Computer-Aided Engineering and Design Commons^™

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

All Dissertations

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 …

Dynamic Angle Of Repose Of Ss316l Powders Fabricated By Gas Atomization For Additive Manufacturing Applications, S. M. Mahid

Student Research Symposium

Metal additive manufacturing (AM) techniques, unlike conventional manufacturing methods like turning and milling, construct objects by incrementally adding layers of material. Various processes can be used to 3D print including laser or electron beams to melt or sinter metallic powder particles.

A Study On High-Frequency Bending Fatigue, Microhardness, Tensile Strength, And Microstructure Of Parts Made Using Atomic Diffusion Additive Manufacturing (Adam) And Additive Friction Stir Deposition (Afsd), Hamed Ghadimi

LSU Doctoral Dissertations

This dissertation reports the findings of several studies on the mechanical and microstructural properties of parts made using atomic diffusion additive manufacturing (ADAM) and additive friction stir deposition (AFSD). The design of a small-sized bending-fatigue test specimen for an ultrasonic fatigue testing system is reported in Chapter 1. The design was optimized based on the finite element analysis and analytical solution. The stress–life (S–N) curve is obtained for Inconel alloy 718. Chapter 2 presents the findings of ultrasonic bending-fatigue and tensile tests carried out on the ADAM test specimens. The S-N curves were created in the very high-cycle fatigue regime. …

Optimum Design Of Metallic And Plastic Cylindrical Gears Using Naturally-Inspired Algorithms: A Review, Marah Elsiedy, Hesham Hegazi, Ahmed Elkassas, Abdelhameed Zayed

Journal of Engineering Research

Abstract- Nowadays, several machinery and vehicles utilize mechanical elements which transmit power ranges from low, middle, and high levels depending on the type of equipment needed. Gears are the most influential design elements on any process during the running of a specific application, moreover engineers tried to obtain the optimality of a gear design which is a more compact, reliable- long service with simply operating features by following a systematic calculation of the mathematical model from standards and handbooks, however this process doesn't give the optimal design of the gears. Optimization techniques have been added to the design process for …

Sustainable Phone Housing, Jonah Milnor

All Undergraduate Projects

Most commercially available smartphones posed a challenge to consumers due to the use of adhesives, which not only served to seal out dust and water but also hindered repairability and hardware replacement. Drawing inspiration from successful smartwatch designs employing gaskets for water resistance, this project aimed to adapt such design principles to the smartphone form factor.

Utilizing SolidWorks for design and subsequent 3D printing and CNC machining for prototyping, 3D models of a smartphone housing were crafted. The objective was to attain a level of water and dust resistance equivalent to that of model smartphones, utilizing sealing methods equivalent to …

Generalizable Fugitive Carrier Method For 3d Printing Of Hydrogels, Hakan Arslan

Mechanical and Aerospace Engineering Dissertations - Archive

Hydrogels, with physical characteristics resembling biological soft tissues, hold great potential for bioinspired and biomedical applications. However, using them in additive manufacturing systems has challenges because of their poor mechanical and rheological properties. In response to these challenges, we introduce a fugitive carrier method, a novel and generalizable approach for materials incompatible with pneumatic-based extrusion three-dimensional (3D) printers. Our developed fugitive carrier method allows the 3D printing of a broad spectrum of hydrogel precursors with low viscosity while retaining their inherent properties. This technique has been successfully demonstrated by creating biomimetic structures with anisotropic and programmable systems utilizing temperature-sensitive hydrogel …

Stanley Black And Decker Slag Removal Design Project, Colt Hemphill, Kyle Stober, Andrew Raymond, Robert Artrip

Williams Honors College, Honors Research Projects

My group given the task of designing a system to remove the slag of large metal plates. Removing this slag is an important step in creating the final assembly of a model. Currently we the operators are flipping the plates using a large magnet and crane. The issue that we see with the current method is the risk of injury while having the plate suspended in the air. These plates can reach upwards of 600lbs and poses a serious threat to the operators if the magnet is not secured correctly. Our new system for removing the slag is designed to …

Battery Dunnage, Paul Hirsch, Alex Cox, Ben Strubbe

Williams Honors College, Honors Research Projects

Schaeffler is launching a new assembly line for a battery in 2025. As part of the project, it is necessary to design and fabricate a reusable dunnage (packaging) specialized for the battery, meant for safe domestic transportation in the United States. Through an iterative process, the team developed a final dunnage design out of steel components that had a maximum footprint of 62 in X 43.5 in X 29.25 in and a weight of 821.682 lbs. The dunnage is stackable on itself up to two high, weighing a total of 4,918.724 lbs. when loaded with four batteries. The design was …

3d Printed Drone (Body And Controls), Michael Dick, Hayden Pinkelman, Tanner Henderson, Logan Prince

Williams Honors College, Honors Research Projects

The objective is to build a scaled down model of a 3D printed drone capable of carrying a payload scalable to 50 lbs. for a wide array of applications. Some applications of the drone could include delivering support materials during natural disasters, such as foam to put out fire or medical aid packs to provide aid to injured people, food or package delivery, or military applications. The project has been split up into two groups. One group will be focusing on the propulsion aspect of the project, such as the electric motors and airfoil. Simultaneously, this group will design the …

Zips Racing Electric Brakes Design, Zachary Koneval, Andrew Thompson, Cory Baczkowski

Williams Honors College, Honors Research Projects

The Zips electric racing team is a collegiate team full of engineering students to make a formula electric car that competes against other universities and their cars. But before the cars make it to competition they go through a series of tests to make sure the car is able to perform in all of the actual competition stages. One of the tests for the cars is the brakes test. Where the car has to lock up all four wheels at once and stop in a square that is on the ground. So in this report we have detailed out our …

Schaeffler E-Axle Value Engineering, Andrew Powers

Williams Honors College, Honors Research Projects

This project aims to design a manufacturable E-Axle end housing that improves system performance while reducing cost. The project is focused on utilizing Schaeffler's manufacturing competencies to achieve a simple assembly with a significant reduction in cost per part, while using existing machines or processes within the company. The design development process will follow the conceptual design stage through Finite Element Analysis and classical engineering calculations. Cross-functional design reviews will be conducted to ensure that agreement can be reached on the manufacturing feasibility of the design. Concepts will be entered in a decision analysis sheet to identify the best one …

Mechanical Characterization Of Functionally Graded M300 Maraging Steel Cellular Structures, Bradley Jay Sampson

Theses and Dissertations

Traditional methods for increasing the energy absorption of a structure involve using a stronger material or increasing the volume of the structure, resulting in a higher cost or additional weight. Additive manufacturing (AM) can be used to maximize the energy absorption of materials with the ability to create complex geometries such as cellular structures. Previous work has shown that the energy absorption of additively manufactured parts can be improved through functionally graded cellular structures; however, this strategy has not been applied to ultra-high strength steel materials. This work characterizes the effect of multiple functional-grading strategies (e.g. uniform, rod-graded, size-graded) on …

Code To Combustion: Cnc Rotor Replication Using Cam, Luis Luna

Publications and Research

In the current landscape, computer-aided design (CAD) and computer numerical control (CNC) technologies have greatly enhanced manufacturing processes, allowing rapid and high-precision production. This project will focus on recreating a Wankel engine rotor, using SolidWorks for design and Mastercam for Computer-Aided Manufacturing (CAM) simulations. The process begins with SolidWorks, which is used for a template of a high-precision rotor model. Mastercam is then utilized for the CAM programming, allowing for the creation of intricate tool paths and tool usage simulations. This approach is vital for complex objects like the Wankel engine rotor, which demands high precision. The primary objective of …

Cnc Retrofits, Fabian Samano, Murat Askin, Daniel Lonczak, Zane Campise

Mechanical Engineering

The Boxford CNC Lathe is a machine used for educational purposes. The goal of the CNC Retrofits project is to improve the Boxford MT2’s performance and functionality to enable Mr. Lonczak to manufacture customized ballpoint pens. Within this Final Design Review (FDR) document, we present design updates since the CDR and implementation/assembly techniques. This work culminates in a solution to Mr. Lonczak’s needs which is analyzed in three subsystems: main control, spindle position tracking, and user interface. Within this report, we show the results of each subsystem’s verification process. These results prove that the design concept was met by describing …

Kwad - Ksu All Weather Autonomous Drone, Nick Farinacci, Sebastian Gomez, Stewart Baker, Ed Sheridan

Symposium of Student Scholars

"KWAD" or "KSU all-Weather Autonomous Drone" project was sponsored by Ultool, LLC to the KSU Research and Service Foundation to create a lightweight drone capable of capturing HD video during all-weather operations. The conditions of all-weather operation include rainfall of one inch per hour and wind speeds of up to twenty miles per hour. In addition, a global minimum structural safety factor of two is required to ensure the system's integrity in extreme weather conditions. Potential mission profiles include autonomous aerial delivery, topological mapping in high moisture areas, security surveillance, search and rescue operations, emergency transportation of medical supplies, and …

Additive Manufacturing And Characterization Of Auxetic Structures, Jayesh P. Moore, Stephanie R. Ruzicka

College of Engineering Summer Undergraduate Research Program

An auxetic structure is an arrangement of unit cells that under a uniaxial load experiences expansion in both the longitudinal and transverse directions, resulting in a negative Poisson’s ratio (NPR). Research in auxetics has led to new insights into how non-linear mechanical reactions can be applied to various engineering fields. This project utilized stereolithography (SLA) 3D printing to manufacture auxetic test specimens to analyze of geometry-driven NPRs. With the distinctive mechanical properties of auxetic structures and vast applications, the future of product development of these geometries seems promising.

Additive Manufacturing For Medical Education, Michael Noon

College of Engineering Summer Undergraduate Research Program

A growing body of evidence is suggesting that anatomical knowledge, the keystone of many medical specialties, is suffering among new graduates. While a host of reasons are provided, one common thread that many point to is the decline of cadaver dissections in the classroom. Many virtual audio-visual tools are used to address this gap, yet evidence has shown their ineffectiveness. Given this gap, the high degree of flexibility found in additive manufacturing (AM), and the many uses AM has already found in the medical field, we propose its use to fill this gap, allowing for students to learn with touch …

Modeling, Control, And Hardware Development Of A Thrust-Vector Coaxial Uav, Andrew North

Doctoral Dissertations and Master's Theses

This thesis introduces a unique thrust vector coaxial unmanned aerial vehicle (UAV) configuration and presents a comprehensive investigation encompassing dynamics modeling, hardware design, and controller development. Using the Newton-Euler method, a dynamic model for the UAV is derived to gain in-depth insights into its fundamental flight characteristics. A simple thrust model is formulated and modified by comparing it with data obtained from vehicle testing. The feasibility of manufacturing such a vehicle is assessed through the development of a hardware prototype. Finally, a linear state feedback controller is designed and evaluated using the non-linear dynamics model. The results demonstrate successful validation …

Headlamp/Bike Light Damping System, Ethan Reece Clark, Alec Stonehouse, Omeed Ostry, Mitchel Anderson

Mechanical Engineering

The task for this project is to design a headlamp and/or bike light that absorbs the impact shocks from the user’s actions. The user that the system is being designed for may be riding a bike or running on a trail in the evening or early in the morning where the light needs to be stabilized and their path must be illuminated. This report presents the final design chosen after months of prototyping and design iteration. It encompasses the system design, design verification through testing, implementation, future recommendations, and lessons learned throughout the process. The chosen design utilizes a fully …

The Center For Centering Dome, Olek Piechaczek, Ryan M. Scharf

Architectural Engineering

The Center for Centering seeks to create a large-scale healing center, conducive to individual centering of the mind and body. This mobile installation provides a relaxing, enclosed space while still maintaining a connection to the outdoors. The clients liked the idea of having a pop-up installation that could be easily set up as a touring display. With a deadline for installation looming in June 2022, a team of students had five months to design and manufacture the structure.

In winter 2022, the students developed custom geometry to minimize the number of individual parts and built a ¼ scale model of …

Prove Primary Battery Structure, John D. Burkhart, Andy Mccormick, Ryan Yu, Soren Barclay

Mechanical Engineering

In conjunction with Prototype Vehicle (PROVE) Laboratory, our group designed, manufactured, and tested a prototype structure to house the battery boxes for PROVE’s endurance vehicle. Our structure was designed to support the batteries during normal use, and in the event of a front crash. Our design is comprised of a secondary composite box to house the battery boxes, a bottom plate to affix the secondary box to the chassis floor, a horizontal plate fastened to the chassis, and a brace structure welded to the chassis. From the outset, we chose to use a secondary box, the primary battery boxes must …

Programmable Vibration Table Retrofit With Eagle Medical, Jonathan Ilagan, Madhav Asok, Max Lewter

Biomedical Engineering

This project aimed to repair and upgrade a vibration table used for package testing for the sponsor, Eagle Medical - a medical packaging and sterilization company based in Paso Robles, California. The current vibration table is not programmable and lacks circuit diagrams, making it difficult to repair. In addition, it is not functional due to internal circuitry issues and power requirements. To address these issues, the team will implement several upgrades to improve the product and allow for better random cyclic vibration testing. A full assessment of the existing vibration table will be conducted to ensure the viability of these …

Electromagnetically Actuated Modular Robots With Controlled Self-Assembly And On-Demand Disassembly, Anuruddha Bhattacharjee

Mechanical Engineering Research Theses and Dissertations

Modular reconfigurable robots, with on-demand assembly and disassembly, offer the possibility of mesoscale (milli- and microscale) manufacturing. However, most of the existing modular robotic platforms currently being designed and functionalized rely on complex actuation and assembly mechanisms and so lack further scalability and transformability required for mesoscale applications. Therefore, this dissertation seeks to develop a novel scalable modular robotic platform with controlled self-assembly, disassembly, and reconfiguration techniques using an external electromagnetic field. While current cutting-edge research in this area uses a single magnet to move one module at a time into the target position, this dissertation explores processes to move …

Crafting Comfort: The Design And Production Of A High-End Poolside Lounge Chair, John Hollis Tackett, Robert Griffis

Honors Theses

This report focuses on the development, design, and manufacturing of the Adjustable Lounge Chair, a high-end poolside lounge chair created to address un-met customer demand in the market. The investigation began with a market analysis to identify sought-after features not currently offered by competitors' products. This analysis drove the design of the chair, which was developed using CAD software, followed by the construction of a physical prototype to validate the concept.

The chair's innovative features include adjustable lumbar support and chair height, as well as a removable face-piece that enables users to comfortably lie prone without straining their necks. These …

The Engineering Challenges Of Designing And Manufacturing A Tensegrity Cup Stand, Yaniv Goulet, Daniel Ferro

Honors Theses

Progressing from a simple idea into a fully developed product is one of the main goals of any engineer. Through Haley Barbour Center for Manufacturing Excellence’s capstone program, the team was tasked with realizing a tensegrity cup stand. The tensegrity structure consists of a top and a bottom of some form only supporting itself by tension. The team had to research the concept, create an initial design, create a prototype of the product, improve the design after the prototype’s mistakes, apply lean principles to improve the manufacturing efficiency, and analyze all the economic impacts of the engineering decisions. In the …

Exploring Methods For Recycling Filament Waste In 3d Printing, Max Rios Carballo

Publications and Research

The goal of the current study is to investigate cutting-edge techniques for recycling filament waste from 3D printing procedures. Appropriate waste management techniques are required to reduce this trash's harmful environmental consequences. The goal of the project is to look at new methods for recycling filament waste in order to minimize disposal and encourage reuse. To acquire data from pertinent papers and research, a thorough literature review methodology was used. The findings show that this issue may be resolved utilizing a variety of recycling techniques, including shredding, melting, and re-extrusion. The type of filament waste and the intended goal will …

Engineering 3d Architected Metamaterials For Enhanced Mechanical Properties And Functionalities., Huan Jiang

Electronic Theses and Dissertations

Compared with conventional materials, architected metamaterials have shown unprecedented mechanical properties and functionalities applications. Featured with controlled introduction of porosity and different composition, architected metamaterials have demonstrated unprecedent properties not found in natural materials. Such design strategies enable researchers to tailor materials and structures with multifunctionalies and satisfy conflicting design requirements, such as high stiffness and toughness; high strength with vibration mitigation properties, etc. Furthermore, with the booming advancement of 3D printing technologies, architected materials with precisely defined complex topologies can be fabricated effortlessly, which in turn promotes the research significantly. The research objectives of this dissertation are to achieve …

Structural Design And Fabrication Of A Test Chamber To Test Ppes For Effective Particle Filtration, Matthew G. Adharsingh

Honors College Theses

This research project aims to design and fabricate a test chamber for testing Personal Protective Equipment (PPE) to ensure effective particle filtration. The chamber has a special purpose, which is to measure ultrafine and submicron particles concentration in the air and test the ergonomic design of PPE based on its effective filtration. The project also considers the environmental aspects of the chamber such as the level of noise and vibration. The chamber will be designed to measure upstream and downstream particle count. Initially, the chamber was going to be made from wood, but the research team encountered difficulties in the …

Creativity, Craftsmanship, And Connection: Large-Format Sculpture Design, Jacqueline L. Puga, Gordon Hoople

The Transdisciplinary STEAM+ Journal

Artistry is a concept that is not usually explored in engineering yet is an invaluable skill that touches everything from product design to systems thinking. This past summer I developed conceptual designs for a large format sculpture that required connecting engineering knowledge with artistic vision. The initial phase required constant inspiration and creativity. The first step was to look at previous sculptures showcased throughout the world, such as at venues like “Burning Man,” to understand the possibilities or limitations of the space provided. Sketching varied and numerous ideas was essential in our design process. Next, we took our favorite ideas …

Launching A 3d Printing Program For Students: Recommendations And Best Practices For Libraries, Wilhelmina Randtke, Lee Bareford

Georgia Library Quarterly

The Georgia Southern University Libraries launched a 3D printing program for students in July 2022. Prior to launch, library employees at two of Georgia Southern University’s campuses investigated options for implementing safe, affordable, and sustainable 3D printing in existing academic libraries without retrofitting costly ventilation systems into existing facilities. This article describes the reasons why the Georgia Southern University Libraries thought that a 3D printing program could fulfill a service need for students across university colleges and departments and outlines some of the challenges, best practices, and unique innovations that the library’s employees experienced throughout the program launch process. The …