Mechanical Engineering Commons^™

Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Directed energy deposition (DED) has been widely used for component repair. In the repair process, the surface defects are machined to a groove or slot and then refilled. The sidewall inclination angle of the groove geometry has been recognized to have a considerable impact on the mechanical properties of repaired parts. The objective of this work was to investigate the feasibility of repairing various V-shaped defects with both experiments and modeling. At first, the repair volume was defined by scanning the defective zone. Then, the repair volume was sliced to generate the repair toolpath. After that, the DED process was …

Time-Dependent System Reliability Analysis With Second-Order Reliability Method, Hao Wu, Zhangli Hu, Xiaoping Du

Mechanical and Aerospace Engineering Faculty Research & Creative Works

System reliability is quantified by the probability that a system performs its intended function in a period of time without failures. System reliability can be predicted if all the limit-state functions of the components of the system are available, and such a prediction is usually time consuming. This work develops a time-dependent system reliability method that is extended from the component time-dependent reliability method using the envelope method and second-order reliability method. The proposed method is efficient and is intended for series systems with limit-state functions whose input variables include random variables and time. The component reliability is estimated by …

Adaptive Kriging Method For Uncertainty Quantification Of The Photoelectron Sheath And Dust Levitation On The Lunar Surface, Xinpeng Wei, Jianxun Zhao, Xiaoming He, Zhen Hu, Xiaoping Du, Daoru Han

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper presents an adaptive Kriging based method to perform uncertainty quantification (UQ) of the photoelectron sheath and dust levitation on the lunar surface. The objective of this study is to identify the upper and lower bounds of the electric potential and that of dust levitation height, given the intervals of model parameters in the one-dimensional (1D) photoelectron sheath model. To improve the calculation efficiency, we employ the widely used adaptive Kriging method (AKM). A task-oriented learning function and a stopping criterion are developed to train the Kriging model and customize the AKM. Experiment analysis shows that the proposed AKM …

Fuel Cell Having Corrugated Membrane Electrode Assembly, Jonghyun Park

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An electrochemical reaction cell comprising an anode electrode, a cathode electrode, and a membrane electrode assembly (MEA). The MEA is positioned between the anode electrode and the cathode electrode. The anode electrode, the cathode electrode, and the MEA each have a corrugated shape and are contained within a recess of a housing.

Absorption Of Nitrogen During Pulsed Wave L-Pbf Of 17-4 Ph Steel, Ben Brown, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples …

Non-Prehensile Manipulation Of A Devil-Stick: Planar Symmetric Juggling Using Impulsive Forces, Nilay Kant, Ranjan Mukherjee

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Juggling a devil-stick can be described as a problem of non-prehensile manipulation. Assuming that the devil-stick remains confined to the vertical plane, the problem of juggling the stick between two symmetric configurations is considered. Impulsive forces are applied to the stick intermittently and the impulse of the force and its point of application are modeled as control inputs to the system. The dynamics of the devil-stick due to the impulsive forces and gravity is described by half-return maps between two Poincaré sections; the symmetric configurations are fixed points of these sections. A coordinate transformation is used to convert the juggling …

On The Applicability Of Continuum Scale Models For Ultrafast Nanoscale Liquid-Vapor Phase Change, Anirban Chandra, Zhi Liang, Assad A. Oberai, Onkar Sahni, Pawel Keblinski

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Continuum Methods Are Efficient in Modeling Multi-Phase Flow at Large Time and Length Scales, However, their Applicability to Nanoscale Systems and Processes is Questionable. When Mean Free Path and Average Time between Atomic Collisions Are Comparable to the Characteristic Length and Time Scales of Interest, the Continuum Hypothesis Approaches its Spatial and Temporal Limit. Here We Discuss the Implications of Modeling Such a Limiting Problem Involving Liquid-Vapor Phase Change using Continuum Equations of Mass, Momentum, and Energy Conservation. Our Results Indicate that, Continuum Conservation Laws Can Correctly Represent the Dynamics of the Specific Problem of Interest Provided Appropriate Constitutive Relations …

Dynamics Of A Pair Of Paramagnetic Janus Particles Under A Uniform Magnetic Field And Simple Shear Flow, Christopher Sobecki, Jie Zhang, Cheng Wang

Mechanical and Aerospace Engineering Faculty Research & Creative Works

We numerically investigate the dynamics of a pair of circular Janus microparticles immersed in a Newtonian fluid under a simple shear flow and a uniform magnetic field by direct numerical simulation. Using the COMSOL software, we applied the finite element method, based on an arbitrary Lagrangian-Eulerian approach, and analyzed the dynamics of two anisotropic particles (i.e., one-half is paramagnetic, and the other is non-magnetic) due to the center-to-center distance, magnetic field strength, initial particle orientation, and configuration. This article considers two configurations: the LR-configuration (magnetic material is on the left side of the first particle and on the right side …

Computational Analysis Of High Carbon Steel For Optimal Design, Muhammad Zubair, Aneela Wakeel, M. Mustafa Azeem, Aneeqa Tabbassum

Civil, Architectural and Environmental Engineering Faculty Research & Creative Works

To increase the reliability of materials the computational analysis has been considered a vital tool for designing the components in the mechanical and nuclear engineering. By increasing a high percentage of carbon in liquid steel subsequently enhance the hardness, elasticity and toughness of the materials. In this research high carbon steel has been used due to its wear resistance properties in order to increasing hardness and strength. The findings of this research reveal the high carbon steel a good replacement material for conventional iron due to its low weight. Modeling and analysis of the steel, metallic glass and high carbon …

Variational Inference For Morphological Modification To 3d Geometry : An Application To The Support Generation For Metal Additive Manufacturing, Mugdha Swanand Joshi

Masters Theses

"A key issue in metal additive manufacturing (AM) processes is the optimization of support geometry. Correct selection of support strategy can reduce build time, improve surface finish, reduce support removal time, and maximize build success. Strategies used to design support structure are time consuming and need skilled personnel. In this research we have deployed a deep generative model capable of making morphological modifications to the part. However, it is not similar to topology optimization where the aim is to reduce or eliminate support structure. The proposed model can make necessary changes to the part in order to transform it into …

Design And Development Of A Variable Resistance Hand Exerciser Using A Compliant Mechanism, Jyothi Komatireddy

Masters Theses

"Rehabilitation exercise plays a vital role in recovering from an injury or illness condition by improving flexibility and restoring muscle strength. If not done correctly, exercising can cause more damage to the health condition than in healing. Understanding the muscle’s resistance level while performing an exercise helps design the exercising equipment not to overstrain the muscle during operation. This research presents a methodology to develop a variable-resistance hand exerciser by using a compliant cam-follower mechanism. The proposed design comprised a compliant follower and a rigid cam. The rigid cam is synthesized using the human hand force-deflection profile as an input …

Layer-To-Layer Feedback Control For Direct Energy Deposition Additive Manufacturing, Michelle Gegel

Doctoral Dissertations

"Additive manufacturing (AM) has garnered much attention in recent years, some calling it the fourth industrial revolution. It was first used to create rapid prototypes, although recent efforts have been made to advance the technology towards production of functional parts. This requires advancement in the materials used in AM, as well as the ability to produce quality parts repeatably. More specifically, direct energy deposition (DED) of metal powders is a process capable of producing and repairing parts with complex geometries; however, it is not widely used in industry due to challenges with quality control. In this process, metal powder is …

Enthesis Strength, Toughness And Stiffness: An Image-Based Model Comparing Tendon Insertions With Varying Bony Attachment Geometries, Mikhail Golman, Victor Birman, Stavros Thomopoulos, Guy M. Genin

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Tendons of the body differ dramatically in their function, mechanics and range of motion, but all connect to bone via an enthesis. Effective force transfer at the enthesis enables joint stability and mobility, with strength and stiffness arising from a fibrous architecture. However, how enthesis toughness arises across tendons with diverse loading orientations remains unclear. To study this, we performed simultaneous imaging of the bone and tendon in entheses that represent the range of tendon-to-bone insertions and extended a mathematical model to account for variations in insertion and bone geometry. We tested the hypothesis that toughness, across a range of …

Modeling Rack Force For Steering Maneuvers In A Stationary Vehicle, Nilay Kant, Raunav Chitkara, Prerit Pramod

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A steering system converts circular motion of the steering wheel into yaw motion of the road-wheels. In absence of a steering assist mechanism, the driver torque overcomes the tire-road friction forces, which is transmitted to the steering rack through tie rods attached to the road-wheels. The net force acting on the rack is then transmitted to the steering wheel through mechanical linkages which results in natural haptic feedback, commonly referred to as the steering feel. In an electric/hydraulic power steering, an electro-mechanical actuator applies assist force, which reduces the torque required by the driver. In order to maintain stability of …

Simulation And Modeling Of Hypersonic Turbulent Boundary Layers Subject To Adverse Pressure Gradients Due To Concave Streamline Curvature, Gary L. Nicholson, Junji Huang, Lian Duan, Meelan M. Choudhari

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Direct numerical simulations (DNS) of adverse-pressure-gradient turbulent boundary layers over a planar concave wall are presented for a nominal freestream Mach number of 5, with the objective of assessing the limitations of the currently available Reynolds-averaged Navier-Stokes (RANS) models. The wall geometry and flow conditions of the DNS are representative of the experimental data for a Mach 4.9 turbulent boundary layer that was tested on a two-dimensional planar concave wall model in the high-speed blow-down wind tunnel located at the National Aerothermochemistry Laboratory at Texas A&M University (TAMU). The DNS was validated against the experimental results of TAMU for the …

Effect Of Nonlinear Mixing On Electrospray Propulsion Predictions, Mitchell J. Wainwright, Joshua L. Rovey

Mechanical and Aerospace Engineering Faculty Research & Creative Works

No abstract provided.

The Effect Of Laser Welding Modes On Mechanical Properties And Microstructure Of 304l Stainless Steel Parts Fabricated By Laser-Foil-Printing Additive Manufacturing, Chia Hung Hung, Wei Ting Chen, M. Hossein Sehhat, Ming C. Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The success of laser-foil-printing (LFP) additive manufacturing depends critically on the laser welding of sheet metals onto the substrate or the previous layer during the part fabrication process. The welding can be generally categorized into two modes: conduction mode and keyhole mode. In this study, 304L stainless steel parts fabricated by the LFP process using the two laser welding modes are compared. The porosity, microstructure, and tensile properties of the fabricated parts in these two modes are measured and compared in the laser scanning direction (X) and part building direction (Z). The parts fabricated in the conduction mode have a …

Identification Of Neuromarkers Using Structural And Functional Neuroimaging, Sreevalsan Sanathanan Menon

Doctoral Dissertations

"One of the grand challenges in science is understanding the human brain. Recent advances in magnetic resonance imaging have opened unmatched opportunities to demystify neural circuitry. In this research, the spatially and temporally complex neuroimaging data were used to identify neuromarkers that aids in quantifying a brain’s health. In the first part, a comparison of static and dynamic functional connectivities was made to study their efficacies in identifying intrinsic individual connectivity patterns. Results show that the intrinsic individual connectivity pattern can be used as a ‘fingerprint’ to distinguish among and identify subjects and their biological sex and is more accurately …

Investigation Of The Sensitivity Of Human Arm To Small Interaction Forces During Physical Human-Robot Interaction (Phri), Fazlur Rashid

Masters Theses

“Understanding the human motor control strategy during physical interaction tasks is crucial for developing future robots for physical human-robot interaction (pHRI). Effective pHRI depends on humans communicating their intentions for movement with robots. In physical human-human interaction (pHHI), small interaction forces are known to convey their intent between the partners. It is speculated that small interaction forces contain significant information to convey the movement intention of pHHI. However, the mechanism underlying this interaction strategy is largely unknown. Hence, the aim of this work was to investigate what affects humans’ sensitivity to the interaction forces. The hypothesis was that small interaction …

Fabrication Of Silicon Nitride Parts By Ceramic On-Demand Extrusion Process, Sachin Choudhary

Masters Theses

“Ceramic On-Demand Extrusion (CODE) is a patented solid freeform fabrication method for manufacturing high-density monolithic ceramic parts. In the past 5-6 years, the technology has been successfully implemented to fabricate alumina and zirconia parts. The mechanical characterizations also show CODE’s high potential in achieving desired structural properties. The present study covers the fabrication of silicon nitride parts by CODE process, which entailed the design of paste formulation for achieving rheology suitable for dimensional control in fabricated parts and determining firing temperature and the content of sintering additives for silicon nitride green bodies fabricated by CODE. The density, hardness, and fracture …

Research And Development Of A Laser Hot Wire Deposition Process, Christopher Croft

Masters Theses

“Laser hot wire directed energy deposition (DED) is an increasingly popular method for improving deposition rates and overall reduction of build times in DED processing. While there is clear benefit, it is important to fully understand the impact of preheating the wire. This work focuses on developing a model that describes bead geometry output using all factors including the wire preheat. The model was fit with over 150 data points that explored a large range of each factor. The resulting model was then leveraged to evaluate a process control variable. The technique chosen used feedback from the hot wire system …

Physics-Based Modeling Of Lithium-Ion Batteries For Control And Estimation Applications, Brody J. C. Riemann

Masters Theses

“Lithium-ion batteries are extensively used in many application areas like consumer electronics, electric vehicles, and microgrids. As the world moves towards further electrification of vehicles and more widespread use of renewable energy sources, the need for large-scale battery storage systems will grow. To effectively replace conventional methods, batteries will need to be charged quickly while accounting for degradation to maximize lifetime. Further, larger batteries require more detailed safety monitoring, which is implemented using a battery management system (BMS). A BMS is responsible for state of charge (SOC) estimation, state of health (SOH) estimation, cell balancing, regulating voltage and current according …

Theoretical Study Of Magnetic Particles In A Shear Flow Subjected To A Uniform Magnetic Field, Christopher A. Sobecki

Doctoral Dissertations

"Magnetic manipulation of non-spherical magnetic microparticles is important for applications in shape-based and magnetic-based separations such as waste management, disease diagnostics, drug delivery, and mining. Manipulations of magnetic microparticles also include chain formation to assemble compositions for electronics, drug loading designs, and magnetorheological fluids for smart armor, hydraulic brakes, and dampers. In microfluidic devices, separation-formation-effectiveness depends on the shape of the channel, the shear rate, and the magnetic field strength and direction.

Particle separation and chain formation involved highly complex and computational expense-demanding studies in microfluidic devices, magnetic fields, and particle- particle/wall interactions. This research took complex experimental studies and …

Computational Intelligent Impact Force Modeling And Monitoring In Hislo Conditions For Maximizing Surface Mining Efficiency, Safety, And Health, Danish Ali

Doctoral Dissertations

"Shovel-truck systems are the most widely employed excavation and material handling systems for surface mining operations. During this process, a high-impact shovel loading operation (HISLO) produces large forces that cause extreme whole body vibrations (WBV) that can severely affect the safety and health of haul truck operators. Previously developed solutions have failed to produce satisfactory results as the vibrations at the truck operator seat still exceed the “Extremely Uncomfortable Limits”. This study was a novel effort in developing deep learning-based solution to the HISLO problem.

This research study developed a rigorous mathematical model and a 3D virtual simulation model to …

Fabrication, Characterization Of High-Entropy Alloys And Deep Learning-Based Inspection In Metal Additive Manufacturing, Wenyuan Cui

Doctoral Dissertations

"Alloying has been used to confer desirable properties to materials. It typically involves the addition of small amounts of secondary elements to a primary element. In the past decade, however, a new alloying strategy that involves the combination of multiple principal elements in high concentrations to create new materials called high- entropy alloys (HEAs) has been in vogue. In the first part, the investigation focused on the fabrication process and property assessment of the additive manufactured HEA to broaden its engineering applications. Additive manufacturing (AM) is based on manufacturing philosophy through the layer-by-layer method and accomplish the near net-shaped components …

Thermomechanical Simulation And Process Optimization For Hot Rolling Of Steel, Shouvik Ganguly

Doctoral Dissertations

"Hot rolling is a manufacturing process that involves large material deformation, complicated geometries, contact conditions and non-uniform temperature gradients. Steel industries are motivated to prevent hot rolled steel products to be defect free and with desired shape and size. In order to simulate the process accurately, it is essential that the material model for steel accounts for the viscoplasticity and changes in properties that occur in steel at elevated temperatures as grain growth and recrystallization.

The healing of existing voids during hot rolling was investigated using finite element simulations. Voids are highly undesirable as they not only degrade the product …

Fabrication Of 304l Stainless Steel And Aluminum Parts By Laser Foil Printing And Process Automation, Chia-Hung Hung

Doctoral Dissertations

"This work presents research conducted on a novel metal additive manufacturing process, called Laser Foil Printing (LFP), to fabricate metal parts with various geometries layer by layer using metal foil as the feedstock. To investigate the processability and characteristics of LFP for fabricating metal parts, the materials included 304L stainless steel and Al-1100 aluminum alloy. The LFP process parameter windows for both 304L and Al-1100 were determined, and the optimal process parameters with stable formation of the melt pools were selected to fabricate dense metal parts. The microstructure and properties of LFP-fabricated parts were characterized and analyzed using tensile testing, …

Numerical And Experimental Study Of Mechanical Properties For Laser Metal Deposition (Lmd) Process Part, Lan Li

Doctoral Dissertations

"Laser Metal Deposition (LMD), also called as, Laser Engineered Net Shaping (LENS), Directed Energy Deposition (DED), is a typical Additive Manufacturing (AM) technology, is used for advanced free-form fabrication. It creates parts by directly melting materials and depositing them on the workpiece layer by layer. In this process, the metal powder or fiber is melted within the melting pool by laser beam or electron beam and quickly solidifies to the deposited layer. LMD technology shows great advantages over traditional manufacturing on complex structure fabrication, including high building rates, easy material replacement and reduced material waste. These merits make the wide …

Dynamic Behavior And Interactions Of Ferrofluid Droplets Under Magnetic Fields In Low Reynolds Number Flows, Md Rifat Hassan

Doctoral Dissertations

Digital microfluidics in combination with emulsion microfluidics are crucial building blocks of droplet-based microfluidics, which are prevalent in a wide variety of industrial and biomedical applications, including polymer processing, food production, drug delivery, inkjet printing, and cell-based assays. Therefore, understanding the dynamics and interactions of droplets as well as the interactions between the droplets and solid surfaces are of great importance in order to improve the performance or product in these applications.

Recently, several studies in the literature have demonstrated the potential of magnetic fields in controlling the behavior of droplets in microscale; however, the fundamental mechanism behind the interesting …

An Investigation Of Unsteady Thermal Exchange Processes In Geothermal Heat Exchangers, Ganesh Ravi Shanker

Doctoral Dissertations

“Geothermal heat exchangers, has become one of the highly recognized non conventional heat exchangers as they utilize renewable energy source earth to initiate the thermal energy transfer. However, these heat exchangers suffer from a expensive installation cost due to their conservative design model, thereby facilitating the need to identify and improve the design. In this dissertation, three gaps, which identifies improvement over conservative design were investigated, to assess the heat exchanger performance. In the first approach, borehole thermal and geometrical properties were investigated keeping the outlet leg of the heat exchanger as adiabatic, which neglects the thermal short-circuiting between the …