Mechanical Engineering Commons^™

Parameter Optimization For Controlling Aluminum Loss When Laser Depositing Ti-6al-4v, Richard Charles Barclay

Masters Theses

"The ability to predict the mechanical properties of engineering materials is crucial to the manufacturing of advanced products. In the aerospace industry, Ti-6Al-4V is commonly used to build structures. Any deviation from the alloy's standard properties can prove detrimental. Thus, the compositional integrity of the material must be controlled. The ability to directly build and repair large, complicated structures directly from CAD files is highly sought after. Laser Metal Deposition (LMD) technology has the potential to deliver that ability. Before this process can gain widespread acceptance, however, a set of process parameters must be established that yield finished parts of …

Effects Of Machining Parameters And Cooling Strategies On Cutting Forces And Surface Integrity In High-Speed Slot End-Milling Of Titanium Alloy, Emenike Chukwuma

Masters Theses

“Paper 1 presents the results of the investigations of the effects of cooling strategies [Emulsion cooling, Minimum Quantity Lubrication (MQL) and Liquid Nitrogen (LN₂)] and machining parameters (feed rate and spindle speed) on cutting force components, cutting temperature and tool wear during slot end-milling of titanium Ti-6Al-4V workpiece. All machining experiments were conducted using four-flute 0.5 inch diameter uncoated solid carbide end-mill on Cincinnati Milacron, Sabre 750 vertical machining center equipped with Acramatic 2100 controller. Cutting force components were acquired and tool wear was indirectly measured from maximum cutting force variation per slot from the first pass to …

Effects Of Machining Parameters On Cutting Forces,Shear Angle And Friction In Orthogonal Turning Of Titanium Alloys, Hilary Onyishi

Masters Theses

“Paper 1 presents the results of the investigations on the effects of machining parameters on cutting forces, shear angle and friction in orthogonal turning of titanium alloy tube. Uncoated fine-grained cemented tungsten carbide (WC/Co) and Physical Vapour Deposition (PVD) TiAlN coated grade turning tool inserts, with 5⁰ and 15⁰ rake angles were used under low and high cutting speeds of 120 and 240m/min, at three different feedrates (0.05, 0.075 and 0.1 mm/rev). The experiments were conducted under flooded coolant to reflect what is practically obtainable in manufacturing industries. The experimental results show that cutting forces at two selected cutting speeds …

Rotary Displacement Piezoelectric Energy Harvester, Headman Sanei

Masters Theses

“This study proposes a novel piezoelectric energy harvester for rotary motion applications. It is based on an annular unimorph plate, mounted on a shaft rotating at a constant angular velocity, under constant amplitude point-wise force. The mathematical model and the analysis was proposed for the inverse problem of a rotating disk under a static stationary force. The disk, however, is assumed to be stationary subjected to a traveling force. The distributed parameter electromechanical equations governing the behavior of the system are provided in closed-form, incorporating both an AC and a simple rectifier circuit. The performance of the energy harvester was …

Manufacturing And Characterization Of Polyurethane Based Sandwich Composites, Stephen Robert Hawkins

Masters Theses

"Composite sandwich structures have been extensively employed in aerospace structures, ship building, infrastructure, etc. due to their light weight and high strength to weight ratio. The understanding of their behavior under impact and environmental conditions is extremely important for the design and manufacturing of these engineering structures since these problems are directly related to structural integrity and safety requirements. Vacuum assisted resin transfer molding (VARTM) is one of the commonly used low cost composite manufacturing processes. Polyurethane (PU) resin system has been observed to have better mechanical properties and higher impact strength when compared to conventional resin systems such as …

Development Of Marker-Based Human Motion Capture Systems For Assembly Simulation And Ergonomic Analysis, Sajeev C. Puthenveetil

Masters Theses

"In aerospace industry, the assembly operator is often exposed to potential ergonomic injuries due to awkward postures while working in confined spaces. Manually generating worker postures in simulation software for ergonomic analysis is cumbersome. This research focuses on the use of marker-based optical motion capture technology to generate human motion simulations in real-time for ergonomic analysis. To address the challenges involved in capturing human motions in a real work environment, an assembly operation was simulated in a four-walled Computer Automated Virtual Environment (CAVE) which provides an immersive 3D environment to the worker performing the assembly operation. Multiple cameras were set-up …

Development Of A New Temporary Fastener For Aerospace Automation, Xiangwen Zhang

Masters Theses

"Temporary fasteners are required in aircraft assembly, especially in the assembly of wings, fuselage, and aircraft skin's substructure prior to drilling holes for permanent fasteners by automated drilling machines. The objective was to develop a temporary fastener that can be installed, clamped, loosened, and removed from one side with a short head length. Published papers, web pages and patents relating to temporary fasteners were reviewed. Then by considering the ability to meet the operation requirements and concerns, a temporary fastener was designed with the following advantages:

• a simple structure that can be easily fabricated
• a short head length to save …

Manufacturing And Performance Evaluation Of Out-Of-Autoclave Sandwich Composites, Sriram Nagarajan

Masters Theses

"Composite sandwich structures are being increasingly employed in applications which require high strength, high in-plane and flexural stiffness coupled with a reduction in weight. Sandwich composites used in the aerospace industry are typically manufactured using high pressure autoclave processing which is expensive and time consuming. A viable low cost alternative is the Out-of-autoclave (OOA) process. One of the most dominant failure modes in sandwich composites is the debonding that occurs at the facesheet skin to core interphase leading to severe degradation of structural properties of the sandwich. A well formed adhesive bond at the skin to core interphase and improved …

Enhancement Of Vortex Induced Vibrations Using Roughness Strips, Ashwin Vinod

Masters Theses

"The current experimental work focuses on studying the effects of surface roughness on vortex induced vibration (VIV) of an elastically mounted circular cylinder which is free to vibrate in a direction transverse to the flow. Flow separation in known to occur due to viscous effects when a fluid flows over a bluff body. The separation of fluid causes shedding of alternating vortices in the downstream region, which in turn impart an alternating force on the bluff body. The vibrations incurred due to such forces are called as Vortex Induced Vibrations (VIV) and have been traditionally known to be harmful to …

Processing Of Continuous Fiber Reinforced Ceramic Composites For Ultra High Temperature Applications Using Organosilicon Polymer Precursors, James Robert Nicholas

Masters Theses

"The current work is on the development of continuous fiber reinforced ceramic materials (CFCCs) for use in ultra high temperature applications. These applications subject materials to extremely high temperatures (> 2000⁰C). Monolithic ceramics are currently being used for these applications, but the tendency to fail catastrophically has driven the need for the next generation of material. Reinforcing with continuous fibers significantly improves the toughness of the monolithic materials; however, this is a manufacturing challenge. The development of commercial, low-viscosity preceramic polymers provides new opportunities to fabricate CFCCs. Preceramic polymers behave as polymers at low temperatures and are transformed into ceramics …

Effects Of Initial Conditions On Rayleigh-Taylor Instability Using Elastic-Plastic Materials, Pamela Susan Roach

Masters Theses

"When an elastic-plastic solid is accelerated by a fluid of lower density, Rayleigh-Taylor instability (RTI) is observed, and the instability is mitigated by the material's mechanical strength, initial conditions, and the acceleration that drives the instability. Such instances of RTI are observed in supernovas, explosive welding, and inertial confinement fusion. In contrast to Newtonian fluids, experimental study of RTI in accelerated solids is traditionally hindered by difficulty to measure material properties and exceedingly small time scales. An understanding of the role initial conditions and material properties have on the growth of RTI will lead to better control of the instability. …

Development Of A Postprocessor For A Multi-Axis Cnc Milling Center, Mihir Satish Adivarekar

Masters Theses

"Most of the current college design and manufacturing curricula are primarily focused on computer aided design (CAD), while less emphasis is given to computer aided manufacturing (CAM). A great opportunity has been missed as the benefits of CAD/CAM cannot then be fully learned. Postprocessor plays a vital role in integration of CAD//CAM with computer numerically controlled (CNC) machines. Hence, postprocessor must be developed accurately. This thesis is composed of one paper. Paper I proposes a novel methodology to determine compensation vectors for the post processor of multi-axis milling center. The new approach that has been implemented in Paper I involves …

A Generalized Approach For Compliant Mechanism Design Using The Synthesis With Compliance Method, With Experimental Validation, Ashish B. Koli

Masters Theses

"Compliant mechanisms offer numerous advantages over their rigid-body counterparts. The synthesis with compliance technique synthesizes compliant mechanisms for conventional rigid-body synthesis tasks with energy/torque specifications at precision positions. In spite of its usefulness, the method suffers from some limitations/problems. The purpose of this work is to investigate these sensitivities with the synthesis with compliance technique and improve upon existing method. A new, simple but efficient, method for synthesis with compliance using an optimization approach is proposed, and its usefulness and simplicity demonstrated over the existing method. The strongly and weakly coupled system of kinematic and energy/torque equations in the existing …

A Friction Prediction Model For Small Si Engines, Avinash Singh

Masters Theses

"A substantial portion of the input fuel energy in an SI engine is lost towards overcoming the frictional forces from various rubbing parts. These frictional losses are very significant in small engines and these losses can be reduced by incorporating some design changes. A semi-empirical friction prediction model was studied and modified with the help of the experimental results for small SI engines. This model is dependent upon engine geometry and speed. The model divides the frictional work into different sub-assemblies of the engine and these sub-assemblies are in turn divided to determine the friction associated with individual components. A …

Dynamic Contact Analysis Of A Piezoelectrically Driven Ultrasonic Crawler-Actuator, Dwight Santiago Maness

Masters Theses

"A standing wave ultrasonic motor (SWUM) is presented in this thesis. The actuator is piezoelectrically powered and operates in the first and second bending modes to move forwards and backwards, respectively. The kinematic stability of the crawler, backed by experimental results is shown in the first paper presented in this thesis. This study demonstrates that in the absence of a preload or kinematic constraints, the crawler shows vertical stability. A full transient analysis using the finite element method is performed characterizing the speed and contact variables is conducted in the second paper. The results show that given enough time the …

Paste Development And Co-Sintering Test Of Zirconium Carbide And Tungsten In Freeze-Form Extrusion Fabrication, Ang Li

Masters Theses

"Ultra-high temperature ceramics are being investigated for future use in aerospace applications due to their superior thermo-mechanical properties, as well as oxidation resistance, at temperatures above 2000°C. However, their brittle properties make them susceptible to thermal shock failure. Components fabricated as functionally graded materials (FGMs) can combine the superior properties of ceramics with the toughness of an underlying refractory metal by fabricating graded composites. This paper discusses the grading of two materials through the use of a Freeze-form Extrusion Fabrication (FEF) system to build FGMs parts consisting of zirconium carbide (ZrC) and tungsten (W). Aqueous-based colloidal suspensions of ZrC and …

Development Of A Methodology For Pseudo-Rigid-Body Models Of Compliant Segments With Inserts, And Experimental Validation, Raghvendra Sharadchandra Kuber

Masters Theses

"Compliant mechanisms have shown a great deal of potential in the last few decades in providing better solutions to design problems with numerous benefits; however, their use has been limited due to current challenges in the material selection. With ever increasing focus on the applications of compliant mechanisms, it is necessary to find alternatives to the existing materials and methods of prototyping. The purpose of this work is to develop a methodology for pseudo-rigid-body models of compliant segments with compliant inserts, comprised of a resilient material placed between the layers of a softer material, to alleviate any creep and strength …

Transmission Shaft Design For Hydrokinetic Turbine With Reliability Consideration, Goutham Pusapati

Masters Theses

"Hydrokinetic energy, a relatively new kind of renewable energy, can be generated from flowing water in rivers or oceans. Hydrokinetic turbines (HKTs) are a major system for hydrokinetic energy, and the reliability of the HKTs is critical for both their lifecycle cost and safety. The objective of this work is to apply advanced methodologies of reliability analysis and reliability-based design to the transmission shaft design for a horizontal-axis, non-submerged HKT. The deterministic shaft design is performed first by considering failure modes of strength and deflection using distortion energy, maximum shear and deflection theories. Then the reliability analysis of the shaft …

Water Management Capabilities Of Bio-Inspired Flow Field Configurations For Polymer Electrolyte Membrane Fuel Cells, Nicholas Warren Freer

Masters Theses

"Fuel cells have received an increasing amount of attention over the past decade for their power production capabilities. Polymer electrolyte membrane (PEM) fuel cells in particular are researched because of their high power density, large range of operating conditions, green products, and ease of scalability. PEM fuel cells do have a number of issues that reduce their overall performance. These issues include variations in reactant distribution, materials issues for the bipolar plate, and flooding caused by poor water management. Variations in the reactant distribution causes lower overall power output due to regions of low reactant density. This means that optimizing …

Experimental Determination Of Colburn And Friction Factors In Small Plate Heat Exchangers With High Surface Enlargement Factors, Andrew H. Pike

Masters Theses

Experiments were conducted to measure the performance of several small brazed plate heat exchangers. A test apparatus was designed and constructed that allowed for the easy switching of the plate heat exchangers, as well as having the ability to electronically monitor and record the inlet and outlet temperatures, pressures, and flow rates. The flow rates and applied electrical power were controlled electronically by the same program which recorded the data. De-ionized water was used as the heat transfer medium to reduce the uncertainty related to fluid properties.

An existing mathematical model was used to create Colburn and friction factors based …

High Capacity Lithium-Ion Battery Characterization For Vehicular Applications, Sazzad Hossain Ahmed

Masters Theses

A lithium-ion battery is one of the key research topics in energy storage technologies. Major characterization tests such as static capacity, open circuit voltage (OCV), hybrid pulse power characterization (HPPC) have been conducted on two different chemistries, LiMnNi and LiFePO₄, high capacity lithium-ion batteries over a wide range of temperatures from 50ºC to -30ºC. Detail analysis of temperature effects on battery capacity and simple models of direct current resistance (DCR) increment and power decrement over temperatures have been proposed using the test results. Electrochemical impedance spectroscopy (EIS) tests have been performed to find out the dominant internal resistances …

Absorber Geometry Optimization For A New Wave Energy Converter, Rachel A. Durren

Masters Theses

Alternative energy technologies are on the forefront of research due to the rising costs of oil and natural gas. One relatively under development source of energy is ocean waves. In order to make the use of ocean waves economically viable, the amount of energy absorbed by wave energy converters (WEC) must be optimized. The research within presents a new conceptual design, "Aqua Fly", for a WEC with emphasis on maximizing the amount of energy absorbed. The energy absorption component of the "Aqua Fly" was isolated and a small scale 2-D study of energy absorption. First, the amount of energy in …

Benchmarking Of A Single-Cylinder Engine Toward The Development Of A Direct Fuel-Injection System, Michael J. Nienhuis

Masters Theses

In this study, the performance and efficiency of a single-cylinder gasoline, fourstroke cycle engine was benchmarked in support of the Formula SAE student project. The development of an engine test stand, instrumentation, data acquisition, and test plan is described in detail. Experimental results in the areas of engine performance and efficiency are discussed. Physical test data were used to refine a previous model of a single-cylinder, gasoline, direct-injection engine. Results from this effort are discussed and compared to those obtained in a preliminary study. The current work advances the development of more efficient power-train technologies for application in small displacement …

Design Of A Catenoidal Shaped Anechoic Termination, Kyle Myers

Masters Theses

An analytical model is developed in this thesis to predict the reflection coefficient of an anechoic termination consisting of a catenoidal horn connected to a tube lined with absorbing material. The theoretical predictions are compared to experimental measurements on a prototype. Comparisons are made for a variety of arrangements, including, an open horn, and a horn connected to absorbing terminations of two different lengths. The absorbing terminations are either open or closed to the environment and the analytical model can account for both these scenarios. The results indicate that the new model can accurately predict the reflection coefficient for each …

Investigating The Effects Of Internally Trapped Residuals On The Performance Of A Homogeneous Charge Compression Ignition (Hcci) Engine, Aaron David Attebery

Masters Theses

"Homogeneous charge compression ignition (HCCI) combustion introduces great opportunity for decreased emissions along with greater engine efficiencies. Implementing an innovative combustion mode such as HCCI presents a great challenge for the engine research community. One such challenge is controlling the innate cyclic variability from this chemical kinetics controlled auto-ignition event when transitioning to or from a SI operating mode. This work includes the study of cycle-to-cycle dynamics that occur within the partial burn regime of an HCCI engine as it approaches the misfire limit. Within this regime there are many successive incomplete combustion events that will impact the next cycle …

Force Sensing Of An Asymmetric Dielectric Barrier Discharge Using Mechanical Resonators, Mark Dawson Emanuel

Masters Theses

"Dielectric barrier discharge (DBD) plasma actuators are of great interest in flow control research and application. DBD plasma actuators are low-cost, lightweight, high voltage devices that have the capability of generating small amounts of thrust on the order of a few tenths of a gram. The thrust is created by rapidly pulsing plasma discharges which correlate to the frequency of the applied alternating current waveform, in the low kilohertz range.

Plasma actuators experience a reactant force generated by the pulsed plasma charging and then expelling air away from the charged surface. This force fluctuates with time as the plasma is …

Development Of Kinectᵀᴿ Applications For Assembly Simulation And Ergonomic Analysis, Chinmay Prakash Daphalapurkar

Masters Theses

"Marker-less motion capture technology has been harnessed for several years to track human movements for developing various applications. Recently, with the launch of Microsoft Kinect, researchers have been keenly interested in developing applications using this device. Since Kinect is very inexpensive (only $110 at the time of writing this thesis), it is a low-cost and a promising substitute for the comparatively expensive marker-based motion capture systems. Though it is principally designed for home entertainment, numerous applications can be developed with the capabilities of Kinect. The skeleton data of a human being tracked by a single Kinect device is enough to …

Process Planning And Control Of Functionally Graded Parts Using Freeze-Form Extrusion Fabrication, Bradley Kenneth Deuser

Masters Theses

"Freeze-form Extrusion Fabrication (FEF) is an additive manufacturing technology that is capable of fabricating complex three-dimensional parts. FEF works by depositing an aqueous-based colloidal ceramic or metal paste in a layer-by-layer fashion below the freezing point of the aqueous medium as to rapidly freeze the paste. The FEF machine in the present study is equipped with three syringes and is capable of mixing each paste in a desired composition ratio by using an inline static mixer. Compensation for the transport delay caused by the static mixer is necessary; therefore, an algorithm was developed to apply a one-dimensional (1D) composition gradient …

Methods Of Optimizing The Gas Exchange Process To Improve Fuel Efficiency Of Small Carbureted Spark Ignition Engines, Cory Hannibal Huck

Masters Theses

"Fuel efficiency of internal combustion engines long has been a topic of concern. Much effort has been made to optimize the fuel efficiency of large automotive type engines. However, for small engine manufactures subject to tight cost constraints, this has only recently become an area of great focus. A method by which the fuel efficiency of an engine can be improved is through optimization of the intake process. Specifically, reductions in flow losses and the choice of appropriate valve event timings can provide ways to make gains towards more fuel efficient operation. The challenge arises when the focus is on …

Advanced Moisture Modeling Of Polymer Composites, Nathan Robert Roe

Masters Theses

"Composite materials absorb moisture from the environment and over time this moisture absorption affects the mechanical performance of the material. In order to determine the long-term moisture effects on the component, representative parts must be tested after having been exposed to an accelerated moisture-conditioning environment. This accelerated environment simulates the worst-case exposure conditions that a part might experience. Currently accepted methodologies for analyzing the time required to condition specimens are limited, only allowing simple geometry and an assumption that diffusivity rates are independent of the flow path or direction. Therefore, a more advanced finite element method is desired. In the …