Computer-Aided Engineering and Design Commons^™

A Maximum Energy Release Rate Computational Framework For Fatigue Crack Trajectory And Life Prediction Under Mixed-Mode Proportional And Nonproportional Loading, Nahla Helmy Matar

Theses and Dissertations

The problem of mixed-mode fatigue crack growth has been a persistent research challenge. The determination of fatigue crack propagation direction directly impacts the safety and integrity of components and structures, making it crucial in various industrial applications, including welded drilling pipes, aerospace, and automotive engineering. Unlike uniaxial loading, mixed-mode cracks tend to change direction frequently (kinking), and nonproportional loading adds to the complexity of the problem. This research aims to estimate the crack propagation direction and fatigue crack life in linear elastic materials subjected to mixed-mode (I+II) loading conditions under proportional or non-proportional cyclic loading. Numerical software was developed based …

Analysis Of Tower Stringset Replacement From 33 Kv To 66 Kv Considering Sagging Clearance, Muhammad Lazuardi Azzura, Anne Zulfia Syahrial, Julius Purnama Eka Kartika

Journal of Materials Exploration and Findings

Efforts to increase the capacity of transmission networks are often undertaken by uprating the operating voltage of existing lines rather than building entirely new infrastructure. Such uprating typically involves the replacement of tower insulator stringsets to withstand higher voltages, while also ensuring that mechanical performance remains adequate. This paper presents an analysis of uprating the Parakan–Sunyaragi transmission line from 33 kV to 66 kV, with particular emphasis on conductor sagging and the resulting clearance from the ground. The methodology employed includes calculations based on catenary equations, analysis of conductor tensile forces, and a comparative evaluation of two widely used insulator …

Structural Design And Finite Element Analysis Of A 54 Ton Freight Wagon Bolster Test Rig Under Vertical Center Plate Load, Shandy Dwi Prayoga, I Dewa Gede Ary Subagia, I Ketut Adi Atmika, Abdul Rohman Farid, Yunior Lanang Satrio

Journal of Mechanical Engineering Science and Technology (JMEST)

Bolster is one of the bogie's components that receives direct loading from the car body and freight movement. One of the problems that occurs in the bolster is permanent deflection during vertical and transversal static loading. Therefore, a static loading test is required to evaluate the structural strength of the bolster. During the static loading test, a rig is required to hold the bolster so that the bolster is in a fixed position. The rig owned by PT. INKA (Persero) showed a plastic deformation at the vertical center plate load (VCP 5.22P). Therefore, a modified design of the rig is …

Lunar Manufacturing Systems And The Role Of Additive Recycling Technologies, Camille A. Newman

Honors Theses

Renewed international interest in sustained lunar exploration has created a growing demand for technologies to support long-duration space exploration. Part of the recent Artemis missions and the Moon to Mars initiative is to improve key mission capabilities and fill critical gaps necessary to sustain lunar habitation. Waste management, recycling systems, and manufacturing systems have been identified as critical technologies that need further development before a sustained mission is possible. This thesis explores the feasibility of an additive manufacturing and recycling system designed to process plastic waste generated during extended lunar habitation. Initial research focused on existing manufacturing and recycling technologies …

Cast In Steel: Horseman's Axe, Sam A. Morris

Create@State

Cast in Steel is a competition between universities across North America started by the Steel Founders Society of America. The competition is centered around giving students the opportunity to learn about casting and the steel industry in general. A prompt of a weapon or tool with some level of historical significance is given to all the teams. The prompt for the 2026 Arkansas State University team, was a Horseman’s Axe. The team designed their rendition of a horseman’s axe, worked with Southern Cast Products as their local industry parter, and fabricated a finished axe to represent Arkansas State University as …

Areosense, Josephine Turney

Williams Honors College, Honors Research Projects

The AeroSense growing system is designed to make indoor aeroponic gardening easy and accessible for everyone. By combining sensors, automation, and AI, the system can monitor and adjust humidity, lighting, and nutrient levels to help plants thrive without requiring expert knowledge. The goal is to create a self-regulating garden that takes the guesswork out of growing fresh herbs and vegetables at home. The project involves building a working aeroponic prototype equipped with misters, pumps, and environmental sensors, all managed by a Raspberry Pi. Using computer vision and machine learning, AeroSense will be able to assess plant health and respond automatically …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Aerodynamics And Heat Transfer In Polymer Blown Film Processing: Experimental And Numerical Investigation, Mohammad Luqman Zulbakri, Nur Atiqah Mat. Rautin, Raa Khimi Shuib, Ku Marsilla Ku Ishak, Auratus Zuratul Ain Abdul Hamid, Mohamad Danial Shafiq, Mohamad Yusof Idroas, Muhammad Khalil Abdullah

Makara Journal of Technology

The effects of airflow dynamics, heat transfer, and mechanical properties on the HDPE blown film extrusion process were examined using a single-lip air ring with a fixed compressed-air valve opening angle of 10°. Reynolds numbers ranging from 9175 to 25911 were analyzed to understand their impact on cooling efficiency, bubble morphology, and film properties. Numerical simulations employing the Standard k−ω turbulence model in ANSYS FLUENT v2023, with mesh refinement achieving y+ ≈ 1, captured detailed flow and heat transfer behavior. Results showed that higher Reynolds numbers significantly enhanced the heat transfer coefficient, with values increasing from 1096 W/m²·K at Reynold …

Active Measurement Of A Micron-Order Gap Under High-Speed And High-Temperature Conditions, Andrew Becker

Doctoral Dissertations and Master's Theses

The hypersonic regime poses numerous challenges that researchers face in the development of hypersonic flight vehicles. Due to their excellent thermomechanical properties, ultra-high-temperature ceramics (UHTCs) have risen as a promising solution to act as a protective barrier between the harsh environment and surface materials of these flight bodies. The mechanical operation of a portable hypersonic simulation device was developed in-house and tested at Argonne National Laboratories (ANL) to gather in-situ material response of prospective UHTC samples when exposed to a hypersonic regime. An edge detection-based algorithm was developed and used in LabVIEW to monitor the health and operation of the …

Design Of A 10-Ton Capacity Solar-Powered Cold Storage At The Cituis Fish Auction Site, Tangerang, Banten, Indonesia, Wardi Wardi, Muhammad Arif Budiyanto

Journal of Materials Exploration and Findings

This study presents the design of a 10-ton capacity solar-powered cold storage system for the Cituis Fish Auction Site (TPI) in Tangerang, Indonesia, as a sustainable solution to support the coastal fisheries sector. The system comprises two temperature zones: an anteroom at 5°C and a freezer room at -30°C, both integrated with a hybrid system utilizing solar panels and batteries. The total power consumption of the cooling system reaches 27.51 kW. The simulation results, obtained using HOMER Pro software, indicate that the hybrid PV system can reduce CO₂ emissions by up to 16,754 kg per year. From an economic …

Shape Memory Behavior In Medium To High Entropy Shape Memory Alloys: Design, Prediction, And Experimental Analysis, Hatim Raji

Theses and Dissertations

This dissertation provides a data-driven system integrating synthetic data generation and machine learning (ML) techniques to create multicomponent SMA compositions with specific transformation temperatures (TTs). Models were trained to represent the nonlinear dependencies influencing martensitic transformation behavior by using elemental, thermodynamic, and process-related aspects. The capacity of the ML models on medium entropy NiTiHfPd and high entropy NiTiHfZrCu systems accuracy was confirmed by experimental validation showing TTs closely matched with model outputs.

3d Printed Fixed Wing Aircraft Competition, Sidney E. Long, Mitchell Heise, Jack Bride, Daniel Salinas

Mechanical Engineering

Cal State LA and Arlington University, Texas are hosting the same 3D printed, fixed wing aircraft competition for 2025. Cal Poly requires a competitive plane that can adhere to each rule and be piloted remotely to achieve the longest time in the air. The plane must utilize solely 3D printing technology for the wings, body, and all other structures. The only off-the-shelf components can be the motor and electronics, as well as mechanical devices such as hinges.

Effect Of Manufacturing And Machining Process On Recycled Composite Connecting Rods Under Tension And Compression, Walter W. Oppelt

Master's Theses

Carbon fiber reinforced polymer (CFRP) is an engineering material renowned for its high-strength and low-density material properties. Such properties make CFRPs especially useful for applications across many industries, including aerospace, automotive, marine, sporting goods, oil and gas, and more. However, with such favorable material properties comes the cost of high energy usage required to produce raw carbon fiber. Recycled carbon fiber (rCF) has emerged as a promising alternative, offering a significant reduction in energy usage. This research explores the viability of applying recycled CFRPs to internal combustion engines to both reduce energy costs during manufacturing and while in use. Mechanical …

Model-Based Design Of Compressed Lithium-Metal Pouch Cell Battery Modules For Evtol Applications, Scott J. Stirling

Master's Theses

Batteries with higher specific energy and power are essential for extending the range and performance of electric vertical takeoff and landing aircraft (eVTOLs). Anode-free lithium-metal pouch cells offer strong potential at the cell-level but require high compressive pressures to enhance cycle life and discharge performance. These pressures necessitate heavier structural components, reducing packaging efficiency at the module level.

To evaluate this tradeoff, a full-factorial enumeration model was developed to explore viable module designs within a constrained packaging volume. The model scales subsystem masses, enforces design rules and material limits, and accounts for large (~20%) cell thickness changes during cycling.

Results …

Thermal Modeling Techniques For Additively Manufactured Porous Metals, Lucas D. Rambo

Master's Theses

Advances in additive manufacturing have enabled the creation of metallic components with tailored porosity, offering design flexibility for thermal, structural, and fluid transport applications. This thesis investigates the effective thermal conductivity (ETC) of porous Inconel 625 (IN625) and Inconel-ceramic composites (IN625-RAM2) fabricated by Laser Powder Bed Fusion (LPBF) using Elementum 3D’s PermiAM technology. Experimental measurements of thermal conductivity using the laser flash method are compared to numerical models built from micro-computed tomography data. Simulations were performed using both finite element (FE) and finite volume (FV) methods to evaluate thermal transport in real microstructures. The study investigates the effects of micro- …

Developing Reduced Order Models For Gas Bubble Formation In Irradiated Metals Using Integrated Phase Field Modeling And Koopman Operator Theory, John M. Eggemeyer V

All Theses

Irradiation damage in materials is prevalent in nuclear components, posing significant risks in the safety and reliability of nuclear reactors. Phase field models offer a versatile framework for modeling irradiation damage in materials at mesoscales. Such high fidelity method has been used to model the formation of fission gas bubbles superlattice, a microstructure array occurs at certain irradiation conditions (dose, dose-rate, and temperature). To overcome the high computational cost of phase field modeling, Koopman operator theory is applied to create reduced order models, allowing for instantaneous simulations of fission gas bubble behaviors. These low fidelity models are integrated into machine …

Mechanistic Insights Into Polymer-Assisted Graphene Exfoliation: The Roles Of Velocity, Adhesion, Cohesion, Temperature, Peeling Mode, And Edge Defect Via Coarse-Grained Molecular Dynamics, Linjiale Dai

All Theses

Graphene exfoliation is a critical step in the fabrication of high-quality graphene

layers. However, the underlying fracture mechanisms remain poorly understood. In this

work, I employed coarse-grained (CG) molecular dynamics (MD) simulations to

investigate how factors such as interfacial binding energy, substrate cohesion, temperature,

peeling mode, and edge defects influence the outcome of the exfoliation process. To model

polymer-assisted mechanical exfoliation, I used a finite-size system in which multilayer

graphene (MLG) is sandwiched between two thin polymer films. Leveraging the

spatiotemporal efficiency of the CG model, I performed fifty simulation iterations per

parameter set and analyzed the results from a …

Development Of Planetary Drive System For Formula Sae Electric Race Car, Brian Wong, Bradley Maruoka, Joshua Charles Fine, Madison Kai

Mechanical Engineering

Hub motors are compact electric motors mounted directly on each outboard wheel hub. Utilized in Formula SAE and Formula Student vehicles, this configuration offers several advantages over traditional drivetrains, including packaging optimization within the chassis, vehicle traction, and improved efficiency. Although hub motors are not yet common in 4WD vehicles, they are being explored for use in EVs and may become more common in the future. Every year, Cal Poly Racing FSAE designs and builds a formula-style race car. To improve drivetrain performance, the team is investigating the achievability of a hub motor 4WD drivetrain, requiring extensive research, development, and …

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. …

Investigation Using Single Point Incremental Forming (Spif) To Fabricate Patient-Specific, Titanium Orbital Floor Implants, Elizabeth M. Mamros, Lauren E. Blaha Md, Christian A. Kauffman Md

Faculty Conference Papers and Presentations

The floor of the human orbit is composed of thin bone that is prone to traumatic fracture. This leads to a loss of support for the eye, which can cause vision changes. Therefore, fractures may need surgical reconstruction using a thin, sheet-like implant. Titanium implants are available off-the-shelf in standard sizes, but fitting to each patient’s unique anatomy requires surgeons to cut, file, and bend these plates. This can be time-consuming and imprecise. To both save time and ensure a perfect fit for the patient, a custom plate can be created prior to surgery. This investigation focuses on single-point incremental …

Neural Operator And Physics-Informed Deep Learning Approaches For Inverse Design Of Composites And Manufacturing Processes, Minglei Lu

All Dissertations

In this dissertation, artificial intelligence (AI) models are designed and used to accelerate inverse design of composites and manufacturing processes. The critical bottlenecks in machine learning (ML) including data availability, data quality, model generalization and adaptation, interpretability, physical consistency, and the ’black box’ nature of models for the inverse design are addressed. And the proposed AI models are tested under different engineering scenarios. Firstly, a fast deep neural operator (DNO) structure was developed to significantly reduce training time. This model was tested in the context of additive manufacturing, a transformative industrial technology that allows for the creation of materials with …

Investigation Of Conductive Die-Top Thermal Capacitors During Short Circuit Operation Of Silicon Carbide Devices, Youssef Abotaleb

Department of Electrical and Computer Engineering: Dissertations, Theses, and Student Research

Silicon carbide (SiC) power devices have garnered significant attention in recent years due to their superior thermal and electrical properties compared to traditional silicon devices. However, SiC power devices suffer from severe reliability issues arising from their mechanical properties. This is because the Young's modulus of SiC is about three times larger than that of silicon, which correspondingly raises the mechanical stresses acting on the bonding structure, often leading to device failure under power shock events.

Traditional packaging materials and designs tend to constrain SiC performance, as hot-spot temperature resulting from a power shock is one of the key factors …

An In-Situ Method For Quantifying Entropy Generation In Fatigue Via A Novel Thermographic Approach, Peyton J. Wilson

LSU Master's Theses

This work features a new approach that is used to measure the rate of plastic work during a cyclic fatigue test, based on the first and second laws of thermodynamics. Using the one-dimensional Fourier heat equation coupled with the concept of fracture fatigue entropy, the rate of plastic work during fatigue can be measured without the need to interrupt a fatigue test, and the accumulated entropy to failure can be quantified. Experimental fatigue tests are conducted on Aluminum 6061-T6 specimens under cyclic axial loading and Carbon Steel 1018 specimens under fully reversed cyclic bending loading. The obtained results in addition …

Investigation Of Distributed Additive Manufacturing For 3d Printed Headband Component During Global Supply Chain Disruptions, Elizabeth M. Mamros, Saketh Kantipudi, Matthew C. Eaton, Jinjin Ha, Brad L. Kinsey

Faculty Conference Papers and Presentations

During the COVID-19 global pandemic, a shortage of personal protective equipment (PPE) occurred. Manufacturers of these critical products were unable to keep up with the growing demands as the situation evolved. Most face shields, a common type of PPE, include a headband component to provide the appropriate fit for the user and curvature for the clear face shield attachment. To mitigate this shortage in the local region, the Portsmouth Naval Shipyard (PNSY) generated a computeraided design (CAD) file for the headband component and asked the University of New Hampshire (UNH) to manufacture it with all available 3D printers, including printers …

A Computational Investigation Of Wood Selection For Acoustic Guitar, Jonah Osterhus

Senior Honors Theses

The acoustic guitar is a stringed instrument, often made of wood, that transduces vibrational energy of steel strings into coupled vibrations of the wood and acoustic pressure waves in the air. Variations in wood selection and instrument geometry have been shown to affect the timbre of the acoustic guitar. Computational methods were utilized to investigate the impact of material properties on acoustic performance. Sitka spruce was deemed the most suitable wood for guitar soundboards due to its acoustic characteristics, strength, and uniform aesthetic. Mahogany was deemed to be the best wood for the back and sides of the guitar body …

The Analysis Of Mechanical Exfoliation Of Graphene For Various Fabrication And Automation Techniques, Lance Yarbrough

Physics Undergraduate Honors Theses

Mechanical Exfoliation

The Analysis Of Mechanical Exfoliation Of Graphene For Various Fabrication And Automation Techniques, Lance Yarbrough

Mechanical Engineering Undergraduate Honors Theses

Mechanical Exfoliation of Graphene is an often-overlooked portion of the fabrication of quantum devices, and to create more devices quickly, optimizing this process to generate better flakes is critical. In addition, it would be valuable to simulate test pulls quickly, to gain insight on flake quality of various materials and exfoliation conditions. Physical pulls of graphene at various temperatures, pull forces, and pull repetitions were analyzed and compared to the results of ANSYS simulations, solved for similar results. Using ANSYS’ ability to predict trends in exfoliations, flake thickness and coverage using stress and deflection analyses were investigated. Generally, both strongly …

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 …

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. …