Mechanical Engineering Commons^™

Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom

Mechanical Engineering

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …

Faculty Instruction Face Shield Project, David Holden, John Schneiderhan

Michigan Tech 3D Designs

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

Experimental Study On Plugging Behavior Of Degradable Fibers And Particulates Within Acid-Etched Fracture, Lufeng Zhang, Fujian Zhou, Wei Feng, Maysam Pournik, Zhun Li, Xiuhui Li

Mechanical Engineering Faculty Publications

As proven from field practices in North America and Northwest China, temporary plugging and diverting acid fracturing is an indispensable technology to enhance stimulation effect and hydrocarbon production of complex carbonate reservoirs. It's well-known that the key to the success of this technology lies in creating a temporary plugging within the previously created fractures. Consequently, many scholars have conducted laboratory experiments to investigate the plugging behavior of fibers and particulates. However, the current devices nearly have certain limitations in simulating temporary plugging experiments. Aiming at this problem, this paper introduced the fracture temporary plugging evaluation system with large fracture size, …

Mechanical Lift Assist Hoist, Jacob Vanblaricom

All Undergraduate Projects

Pneumatic Gripper for Cast Products

By: Jacob VanBlaricom

Mentors: Craig Johnson ([email protected]), Kurt Gray ([email protected] ),

Ted Bramble ([email protected]) , Travis Lamberte ([email protected] )

The Team was tasked by NorthStar Casteel to create a device that would allow for easy mobility and manipulation of unfinished cast products. The device is needed to increase manufacturing time and decrease worker strain. In order to do this the team designed a custom gripper to match the castings produced at this facility. The gripper was powered by a pneumatic system due to the speed and reliability in this …

Prosthetic Hand: Structure, Riley Smith, Riley Smith

All Undergraduate Projects

The objective of this project was to design the structure of a prosthetic hand that has articulating fingers and thumb in order to grip various objects. A design was developed that can add to the available options of prosthetics on the market.

In order to create a base hand for the project, the hand was modeled off of rough human hand dimensions. Analyses determined the feasible size of components. Once a base size was found the movement system in both grip and return form were developed and refined. With the parts being modeled in Solidworks and 3D printed, iterations of …

Conception D’Oreilles Artificielles Réalistes Dédiées À L’Étude Du Confort Acoustique Et Physique Des Protecteurs Auditifs Intra-Auriculaires, Simon Benacchio, Olivier Doutres, Éric Wagnac, Franck Sgard

Rapports de recherche scientifique

Au Québec, environ 360 000 travailleurs sont exposés quotidiennement à des niveaux de bruit susceptibles d’engendrer des problèmes d’audition. Les protecteurs auditifs individuels sont souvent utilisés pour pallier ce problème. Cependant, l’inconfort lié à l'utilisation de ces protecteurs limite la durée du port et donc l'efficacité de la protection. Le développement d'outils de conception acoustique minimisant les sources d’inconforts auditifs et physiques de ces protecteurs tout en assurant une atténuation adéquate constitue le contexte de cette recherche.

La présente étude se concentre sur deux indicateurs du confort associés au port des bouchons d’oreille : l’atténuation et l’effet d’occlusion. L’atténuation quantifie …

Dynamic Testing: An Experimental Approach To Defect Identification In Additive Manufactured Parts, Aimee Allen

Dissertations, Master's Theses and Master's Reports

Today’s additive manufacturing (AM) industry produces specialized parts at low volume or with complex geometries. Traditional testing methods are effective, but costly and time consuming to perform. The AM industry lacks an optimized testing method for identifying internal defects that occur in parts. The evaluation of multiple parts printed on the same build plate for internal defects using various nondestructive (dynamic) testing techniques is presented. From these experiments, perspective was gained on when and how dynamic testing can be used to find defects. Insight gained from these experiments can help the industry in future testing for internal defects.

Binder Saturation, Layer Thickness, Drying Time And Their Effects On Dimensional Tolerance And Density Of Cobalt Chrome - Tricalcium Phosphate Biocomposite, John Ruprecht

All Graduate Theses, Dissertations, and Other Capstone Projects

Traditional metals such as stainless steel, titanium and cobalt chrome are used in biomedical applications (implants, scaffolds, etc.) but suffer from issues such as osseointegration and compatibility with existing bone. One way to improve traditional biomaterials is to incorporate ceramics with these metals so that their mechanical properties can be similar to cortical bones. Tricalcium phosphate is such a ceramic with properties such that it can be used in the human body. This research explores the use of the Binder Jetting based additive manufacturing process to create a novel biocomposite made of cobalt chrome and tricalcium phosphate. Experiments were conducted …

Static Response Calibration Of 3d Printed Thin Walled Structures Using Fused Deposition Modelling, Akhilesh Ravindra Kulkarni

Mechanical and Aerospace Engineering Theses - Archive

3-D printing has enabled flexible, tool-less fabrication that yields numerous benefits. One benefit is unique and complex structural arrangements that increase design freedom to minimize weight. Such arrangements can be guided by advanced topology, shape, and sizing optimization tools using appropriate process constraints to ensure a printable design and can include highly integrated structural details such as stiffeners, flanges, frames, and other connections. 3D printing thin wall aircraft structures presents challenges for material and structural characterization. 3D printing enables integrated structural details, each detail is affected by the print process capability to fabricate the local geometry and deviations from designed …

Material Characterization And Fracture Prediction Of Fdm Printed Parts, Sanchita Sheth

Mechanical and Aerospace Engineering Theses - Archive

In order to take advantage of the design freedom that Additive Manufacturing offers, most applications require reliable material characterization. This can ensure that a design performs within its environment and life requirements. This work discusses two models. One investigates the raster angle dependency of stiffness properties and the other numerically predicts fracture in Fused Deposition Modeling (FDM) printed polymer parts. Pre-processing of FDM geometry was done in Abaqus CAE (SIMULIA TM). FEA and post-processing was done in BSAM, which is a damage prediction software developed for composites. BSAM uses a regularized extended finite element approach of Discrete Damage Modeling. In …

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 …

Characterization Of Thermo-Mechanical Properties Of Copper Nano-Particles Infused Acrylonitrile Butadiene Styrene (Abs)- 3d Printed Specimens, Viswajit Talluru

Mechanical and Aerospace Engineering Theses - Archive

Now a days the use of metal nanoparticle infused polymer is becoming widespread, since the development of polymer with enhanced thermal properties are being used for the growth of electronic packaging industry. In this study, copper nanoparticles are mixed with the Acrylonitrile Butadiene Styrene (ABS) thermoplastic in varying mass proportions, to observe the changes in thermal and structural properties of ABS. As expected, the extruded wire with high nano-particle concentration exhibited much higher thermal conductivity than its raw ABS form. For the case of 2% copper nanoparticle infused ABS using one dimensional steady state heat flux method though extrude wire …

Exploring Convergence Of Snake Skin-Inspired Texture Designs And Additive Manufacturing For Mechanical Traction, Catherine Sue Tiner

Graduate Theses and Dissertations

This research focuses on the understanding, development, and additive manufacture of a 3D printed snake skin-inspired texture pattern. The design functionalities of snake skin were determined through the study of the snake species Python Regius otherwise known as the ball python. Each scale of a snake has hierarchical texture with hexagonal macro-patterns aligned on the ventral surface of the skin with overriding anisotropic micro textured patterns such as denticulations and fibrils. Using a laser-powder bed fusion (L-PBF) process, 420 stainless steel samples were 3D printed which closely resemble the above described directional texture of natural snake skin. This printed surface …

Open Source Waste Plastic Granulator, Arvind Ravindran, Sean Scsavnicki, Walker Nelson, Peter Gorecki, Jacob Franz, Shane Oberloier, Theresa K. Meyer, Andrew Barnard, Joshua M. Pearce

Michigan Tech Publications, Part 1

In order to accelerate deployment of distributed recycling by providing low-cost feed stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic granulator system. It is designed, built, and tested for its ability to convert post-consumer waste, 3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule printers. The technical specifications of the device are quantified in terms of power consumption (380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device can be fabricated for less than $2000 USD in materials. The experimentally measured power use …

Mechanical Properties And Applications Of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing, Matthew J. Reich, Aubrey Woern, Nagendra Gautam Tanikella, Joshua M. Pearce

Michigan Tech Publications, Part 1

Past work has shown that particle material extrusion (fused particle fabrication (FPF)/fused granular fabrication (FGF)) has the potential for increasing the use of recycled polymers in 3D printing. This study extends this potential to high-performance (high-mechanical-strength and heat-resistant) polymers using polycarbonate (PC). Recycled PC regrind of approximately 25 mm² was 3D printed with an open-source Gigabot X and analyzed. A temperature and nozzle velocity matrix was used to find useful printing parameters, and a print test was used to maximize the output for a two-temperature stage extruder for PC. ASTM type 4 tensile test geometries as well as ASTM-approved …

3d Printing A Microfluidic Chip Capable Of Droplet Emulsion Using Ninjaflex Filament, Robert Andrews

Mechanical Engineering Undergraduate Honors Theses

This paper details an investigation into methods and designs of 3D printing a microfluidic system capable of droplet emulsion using NinjaFlex filament. The specific field in which this paper’s experiment is rooted is dubbed “BioMEMS,” short for bio microelectromechanical systems. One prominent research area in BioMEMS is developing a “lab on a chip.” Essentially, the goal is to miniaturize common lab processes to the micro scale, rendering it possible to include these processes in a small chip. Reducing necessary sample sizes, shortening the reaction times of lab processes, and increasing mobility of lab processes can all be realized through microfluidic …

Experimental Study Of Condensation In Different 3d Printed Regenerators In A Thermoacoustic Cooler, Aibek Bekkulov

Theses and Dissertations

Thermoacoustics (TA) deals with the conversion of heat into sound and vice versa. Device that converts heat into acoustic work is called TA heat engine, while the device that transfers energy from a low temperature reservoir to a high temperature one by utilizing acoustic work is called TA cooler. A simple construction of TA cooler includes an acoustic speaker, a resonator tube and a regenerator stack in which the temperature gradient is being imposed. Such a TA cooler has several advantages over traditional compression/expansion cooling machine such as its simplicity of the construction, high reliability and lack of toxic refrigerants. …

Design And Process Of 3d-Printed Parts Using Composite Theory, Jordan Garcia

Theses and Dissertations--Mechanical and Aerospace Engineering

3D printing is a revolutionary manufacturing method that allows the productions of engineering parts almost directly from modeling software on a computer. With 3D printing technology, future manufacturing could become vastly efficient. However, it is observed that the procedures used in 3D printing differ substantially among the printers and from those used in conventional manufacturing. In this thesis, the mechanical properties of engineering products fabricated by 3D printing were comprehensively evaluated and then compared with those made by conventional manufacturing. Three open-source 3D printers, i.e., the Flash Forge Dreamer, the Tevo Tornado, and the Prusa, were used to fabricate the …

Rasters Vs Contours For Thin Wall Ultem 9085 Fdm Applications, Vausman Kota

Browse all Theses and Dissertations

Currently many components are additively manufactured via fused deposition modeling (FDM). However, FDM results in gaps between passes which produces a poor surface finish and porous material that is difficult to hold pressure. Commercial scale air systems require a pressure to be maintained within thin walled components with minimal post processing and clean up after fabrication. A design of experiments (DOE) was created to identify the optimal raster vs contour ratio for UTLEM 9085 CG fabricated using FDM at different build angles and wall thicknesses. A custom-built pressurized test system was developed, the leak rates were calculated and the surfaces …

3d Printing Of Hybrid Mos2-Graphene Aerogels As Highly Porous Electrode Materials For Sodium Ion Battery Anodes, Emery Brown, Pengli Yan, Halil Tekik, Ayyappan Elangovan, Jian Wang, Dong Lin, Jun Li

Department of Mechanical and Materials Engineering: Faculty Publications

This study reports a 3D freeze-printing method that integrates inkjet printing and freeze casting to control both the microstructure and macroporosity via formation of ice microcrystals during printing. A viscous aqueous ink consisting of a molecular MoS₂ precursor (ammonium thiomolybdate) mixed with graphene oxide (GO) nanosheets is used in the printing process. Post-treatments by freeze-drying and reductive thermal annealing convert the printed intermediate mixture into a hybrid structure consisting of MoS₂ nanoparticles anchored on the surface of 2D rGO nanosheets in a macroporous framework, which is fully characterized with FESEM, TEM, XRD, Raman spectroscopy and TGA. The resulting …

Mechanical Characterizations Of 3d-Printed Plla/Steel Particle Composites, Hozhabr Mozafari, Pengfei Dong, Haitham Hadidi, Michael P. Sealy, Linxia Gu

Department of Mechanical and Materials Engineering: Faculty Publications

The objective of this study is to characterize the micromechanical properties of poly-L-lactic acid (PLLA) composites reinforced by grade 420 stainless steel (SS) particles with a specific focus on the interphase properties. The specimens were manufactured using 3D printing techniques due to its many benefits, including high accuracy, cost effectiveness and customized geometry. The adopted fused filament fabrication resulted in a thin interphase layer with an average thickness of 3 μm. The mechanical properties of each phase, as well as the interphase, were characterized by nanoindentation tests. The effect of matrix degradation, i.e., imperfect bonding, on the elastic modulus of …

Developing A Commercial Product Using A Consumer Grade 3d Printer, Calvin Smith

All Graduate Theses, Dissertations, and Other Capstone Projects

The development of affordable, quality, consumer grade 3D printers has allowed entrepreneurs to develop new products and start small businesses. As the print quality of consumer grade printers has improved entrepreneurs have been able to develop consumer quality products without the traditional expense of mass manufacturing. This change from mass manufacturing to small scale and custom production has allowed for the growth of small businesses. Websites such as www.etsy.com show hundreds of small businesses based on 3D printing, these businesses showcase thousands of products ranging from useful household items to cosplay. This thesis covers the process of a small business …

Developing A Testing Instrument To Evaluate The Performance Of 3d-Printed Body-Powered Prosthetic Hands, Araz Al-Dawoodi

All Graduate Theses, Dissertations, and Other Capstone Projects

A 3D printed prosthetic hand is an open source technology that became a good substitution for many products in the market. For many reasons, Low-cost, easy made / easy build. As an open source product, 3D printed prosthetic designs are available to anyone around the world, a good option for young children because they need to have a new prosthetic more frequent until they reach the adulthood age. Most families cannot pay a thousand dollars technology. From the research, it found that that there are not enough studies cover the open source wrist body-powered prosthetic. Other studies covered products used …

Remanufacturing Of Precision Metal Components Using Additive Manufacturing Technology, Xinchang Zhang

Doctoral Dissertations

"Critical metallic components such as jet engine turbine blades and casting die/mold may be damaged after servicing for a period at harsh working environments such as elevated temperature and pressure, impact with foreign objects, wear, corrosion, and fatigue. Additive manufacturing has a promising application for the refurbishment of such high-costly parts by depositing materials at the damaged zone to restore the nominal geometry. However, several issues such as pre-processing of worn parts to assure the repairability, reconstructing the repair volume to generate a repair tool path for material deposition, and inspection of repaired parts are challenging. The current research aims …

An Analytical Design Of Experiments Method For Fatigue Constrained Design Optimization Of A 3d Printed Structure, Ashish Pokharel

Mechanical and Aerospace Engineering Theses - Archive

A design of experiments approach has been used to analytically determine a low cycle fatigue (LCF) constraint for use in design optimization of 3D printed structures. In context of metal additive manufacturing, the process of melting, solidification and consolidation of metal powder introduces very high temperature gradient field within the build which in turn results in high compressive stresses at the core and tensile stresses at the outer surface of the part after it has cooled down to room temperature post build. An approach of finite element modeling in ANSYS Additive has been used to develop a residual stress profile …

Shape-Stabilization Of Pcm/Hdpe Composites With 3d-Printing Applications For Battery Thermal Management, Thomas Benjamin Freeman

Doctoral Dissertations and Master's Theses

Phase-change materials (PCMs) are a useful alternative to more traditional methods of thermal management of Li-ion batteries in electric or hybrid-electric vehicles. PCMs are materials which absorb large amounts of latent heat and undergo solid-to-liquid phase change at near-constant temperature. The goal of this thesis is to experimentally investigate the thermal properties of a novel shape-stabilized PCM/HDPE composite extruded filament. The extruded filament can then be used in a 3D printer for custom PCM/HDPE shapes. These custom PCM/HDPE shapes can be used to help reduce weight, energy consumption, and complexity of the thermal management of the ESS. The PCM used …

Efficacy Of Eluted Antibiotics In 3d Printed Orthopaedic Implants, Mohammed Mehdi Benmassaoud

Theses and Dissertations

Costs associated with musculoskeletal diseases in the United States account for 5.7 % of the Gross Domestic Product (GDP) [1]. As such, there is a need to pursue new ideas in orthopaedic implants that can decrease cost and improve patient care. In the recent years, 3D printing using Fused Deposition Modeling (FDM) or Stereolithography (SLA) has opened several exciting possibilities to create orthopaedic implants. Such implants can be engineered to release antibiotics in a controlled manner either by infusing the drug into the material during manufacturing or by using built-in design features such as micro-channels and reservoirs [2]. The use …

A Multiphysics Study Of Interfacial Properties Of 3d Printed Filaments, Alireza Rezaee

Mechanical and Aerospace Engineering Dissertations - Archive

Fused Deposition Modeling has become the most popular 3-D printing method over the last decade. Due to its potential to save time, cost and, labor, there is a great deal of interest to use this technique for production of functional load carrying parts and assemblies in bio-medical, automotive, aerospace, and oil and gas industries. In general, materials used in FDM process are isotropic; however, parts printed using FDM process show anisotropic mechanical properties with inconsistent properties in the transverse direction to the filaments’ cross-section. This anisotropic behavior is due to the fabrication process, and the inconsistency in the transverse mechanical …

A Study Of Effect Of Bond Length On Bond Strength Using Transient Heat Transfer Analysis, Junaid Mohamed Baig

Mechanical and Aerospace Engineering Theses - Archive

It is important to understand the mechanical properties of the bonding between the adjacent layers of 3D printed parts build by fused deposition modeling. The bonding process is highly nonlinear and depends on various geometrical and thermal process parameters. This work aims to quantify the degree of bonding by calculating bond potential between the extruded layers using finite element heat transfer analysis. Successive transient analysis were carried out using this model by constantly updating the boundary conditions and geometric model during the deposition of the extruded bead. Temperatures at critical points were calculated over a period to calculate the bond …

Modeling And Validations Of Control Parameters For Material Extrusion-Based Additive Manufacturing Of Thixotropic Aluminum Alloys., Lars Herhold

Electronic Theses and Dissertations

Additive Manufacturing (AM) with metals has been accomplished mainly through powder bed fusion processes. Initial experiments and simulations using Material Extrusion Additive Manufacturing (MEAM) have been performed by various researchers especially using low melting alloys. Recently Stratasys Inc. submitted a patent application for the use of their Material Extrusion technology also called Fused Deposition Modeling (FDM) where they describe the process using thixotropic semi-solid alloys. Currently this process using semi-solid, engineering type alloys such as A356 or THIXALLOY 540 aluminum have not been researched to evaluate the control parameters. This research combines the in-depth knowledge of applying thixotropic semi-solid aluminum …