Mechanical Engineering Commons^™

Estimation Of The Fatigue Life Of Additively Manufactured Metallic Components Using Modified Strain Life Parameters Based On Surface Roughness, Peter Grohs

Masters Theses

In this study, a method is developed to estimate the effects of surface roughness on the fatigue life of additively manufactured titanium Ti6Al4V, aluminum 7075–T6, and steel 4340 alloys through modified strain life parameters using finite element analysis (FEA). This method is highly beneficial to the fatigue analysis of as-built additively manufactured metal components, which possess rough surfaces that reduce fatigue life significantly but are challenging to analyze directly using finite element simulation because of complex geometries, i.e., modeling an exact surface profile is arduous.

An effective stress concentration factor, incorporating roughness data, is defined to quantify their effects on …

Gearbox Baffle Optimization, Megan Arduin

Masters Theses

Current literature reveals there is limited consensus on the placement of baffles within a gearbox to reduce churning losses. Thus, there is a need for a process to identify baffle clearances that result in maximum and minimum churning losses. There are two types of baffles: axial and radial. While both axial and radial baffles cause reductions in churning losses to various degrees, the focus is on the effect of radial baffles. The effect of a board (rectangular plate) baffle location on the churning losses of a single gear gearbox are evaluated using computational fluid dynamics (CFD) implemented in Ansys. Several …

Modeling And Simulation With Optimal Gear Ratio For A Forward-Looking, Velocity-Driven, Power-Split Hybrid Electric Vehicle, Sonal Babasaheb Kanap

Masters Theses

Increases in vehicle demand and fossil fuel consumption are major contributors to environmental problems, such as air pollution and climate change. This has led to research on alternative, energy-efficient vehicle technologies. Automobile users are now preferring comfortable vehicles with minimal fuel consumption and with more efficient engines. Hybrid cars are becoming common because of their advantage of running cleaner and with better gas mileage. A hybrid car runs on the power of both an electric motor and a gasoline engine. This mechanism helps cut fuel consumption and conserve energy. An additional advantage is a regenerative braking system that helps recharge …

Cfd Study Of Aerodynamic Drag Reduction Tool Of A Generic Sports Utility Vehicle (Suv), Samira Ishrat Jahan

Masters Theses

The Sports Utility Vehicle (SUV) has been a popular automobile choice in North America for over 50 years due to its seating and hauling versatility and good towing capacity. This widespread popularity has resulted in manufacturers pushing for increased horsepower and cabin size. Unfortunately, the limiting factor has been fuel economy which is governed by the vehicle aerodynamics. A reduction in aerodynamic drag can result in better fuel economy. The goal of this study is to reduce the aerodynamic drag of a generic SUV and the efficient application of drag reduction devices to control flow separation. An initial study has …

Algorithm For Geodetic Positioning Based On Angle-Of-Arrival Of Automatic Dependent Surveillance-Broadcasts, Richard Allen Gross

Masters Theses

This paper develops a non-precision, three-dimensional, geodetic positioning algorithm for airborne vehicles. The algorithm leverages the proliferation of Automatic Dependent Surveillance – Broadcast (ADS-B) equipped aircraft, utilizing them as airborne navigation aids to generate an RF Angle-of-Arrival (AOA) and Angle-of-Elevation (AOE) based geodetic position. The resulting geodetic position can serve as a redundant navigation system for use during locally limited Global Navigation Satellite System (GNSS) availability, be used to validate on-board satellite navigation systems in an effort to detect local spoofing attempts, and be used to validate ADS-B position reports.

The navigation algorithm is an implementation of an Extended Kalman …

Optimal Energy Management For Forward-Looking Serial-Parallel Hybrid Electric Vehicle Using Rule-Based Control Strategy, Abhijit Bhaskar Jadhav

Masters Theses

In today’s sophisticated era of technology, resolving environmental problems is a matter of grave concern. Developing hybrid electric vehicles is a good step towards environmental preservation, since they use less fuel compared to conventional vehicles because of the combination of electric and mechanical energy. A hybrid electric vehicle reduces dependence on fossil fuels and hence lowers emissions. Specifically, a hybrid powertrain that includes a conventional gasoline engine and a brushless DC motor offers great potential to meet stringent CO₂ regulations and fuel economy requirements. This thesis focuses on the effects of initial state of charge (SOC) stored in Hybrid …

Training Set Density Estimation For Trajectory Predictions Using Artificial Neural Networks, Zachary Reinke

Masters Theses

Demand on earth orbiting surveillance systems in increasing as more equipment is put into orbit. These systems rely on predictive techniques to periodically track objects. The demand on these systems may be reduced if object trajectory data to develop scalable training sets used for training artificial neural networks (ANNs) to predict trajectories of a dynamic system. These methods use multi-variable statistics to analyze data energy content to provide the ANN with low density, feature-rich, training data. The developed techniques have been shown to increase ANN prediction accuracy while reducing the size of the training set when applied to a linear …

Controlled Switching In Kalman Filtering And Iterative Learning Controls, He Li

Masters Theses

“Switching is not an uncommon phenomenon in practical systems and processes, for examples, power switches opening and closing, transmissions lifting from low gear to high gear, and air planes crossing different layers in air. Switching can be a disaster to a system since frequent switching between two asymptotically stable subsystems may result in unstable dynamics. On the contrary, switching can be a benefit to a system since controlled switching is sometimes imposed by the designers to achieve desired performance. This encourages the study of system dynamics and performance when undesired switching occurs or controlled switching is imposed. In this research, …

Characterization Of The Surface Condition In Aa6061 Resulting From Deep Rolling As A Function Of Common Industrial Parameters, Andrew Kenneth Layer

Masters Theses

"Roller burnishing is widely used in industry to improve the surface finish and fatigue life of components. As weight reduction continues to grow in the automotive and transportation industries, deep rolling can help maintain product performance by mitigating the increase in component stresses resulting from lower weight systems. Deep rolling parameters such as tool, applied angle, feed rate, spindle speeds, and relative tool direction all affect cycle time, product performance, and appearance. The effects of common industrial parameters on the resultant surface roughness and residual stress profiles were studied in this investigation. The samples were manufactured on a CNC lathe …

Multiphysics Prediction Model Of Microwave Curing For Thick Polymer Composites, Siva Dasari

Masters Theses

"Microwave curing technologies have many advantages over the traditional thermal curing methods for the manufacturing of fiber reinforced polymers, especially the processing speed and energy efficiency. Energy can be instantaneously transferred through applied electromagnetic fields and heat is generated based on dipolar rotational interactions. Microwave curing processes have been used for glass fiber composites but there are significant challenges associated with microwave curing of carbon fiber composites. Efficient heating may be difficult due to high dielectric loss associated with carbon fibers. Laminate quality will be highly dependent on the uniformity of the electromagnetic field in the material. In this work, …

Laser Machining Countersinks In Carbon Fiber Reinforced Polymer, Leon James Neely Hill

Masters Theses

“Laser machining countersinks with a frequency doubled Q-switched diode pumped Nd:YAG laser is demonstrated. Tests were conducted in 0.100" thick IM7 prepreg CFRP with [0,90]3S orientation. The HAZ is minimized to avoid stress concentrations in the epoxy matrix. A chamber and filtration system was designed and built to contain the byproducts produced in the machining process. The variables investigated are the number of repetitions in the offset path, the plunge rate, and the line energy. The research was performed over one baseline study, one parameter space exercise, two full factorial experiments, and one repeatability study. Assessment was done under an …

Performance Evaluation Of Bmi Resin System For Thin-Ply Composites, Manoj Kumar Reddy Rangapuram

Masters Theses

"Composites materials are increasingly being used in aerospace applications over the past few years. The unique properties like high strength to weight ratio, thermal stability, fatigue and corrosion resistance set them apart from the conventional materials. Composite materials are well suited for the applications where weight is the primary concern in the design. Composites structures are vulnerable to mechanical as well as thermal loadings. Transverse micro-cracking and delamination are the most common type of failures in composite materials. The thickness of the ply being used play a key role dictating the properties of the resultant composite structure. As the ply …

Aerosol-Jet Printing And Flash Sintering Of Conformal Conductors On Non-Planar Surfaces, I-Meng Chen

Masters Theses

”The printed electronics have been broadly applied in our daily lives, many new manufacturing methodologies are studied and investigated. The research here presented the full manufacturing process of printed conductors of aerosol printing and flash sintering techniques on substrates such as planar and non-planar surfaces.

The aerosol printing (AJP) was introduced because of its simplicity in experimental setup and flexibility of printing. It produces less ink waste and consumes less manufacturing cost. Furthermore, it has the direct-write ability to print in any customized patterns or shapes on non-planar surfaces. In this study, the Cu NPs was selected as the functioning …

Light Touch Based Virtual Cane For Balance Assistance During Standing, Sindhu Reddy Alluri

Masters Theses

"Can additional information about one's body kinematics provided through hands improve human balance? Light-Touch (LT) through hands helps improve balance in a wide range of populations, both healthy and impaired. The force is too small to provide any meaningful mechanical assistance -- rather, it is suggested that the additional sensory information through hands helps the body improve balance.

To investigate the potential for improving human balance through biofeedback through hands, we developed a Virtual Cane (VC) for balance assistance during standing. The VC mimics the physical cane's function of providing information about one's body in space. Balance experiments on 10 …

The Effect Of Cell Size And Surface Roughness On The Compressive Properties Of Abs Lattice Structures Fabricated By Fused Deposition Modeling, Leah Hope Mason

Masters Theses

"Postprocessing is an important step in many manufacturing methods, but it is especially important for additive manufacturing. Researchers looking to improve the surface roughness of acrylonitrile butadiene styrene (ABS) parts fabricated by fused deposition modeling (FDM) have determined that acetone smoothing not only achieves improved surface roughness but increases compressive strength as well. This could be very beneficial to lattice structures, which are known for already having an excellent strength to weight ratio. If the compressive strength of ABS lattice structures could be improved even further using acetone smoothing, it could expand the applications for plastic lattice structures and improve …

Optimization Of Analytical Inverse Heat Transfer Recovery Solution, Nathan Schick

Masters Theses

This thesis describes the different methods used when trying to solve inverse heat transfer problems, particularly those involving recovering heat flux. There are currently several techniques to measure the temperature history in an object subjected to heat transfer using various temperature sensors, however these types of sensors are gradually being replaced by Temperature Sensitive Paints (TSP), a technique that is more accurate and provides a better spatial resolution. TSP is a polymer that is applied on a base object. Changes in temperature in the polymer result in variations of the luminescence intensity in the paint. These variations can be captured …

Design Of A Portable Biogas Purification And Storage System, Anilkumar Kosna

Masters Theses

Biogas is produced from the decomposition of organic materials like manure, sewage sludge or crop fodders in anaerobic digesters. It consists mainly of 40 – 75 % of methane (CH₄), 15 – 60 % of carbon dioxide (CO₂) and trace amounts of other components. The principle constituents of biogas are similar to natural gas. Natural gas has 87 – 97 % of methane (CH₄) and 0.1 – 1 % of carbon dioxide. Natural gas is known to be an alternative fuel with a wide range of applications. The commercial purification technologies exist for large-scale …

Liquid-To-Liquid Low Grade Waste Heat Recovery Using A Two-Channel Loop, Waleed Farwana

Masters Theses

The use of thermoelectric generators (TEGs) for producing electric energy from low grade “waste heat” has been theorized to provide a sustainable and low-cost energy source for electric power plants. The purpose of this study is to model and experimentally validate a TEG device that takes advantage of low grade waste heat (approximately 100-150 degrees Celsius) in liquid form in order to generate power that can be used for various applications in the surrounding environment. This research aims to demonstrate that optimized TEG designs bear the potential to compete with other methods of low grade waste heat energy harvesting in …

Variable Reluctance Virtual Torque Sensor For Automotive Applications, Vivek Iddum

Masters Theses

Torque sensing has been realized as one of the critical aspects in improving the dynamic vehicle performance in automotive systems. This thesis mainly presents the work on the development of a novel torque measurement method based on the estimation of nth-order flywheel angular acceleration from the variable reluctance flywheel speed sensor pulses. The number of firings in the engine determine the order of the harmonic to be used for torque estimation. The nth-order flywheel angular acceleration is computed using a micro-controller with built in timer counter and an associated signal conditioning circuit. The pulses obtained from the flywheel speed sensor …

Mathematical Modeling And Empirical Validation Of A Conceptual Exoskeleton For Astronaut Glove Augmentation, Joseph Kissling

Masters Theses

Space presents numerous difficulties for astronauts conducting their work, not the least of which is the spacesuit that is worn to protect them from space. It has long been known that a spacesuit is difficult to work in, especially the rigid and pressurized gloves that put strain on the astronaut's hands, frequently leading to injuries. Astronaut gloves inhibit more than 50% of their strength in some cases [1]. NASA and other space agencies have been working to alleviate these problems by attempting to mechanically augment the gloves to reduce the exertions of the astronaut. To date, no augmentation systems have …

Control-Oriented Automatic Transmission- Based Powertrain Modeling And Simulation With Judder, Harshal B. Kundale

Masters Theses

This work presents automatic transmission-based powertrain modeling. The powertrain consists of an engine, torque converter with lock up clutch, transmission gearbox, propeller shaft, and vehicle body. Simplified powertrain component models are developed for vehicle powertrain dynamic response analysis and future control work. The powertrain components are modeled with algebraic and first order non-linear differential equations. A MATLAB-based powertrain simulation system is developed to investigate the transient characteristics during lock up of torque converter. Simulation results are used in the determination of effects of judder on torque and angular velocity. Clutch judder is a self-excited vibration that occurs during the clutch …

Experimental Comparison Between Hollow Cathodes With Cermet, Lanthanum Hexaboride, And Barium Oxide Insert Materials, Nagual Simmons

Masters Theses

This thesis compares two different hollow cathode assemblies (HCA) using three different insert materials. NASA’s Jet Propulsion Laboratory (JPL) provided the H6 HCA and the Lanthanum Hexaboride (LaB₆) insert. A barium oxide (BaO) insert was purchased from Ebeam and used with the H6 HCA. The novel Cermet material was purchased from Plasma Controls, LLC and the HCA was based on the JPL H6 HCA. Plasma properties in the external region of all three inserts and the internal region of the LaB₆ were determine using two separate Langmuir probes. Various operating points were tested at a combination of …

Investigation Of Discrete Element Methods For Stud To Turf Interactions, Justin Rittenhouse

Masters Theses

Artificial turf is frequently used in sports today and attempts to advantageously replicate a natural grass/soil playing surface. Despite numerous advantages, the technology is correlated with an increase in injuries. The concept behind this research is to create and validate a discrete element model (DEM) for the ground/foot interaction through the use of open source software. After validation, the goal is to analyze an arrangement of studs to determine what role stud geometry plays on torque [N-mm] and force [N] generation. The validation data was provided through laboratory experiments. Three football studs attached to a rigid bracket were turned at …

Determination Of Chemical Notch, KChem On Aluminum And Steel When Subjected Under Slow Strain Rate Test In Corrosive Environment, Joshua Teo Lee Kuok

Masters Theses

When designing for any mechanical components or system, the question would arise as to how the material would react to the loads subjected on it? Would the component survive its service load? How would it react to environmental corrosion? To answer these questions, the technique used in this thesis paper is the Slow Strain Rate Test (SSRT) method. Aluminum and steel were chosen as the material to be tested in this paper. Al 7075-T651, and Al 6061-T651 was chosen due to its wide range of application, high strength to weight ratio and ease of machinability. It is highly used in …

Forward-Looking, Velocity-Driven, Powertrain Modeling And Optimal Control For Continuous Variable Transmission, Paresh Deshmukh

Masters Theses

This thesis is the second part of a two-part study focused on improving Continuous Variable Transmission (CVT) ratio management and control. The objective of the overall project was to develop a methodology for a vehicle with a CVT and a downsized gasoline engine to deliver the maximum vehicle fuel economy within drivability and performance constraints. The first part of this study, as described in [1], focuses on developing a cycle driven model for optimizing the CVT ratio. The study presented in this paper focuses on developing a velocity driven model to simulate the real-time behavior of a vehicle. The results …

Laser-Aided Additive Manufacturing Of Glass, John Michael Hostetler

Masters Theses

“This thesis presents various approaches for the laser-aided additive manufacturing of glass. First, a technique is investigated to create free-form, low to zero coefficient of thermal expansion structures out of silica-gel. A CO₂ laser was coupled through a gantry system and focused onto a binder-free silica-gel powder bed (15-40 μm particles). Prior to writing each layer, powder is dispensed by sifting it onto the build platform as opposed to a conventional wiper system, avoiding contacting and potentially damaging sensitive parts. After deposition, the parts are annealed in a furnace to increase their strength. The influence of various process parameters …

Advanced Process To Embed Optical Fiber Sensors Into Casting Mold For Smart Manufacturing, Raghavender Reddy Jakka

Masters Theses

"Optical fiber sensors embedded in metals with distributed sensing can sense temperature at multiple points with single fiber. This is useful for smart manufacturing like structural health monitoring in aerospace industry and smart molds in manufacturing plants. There is a huge difference in thermal coefficient of expansion for fiber and metal. This is the reason for the increase in sensitivity for embedded fiber sensors. However, at high temperatures, the stress on the fiber increases, eventually damaging the sensor. The fiber-metal interface determines the sensor performance. A tight interface results in high sensitivity and a gap in the interface enhances sensing …

Controlling Phase Fractions Of 304l-Ss In Selective Laser Melting Using Cooling Rate, Eberechukwu Anthony Okoro

Masters Theses

"This study examines the thermal profile and the ferrite-austenite phase fractions upon heating and cooling of 304- stainless steel powder via Selective Laser Melting (SLM). Experiments were performed to validate the ABAQUS finite element model, while the phase transformation simulation was performed using MatCalc and ThermoCalc. A correlation between the thermo-mechanical changes in ABAQUS and the microstructural changes from MatCalc was obtained by matching their cooling rates. The result indicates that cooling rate has a significant effect on the phase fractions of FCC and BCC formed in 304L stainless steel via the SLM process. The results also indicate that for …

Investigation Of The Information Provided By Light Touch For Balance Improvement In Humans, Anirudh Saini

Masters Theses

"This study investigates the information provided by Light Touch (LT) in improving human postural stability without mechanical assistance. Light Touch, an interaction force with a magnitude about 1 N, is known to improve postural stability in humans during quiet standing. However, the nature of the information from LT that helped improve balance is yet unknown. In this work, we hypothesized that LT provides information about one's body kinematics. We used a haptic robot to provide modulated, measurable light interaction force on the high back haptic location of humans to provide body kinematics-dependent information through LT. Standing balance experiments were performed …

Computational Investigation Of Polymer Electrolyte Membrane Fuel Cell With Nature-Inspired Fibonacci Spiral Flow Field, Suleyman Kose

Masters Theses

"Polymer electrolyte membrane fuel cells (PEMFC) are promising clean energy devices. The flow field design has crucial role in PEMFC performance for effective distribution of reactants and removal of products. Several nature-inspired flow field designs have recently been proposed in the literature. Common characteristics of these designs were sudden changes in the flow direction through sharp bends and flow field geometries restrained to areas having corners. In this thesis, Fibonacci spiral configuration, which is found in the nature from hurricanes to seashells, was considered for flow field pattern of a PEMFC. Contrary to the bio-inspired designs proposed in previous studies, …