Mechanical Engineering Commons^™

Effect Of Gating Design On Filling And Inclusion Control In An Al-Killed Cr-Mo-Ni Steel, Kingsley T. Amatanweze, Koushik Balasubramanian, Soumava Chakraborty, Viraj A. Athavale, Mario F. Buchely, Laura N. Bartlett, Ronald J. O'Malley, Daniel M. Field, Krista R. Limmer, Katherine M. Sebeck

Materials Science and Engineering Faculty Research & Creative Works

The effect of gating system design on the inclusion population and size distribution in an aluminum-killed low-alloy advanced high strength steel casting was studied. A mold with four different gating systems: pressurized and non-pressurized with side risers, naturally pressurized with a side riser, and naturally pressurized with a top riser, was designed using computational fluid dynamics and solidification software. The design allowed inclusion populations in castings produced with each gating system to be compared during the same pouring event. Samples taken from different positions just below the top surface of each casting were analyzed using an SEM/EDS system with automated …

In-Situ Thermographic Monitoring And Numerical Simulations Of Laser-Foil-Printing Additive Manufacturing, Tunay Turk, Tao Liu, Chia Hung Hung, Richard Billo, Jonghyun Park, Ming C. Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser-foil-printing (LFP) is an additive manufacturing (AM) technique offering advantages over traditional powder-based methods. A deeper understanding of the melt pool dynamics is crucial for optimizing process parameters and achieving high-quality builds. This paper presents a combined approach utilizing numerical simulations and in-situ thermographic monitoring to investigate the relationship between scanning strategies, melt pool dimensions, and cooling rate in LFP. The numerical simulations are employed to predict melt pool behavior using a time-dependent thermal finite element analysis (FEA). Results demonstrate that the simulations accurately predict melt pool dimensions, showing strong agreement with experimental data. Simultaneously, real-time melt pool dynamics were …

Implementation Of Miniature Tensile Specimens In Mechanical Properties Assessment Of Directed Energy Deposited Ti-6al-4v: As-Built And Heat Treated, Saeid Alipour, Sung Heng Wu, Frank Liou, Arezoo Emdadi

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Within the last two decades, additive manufacturing (AM), a. k.a. 3D printing, has provided promising solutions for producing near-net-shape components with intricate geometries. From the material perspective, titanium alloys, one of humankind's most essential structural materials, are being considered the first candidate for AMed parts due to their unique characteristics in strength-weight-corrosion combinations. However, measuring the mechanical properties of designed geometry remains a challenge due to the ineffectiveness of conventional standard tensile specimens in assessing the site-specific and intricate geometries. In AM, the current approach often consists of evaluating standard-sized samples with the assumption that components with complex geometries possess …

High Voltage Junction Box For Demonstrator Vehicle, Benjamin Lubowicki, Ryan Dorste

Williams Honors College, Honors Research Projects

Schaeffler, our industry sponsor for this project, is designing a battery pack for a demonstration vehicle that requires a high voltage junction box to route power to the vehicle. The project type is a unique design of a mechanical component, mechanism, and process. Our objective for this project is to assemble provided electro-mechanical components into an enclosure following a provided electrical diagram. The expected deliverables are the following: 3D CAD assembly of final product, FEA analysis of designed components, 2D print of final product, fabrication and assembly of designed parts, technical report documenting design process and installation. The skills required …

Automatic Scoring Cornhole Board System, Eric Diffendal, Jonah Harsh, Connor Lengel, Brett Sukie

Williams Honors College, Honors Research Projects

The objective is to create a self-scoring cornhole board that can detect and calculate each team's score based on the bags thrown each round and to be created at a low cost/eventually being sold at the current cost of a normal board. When playing cornhole, the game is simple: throw a bag on the board; however, the scores are variable (deduct and add) across each round. The most common issue when playing cornhole is miscalculations of the scores and forgetting the correct scores. Thus, this invention will make gameplay easy for all to play.

Experimental Comparison Of Cycle Modifications And Ejector Control Methods Using Variable Geometry And Co2 Pump In A Multi-Evaporator Transcritical Co2 Refrigeration System, Gabriele Toffoletti, Riley Barta, Steven M. Grajales, Haotian Liu, Davide Ziviani, Eckhard A. Groll

School of Mechanical Engineering Faculty Publications

To reduce the direct global warming impact of refrigerants in HVAC&R applications, low-global warming potential (GWP) refrigerants, including natural refrigerants, have been extensively investigated as alternatives to hydrofluorocarbon (HFC) refrigerants. Among the natural refrigerants, Carbon Dioxide (CO2) offers several advantages, such as excellent transport and thermo-physical properties, being neither toxic nor flammable, and having a low price and high availability around the world. However, the high critical pressure and low critical temperature of CO2 often lead to transcritical operation, resulting in lower efficiency due to the additional compressor power necessary to achieve transcritical operation relative to subcritical HFC cycles. Therefore, …

Range And Accuracy And Of In-Plane Anisotropic Thermal Conductivity Measurement Using The Laser-Based Angstrom Method, Aalok U. Gaitonde, Justin A. Weibel, Amy M. Marconnet

CTRC Research Publications

High heat fluxes in electronic devices must be effectively dissipated to prevent local hotspots, which are critical for long-term device reliability. In particular, advanced semiconductor packaging trends toward thin form factor products increase the need for understanding and improving in-plane conduction heat spreading in anisotropic materials. The 2D laser-based Ångstrom method, an extension of traditional Ångstrom and lock-in thermography techniques, measures in-plane thermal properties of anisotropic sheet-like materials. This method uses non-contact infrared temperature mapping to measure the thermal response to periodic laser heating at the center of a suspended sample. The spatiotemporal temperature data are analyzed via an inverse …

Rapid Convective Quench Apparatus Design, Samuel Fenik, Tyler Horvath, Dane Manias, Nicholas Michel

Williams Honors College, Honors Research Projects

In this project, we will research, model, and simulate the heat transfer of a red-hot steel plate undergoing a rapid quenching process by high pressure water jets. Our objective is to quench the steel plate in such a way so that the steam formed from the initial water contact does not inhibit the oncoming water from making proper contact with the plate. After sufficient research has been done, we will design an apparatus which will perform the optimal quenching method and record temperature data with the goal of obtaining the heat transfer coefficient. The purpose of our project is to …

Cochlear Electrode Insertion Training Model, Sarah Powell, Kaelyn E. Kraley, Nathan J. Smith

Williams Honors College, Honors Research Projects

Cochlear implant surgery is a delicate procedure performed by Otolaryngologists (ENTs) to implant an electronic device into the inner ear to provide a sense of sound for people who are profoundly deaf or hard of hearing. The current practices of training involve cadavers and 3D-printed models. Cadavers are commonly used but are expensive, single-use, and do not provide visual and haptic feedback, which are essential for medical students. 3D printed models are less commonly used and are hard to fabricate and not as realistic. If medical students are not properly trained for this delicate procedure, then risks are significantly increased …

Head Mounted Surgical Robot, Mason Currens

Williams Honors College, Honors Research Projects

The purpose of this design project is to utilize a six degree of freedom, robotic system that will be head mounted device that can either assist in, or perform, facial and optical surgery. The six degree of freedom idea came from current systems used in flight simulations. By optimizing the system to fit the figure of a patient’ s head, many of the present errors in surgical robotics can be reduced. One of the major errors when using a facial tracking robot is sudden impulses, such as a cough or a twitch, that the robot can't precisely track. Mounting the …

Cost-Effective Brake Rotor Resurfacing Tool, Raider Morgan, Benjamin Vaughan

Williams Honors College, Honors Research Projects

Brake rotors can develop uneven spots over time, causing vibration and poor braking performance. Commercial brake lathes are effective but often too expensive or complicated for at-home mechanics. This project aimed to create a low-cost tool, around $200–$300, to resurface four rotors in under two hours. We explored two main designs: a pad file system and a motorized endmill powered by a handheld drill. Calculations ultimately showed that the pad file was not viable, so the final prototype produced was the endmill-based design. Our testing showed we were limited by poor stiffness in the endmill and unforeseen loading. Although the …

Zips Baja Chassis Manufacturing Design, Alex Love, David Scruppi

Williams Honors College, Honors Research Projects

The Society of Automotive (SAE) annually organizes collegiate design team competitions for university organizations nationwide. Baja SAE tasks teams comprised entirely of students with developing, iterating, manufacturing, testing, and competing with an offroad race buggy in accordance with all SAE regulations. Teams are responsible for producing a tech compliant vehicle for each competition season, travelling across the United States to put their designs to the test. In the 2022-2023 competition season, SAE introduced ruleset clarifications on the chassis manufacturing process, essentially mandating the production of all vehicle frames to be manufactured entirely in house with no external assistance. A chassis …

Akronauts Turbopump Research Project, Gerald Drabeck Iii, Michael Mccalla, Joshua Skelton

Williams Honors College, Honors Research Projects

The idea of this project is to design a turbo pump template capable of fitting into future Akronauts rocket designs. This allows the rockets to travel higher due to the reduced net weight. Many methods were used to verify the rigidity and feasibility of the design, such as Finite Element Analysis and fluid dynamics simulations.

Smart Material Actuated Flap, James Lyons, Kristofer Johnson

Williams Honors College, Honors Research Projects

The objective of this project is to develop and evaluate a smart material actuated aerodynamic control surface to determine the viability of these new systems as alternatives to conventional electromechanical and hydraulic systems. The research will begin with the selection of a control surface and actuator design. The concept will then be tailored to create an experimental model for the purposes of this project. Smart materials that suit the model requirements will be selected and procured. Next, the actuators will be shape trained and characterized to meet the model requirements. Then, a benchtop model will be produced for design verification, …

Kb Bioenergy Mobile Dewatering System Research, Wyatt Balser, Nathan Szymczak

Williams Honors College, Honors Research Projects

This report outlines the design and development of a mobile skid-mounted dewatering system intended for high-solids sludge processing at wastewater treatment facilities. The goal was to create a self-contained, transportable unit capable of reliably separating water from sludge using a screw press, while integrating upstream processes such as polymer conditioning, sludge maceration, and pumping. The final design prioritizes serviceability, structural integrity, and operational simplicity, featuring a consolidated equipment layout, engineered piping diagrams, and vendor-specified components.

Throughout the project, multiple design alternatives were evaluated using a weighted decision matrix, leading to the selection of a skid platform over a trailer configuration …

Frictionless System For Planetary Simulant Testing, Hailey Zackiewicz, Morganne Neuman

Williams Honors College, Honors Research Projects

The engineering design process is used to create a frictionless system for planetary simulant testing. Research about different types of bearing is used to brainstorm ideas about how to construct a tray and rail system with minimal friction. Using thought-walkthroughs and a weighted decision matrix, it will be determined which ideas can move forward with a tabletop experiment. Based on the results of the experiment, it will be determined which system will be fabricated and installed for the testing system.

Dual Rotating Mount For Forward Facing Sonar, Javid Miller

Williams Honors College, Honors Research Projects

This project aims to create a mount for forward facing sonar (FFS) that will allow anglers to be able to rotate their sonar transducer manually, or in unison with their trolling motor. When in use with the trolling motor, the rotation will be transferred using a belt and pulley assembly. This assembly will be able to be disengaged to allow for manual rotation. This device is designed for use with the Minn Kota Ultrex trolling motor.

Mid-Wave Infrared Imaging Of Supersonic Combustor Exhaust Flow, Nathan Childs

Browse all Theses and Dissertations

A study was completed on the application of mid-wave infrared (MW-IR) imaging for diagnostics in supersonic combustion exhaust flows, with the objective of enhancing optical access and measurement accuracy. Other optical based techniques of thermography require complicated setups and analysis to determine the temperature of a flow with high accuracy, where MW-IR is a more simplistic "point and shoot" technique. The simplicity of MW-IR comes with the trade off of gaining simplicity but adding uncertainty into the measurements. The MW-IR camera was positioned to view the exhaust of the combustor to provide an unobstructed view of the flow, addressing limitations …

Laminar Separation Control Of An Eppler 387 Airfoil, Vincent R. Sheeler

Browse all Theses and Dissertations

A variety of aerodynamic devices operate at low Reynolds number conditions, such as unmanned aerial vehicles and low-pressure turbines in gas turbine engines. At low Reynolds numbers, many airfoils experience laminar boundary layer separation as the fow lacks the energy to overcome the adverse pressure gradient. Researchers have documented a variety of methods which can suppress laminar separation, and now focus on ways to reduce energy requirements to provide efective fow control. Aspects of fow control strategy such as actuator location and pulsing at frequencies which exploit natural instabilities in the fow can reduce energy requirements. In a study by …

Design And Development Of A Rapid Tensile Quench Rig, Tyler Jewell, Justin Naylor

Williams Honors College, Honors Research Projects

This report outlines the design process and implantation of a tensile quenching rig that incorporated forced convection and a frequency generator. When any metal is quenched, a vapor barrier forms around it. When this happens, it limits the heat flux that may occur until the barrier turns into just nucleate boiling. The vapor barrier acts as an insulator and causes the heat flux to fluctuate, causing uneven hardening which would limit the use of some materials. To combat this effect, we are trying to use forced convection, and something new, which is adding high frequency waves into the quenching process. …

Optical Study Of Small Jet Engine Combustion Ignition, Bryce Anthony Ullman

Browse all Theses and Dissertations

Improving the ignition reliability in small-scale gas turbine engines is critical for safety aspects of auxiliary power units (APUs). To better understand the ignition characteristics of these small-scale combustors, an optically accessible combustor is designed and tested. The combustor accommodates twelve prevaporizer tubes (PVTs) in accordance with the commercial-off-the-shelf (COTS) rendition and allows for interchangeable materials (quartz and Inconel) and igniter positions. Another notable design feature introduces a quartz outer combustor liner to allow visualization into key regions of the combustor. The study aims to replicate a COTS ignition sequence using glow plug igniters and examine the effects of different …

Computational Analysis Of A Hafnium-Titanium Alloy Mechanical Properties From First Principles, Abdul Mughni

Browse all Theses and Dissertations

Hafnium and titanium, along with zirconium, are refractory metals with unique properties suitable for extreme-environment applications. Utilizing alloys based on these elements can provide suitable materials with engineered properties. Understanding their mechanical properties is necessary to determine appropriate applications. This thesis research aims at employing quantum-based atomistic simulations to estimate mechanical properties of pristine hafnium, titanium and an alloy based on these elements. The results are compared to available experimental data and the corresponding implications are explored.

Data-Driven Prediction Of Temperature Distribution In Multi-Laser Powder Bed Fusion Using Convolutional Neural Networks, Majid Dousti

Browse all Theses and Dissertations

Additive Manufacturing (AM), particularly Laser Powder Bed Fusion (L-PBF), has gained significant traction in fabricating complex, high-performance metallic components. However, the inherent complexity and computational cost of high-fidelity simulations pose challenges for real-time monitoring and optimization of multi-laser powder bed fusion processes. This study proposes a data-driven surrogate modeling approach using a deep learning architecture to efficiently and accurately predict three-dimensional temperature distributions during ML-PBF. A 3D convolutional neural network (CNN) model, named Decoder-CNN, is developed and trained on a dataset of simulated thermal fields corresponding to various process configurations, including different laser power, scanning speed, and beam arrangements. The …

Evaluating Geometric Accuracy In 3d Printing (3dp) Comparative Study Of Different 3dp Processes Using Cmm And Vision Measurement Tools, Alexander Adams

Browse all Theses and Dissertations

This study investigates how various additive manufacturing (AM) technologies and parameters influence part quality by fabricating three uniquely designed artefacts. Artefact 1 is a rectangular block with stepped arches, thin and solid extruded features, and holes of varying shapes and sizes. Artefact 2 consists of a base plate with angled overhangs from 15 to 90 degrees. Artefact 3 includes a tall cylinder, a five-step cylinder, and two half arches of different scales. Each artefact was printed ten times using: metal PBF (Inconel 718), nylon PBF (Nylon 12), Vat Polymerization (GRY photopolymer), and material extrusion (nylon carbon fiber). Dimensional analysis was …

Using Unsupervised Machine Learning To Experimentally Categorize Separation On Low-Pressure Turbine Blades, Aaron B. Suter

Browse all Theses and Dissertations

Laminar boundary layer separation can significantly degrade the efficiency of Low-Pressure Turbine (LPT) blades. While active flow control (AFC) methods can mitigate these losses, energy-efficient implementation requires activating the system only when performance decreases. This study validates an unsupervised machine learning framework that utilizes sparse, discrete surface-pressure measurements to distinguish between high and low aerodynamic loss states. A fuzzy c-means (FCM) clustering model was trained on limited pressure data obtained in a low-speed linear cascade across Reynolds numbers from 30,000 to 160,000 and used to categorize the flow regime in real time. At Re = 40,000, vortex generator jet (VGJ) …

Utilizing Optimization Tools For Passive Flow Control Passage Loss Reduction In Low-Pressure Turbines, Bryant Robert Duane Burton

Browse all Theses and Dissertations

Low-pressure turbines (LPTs) play a crucial role in fuel efficiency and thrust generation of aero-engines. Traditional LPT designs, however, involve multiple stages and numerous blades, resulting in increased weight and manufacturing costs. The challenge of modern- day researchers is to reduce the weight and cost but maintain the high efficiency of LPTs. To address this, one approach is to increase the aerodynamic loading of individual blades, reducing the blade count. However, this can lead to increased secondary losses caused by flow separation, particularly in the endwall regions. This research focuses on optimizing the blade profile at the junction with the …

Quantification Of Porosity In Hfb2–20%Sic Using Convolutional Neural Networks, Cameron J. Floyd

Browse all Theses and Dissertations

Ultra-high-temperature ceramics, commonly used in aerospace applications, operate in high-temperature oxidizing environments where a surface scale forms and regulates oxy gen access. For hafnium diboride–silicon carbide (HfB2–SiC), that scale consists of a borosilicate glass layer over a porous HfO2 skeleton. Oxygen transport through this poros ity governs the kinetics of mechanistic models, requiring reproducible inputs for accurate pore fraction (PF), pore-size distributions, and ultimately tortuosity. This thesis replaces rule-based SEM thresholding with a convolutional neural network that segments pores and predicts the pore-radius distribution for transport models. The resulting calibrated porosity maps and size distributions transfer within the acquisition domain …

Effect Of Build Orientation And Environmental Conditions On Mechanical And Geometric Properties Of Polymeric Parts Fabricated By The Powder Bed Fusion Process, Adedamola O. Adeyemi

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Polyamide-12 (aka PA12) is a synthetic thermoplastic polymer that has been used in various applications, including the electronic and electrical, oil and gas industrial manufacturing and automotive industry. There are several ways to manufacture parts with PA12 and PA12 based composites. Injection molding, a traditional manufacturing process, has been the standard manufacturing route for polymers for a long time. Recently, however, additive manufacturing (AM) processes, such as powder bed fusion (PBF) and material extrusion (ME) have been introduced. PBF is a manufacturing process characterized by the selective sintering of successive layers of powdered material. It is the most effective AM …

Process To Design And Analyze Dynamic Environment Test Fixtures (Pdadye), Cora J. Taylor

Dissertations, Master's Theses and Master's Reports

Vibration qualification testing is an important requirement in many industries. In-lab testing is intended to evaluate a component’s life expectancy by exposing it to a dynamic environment similar to what it may experience in its field condition. To successfully perform these tests, it is imperative that the field boundary conditions (BCs) of the component of interest are replicated as closely as possible in the lab. One approach to achieving accurate dynamic environment testing is to design a fixture that sufficiently represents the impedance of the next-structure (field structure). The process to design and analyze dynamic environment test fixtures (PDADyE) is …

Measuring Occupant Controlled Ventilation And Cooking Frequency To Aid In Modeling Energy Performance Of Northern Michigan Homes, Jacob J. Chizek

Dissertations, Master's Theses and Master's Reports

This research investigates the real-world interplay between energy efficiency and indoor air quality. We explore how home ventilation strategies, heating systems, and weatherization levels in rural homes interact. As part of a larger study on air quality, 17 homes participated in the study. Specifically, this research shows the results and methods for monitoring cooking frequency, kitchen range hood use, and bathroom fan use over two, month-long study periods to build accurate energy and contaminant transport models of homes that were studied. Energy audits to document home characteristics were conducted, including blower door testing and detailed qualitative data regarding the homes’ …