Mechanical Engineering Commons^™

Assessment Of Small-Scale Mechanical Damage On Safety Performance Of Lithium-Ion Batteries, Maher A. Almohammedali

Wayne State University Dissertations

Battery safety studies of Li-ion batteries (LIBs) related to mechanical abusive loadinginvolving contact compression of hard objects, bending and nail penetration usually show that LIBs can withstand some mechanical deformation prior to internal short circuit (ISC). Stress or strain-based criteria has been suggested to understand local conditions between the anode, cathode and the separator due such abusive mechanical loading. A strain-based criterion has also been developed at Wayne State and reported in open literature (Newaz et al.) Focus of such work has been to determine strain levels that may rupture the separator putting in contact the anode and cathode leading …

Workforce Development Strategies In Additive Manufacturing, Mel Cossette, Ismail Fidan, Gaffar Gailani, Angran Xiao

Publications and Research

Additive Manufacturing (AM), also known as 3D Printing (3DP), is one of the newest manufacturing technologies with growing utilization in our daily life. Parallel to this growth, new materials, machines, and specific processes are being developed to produce parts in better-finished quality, at lower cost, and with shorter production time. However, workforce education in this evolving field has not advanced at the same pace as the technology, lacking proven curriculums, high-quality/accredited degree programs, and specialized advanced degrees. In this paper, some best practices established by the authors are introduced. The list is far from exhaustive but is proven to be …

Visualization And Validation Of Twin Nucleation And Early-Stage Growth In Magnesium, Lin Jiang, Mingyu Gong, Jian Wang, Zhiliang Pan, Xin Wang, Dalong Zhang, Y. Morris Wang, Jim Ciston, Andrew M. Minor, Mingjie Xu, Xiaoqing Pan, Timothy J. Rupert, Subhash Mahajan, Enrique J. Lavernia, Irene J. Beyerlein, Julie M. Schoenung

Department of Mechanical and Materials Engineering: Faculty Publications

The abrupt occurrence of twinning when Mg is deformed leads to a highly anisotropic response, making it too unreliable for structural use and too unpredictable for observation. Here, we describe an in-situ transmission electron microscopy experiment on Mg crystals with strategically designed geometries for visualization of a long-proposed but unverified twinning mechanism. Combining with atomistic simulations and topological analysis, we conclude that twin nucleation occurs through a pure-shuffle mechanism that requires prismatic-basal transformations. Also, we verified a crystal geometry dependent twin growth mechanism, that is the early-stage growth associated with instability of plasticity flow, which can be dominated either by …

Chemical Clean Automated Loader, Jordyn Bryner

Williams Honors College, Honors Research Projects

TTM Technologies (TTM) is a global printed circuit board (PCB) manufacturer. The work described in this report was completed in the TTM North Jackson, Ohio location. This plant focuses primarily on the manufacturing of rigid and rigid-flex PCBs for the aerospace and defense industry. TTM North Jackson has an ongoing labor dependency issue due to the shortage of workers the nation is facing. To solve this problem, TTM has focused the efforts of their new engineers and interns on automating processes that are labor dependent. The goal is to provide design guidance to be used later by TTM to automate …

Npt Test Machine, Lauren Cash

Williams Honors College, Honors Research Projects

Located at the Research facility at The Goodyear Tire & Rubber Company, the Non-Pneumatic Tire (NPT) Program is currently in the prototype phase. However, airless tire structures are quickly gaining popularity as an alternative to a traditional pneumatic tire. The NPT Test Machine is a measurement fixture that will perform a series of evaluations to determine the stiffness of an NPT; this will allow the program to expand and evolve more rapidly into a manufacturing phase. In this Senior Design Project, a complete test solution was researched, designed, built, programmed, and validated so that data can be collected, and tires …

Schaeffler E-Motor, Jenne Harasin, Zachary Zatta, Christopher Tvaroch

Williams Honors College, Honors Research Projects

This project will be focusing on the work accomplished at Schaeffler to convert an existing internal combustion engine, Ford F-250 truck, into a battery electric vehicle. This report focuses on the vehicle's integration with an emphasis on the bearing design, e-Axle housing's method for mounting, bus bar design, resolver design, differential options, wiring for low and high voltage, and oil pump and cooling system for e-Beam. The bearings for the differential as well as the power transmission system from the electric motor to the e-Axle will need to be specified. By late summer 2022, Schaeffler will have a working prototype …

Grinding And Super-Finishing Test Machine Project, Michael Simon

Williams Honors College, Honors Research Projects

A research project in The University of Akron to study grinding and super-finishing of silicon nitride ceramic was initiated by Dr. Siamak Farhad and sponsored by the Timken Company, with the assistance of undergraduate students Michael Simon, Ryan Hosso and Mathew Rozmajzl. The study required analysis of forces and scratches generated during grinding processes of silicon nitride samples. A testing assembly was designed and constructed to record the forces generated during grinding and super-finishing of silicon nitride samples in a computer-numerical-control machine. Silicon nitride samples were subjected to desired grinding and super-finishing operations and all forces generated during the process …

Design Of Composite Joints Using Machine Learning Approaches, Natalie Richards

Williams Honors College, Honors Research Projects

Adhesively bonded joints have an advantage in joining dissimilar engineering materials due to their high structural efficiency and being lightweight. These joints are either between two opposite laminates or between a composite laminate and a metal structure. The aerospace and automotive industries have seen an increase in utilizing these adhesive joints in their engineering applications. Joint strength along with the failure mode (adhesive, delamination, etc.) is the most important parameter to evaluate when understanding the capability of the adhesive joint. In this paper, a regression and a classification machine learning (ML) model are utilized to predict the failure load and …

Golf Club Cleaner, Owen Roach, Chris Wertenberger, Michael Skerlong

Williams Honors College, Honors Research Projects

Cleaning golf clubs can be a tedious process, however a necessary one to maintain equipment. Clubs are normally cleaned by filling a bucket with soap and water, soaking all the clubs to be cleaned, then scrubbing each one individually. An automatic club cleaner would make this process much easier and more enjoyable. Using electric motors, the club cleaner would have spinning brushes in soap and water to quickly and easily clean the club head. The machine would have different sections for cleaning the club head, polishing the club face, and cleaning the grip. The cleaner should be inexpensive and easy …

Multi-Platform Suppressor Design Project, Wyatt A. Openshaw, Alex B. Chiples

Williams Honors College, Honors Research Projects

The Multi-Platform suppressor is a design that is meant to bridge the gap in the suppressor market by being compatible and configurable with both rifle and pistol platform firearms. In the specific design and prototype referenced in this report, the Multi-Platform suppressor was designed to be used with 9mm pistol and 5.56x45mm rifle calibers with safety, effectiveness, and practicality in mind. To achieve this, the suppressor is configurable, utilizing a Nielsen device in the pistol configuration and a solid mount adapter that replaces the Nielson device piston and spring while in the rifle configuration. This allows the suppressor to retain …

Nject-3d, Kody Rinkevich, Logan Henderson, Nathaniel Anderson, James Patton, Cameron Wilson

Williams Honors College, Honors Research Projects

NJECT-3D is a student initiated design project where the utilities of a 3D printer and an injection molding machine are integrated into one cohesive unit. The goal of our project was to test the limits of rapid prototyping by utilizing printed molds. We developed an automated system where a mold can be printed on a 3D printer, translated from said 3D printer to an injection molder, then compressed and injected at said injection molder to output a finalized injection molded part.

Induction Brazing, Austin Squire, Scott Compton, Logan Hathaway, Michael Fleming

Williams Honors College, Honors Research Projects

Our team would like to research and explore ways of designing a portable device that uses induction heating/brazing to connect two exhaust pipes together.

Innovated Manual Wheelchair Propulsion, Jacob Eveleth, Abigail Steineman, James Murray, Garrett Best

Williams Honors College, Honors Research Projects

The goal of this project is to provide a manual wheelchair propulsion system that provides an easier way of moving the chair for the user. Our already-defined set of constraints and goals provides a clear end-goal for our group in accomplishing this task. We plan to have a 3D CAD model of the design by the end of the Spring 2022 semester. The first half of the Fall 2022 semester will be dedicated to developing a plan for prototyping, and the second half of the semester we plan to have the prototype created for use. So far, we have utilized …

Molecular Dynamics Simulation Study Of A Polymer Droplet Transport Over An Array Of Spherical Nanoparticles, Anish Thomas

Browse all Theses and Dissertations

This study uses molecular dynamics simulations to evaluate the dynamic behavior of a partially wetting polymer droplet driven over a nanostructured interface. We consider the bead-spring model to represent a polymeric liquid that partially wets a rough surface composed of a periodic array of spherical particles. Results show that at sufficiently small values of external force, the droplet remains pinned at the particle's surface, whereas above the threshold its motion consists of alternating periods of pinning and rapid displacements between neighboring particles. The latter process involves large periodic variation of the advancing and receding contact angles due to the attachment …

Printing, Characterization, And Mechanical Testing Of Additively Manufactured Refractory Metal Alloys, Brianna M. Sexton

Browse all Theses and Dissertations

Refractory metal alloys in the tungsten molybdenum rhenium ternary system were additively manufactured using laser power bed fusion. Four ternary alloys with varying concentrations of tungsten, molybdenum, and rhenium were manufactured and manufactured again with an addition of 1 wt% hafnium carbide. Samples were heat treated to heal cracks, reduce porosity, and reduce inhomogeneity. Material microstructure was characterized before and after heat treatment using microscopy, energy dispersive x-ray spectroscopy, and electron backscatter diffraction mapping. Mechanical testing was conducted on both three-point bend specimens and compression specimens, resulting in maximum bending strengths of 677.86 MPa, and maximum compression 0.2% yield strengths …

A Digital Twin For Synchronized Multi-Laser Powder Bed Fusion (M-Lpbf) Additive Manufacturing, Shayna Petitjean

Browse all Theses and Dissertations

One of the technological challenges in the widespread application of additive manufacturing is the formation of undesired material microstructure and defects. Specifically, in metal additive manufacturing, the microstructural formation of columnar grains in Ti-6Al-4V is common and results in anisotropic mechanical properties and a reduction in properties such as ductility and endurance limit. This work presents the application of hexagonal and circular arrays of synchronized lasers to alter the microstructure of Ti-6Al-4V in favor of equiaxed grains. An anisotropic heat transfer model obtains the temporal/spatial temperature distribution and constructs the solidification map for various process parameters, including laser power, laser …

Behavior Of 3d Printed Polymeric Triply Periodic Minimal Surface (Tpms) Cellular Structures Under Low Velocity Impact Loads, Jesse James Leiffer

Browse all Theses and Dissertations

Surface-based lattice structures such as triply periodic minimal surface (TPMS) lattices are lightweight structures that are widely being investigated for applications in automotive, aerospace, military, railway, and naval structures. Due to the recent advent of three-dimensional (3D) printing (3DP) technologies, architected cellular materials such as surface- or strut-based periodic lattice cell structures have emerged as a unique class of lightweight metamaterials. These materials possess enhanced strength to weight ratio, high stiffness, exceptional capabilities in reducing noise and vibration, insulating heat, and effective impact energy absorption. Understanding the impact behavior of such materials are important so that they can be reliably …

Contact Simulation For Evaluating Patient Specific Surgical Guide Stability, Vincent Nierste

Electronic Theses and Dissertations

This study proposes a novel computational method to quantify guide stability for Patient Specific Instrumentation (PSI) guides. A finite element contact model was used to analyze the final position of PSI guides on a femur across a range of loading parameters representing forces applied by a surgeon during operative use. Separate segmentation methods were used for the guide and bone geometry to represent differences between segmentation and actual patient geometry. The region of loading parameters over which the guide exhibited a consistent final position was measured and reported as Guide Stability Score. The model was verified using cadaver specimens for …

Numerical Design Of Steerable Guidewires, Onkar Prakash Salunkhe

Dissertations, Master's Theses and Master's Reports

Biomedical devices are an integral part of the medical industry nowadays. With the increase in cases of heart disease, catheterization procedures are becoming more frequent. Small-scale actuators are needed for the guidance of small-scale catheters and guidewires to remote targets in the human body. Numerical modelling is needed to guide the experiments in developing such steerable devices and to optimize their design. Here, we designed small-scale steerable guidewires by first developing bending actuators and then assembling them with guidewires. The actuators use materials with strain response to electric potential in a very low voltage range that is not harmful to …

Development And Validation Of A Force Measuring Device For A Laboratory Wave Tank, Jacob K. Colling

Dissertations, Master's Theses and Master's Reports

The ability to predict the hydrodynamic force exerted on floating bodies plays a critical role in creating more effective control strategies for wave energy converters (WECs). Developing a test apparatus capable of directly measuring the forces exerted on a floating body subjected to a wavefield provides the means to validate theoretical prediction methods with experimental results and to develop data-based prediction methods for hydrodynamic forces. This report will discuss the development and validation of a device that measures the total vertical force exerted on a test artifact. The device requirements and design are discussed to examine the factors taken into …

Oxidative Aging And Fracture Behavior Of Polymers And Composites: Theory, Modeling And Experiments, Shabnam Konica

Dissertations, Master's Theses and Master's Reports

Polymers and their composites (PMC) have emerged as effective alternative materials in structural, aerospace, and automotive industries due to their lightweight and tunable properties compared to metals. However, these materials tend to degrade during their operations in extreme environments. In this work, two extreme conditions are considered: - i) high-temperature oxidative degradation of polymers and polymer-based composites ii) Fracture and damage of polymer-based composites under thermo-mechanical loading.

Polymer oxidation starts when oxygen from the ambient diffuses into the bulk material and initiates chemical reactions to develop a coarse, brittle oxide layer on the exposed surface. The oxidative degradation process is …

Model Predictive Control Of Energy Systems For Heat And Power Applications, Chethan Ramakrishna Reddy

Dissertations, Master's Theses and Master's Reports

Building and transportation sectors together account for two-thirds of the total energy consumption in the US. There is a need to make these energy systems (i.e., buildings and vehicles) more energy efficient. One way to make grid-connected buildings more energy efficient is to integrate the heating, ventilation and air conditioning (HVAC) system of the building with a micro-scale concentrated solar power (MicroCSP) sys- tem. Additionally, one way to make vehicles driven by internal combustion engine (ICE) more energy efficient is by integrating the ICE with a waste heat recovery (WHR) system. But, both the resulting energy systems need a smart …

Passivity-Based Numerical Modeling And Grid Integration Strategies For Wave Energy Converter Arrays, Salman Husain

Dissertations, Master's Theses and Master's Reports

The body of work presented here develops numerical time-domain models of Wave Energy Converter (WEC) arrays or wave farms. It will be shown here that a cluster of WECs can be more effective in extracting oceanic energy, can facilitate deployment logistics, and help with grid integration. The objectives of this work are: (i) developing a theoretical metric to evaluate the energy extraction potential of a WEC array, (ii) developing an algorithm that ensures the stability of the time-domain models of WEC arrays, and (iii) identifying strategies that facilitate grid integration and power management of a WEC array. In the process …

Molecular Modeling Of High-Performance Thermoset Polymer Matrix Composites For Aerospace Applications, Prathamesh P. Deshpande

Dissertations, Master's Theses and Master's Reports

The global efforts from major space agencies to transport humans to Mars will require a novel lightweight and ultra-high strength material for the spacecraft structure. Three decades of research with the carbon nanotubes (CNTs) have proved that the material can be an ideal candidate for the composite reinforcement if certain shortcomings are overcome. Also, the rapid development of the polymer resin industry has introduced a wide range of high-performance resins that show high compatibility with the graphitic surface of the CNTs. This research explores the computational design of these materials and evaluates their efficacy as the next generation of aerospace …

On-Ice Detection, Classification, Localization And Tracking Of Anthropogenic Acoustic Sources With Machine Learning, Steven J. Whitaker

Dissertations, Master's Theses and Master's Reports

Arctic acoustics have been of concern in recent years for the US navy. First-year ice is now the prevalent factor in ice coverage in the Arctic, which changes the previously understood acoustic properties. Due to the ice melting each year, anthropogenic sources in the Arctic region are more common: military exercises, shipping, and tourism. For the navy, it is of interest to detect, classify, localize, and track these sources to have situational awareness of these surroundings. Because the sources are on-water or on-ice, acoustic radiation propagates at a longer distance and so acoustics are the method by which the sources …

Characterization Of Hydraulic Flow Noise Induced By Spool Valves, Carter A. Paprocki

Dissertations, Master's Theses and Master's Reports

The purpose of the hydraulic flow noise research was to investigate the relationship between operational valve parameters and flow noise generation. The primary consideration was correlating the flow noise generated by the valve with the distinct valve open positions. This data would allow future valve designs to account for features that cause increased flow noise and move those features away from high flow valve displacements. By implementing this, companies would be able to design quieter hydraulic systems that will not expose operators to the current levels of sound found on machines. The experiments were conducted using two valves with different …

Development Of Advanced Models For Pre-Ignition Prediction In Gas Engines And Analytical Model For Wallfilm Evaporation, Ankith Ullal

Dissertations, Master's Theses and Master's Reports

Ever-changing regulations aimed at improving efficiency and reducing harmful emissions have resulted in many power-generation device (engine) manufacturers to adopt new strategies. Computer simulation of these new strategies of power generation requires more accurate and higher fidelity modelling tools. In the present study, two such models are developed. The first model deals with pre-ignition phenomena driven by lubricant (lube) oil in natural gas engines and the second model is relevant to prediction of wallfilm evaporation by employing analytical solutions to transport governing equations for boundary layers.

Pre-ignition in engines has been the subject of current research with the advent of …

Partially Stratified Combustion Of Natural Gas For Spark Ignition Engines, Philip S. Zoldak

Dissertations, Master's Theses and Master's Reports

In this work, the advantages of partially stratified direct injection natural gas versus premixed port-fueled injection natural gas spark ignited engines has been studied. The volumetric efficiency, ratio of specific heats and turbulent kinetic energy was found to be higher with direct injection versus port-fueled injection thus improving thermal efficiency. A background study of optical chamber experimental data was performed to develop an understanding on the effect of pressure ratio on direct injection of methane under both fully-expanded (sub-sonic) and under-expanded (super-sonic) conditions. Under-expanded jets had a noticeable advantage in terms of turbulent kinetic energy, which led to enhanced air …

Optimal Control Of Nonlinear Wave Energy Converters In Heave For Maximum Power Extraction, Kevin Nelson

Dissertations, Master's Theses and Master's Reports

The marine renewable energy community is interested in maximizing the power generated by nonlinear wave energy converters. Optimal control methods provide a tool to achieve this aim and can also help to inform the buoy design. An energy-optimal control law for a class of non-linear buoy models is derived and is shown to be singular. The solution approach is illustrated using an hourglass-shaped buoy having a cubic, hydrostatic nonlinearity. The optimal control law is only valid on singular arcs, and a method to search for these arcs is presented. Two singular arcs are found for the hourglass buoy model and …

Concept Evaluation And Development Of A Novel Approach For Integration Of Turbogeneration, Electrification And Supercharging On Heavy Duty Engines, Satyum Joshi

Dissertations, Master's Theses and Master's Reports

While many technologies such as electrically assisted turbocharging, exhaust energy recovery and mild hybridization have already proven to significantly increase heavy-duty engine efficiency, the key challenge to their widespread adoption has been their cost effectiveness and packaging. This research specifically addresses these challenges through evaluation and development of a novel technology concept termed as the Integrated Turbogeneration, Electrification and Supercharging (ITES) system. The concept integrates a secondary compressor, a turbocompound/expander turbine and an electric motor through a planetary gearset into the engine cranktrain. The approach enables a reduced system cost and space-claim, while maximizing the efficiency benefits of independent technologies. …