-St. Louis …

Experiments And Modeling Of Shear-Driven Film Separation, J. L. Wegener

Masters Theses

"Dynamic thin liquid films driven by an adjacent gas flow have been subject to many investigations due to the presence of such films in many engineering applications. More specifically though, the behavior of such films at a sharply expanding corner has received little attention, but can be observed in internal combustion engines, liquid atomizer systems, refrigerant flows in evaporators, and film drag over wetted surfaces. Efforts to validate computational models of the propagation and separation of films are limited by the lack of reliable non-intrusive techniques to measure and analyze dynamic film parameters. In this study, film propagation models and …

Decision-Based Design Under Uncertainty With Intervals, Sashank Vasireddy

Masters Theses

"Design requires a series of decisions, and one of the major challenges engineering designers face is making decisions under uncertainty. The engineering designer must choose the best design among various alternatives. This work evaluates the use of utility functions to make decisions under uncertainty with both random and interval variables. Uncertainty cannot be eliminated completely, but it can be reduced. Most current methods treat only aleatory uncertainty. Here, however, both aleatory and epistemic uncertainties are addressed in the context of engineering design. Methods such as moment matching method and worst case analysis are used to incorporate uncertainty into design problems"--Abstract, …

Verifying Module Heuristics For Large Scale Products, Rachel Marie Day

Masters Theses

"Decreasing time and costs is a major objective in many businesses today. Including modularity in the early design phases can effectively decrease time spent on and costs associated with a project. The task of identifying modules within a product early in the design process (when decisions are less expensive) is made less daunting by using the techniques of functional modeling and module heuristics. The two papers that form this thesis discuss the results of the efforts to verify the module heuristics on large products. Observations on needed modifications to the functional modeling technique and original module heuristics are reported along …

Modeling And Simulation Of Electrochemical Magneto Hydro Dynamics, Debamoy Sen

Masters Theses

"This thesis focuses on how the electrochemical magneto hydro dynamic problem is solved through numerical simulation for a two dimensional millielectrode electrochemical cell and a three dimensional microelectrode array cell. Electrochemical processes are enhanced by magnetic fields through the introduction of body forces such as Lorentz force. Through modeling and numerical simulations, experimental results can be integrated with theory. Such simulations will aid in the prediction of mass transfer limited currents and visualization of flow profiles in an electrochemical cell. The numerical solution of the equation system is made possible by the finite volume method used in the FLUENT Computational …

On-Line Depth Measurement Of Micro-Scale Laser Drilled Holes, Rock Allen Powell

Masters Theses

"A micron-precision micro-hole depth detection scheme has been developed which utilizes a confocal structure and a photomultiplier tube as a photodetector. This scheme is experimentally confirmed to posses an accuracy of greater than 95% for micro-holes on the order of one-hundred microns in diameter and tens of microns in depth and could be easily be integrated for the control of industrial and research oriented laser micro-machining process"--Abstract, page iii.

Reliability-Based Design With System Reliability And Design Improvement, Gagandeep Singh Saini

Masters Theses

"This thesis focuses on developing a methodology for accurately estimating series system probability of failure. Existing methods for series system based design optimization are not that accurate because they assign reliability to each failure mode; as a result complete system reliability goes down. According to method proposed in this work, the user will assign required system reliability at the start and then optimizer will apportion reliability to every failure mode in order to meet required system reliability level. Detlevson second order upper bounds are used to estimate system probability of failure. Several examples have been shown to verify the results …

Development Of Extrusion On Demand For Ceramic Freeze-Form Extrusion Fabrication Processes, Parimal Sanjay Kulkarni

Masters Theses

"Freeze-form Extrusion Fabrication (FEF) is a Solid Freeform Fabrication method. It involves the deposition of a ceramic paste in a layer by layer manner to construct a three dimensional structure. The ceramic paste used in this process consists of a high solids loading of ceramic powder mixed with water and a nominal amount of an aqueous organic binder. These characteristics make the process environmentally friendly. Also the absence of dies or molds in the process makes it suitable for fabrication of materials like ceramics. In the past, parts have been fabricated with continuous extrusion of a ceramic paste. In FEF, …

Investigation Of Selective Laser Sintering Of Zirconium Diboride Parts, Shashwatashish Pattnaik

Masters Theses

"This research investigates the fabrication of three-dimensional parts from ZrB₂, an ultra high temperature ceramic (UHTC), using the selective laser sintering (SLS) process. Based on an experimental investigation, optimum values for the SLS parameters (scan speed, laser power, energy density, scan spacing and layer thickness), used on a DTM Sinterstation 2000, were determined to build green ZrB₂ parts with high integrity and sharp geometrical features. This was done by melting the polymer binder used to bond the ceramic particles layer-by-layer according to the cross-section of a CAD model. The use of a sacrificial plate to eliminate cracks in the bottom …

Procedure To Validate Direct Numerical Simulations Of Wall-Bounded Turbulence Including Finite-Rate Reactions, Lian Duan, M. Pino Martín

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper first discusses the constitutive relations and surface catalytic model for direct numerical simulation of wall-bounded turbulence including finite-rate chemistry and gas-surface interaction and then provides a systematic procedure to test the validity of the simulations by dividing the whole problem into different components and testing each component separately. Namely, comparisons against similarity solutions and other established hypersonic boundary-layer solutions are used to test the validity of laminar mean flow with and without gas-phase chemical reactions; comparisons against the analytic solution for the one-dimensional diffusion equation are used to test the validity of the surface catalysis boundary condition; and …

Modeling And Simulation Of High Pressure Composite Cylinders For Hydrogen Storage, Jianbing Hu

Doctoral Dissertations

"Composite hydrogen cylinders provide an efficient means of storage of hydrogen gas for modern hydrogen vehicles. Safety issues arising from the high gas pressure, temperature variation, fire attack, and fracture failures are the main concerns. The focus of this study is to develop a Finite Element (FE) model to predict the performance of composite cylinders subjected to extreme mechanical/thermal loadings and provide guidance for design optimization"--Abstract, page iv.

Fundamentals Of Friction Stir Spot Welding, Harsha Badarinarayan

Doctoral Dissertations

"The recent spike in energy costs has been a major contributor to propel the use of light weight alloys in the transportation industry. In particular, the automotive industry sees benefit in using light weight alloys to increase fuel efficiency and enhance performance. In this context, light weight design by replacing steel with Al and/or Mg alloys have been considered as promising initiatives. The joining of structures made of light weight alloys is therefore very important and calls for more attention. Friction Stir Spot Welding (FSSW) is an evolving technique that offers several advantages over conventional joining processes.

The fundamentals aspects …

Information Archival And Reuse: Drawing Conclusions From The Past, Matt R. Bohm

Doctoral Dissertations

"Over the last few decades design researchers have put forward theories and proposed methodologies that increase the chance that a design team will reliably arrive at the optimal solution to a given design problem. Studies, however, bear out that theories and methodologies alone will not guarantee an optimal or even good design solution. Instead, a breadth of knowledge across multiple engineering domains and the time and tools to thoroughly evaluate the design space are as important as any prescriptive design method. This work presents a set of underlying engineering technologies to define, archive and reuse product design knowledge to provide …

Translating Terms Of The Functional Basis Into Biologically Meaningful Keywords, Hyunmin Cheong, L. H. Shu, Robert B. Stone, Daniel A. Mcadams

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Biology has long been recognized as an excellent source of analogies and stimuli for engineering design. Previous work focused on the systematic identification of relevant biological analogies by searching for instances of functional keywords in biological information in natural language format. This past work revealed that engineering keywords couldn't always be used to identify the most relevant biological analogies, as the vocabularies between biology and engineering are sufficiently distinct. Therefore, a method of identifying biologically meaningful keywords that correspond to engineering keywords was developed. Here, we apply and refine this method by generating biologically meaningful keywords for the terms of …

A Retrospective On Twenty Years Of The Design Theory And Methodology Conference, Jacquelyn K. Stroble, Robert L. Nagel, Kerry R. Poppa, Matt Robert Bohm, Robert B. Stone

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Since its birth from the Design Automation Conference (DAC) and the Association for the Advancement of Artificial Intelligence (AAAI) twenty years ago, the Design Theory and Methodology (DTM) Conference has accepted 769 papers for presentation in a total of 179 tracks. Papers have covered advances in design theory and methods as well as design education, decision making, product development, collaborative endeavors, case studies, information processing, computational methods and industrial applications. through the years tracks have evolved to better define existing research topics and branched to spawn new areas of interest. This paper presents a retrospective of the past twenty years …

Determination Of Vibrational Energy Levels And Transition Dipole Moments Of Co2 Molecules By Density Functional Theory, Zhi Liang, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An Efficient Method is Presented to Calculate the Intra-Molecular Potential Energies and Electrical Dipole Moments of CO2 Molecules at the Electronic Ground State by Solving the Kohn-Sham (KS) Equation for a Total of 101 992 Nuclear Configurations. the Projector-Augmented Wave (PAW) Exchange-Correlation Potential Functionals and Plane Wave (PW) Basis Functions Were Used in Solving the KS Equation. the Calculated Intra-Molecular Potential Function Was Then Included in the Pure Vibrational Schrödinger Equation to Determine the Vibrational Energy Eigen Values and Eigen Functions. the Vibrational Wave Functions Combined with the Calculated Dipole Moment Function Were Used to Determine the Transition Dipole Moments. …

Three-Dimensional Modeling Of The Plasma Arc In Arc Welding, Gu Xu, J. Hu, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Most previous three-dimensional modeling on gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) focuses on the weld pool dynamics and assumes the two-dimensional axisymmetric Gaussian distributions for plasma arc pressure and heat flux. In this article, a three-dimensional plasma arc model is developed, and the distributions of velocity, pressure, temperature, current density, and magnetic field of the plasma arc are calculated by solving the conservation equations of mass, momentum, and energy, as well as part of the Maxwell's equations. This three-dimensional model can be used to study the nonaxisymmetric plasma arc caused by external perturbations such as …

A Plasma Model Combined With An Improved Two-Temperature Equation For Ultrafast Laser Ablation Of Dielectrics, Lan Jiang, Hai-Lung Tsai

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It remains a big challenge to theoretically predict the material removal mechanism in femtosecond laser ablation. To bypass this unresolved problem, many calculations of femtosecond laser ablation of nonmetals have been based on the free electron density distribution without the actual consideration of the phase change mechanism. However, this widely used key assumption needs further theoretical and experimental confirmation. by combining the plasma model and improved two-temperature model developed by the authors, this study focuses on investigating ablation threshold fluence, depth, and shape during femtosecond laser ablation of dielectrics through nonthermal processes (the Coulomb explosion and electrostatic ablation). The predicted …