Mechanical Engineering Commons^™

Optimized Tip Cooling Using Am Process, Alberto H. Gamez, Lourdes Sarmiento Martinez, Andrew Van Bogelen

Mechanical Engineering

This Final Design Review (FDR) reports on the senior design project undertaken by our team of mechanical engineering seniors at California Polytechnic State University, San Luis Obispo. This project seeks to use the additive manufacturing process to improve the existing design of a Taurus 60 gas turbine injector tip. The current injector tip is owned by Solar Turbines, a designer and manufacturer of gas turbines for electric generation, propulsion, as well as natural resource transportation. The challenge at hand is to design a new injector tip that will be reliable for at least 60,000 hours and provide ease of replacement, …

Mechanical Interfacial Locking And Multiscale Modeling Of Reinforced Thermoplastic Composites For Structural Applications, Anmol Kothari

All Dissertations

The ever-growing pressure of reducing the adverse impact of transportation systems on environment has pushed industries towards fuel-efficient and sustainable solutions. While several approaches have been used to improve fuel efficiency, the light-weighting of structural components has proven broadly effective. In this regard, reinforced thermoplastic composites (RTPC), owing to their high recyclability, higher impact strength and fast cycle times, have become competitive candidates at an industrial scale. However, to implement RTPC toward large scale structural applications several challenges pertaining to material design and manufacturing effects need to be addressed. To this end, a computational study is carried out to address …

A Manufacturing-To-Response Pathway For Formed Carbon Fiber Reinforced Polymer Composite Structures, Madhura Limaye

All Theses

Over the past decade, there has been an increased adoption of thermoplastic and thermoset based continuous carbon fiber reinforced polymer (CFRP) composites for structural applications in several industries. Among the different manufacturing methods, thermoforming process for thermoplastic based continuous CFRP’s offer a major advantage in reducing cycle times for large scale productions. Similarly, out-of-autoclave curing process for thermoset based continuous CFRP’s using heated tooling enables production of large composite structures. However, these manufacturing processes can have a significant impact on the structural performance of parts by inducing undesirable effects. These effects include inhomogeneous fiber orientations, thickness variations, and residual stresses …

Development Of Triangular And Tetrahedral Finite Elements For Solutions To Thermoelastic Instabilities Using Hotspotter, Cortney Samuel Leneave

Electronic Theses and Dissertations

The objective of the work presented in this thesis is to develop first-order triangular and tetrahedral elements for solutions to Thermoelastic Instabilities (TEI) regarding sliding friction systems in Hotspotter.

Hotspotter software uses a finite element method and an eigenvalue method and is an important tool because currently no other commercial software exists which solves the TEI problem for critical velocities and wave numbers of a system. Hotspotter currently uses quadrilateral and hexahedral elements for two and three dimensional analysis, respectively. Typically, tri and tet elements are used in industry when doing static and dynamic stress analysis. Therefore, the Hotspotter user …

Additively Manufactured Metallic Cellular Structures, Okanmisope Aziel Fashanu

Doctoral Dissertations

"Cellular structures are lightweight structures with excellent mechanical, thermal, and acoustic properties. They offer promise in a series of applications, including lightweight applications, sandwich cores, mechanical damping, acoustic absorption, strain isolation, and thermal management. The manufacturing of these complex cellular structures is expensive and time-consuming, which hinders the adoption of these structures in many industries. Advancement in manufacturing technologies, such as additive manufacturing (AM), however, have changed this. AM allows for the rapid and less expensive manufacturing of complex cellular structures. This work aimed to investigate the performance of additively manufactured cellular structures for lightweight and sandwich core applications. In …

Experiments And Modeling Of The Chemo-Mechanically Coupled Behavior Of Polymeric Gels, Nikola Bosnjak

Dissertations

Polymeric materials consist of mutually entangled or chemically crosslinked long njitmolecular chains which form a polymer network. Due to their molecular structure, the njitpolymeric materials are known to undergo large deformation in response to various njitenvironmental stimuli, such as temperature, chemical potential and light.

When a polymer network is exposed to a suitable chemical solvent, the solvent molecules are able to diffuse inside the network, causing it to undergo a large volumetric deformation, known as swelling. In addition to volumetric deformation, this process involves the chemical mixing of the polymer network and solvent molecules, and is typically environmentally responsive. A …

Blast Shock-Wave Characterization In Experimental Shock Tubes, Sudeepto Kahali

Dissertations

Blast-induced traumatic brain injuries have affected U.S. soldiers deployed for extended periods in the gulf and Afghanistan wars. To identify the biomechanical and biochemical mechanisms of injury, critical in the identification of diagnostic and therapeutic tools, compressed gas-driven shock tubes are used by investigators to study shockwave-animal specimen interactions and its biological consequences. However, shock tubes are designed and operated in a variety of geometry with a range of process parameters, and the quality of shock wave characteristics relevant to field conditions and therefore the study of blast-induced traumatic brain injuries suffered by soldiers is affected by those conditions. Lab-to-lab …

Parametric Study Of Residual Stresses In Wire And Arc Additive Manufactured Parts, Hisham Khaled Jamil Abusalma

Mechanical & Aerospace Engineering Theses & Dissertations

Wire and Arc Additive Manufacturing (WAAM) is a cost-effective additive manufacturing process due to its capability to fabricate large metal parts with high deposition rate and low equipment cost. Although this method is gaining popularity in manufacturing industry, more research is needed to understand process parameters’ effects on residual stress (RS) distribution and part distortion. As such, a 3D thermo-elastic-plastic transient model was established in ABAQUS and employed to investigate the effect of process parameters such as the torch speed, the deposition power and the interlayer dwell time on RS distribution and distortion in WAAM part. The numerical model utilized …

Friction Predication On Pin-To-Plate Interface Of Ptfe Material And Steel, Zhuming Bi, Donald W. Mueller

Friction

In this paper, the friction behavior at a pin-to-plate interface is investigated. The pin and plate are made of Polytetrafluoroethylene (PTFE) and steel, respectively, and there is a reciprocating motion at the interface. Governing mathematical models for the relations of design variables and frictions are investigated, and a general procedure is proposed to solve the developed models and predict the friction forces at the interface subjected to given test conditions. Novel models have been developed to represent intrigued friction behaviors affected by various factors such as pin geometrics and finishes, lubrication conditions, and reciprocating speed. The test data from experiments …

Finite Element Analysis Investigation Of Hybrid Thin-Ply Composites For Improved Performance Of Aerospace Structures, Alana M. Zahn

Mechanical & Aerospace Engineering Theses & Dissertations

Commercial and private aircraft have a need for strong yet light materials in order to have the most ideal performance possible. This study looks at the use of thin-ply composite materials to improve the performance of aircraft structures by means of weight savings and/or strength increase when compared to laminates that are composed of exclusively standard-ply materials. In order to perform an investigation based solely on finite element analysis, validation efforts were performed using test data from open hole tension, open hole compression, notched tension, and notched compression specimens. Once the models were validated sufficiently, the same modeling practices were …

Energy Harvesting Using Flextensional Piezoelectric Energy Harvesters In Resonance And Off-Resonance Modes, Mohamed A. Shabara

Mechanical & Aerospace Engineering Theses & Dissertations

Energy harvesting technologies are integrated into various modern devices and systems. These systems include Artificial Intelligence (AI) systems, Internet of Things (IoT), various types of energy harvesters are integrated in many engineering applications such as automotive, aerospace and ocean engineering. In order to develop a fully functioning stand-alone system, it is essential to integrate it with a built in power source such as a battery or a power generator. Also, in many situations, city power sources might not be available. Therefore, reliable, renewable and sustainable local power generators are desired. Piezoelectric energy harvesting (PEH) technologies, which are piezoelectric material-based devices, …

Influence Of Dynamic Multiaxial Transverse Loading On Ultrahigh Molecular Weight Polyethylene Single Fiber Failure, Frank David Thomas

Theses and Dissertations

High performance fibers such as ultrahigh molecular weight polyethylene (UHMWPE) are often used for ballistic impact applications in the form of textile fabrics and composite laminates. In order to predict the ballistic performance of such materials, single-fiber experiments are performed to quantify the material behavior at smaller length scales, which can be applied to larger length scales as a result. Failure of UHMWPE is well understood as a function of simple tension at low and high strain rates, as well as under various multiaxial loading states. However, experimental characterization of single UHMWPE fibers under transverse loading at high strain rates …

Compaction And Residual Stress Modeling In Composite Manufactured With Automated Fiber Placement, Von Clyde Jamora

Mechanical & Aerospace Engineering Theses & Dissertations

Automated fiber placement is a state-of-the-art manufacturing process that allows for complex layup patterns and can quickly place, cut, and restart composite tows. However, with this type of manufacturing process layup defects are inevitable, and manufacturing defects propagate after curing. Process modeling is the considered approach for exploring the defect prediction. Two different but related works were conducted, which are the thermochemical and hyperelastic model and the residual deformation model. For the model before cooling, a hyperelastic model and a thermo-chemical were made to simulate the compaction and heat transfer. Temperature dependent properties that are a function of degree of …

Predictive Model For Thermal And Stress Field In Selective Laser Melting Process -- Part I, Lan Li, Lei Yan, Wenyuan Cui, Yitao Chen, Tan Pan, Xinchang Zhang, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

During the part forming in laser powder bed fusion process, thermal distortion is one big problem due to the thermal stress which is caused by the high cooling rate and temperature gradient. Therefore, it is important to know the effect of process parameters on thermal and stress evolution in the melt zone. In this paper, a 3D finite element model for Selective Laser Melting (SLM) process based on sequentially coupled thermo-mechanical field analysis was developed for accurately predicting thermal history and surface features, like distortion and residual stress. Temperature dependent material properties for performed material 304L stainless steel are incorporated …

Predictive Model For Thermal And Stress Field In Selective Laser Melting Process -- Part Ii, Lan Li, Lei Yan, Yitao Chen, Tan Pan, Xinchang Zhang, Wenyuan Cui, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Finite Element Analysis (FEA) is used to predict the transient thermal cycle and optimize process parameters to analyze these effects on deformation and residual stresses. However, the process of predicting the thermal history in this process with the FEA method is usually time-consuming, especially for large-scale parts. In this paper, an effective predictive model of part deformation and residual stress was developed for accurately predicting deformation and residual stresses in large-scale parts. An equivalent body heat flux proposed from the single layer laser scan model was imported as the thermal load to the layer by layer model. The hatched layer …

Elastic Linear Analysis Of Connecting Rods For Single Cylinder Four Stroke Petrol Engines Using Finite Element Method, Didin Zakariya Lubis, Andoko Andoko

Journal of Mechanical Engineering Science and Technology (JMEST)

A connecting rod is one of the most critical parts in engine assembly which transfers energy from the piston to the crankshaft. The connecting rod mainly undergoes tensile and compressive loading under engine cyclic process. The forces acting on the connecting rod are forces due to maximum combustion pressure and forces due to the inertia of the connecting rod. This research aimed to analyze the design of the connecting rod of single-cylinder four-stroke engines. This study used CAD software for modeling and structural design. Stresses generated across all the locations of the connecting rod were evaluated using FEA Software. Elastic …

Modeling Thermal And Mechanical Cancellation Of Residual Stress From Hybrid Additive Manufacturing By Laser Peening, Guru Madireddy, Chao Li, Jingfu Liu, Michael P. Sealy

Department of Mechanical and Materials Engineering: Faculty Publications

Additive manufacturing (AM) of metals often results in parts with unfavorable mechanical properties. Laser peening (LP) is a high strain rate mechanical surface treatment that hammers a workpiece and induces favorable mechanical properties. Peening strain hardens a surface and imparts compressive residual stresses improving the mechanical properties of a material. This work investigates the role of LP on layer-by-layer processing of 3D printed metals using finite element analysis. The objective is to understand temporal and spatial residual stress development after thermal and mechanical cancellation caused by cyclically coupling printing and peening. Results indicate layer peening frequency is a critical process …

Application And Evaluation Of Full-Field Surrogate Models In Engineering Design Space Exploration, Christopher Murray Thelin

Theses and Dissertations

When designing an engineering part, better decisions are made by exploring the entire space of design variations. This design space exploration (DSE) may be accomplished manually or via optimization. In engineering, evaluating a design during DSE often consists of running expensive simulations, such as finite element analysis (FEA) in order to understand the structural response to design changes. The computational cost of these simulations can make thorough DSE infeasible, and only a relatively small subset of the designs are explored. Surrogate models have been used to make cheap predictions of certain simulation results. Commonly, these models only predict single values …

Analysis And Control Of Fiber-Reinforced Elastomeric Enclosures (Frees), Soheil Habibian

Master’s Theses

While rigid robots are extensively used in various applications, they are limited in the tasks they can perform and can be unsafe in close human-robot interactions. Soft robots on the other hand surpass the capabilities of rigid robots in several ways, such as compatibility with the work environments, degrees of freedom, manufacturing costs, and safe interactions with the environment. This thesis studies the behavior of Fiber-Reinforced Elastomeric Enclosures (FREEs) as a particular type of soft pneumatic actuator that can be used in soft manipulators. A dynamic lumped-parameter model is created to simulate the motion of a single FREE under various …

Nonprehensile Manipulation Of Deformable Objects: Achievements And Perspectives From The Rodyman Project, Aykut C. Satici

Mechanical and Biomedical Engineering Faculty Publications and Presentations

The goal of this work is to disseminate the results achieved so far within the RODYMAN project related to planning and control strategies for robotic nonprehensile manipulation. The project aims at advancing the state of the art of nonprehensile dynamic manipulation of rigid and deformable objects to future enhance the possibility of employing robots in anthropic environments. The final demonstrator of the RODYMAN project will be an autonomous pizza maker. This article is a milestone to highlight the lessons learned so far and pave the way towards future research directions and critical discussions.

Experimental And Modeling Study Of Compressive Creep In 3d-Woven Ni-Based Superalloys, Hoon-Hwe Cho, Dinc Erdeniz, Keith W. Sharp, David C. Dunand

Mechanical Engineering Faculty Research and Publications

Micro-architectured Ni-based superalloy structures, with Ni-20Cr-3Ti-2Al (wt.%) composition and γ/γ′-microstructure, are created by a multi-step process: (i) non-crimp orthogonal 3D-weaving of ductile, 202 μm diameter Ni-20%Cr wires, (ii) gas-phase alloying with Al and Ti, (iii) simultaneous transient-liquid phase (TLP) bonding between wires and homogenization within wires via interdiffusion, (iv) solutionizing to create a single-phase solid solution, and (v) aging to precipitate the γ′ phase. The creep behavior of these 3D-woven γ/γ′ nickel-based superalloys is studied under uniaxial compression via experiments at 825 °C and via finite element (FE) analysis, using a 3D model of the woven structures obtained …

Impact Of Hysteresis Heating Of Railroad Bearing Thermoplastic Elastomer Suspension Pad On Railroad Bearing Thermal Management, Oscar O. Rodriguez, Arturo A. Fuentes, Constantine Tarawneh

Mechanical Engineering Faculty Publications

It is a known fact that polymers and all other materials develop hysteresis heating due to the viscoelastic response or internal friction. The hysteresis or phase lag occurs when cyclic loading is applied leading to the dissipation of mechanical energy. The hysteresis heating is induced by the internal heat generation of the material, which occurs at the molecular level as it is being disturbed cyclically. Understanding the hysteresis heating of the railroad bearing elastomer suspension element during operation is essential to predict its dynamic response and structural integrity, as well as to predict the thermal behavior of the railroad bearing …

Human Knee Fea Model For Transtibial Amputee Tibial Cartilage Pressure In Gait And Cycling, Gregory Lane

Master's Theses

Osteoarthritis (OA) is a debilitating disease affecting roughly 31 million Americans. The incidence of OA is significantly higher for persons who have suffered a transtibial amputation. Abnormal cartilage stress can cause higher OA risk, however it is unknown if there is a connection between exercise type and cartilage stress. To help answer this, a tibiofemoral FEA model was created. Utilizing linear elastic isotropic materials and non-linear springs, the model was validated to experimental cadaveric data. In a previous study, 6 control and 6 amputee subjects underwent gait and cycling experiments. The resultant knee loads were analyzed to find the maximum …

Finite Element Analysis Of Composite Reactor Pressure Vessel, Tejas Vasant Mhetre

Mechanical and Aerospace Engineering Theses - Archive

Reactor Pressure Vessel is the container designed to hold gases or liquids above atmospheric pressure. The focus of this study is to develop Finite Element Model to predict the performance of composite reactor pressure vessel subjected to extreme pressure and temperature and compare with pressure vessel manufactured using conventional materials. In the first part of the study, a pressure vessel system with Carbon steel material under design pressure and temperature have been analyzed for stresses, deformation and Safety Factor. Various loading cases have been discussed during the analysis of pressure vessel. Composite materials have been a suitable replacement to the …

Finite Element Analysis And Design Improvement Of Aerospace Composite Hinges, Gaurang Girish Sonpal

Mechanical and Aerospace Engineering Theses - Archive

Hinges are the most commonly used mechanical bearings to connect 2 objects for relative rotational motion. Modern day aerospace hinges are generally made using either Aluminum, Steel or bronze. The study analyzes the use of composite material as an alternative to traditional materials for manufacturing these hinges. The research is focused on the Finite element Analysis of a composite hinge as well as an aluminum hinge. The load capacity of both the types of hinges are compared. To improve the design of the composite hinge, a combination of composite material and aluminum is used to model a hybrid hinge design. …

Fea Of Carbon Composite As A Substitute For Steel (A992) In Case Of Square Or Rectangular Hollow Cross-Sections As Beams And Columns, Pradeep Ganesh Pai

Mechanical and Aerospace Engineering Theses - Archive

Improvement to an existing design is an ongoing and never-ending process in every field. The improvement can be in a myriad of areas like an increase in strength, reduction in weight, stiffness to a loading condition and so on. The way it is achieved can range from changing the properties of the material used by incorporating various manufacturing processes or by using an alternative material which can sustain the same loading conditions or for that matter, work better than the existing material. Composite materials like Carbon Fiber, Glass Fiber or Kevlar Fiber reinforced plastics, to name few, are being used …

Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one …

Manufacturing Process Simulation – On Its Way To Industrial Application, Dennis Otten, Tobias A. Weber, Jan-Christoph Arent

International Journal of Aviation, Aeronautics, and Aerospace

Manufacturing process simulation (MPS) has become more and more important for aviation and the automobile industry. A highly competitive market requires the use of high performance metals and composite materials in combination with reduced manufacturing cost and time as well as a minimization of the time to market for a new product. However, the use of such materials is expensive and requires sophisticated manufacturing processes. An experience based process and tooling design followed by a lengthy trial-and-error optimization is just not contemporary anymore. Instead, a tooling design process aided by simulation is used more often. This paper provides an overview …

Tissue Stresses In Stented Coronary Arteries With Different Geometries: Effect Of The Relation Between Stent Length And Lesion Length, Xiang Shen, Song Ji, Yong-Quan Deng, Hong-Fei Zhu, Jia-Bao Jiang, Linxia Gu

Department of Mechanical and Materials Engineering: Faculty Publications

In-stent restenosis after stent deployment remains an obstruction in the long-term benefits of stenting. This study sought to investigate the influence of the relation between stent length and lesion length on the mechanics of the arterial wall with different geometries, including straight and tapered vessels. Results showed that when the length of the stent was longer than the lesion length, the maximum stress in plaque and vessel increased as the length of stent increased. When the length of the stent was shorter than the lesion length, the vessel stress induced by stent inflation was lower; both ends of the stenosis …

Effect Of Process Parameters On The Surface Roughness And Mechanical Performance Of Additively Manufactured Alloy 718, Bo Ryan Whip

Browse all Theses and Dissertations

Metal additive manufacturing (AM) is a method to create complex components in a layer-by-layer process. Currently, there is a lack of understanding in the processing-structure-properties-performance relationship, particularly related to defects inherent to the AM process. This work investigates the relationship of process parameters, as-built surface roughness, and mechanical performance for nickel-based superalloy 718 built using laser powder bed fusion. The surface roughness of components built using varied processing parameters was characterized using both nondestructive and destructive measurement techniques. Finite element analysis was used to study the stress concentration on surface profiles. Statistical correlations are presented between contour processing parameters and …