Mechanical Engineering Commons^™

Analysis Of Approximations In Flash Thermal Diffusivity Measurements Using High‑Fidelity Simulations, Tage T. Burnett, Jakob G. Bates, Matthew R. Jones, Christopher R. Dillon, John Tencer

Faculty Publications

Thermal diffusivity is an important material property for understanding and characterizing transient behavior in many heat transfer applications. This study investigates the accuracy and approximations of inverse mathematical models for measuring thermal diffusivity of materials via the widely used Flash Method. High-fidelity simulations of the Flash Method in copper, silicon carbide, silicon, and glass were performed as numerical experiments and included physics such as in-depth absorption, radial conduction, and surface convection. Data from those numerical experiments were used to estimate material thermal diffusivity using seven traditional and new inverse models. Parker’s original model had relative errors 𝜖< 5% when the approximations it makes were enforced in numerical experiments. Newer models performed well even when experimental restrictions were relaxed. Models that include radial heat conduction were capable of accurately measuring thermal diffusivity (𝜖< 1%) when a Gaussian energy source was used. Models with radial conduction and in-depth material absorption of the laser source could calculate thermal diffusivity for semi-transparent materials such as silicon (𝜖< 1%) and even transparent materials like glass (𝜖< 10%). Convective losses from the material’s front surface had a negligible impact on measurements except for very low thermal diffusivity materials. Using temperatures from many locations of the test material’s surface increased resilience to noise, reducing the distribution of thermal diffusivity measurements by more than an order of magnitude. The models developed in this study could enable a more relaxed Flash Method experimental setup that maintains thermal diffusivity accuracy and extend the utility of the Flash Method to semitransparent materials.

Aerodynamic Performance Of Grid Fins As High Lift Devices, Luke Jeffrey Krick

Senior Honors Theses

Flaps are used in almost all aircraft to increase the amount of lift the wings can produce at low speeds. However, the flaps also increase the amount of drag experienced by the aircraft. The drag induced by the flaps causes energy loss and is unfavorable for aircraft effectiveness. In recent years, grid fins have become a popular choice for aircraft and armaments to control their orientation. First developed for launch escape towers, grid fins are made up of lines that cut the fin into many quadrants, leaving the fin with multiple rectangular shaped open areas. The aim of this study …

Engineering Design And Analysis Using Creo® Cad, Cae, And Manufacturing Applications, Swapnil Moon

Open and Affordable Textbooks

This textbook presents a structured approach to computer-aided design using Creo, integrating CAD, CAE, and CAM workflows within a unified engineering framework. The material emphasizes parametric modeling, design intent, and feature-based modeling as foundations for creating robust and adaptable engineering models. Through progressively structured tutorials, students develop skills in part modeling, assemblies, engineering drawings, mechanism design, simulation, and manufacturing. The text incorporates real-world engineering components and workflows, including structural and thermal analysis, motion simulation, and toolpath generation, reflecting modern engineering practice. Designed for upper-division undergraduate and graduate students, this open educational resource supports hands-on learning and prepares students for industry-relevant …

Introduction To Computer-Aided Design Using Solidworks® : A Structured Approach To Parametric Modeling And Design Intent, Swapnil Moon

Open and Affordable Textbooks

This textbook introduces computer-aided design (CAD) using SOLIDWORKS® through a structured, design-centered approach that emphasizes parametric modeling and engineering reasoning. Rather than focusing solely on software commands, the material develops foundational skills in design intent, constraint-based modeling, and feature relationships to create robust, adaptable models.

The content is organized progressively, beginning with basic sketching and feature creation and advancing to complex part modeling, assemblies, motion studies, and engineering drawings. Each chapter builds upon prior concepts, reinforcing systematic modeling practices and promoting the development of system-level thinking required in real-world engineering design workflows.

Designed for undergraduate students with little or no …

Aquaculture Ecosystem Modeling Aeration Efficiency Optimization Using Cfd, Gabriela Reyes Gomez

Electronic Theses and Dissertations 2020 - Present

The Harbor Branch Oceanographic Institute (HBOI) is developing the Intelligent and Resource Efficient Pond Aquaculture (IREPA) project, which aims to improve aquaculture management through the integration of predictive models and automated technologies. This approach seeks to transition traditional practices toward data-driven systems capable of supporting informed decision-making for aeration management.

This study investigates the effectiveness of different aerator configurations on hydrodynamic circulation and dissolved oxygen (DO) distribution in aquaculture ponds using computational fluid dynamics (CFD). A model was developed in ANSYS Fluent, where the aerator was represented using a power-based formulation and implemented as a moving wall boundary condition. Dissolved …

Design Of Air-Entrained Concrete For Airport Pavements Through Local Aggregate Utilization: Performance Optimization And Economic Analysis, Li Wentao, Rizwan Qadir, Arslan Mushtaq, Hilal Khan, Kamran Jillani

Journal of Sustainable Construction Materials and Technologies

Airport pavement construction in developing countries faces critical challenges balancing international performance standards with economic constraints, while limited research exists on optimizing air-entrained concrete mixes using locally sourced materials for cost-effective solutions. This study investigated the development of economical air-entrained concrete mix designs for airport pavements utilizing Pakistani aggregates and systematic cement content optimization. Comprehensive experimental evaluation included material characterization through petrographic analysis, alkali-aggregate reactivity assessment via accelerated mortar bar testing, and mechanical property development across cement contents from 360-450 kg/m3. Air entrainment was achieved through controlled admixture dosing while maintaining target slump of 50mm. Results demonstrated that locally sourced …

Niu Fsae Brake Rotor Design & Flywheel-Based Test Stand Development, Cody J. Marko, Austin Coyne, Alexander Boyden

Honors Capstones

This project addresses the need for a reliable and validated brake rotor for the Northern Illinois University Formula SAE vehicle following a prior catastrophic rotor failure within the team. Brake rotors in high-performance applications are subjected to significant thermal and mechanical loads, and inadequate design can lead to failure, posing serious safety risks and limiting vehicle performance. To solve this issue, a new brake rotor was designed alongside a dedicated test stand to both improve braking performance and enable experimental validation. The rotor was evaluated using finite element analysis (FEA), including transient thermal and structural simulations, to predict maximum temperature, …

Portable Humidity Chamber, Calvin Wright, Ian Heilers, Sam Taylor

Honors Capstones

This engineering project, sponsored by Crandall Stats and Sensors, focuses on improving the ability to test product performance under controlled environmental conditions by designing a portable humidity chamber capable of maintaining a stable relative humidity between 20 and 80 percent with a tolerance of ±0.5 percent. Consistent humidity is crucial for evaluating how moisture influences material properties, product reliability, and long-term durability in real production environments. Because Crandall conducts testing across multiple facility locations, the chamber must also be lightweight, transportable, and easy for operators to use without specialized training. Developing such a system provides the company with a valuable …

Tribological Evaluation Of A Graphite Coating Using A Custom Miniature Conveyor, Shae Threlfall

Mechanical Engineering Undergraduate Honors Theses

Reducing friction in conveyor systems has significant economic and environmental implications, as a substantial portion of energy losses originates at the belt-bed interface. This thesis outlines the design, construction, and validation of a miniature conveyor tribological test system. Unlike conventional tribometers, which impose concentrated point contacts, the miniature conveyor replicates the distributed load consistent with industrial conveyor systems. It can measure real-time mechanical responses of steel samples coated in a low friction coating.

The mini conveyor was validated by evaluating three materials: uncoated mild steel, PDA/graphite coated steel, and Polytetrafluoroethylene (PTFE). Electrical power, temperature, sound, and acceleration were recorded. Electrical …

Automating Building Feature Recognition In Digital Twin Models Using Computer Vision, Jaron Harbison

Undergraduate Honors Capstone Projects

Standard 3D scans treat all surfaces as generic geometry, but Wi-Fi signals don't. A signal drops by a different magnitude through a wooden door than a concrete wall. Without labeling these materials, Internet Service Providers (ISPs) cannot accurately predict "dead zones". This project addresses that gap by creating a machine learning model that identifies structural and architectural features. This includes features such as walls, doors, windows, and columns directly from RGB-D (Red, Green, Blue, Depth) point cloud data. 

I constructed the model on a custom U-Net architecture featuring a symmetric encoder-decoder structure with skip connections, trained on the StructScan3D dataset …

Ngc - Torch Test Ablation Stand Improvements And Upgrades, Sarah Nelson

Undergraduate Honors Capstone Projects

This capstone project is sponsored by Northrop Grumman (NGC). The goal of the project is to redesign an ablation torch testing system to improve usability, safety, and versatility. Northrop Grumman relies on their ablation torch testing system to conduct quantitative evaluations of materials and high stress and high temperature conditions. The system provides essential data that supports product development, safety validation, and compliance with performance standards. By improving usability, safety, and versatility, NGC will be able to streamline testing operations, increase accuracy of results, and reduce operator risk. The system must allow testing using both a bent and straight torch …

The Expectation Of Pain: Effects On Threshold, Tolerance, And Perception, Emma Paulus

Mechanical Engineering Undergraduate Honors Theses

Brain activity in pain-related regions of the cortex is thought to be influenced by interactions between expectations and incoming sensory information. However, the subjective experience of pain based on expectation has not been thoroughly explored. By changing visual and auditory cues to set expectation levels, a relationship between unconscious expectation of pain and actual sensory pain experienced was characterized. With IRB approval, volunteers were randomly and blindly grouped into low and high pain expectancy groups. Each group completed a survey about initial pain expectations before the muscle stimulation tolerance test, followed by a survey about actual pain perception after the …

Harness: Hybrid Architecture For Resilience In Networked Engineering System Simulations, Daniel Scott

Graduate Theses and Dissertations

This dissertation presents the development of HARNESS, a unified, domain-agnostic framework for the modeling, optimization, and evaluation of complex systems under conditions of degradation and uncertainty. The research addresses a persistent challenge in systems engineering: the lack of a generalizable, behaviorally grounded approach for quantifying resilience and robustness across diverse domains. HARNESS integrates graph-theoretic dependency modeling, GPU-accelerated evolutionary optimization, and agent-based simulation into a modular architecture that enables both system design and diagnostic analysis. The framework models system interdependencies through user-defined components, parameters, and constraints, allowing architectures to evolve dynamically while maintaining structural validity. A mutation-only genetic algorithm with a …

Technology Based Assessment Of Workplace Biomechanical Risk: A Roadmap For Process Improvement, Tamer Adel Mohamed, Noha Mostafa, Ahmed Elsayed

Mechanical Engineering

The main objective of this paper is to develop a methodology for assessing the biomechanical risk in the workplace and design and apply improvements to reduce this risk by redesigning the working process. The risks are measured using Ergonomics tools to assess body posture and lifting index. Kinect sensor and video recordings are utilized to evaluate the joints' positions as an input for body posture data. Then, the specialized CATIA V5 software [26] is used to simulate the workers' bodies in the form of 3D models. Risk factors were assessed, and a new design was developed to be implemented in …

Experimental Investigation Of A Shrouded Dual-Rotor Wind Turbine For Small-Scale Applications, Ahmed Elbaz, Mahmoud Alghrieb Mr

Mechanical Engineering

Small-scale wind power faces significant challenges in areas characterized by low wind speeds and turbulent wind patterns, limiting its contribution to the global energy demand. To spread the use of wind energy even at regions of low wind speeds, the turbine with wind lens concept was introduced in the literature. This device increases the free stream wind speed at the turbine section which enhances power output of the turbine. Other methods involved using dual rotors to augment power output of the turbine too. In the current study, the performance of single and dual rotors was investigated using wind lens to …

Comparative Experimental Analysis Of Vertical And Inclined Bifacial Pv Panels Under Varying Azimuthal Angles In Egypt For Agrivoltaics Systems, Ahmed Elbaz, Yahia Hassanein Nr, Iman Elmahallawi Dr, Tarek Abdelsalam Dr

Mechanical Engineering

The growing deployment of photovoltaic (PV) technologies across a wide range of applications, from residential rooftops to agrivoltaic systems, has created new opportunities, such as harnessing albedo from bright surroundings, as well as challenges, including limited space availability and adverse shading effects, which urge the need for optimising space along with energy use. While vertical bifacial photovoltaic (VBPV) systems may offer a potential solution, their effectiveness against their conventional inclined counterparts remains largely unexplored in different locations. This paper presents an experimental evaluation of the energy performance of vertical and inclined Bifacial PV configurations under the different climatic conditions of …

Effect Of Environmental Conditions On Fracture Of Composite Materials And Thin Films, Victor Birman

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Environmental conditions, i.e., temperature and moisture, affect mechanical properties of materials, including composites. In this paper, we concentrate on one of the aspects of the effect of environment on fracture in a composite lamina. The paper demonstrates an analytical approach to account for the effect of the changes in environment on the strain energy release rate of composite materials and thin films. These analytically determined strain energy release rates should be compared to fracture toughness to predict the susceptibility of the material to fracture. Numerical examples are presented for several polymeric and metal matrix composites using available experimental data for …

A Federated Learning Framework For Data-Sovereign Predictive Maintenance In Distributed Smart Manufacturing, Md Sazol Ahmmed, Sriram Praneeth Isanaka, Frank Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Featured Application: The proposed federated learning framework can be applied in distributed smart manufacturing environments where multiple factories or production facilities collaboratively develop predictive maintenance models without sharing sensitive operational data. This approach is particularly useful for industrial networks involving geographically distributed plants, contract manufacturing partners, and multi-site production systems where data sovereignty and avoidance of raw data sharing are critical. Predictive maintenance enables early detection of machine failures and reduces unexpected production downtime. However, conventional approaches typically rely on centralized data collection and model training which introduce challenges related to data sovereignty, communication overhead and data ownership. To address …

Using Machine-Learning-Based Process Map To Guide Evaluation Of Inconel 625 Mechanical Properties In Laser Foil Printing, Yu Hsiang Wang, Sung Heng Wu, Hung Chu Chiang, Pen Ning Yu, Chia Hung Hung, Ming C. Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Inconel 625 is widely studied in powder-based additive manufacturing, but its processing characteristics and mechanical performance in foil-feedstock laser foil printing (LFP) remain largely unexplored. In this study, a gradient boosting regression (GBR)-based process map was developed for LFP of Inconel 625 using 32 single-track experiments. The GBR model achieved R² values of 0.859 and 0.793 and mean absolute errors of 22.25 μm and 19.83 μm for melt-pool depth and width, respectively, outperforming second- and third-order polynomial regressions in capturing nonlinear melt-pool responses and distinguishing lack-of-fusion, conduction, and keyhole regimes. Three conduction-mode conditions with target depth-to-foil thickness ratios (D/T) …

Electric Charging Arm Mechanism - Echarm, Jacob A. Lewis, Gabriel A. Greer

Mechanical Engineering Student Research

As demand for electric and hybrid vehicles continues to rise, many EV owners rely on home charging in their garages. Gabriel Greer and I’s Senior Design Project, the Electric Charging Arm Mechanism (ECHARM), addresses this by creating a robotic system that autonomously detects a vehicle’s charging port, connects to it, and returns to a rest position when charging is complete. ECHARM is designed as a six-axis robotic arm with wrist and shoulder joints driven by stepper motors through custom cycloidal drive gearboxes. A closed-loop control system using rotary potentiometers ensures precise motion control. At the end of the arm is …

Stakeholder Perspective-Taking In Engineering Design: A Neurocognitive Approach, Megan C. Taylor

Mechanical Engineering Undergraduate Honors Theses

Stakeholder engagement is a critically important yet overlooked phase of engineering design. While addressing stakeholders is known to lead to more thoughtful design outcomes, little work has been done regarding how stakeholder personas influence brain activity while designing. This study asks if the introduction of stakeholder personas- short overviews of people affected by a design problem- affects brain activation in undergraduate students during three design tasks: stakeholder identification, stakeholder needs generation, and stakeholder needs prioritization. To test this, 18 undergraduate mechanical engineering students were given a stormwater management design vignette; one group was given four stakeholder personas, while the control …

Enhancing The Leaning Control And Braking Sensation Of A Virtual Reality Vespa Simulator, Joseph Boccuzzi, Wesley Bleck, Jacob Hannebaum

Honors Capstones

The 71 North Partnership Studio located in Northern Illinois University’s Founders Memorial Library has developed a prototype Vespa simulator featuring an interactive Virtual Reality (VR) game and reactive elements. A previous Mechanical Engineering Senior Design team developed the system and improvements after its original development were sought after over the course of the current school year. The system consists of a stationary bike that allows the rider to lean left and right, which in turn causes their in-game character to turn left and right accordingly, simulating the effect of riding a Vespa scooter within a VR environment. Improvements were made …

Optimization Of Stamped Tool Geometry Using Regression-Based Cost Models And Structural Constraints, Matthew J. Teague

Mechanical Engineering Undergraduate Honors Theses

Stamped steel paint can openers are simple tools but still require sufficient strength for the end user and low material consumption for the manufacturer. The goal of this project is to optimize the stamped design of a paint can opener by reducing material cost while maintaining structural rigidity and device performance. This was achieved in part by simplifying the tool’s geometry so that an equation for the mass could be developed analytically and checked against the simulation’s outputs. First, a 25-run design of experiments was created that varied the shaft length and the endloop diameter. Next, a CAD model for …

A Multi-Criteria Decision And Spatial Modeling Framework For Socially Informed Advanced Air Mobility Implementation Planning, Noah Wesley Bretz

Graduate Theses and Dissertations

Advanced air mobility (AAM) is an emerging mode of transportation that integrates advanced aircraft technologies, such as manned air taxis or unmanned freight drones, to transport people and goods across urban and regional environments. While these technologies promise to transform mobility, successful implementation depends heavily on community acceptance, which is shaped by multiple social factors. This study presents a multi-criteria decision framework to evaluate and prioritize the key social factors influencing AAM adoption. A literature review identified six primary social factors: safety, noise, privacy and cybersecurity, automation, environmental impact, and price and economics. The Analytical Hierarchy Process (AHP) was used …

Effect Of Prefilmer Design On Atomization Behavior In The Pre-Vaporization Tube Of A Small-Scale Annular Gas Turbine Combustior, Amogh G. Natu, Antoine M. Fradet, Cohen Nunes, Daniel R. Guildenbecher

School of Mechanical Engineering Faculty Publications

This work investigates the influence of internal prefilmer geometry on fuel spray atomization in the prevaporization tube (PVT) of a small-scale reverse-flow annular gas turbine combustor. Four configurations are examined: a control with no prefilmer, a planar internal prefilmer, and two angled internal prefilmers at θ = 60◦ and θ = 45◦ . Double-pulsed digital in-line holography (DIH) is used to measure droplet size distributions, spray density, Sauter mean diameter (SMD), and droplet velocities at the PVT exit under conditions scaled to represent nominal ignition conditions. Results show the control design exhibits poor atomization characterized by large droplet diameters, low …

Tau Beta Pi Engineering Mentorship Program, Tyler Black

Undergraduate Honors Capstone Projects

The purpose of this project is to design and implement a student-led engineering mentorship program directed by the members of the Utah Gamma Chapter of Tau Beta Pi on the Utah State University (USU) Logan campus. Retention data show that many undergraduate students who start engineering programs change their degree before graduation due to academic and social challenges that may be mitigated by the support of a peer mentor. The Tau Beta Pi Engineering Mentorship Program selects and trains upperclassman mentors to effectively mentor underclassman engineering students.

The design of the mentorship program is an application of backward design, where …

An Experimental Study Of The Morphology Of Dna-Carbon Nanotube Hybrid Structures In Direct Dna Sequencing, Avery P. Davis

Biomedical Engineering Undergraduate Honors Theses

Hybrid structures formed between single-stranded DNA (ssDNA) and single-walled carbon nanotubes (SWCNT) have emerged as promising components in future direct DNA sequencing technologies due to their unique morphological and electronic properties. The nanoscale configuration of these hybrids, including the DNA wrapping angle, pitch, and contour behavior, directly influences their potential for stable electronic readout. This thesis presents an experimental study of DNA-SWCNT hybrid morphology using a fixed, reproducible wrapping protocol designed to minimize environmental variability and isolate the influence of DNA nucleotide sequence on hybrid structure. As described in prior work, this protocol produces well-dispersed hybrids suitable for high-resolution imaging. …

Extremum Seeking Compensation And Quantification Of Position Sensor Offset Error In Speed-Controlled Permanent Magnet Synchronous Motors, Tessa Biondo

Masters Theses

Position sensor offset errors present a persistent challenge in speed-controlled permanent magnet synchronous motor drives operating under field-oriented control. Even small, constant offsets in the measured rotor position can reduce torque effectiveness, requiring increased current and voltage demand to maintain the commanded speed and resulting in degraded speed regulation performance across a range of operating conditions. These effects are particularly problematic in speed-controlled systems, where speed loop dynamics cause increased electrical effort and limit overall performance. Many existing detection and compensation approaches are either dependent on the system model, require offline calibration, or are primarily designed for torque-controlled operation. This …

Aerodynamic Parameter Estimation For A Scaled F-16: A Simulation-Based Sensitivity Analysis, Kathle C. Tischner

All Graduate Theses and Dissertations, Fall 2023 to Present

The physical motion of an aircraft is determined by the resulting forces and moments acting on the aircraft. These forces and moments can be defined as a mathematical equation where the control deflections, rotation rates, and orientation of the aircraft are multiplied by individual constants and summed together to define the entire force or moment. This method results in a highly accurate model that defines the motion of the aircraft at low angles of attack and sideslip. Initial calculations of the aerodynamic model are created based on analytical estimations based on the physical properties of the aircraft. Additional refinement of …

Development Of A Novel Method For Simultaneously Testing Multiple Specimens To Evaluate Tension-Tension Fatigue Life, Mehedi Hasan Mahfuz

All Graduate Theses and Dissertations, Fall 2023 to Present

The aim of this study is to develop a novel method for rapidly evaluating the tension–tension fatigue life of metals. Fatigue failure, which occurs when materials gradually weaken and fracture under repeated loading, is a critical concern in designing safe and reliable structures such as airplanes, cars, and bridges. Traditional fatigue testing methods are slow, costly, and typically limited to one specimen at a time. To address this, a high-throughput testing method was developed that allows multiple small-scale specimens to be tested simultaneously while following international testing standards. Using stainless steel sub-sized specimens scaled at 1:5 relative to the ASTM …