Manufacturing Commons^™

The Interaction Of The Cotton Piece With The Piles Of The Scrabble Cotton Drum, Fazliddin Egamberdiev, Ilkhom Abbazov, Oybek Kholmuratov, Rashid Kaldybaev

Technical science and innovation

This article presents the results of an analytical study of the process of loosening and cleaning raw cotton from small debris by pileging working bodies of purifiers, on the basis of which directions for further research were chosen to optimize the parameters of the developed pile drum with spherical piles and rubber strips. Cotton entering production contains impurities. The processes of loosening and cleaning the fiber shreds are key in the initial stages of ginning, as they prepare the raw cotton for ginning and directly affect the reliability, productivity of these processes and the quality of the resulting fiber. Weed …

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 …

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 …

Empowering Student Success: Unlocking The Potential Of Project-Based Steel Design Education, Aly Mousaad Aly

Faculty Publications

In the pursuit of student success, it is essential to acknowledge that a singular teaching style does not universally cater to all students. The educator's crucial role lies in creating an optimal learning environment that fosters students' endeavors to excel. This endeavor transcends mere classroom success or employment prospects, encompassing a broader impact on societal well-being. An experiential learning approach, where students actively engage in practical tasks, emerges as the most effective mode of instruction. Integrating project-based learning activities into the curriculum holds immense potential for enhancing student learning. Additionally, the utilization of analysis software tools like FTool and STAAD …

Consumer 3d Printing For Remote Control Aircraft Wings: Development Of Novel Wingbox Structure, Ian Clark

University Honors Theses

Remote control aircraft construction and can be a very expensive and time-consuming hobby. With 3D printer consumer adoption rates skyrocketing, there is a gap between demand for RC aircraft and suitable well-designed models available to creators and hobbyists. By creating and testing two iterations of wingbox geometries, this research aims to help close that gap by producing an easily printable wing structure. While there are improvements that can be made on this work, this research has been effective in generating a novel wingbox structure for FFF 3D printing that has distinct advantages over other designs currently available.

3d Printed Aircraft, Matthew Nagy, Charles D'Amico, Alexis Salgado Medina

Mechanical Engineering

This project is to design, build, and test a 3D-printable aircraft. The goal is to create a final design that will be able to fly for the longest duration possible, around 20 seconds. To determine the correct preliminary design and manufacturing process for a 3D printed RC aircraft, an analysis of multiple design options and manufacturing materials was performed. This allowed for a variety of choices for aircraft type, airfoil design, structure, among other topics to be narrowed down to the most promising option. It has been found that the aircraft will follow a design similar to industry motor-gliders, with …

Disc Golf Throwing Robot, Nevada S. Schultz, Sydney M. Lewis, Erick Edmundo Daza, Rachel Alysse Greenberg, Peter M. Kean

Mechanical Engineering

Disc golf companies need better methods to test disc flight. The scope of this project is to create a disc throwing robot that can throw a disc golf driver 450-500 feet, with control over the speed, spin, and release angle. Research shows that multiple disc-throwing products exist; however, none meet the full requirements of this project. The Cal Poly senior project design team created a proof-of-concept machine. This prototype started as a two-wheel mechanism. Eventually, a third wheel was added, allowing for complete control over disc spin. The three-wheel prototype reached 62 mph when perfectly calibrated. The prototype is accurate, …

Feasibility Of Thermoplastic Extrusion Welding As A Joining Method For Vacuum-Assisted Additively Manufactured Tooling, Chase C. Flaherty

Electronic Theses and Dissertations

In recent years, additive manufacturing (AM) has been successfully utilized for the production of large-scale composite tooling. Within these endeavors, however, limited research has focused on joining methods between printed sections. This work evaluates the feasibility of thermoplastic extrusion welding as a joining method for additively manufactured tooling structures. This joining method was assessed based on industry specifications of conventional thermoset tooling for wind blade manufacturing utilizing the vacuum-assisted resin transfer molding (VARTM) process. The specifications include requirements for the mechanical strength, vacuum integrity, roughness, and hardness of the tool surface. The feasibility of this welded polymer joint was demonstrated …

Effects Of Tempering Temperature On Gas Turbine Fan Cases, Seth Utter

Honors Scholar Theses

The project aimed to investigate the effects of tempering temperature on metals used for gas turbine engine fan cases as a major relevant concern is containing blades in during blade-out events. There are three ways to accomplish this: using a thicker metal, incorporating different materials into the case, or heat treating the metal. This project focused on the third solution: reviewing the impact toughness and hardness of fractured samples and their equivalent ductile-to-brittle transition shear faces. Given its availability, 1045 steel, as opposed to aerospace grade metals, was used for in-house testing. The data obtained from these experiments were then …

Exploring Additive Manufacturing In A Space Environment - A Capstone Design Project Experience, Zain Zafar Khan, Zachary Alan Sobelman, Sharanabasaweshwara Asundi

Mechanical & Aerospace Engineering Faculty Publications

The employment of additive manufacturing in the non-standard environments like space, ships, or submarines has the potential to be an advanced utility not only in the pre-flight production of aerospace components and structures, but also for the onboard manufacturing of components and tools necessary for future space missions. For example, the ability to produce tools and structural components on the International Space Station can provide the space community the opportunity to make repairs and upgrades to the space station without wasting time and resources transporting such materials through additional missions. Additive manufacturing would allow for space missions to use on …

Additive Manufacturing Of Molybdenum For High Temperature Structural Applications, Megan L. Bustin

Theses and Dissertations

This research considered additive manufactured (AM) molybdenum (Mo) and the effect of three variables on microstructure, mechanical properties, and the relationship between the two. Test temperature, laser speed, and shield gas or build atmosphere were varied, and samples tested and analyzed using a three-point bending test, chemical composition, and optical and scanning electron microscopy. The relationship among variables and results using a Design of Experiments was limited compared to the inclusion of every tested sample. Most effects were expected: samples tested at room temperature were brittle without statistical significance; increasing laser speed resulted in decreased ductility and strain, smaller grain …

Smart Manufacturing—Theories, Methods, And Applications, Zhuming Bi, Lida Xu, Puren Ouyang

Information Technology & Decision Sciences Faculty Publications

(First paragraph) Smart manufacturing (SM) distinguishes itself from other system paradigms by introducing ‘smartness’ as a measure to a manufacturing system; however, researchers in different domains have different expectations of system smartness from their own perspectives. In this Special Issue (SI), SM refers to a system paradigm where digital technologies are deployed to enhance system smartness by (1) empowering physical resources in production, (2) utilizing virtual and dynamic assets over the internet to expand system capabilities, (3) supporting data-driven decision making at all domains and levels of businesses, or (4) reconfiguring systems to adapt changes and uncertainties in dynamic environments. …

Development And Testing Of A 1:70 Scale Model Wind Turbine Of The Iea Reference 15 Mw Floating Offshore System, Amber Parker

Electronic Theses and Dissertations

This thesis presents the development of a 1/70th scale performance-matched wind turbine intended for wind and wave basin model testing of commercially viable floating wind turbine structures based off of the International Energy Agency (IEA) Wind 15 MW design. The focus of this demonstration is to test active blade pitch response controls and to provide an experimental dataset for use by modelers and industry for future turbine improvements. Future research is planned to test the turbine in conjunction with an actively damping hull to test the interactions between the two control systems.

Outlined in this thesis are the methods of …

Investigation Of Additively Manufactured Molybdenum-Tungsten-Rhenium Alloys, Randolph T. Abaya

Theses and Dissertations

The process of creating metal components through additive manufacturing is changing the way different industries can avoid the shortcomings of traditional metal production. Metals such as tungsten, molybdenum, and rhenium have many advantages for different applications, especially when alloyed together. In this study, an additively manufactured alloy containing 70% molybdenum, 25% tungsten, and 5% rhenium (70Mo-25W-5Re) is tested for its strength, ductility, hardness, and porosity. The 70Mo-25W-5Re alloy is printed through Laser Powder Bed Fusion (LPBF) under different conditions such as printing speed and printing atmosphere. Additionally, the effects of post printing heat treatment are conducted to understand the advantages …

Effects Of A Nitrogen And Hydrogen Build Atmosphere On The Properties Of Additively Manufactured Tungsten, Dana C. Madsen

Theses and Dissertations

Additively manufactured tungsten was printed in pure nitrogen, nitrogen-2.5% hydrogen, and nitrogen-5% hydrogen atmospheres as part of a 2^3 full factorial designed experiment and subjected to room temperature and high-temperature three-point-bend testing, chemical analysis, hardness testing, and microstructural imaging techniques. The pure nitrogen specimens exhibited the highest strength and ductility at both high temperature and room temperature. Chemical analysis showed a 2-8x reduction in compositional oxygen relative to unprocessed powder. Hardness values for all samples was between 306.8 and 361.5 HV1. It is proposed that adding hydrogen into the build atmosphere reduced the available energy density for tungsten melting by …

Jcati Carbon Fiber Recycler: Oven Enclosure, Margarita Romero

All Undergraduate Projects

Central Washington University partners with Boeing and is funded by the Joint Center of Aerospace Technology Innovation (JCATI) to develop a mechanism that takes carbon fiber wing trimmings from Boeing that are resin coated and recycles carbon fiber. This is done by crushing the wing trimmings and then putting it into a 500°C oven to melt off the resin. This project focuses on the enclosure for the oven and making sure precautions are met such as having the outside surface be less than 45c through heat transfer analysis, argon fills enclosure in 13 minutes through fluid dynamics analysis, and 99% …

Carbon Fiber Recycling: Delamination System, Aaron Eastman

All Undergraduate Projects

The production of composite wings at Boeing causes carbon fiber waste and CWU Mechanical Engineering Technology students have been tasked in designing a carbon fiber recycling system. This project was brought forth and funded by the Joint Center for Aerospace Technology Innovation (JCATI). There are three subsystems that make up the carbon fiber recycling system, the delamination system, shredding system, and the oven. The purpose of this project was to increase the efficiency and effectiveness of the delamination system of the carbon fiber recycling system. The old system reached approximately 30-40 percent delamination with one pass through the system, and …

Jcati Carbon Fiber Shredder 2022, Parker Sudderth

All Undergraduate Projects

This project is a potential solution to keep the carbon fiber waste from airplane manufacturing to a minimum, sponsored by the Joint Center for Aerospace Technology Innovation (JCATI). The design and assembly will be scalable for future industry application. The overall design of the whole carbon fiber recycler consists of a crusher, shredder, and oven. This report is on the caron fiber shredder module. The shredder is tasked with being able to shred the delaminated carbon fiber scrap that directly comes from the crusher. The operation must produce shreds in the proper size to be gathered and delivered to the …

In-Situ Characterization Of Burr Formation In Finish Machining Of Inconel 718, Hamzah M. Zannoun

Theses and Dissertations--Mechanical Engineering

One of the undesirable byproducts that occur during the machining process is the development of burrs, which are defined as rough excess material that forms around the geometric discontinuities of a part. Burrs are especially problematic because they have negative impacts across the triple bottom line: economic, environmental, societal. For one, they are expensive to remove because the deburring process is entirely manual and requires skill. Further, burr material is typically discarded which is adding to the already mounting waste generated from machining such as in coolant and chip disposal. Lastly, there are many societal implications, such as operator injury …

Rehology And Electrical Conductivity Of Particulate Composites In Additive Manufacturing, Bin Xia

Mechanical Engineering Research Theses and Dissertations

Extrusion-based multi-functional additive manufacturing (AM) has been a rapidly developing area in AM recently. Particulate composites are widely used in this area to provide different functionalities with different types of particulate additives. However, there is no systematic understanding of the behavior of particulate composites during extrusion (especially in small nozzles) or of their properties once deposited in the build. This work investigates the properties of the type of particulate composites usually used in additive manufacturing, composed of a polymer matrix material and particulate additives within the micrometer scale. The focus is on the material rheology in the nozzle/capillary (for the …

Accelerated Controller Tuning For Wind Turbines Under Multiple Hazards, Aly Mousaad Aly, Milad Rezaee

Faculty Publications

During their lifecycle, wind turbines can be subjected to multiple hazard loads, such as high-intensity wind, earthquake, wave, and mechanical unbalance. Excessive vibrations, due to these loads, can have detrimental effects on energy production, structural lifecycle, and the initial cost of wind turbines. Vibration control by various means, such as passive, active, and semi-active control systems provide crucial solutions to these issues. We developed a novel control theory that enables semi-active controller tuning under the complex structural behavior and inherent system nonlinearity. The proposed theory enables the evaluation of semi-active controllers’ performance of multi-degrees-of-freedom systems, without the need for time-consuming …

Dji Drone Modification, Sean Lacey, Seth Mancuso, Bryce Mckenzie

Williams Honors College, Honors Research Projects

For this project, we set out to create a lightweight carrying case that would be mounted to a DJI Phantom 3. This case is designed to transport small packages, such as medications, from a delivery vehicle to their final destination. Based on our maximum drone lifting capacity of 600 grams, our case, servomotor, and contents had to weigh less than or equal to that value. The coronavirus pandemic has led to an increase in contactless delivery options along with the push for immunocompromised people to avoid contact with people that may be sick. Our product would help transport necessary supplies …

Mechanical Properties Of Nanomodified Hybrid Gfrp Composite Materials, Micah Rop Kimutai

Electronic Theses and Dissertations

The mechanical behavior of the nanomodified hybrid epoxy matrix was investigated in glass fiber reinforced plastics (GFRP). In this study, five nanocomposites enriched with as received halloysite, nanomer I.28E, HNT-APTES, and the hybrid combinations of the two HNTs with the nanomer I.28E were successfully fabricated. To evaluate the effects and morphological characteristics of the individual fillers and the hybrid configurations on the epoxy resin matrix, TGA, DSC, and DMA were analyzed. To understand the effect of the five configurations on the neat GFRP laminate, mode I interlaminar fracture toughness, tensile, and vibration properties were investigated. Electron microscopy testing techniques were …

Miniaturized Ultraviolet Imager Phase Iii, Bradley D. Albright, Nicolas A. Armenta, Colin W. Harrop

Mechanical Engineering

This document details the work to date, June 9, 2020, done by the Cal Poly Mechanical Engineering senior project team, Miniaturized Ultraviolet Imager: Phase III (MUVI III), sponsored by the University of California, Berkeley – Space Sciences Laboratory (UCB SSL). MUVI III is the third senior project team of an ongoing design, MUVI: the prototype of a 2U sized CubeSat intended to capture aurora images in the ionosphere. The first team, MUVI I, finished development of the UV imager. The second team, MUVI II, designed the mirror mounting and deployable door mechanisms. The goal of MUVI phase III is to …

Safran Seat Attachment System, Craig John Kimball, Tyler Bragg, Lynette Cox

Mechanical Engineering

This final design review (FDR) document outlines the senior design project being carried out by a team of mechanical engineering undergraduate students attending California Polytechnic State University, San Luis Obispo for Safran Seats in Santa Maria, CA. The project originally was to design, build, and test a universal attachment to secure a widebody business class seat to seven aircraft models with different seat track geometry. The goal was to design, document, and create a finished product that fits design, weight, and manufacturing requirements, as well as passes static 9G FWD testing. Structural analysis, manufacturing analysis, FEA, and CAD assemblies will …

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

Rocket Motor Nozzle, Corey Hillegass

Williams Honors College, Honors Research Projects

For this honors research and senior design project, the authors will research, analyze, and manufacture a rocket motor nozzle for the Akronauts rocket design team. This research and design project will improve how the rocket design team will decide and manufacture nozzles going forward. The impact of this improvement allows the rocket design team to take steps toward being self-sustaining by manufacturing student designed parts as opposed to commercially bought parts. This will not only be successful in increasing student impact on future designs, but also provides a technical challenge for the authors and will present as an impressive feat …

Design Of Banner Tow Mechanism For Bush Plane, Kyle Ciarrone, Ivan Martin, Rishabh Gadi, Tyler Brandt

Williams Honors College, Honors Research Projects

The 2019-2020 AIAA DBF objective was to design, build, and test a banner-towing bush plane that carries wooden passengers and luggage. Senior members on the team undertook the creation of the banner tow mechanism subsystem as their senior design project on behalf of the design team due to the challenge of its mechanical design and the aerodynamic considerations regarding its placement and enclosure aboard the aircraft. The competition as well as access to campus resources were canceled due to COVID-19, so full testing and integration of the mechanism was not achieved. However, the engineering design process was experienced from the …

Redesign And Analysis For Landing Gear Components, Daniel Clarke

Williams Honors College, Honors Research Projects

A project for Collins Aerospace, the company I co-op at, where I will redesign several components of a landing gear for a military program. Any structural/stress analysis will also be performed. The goal is to reduce weight while maintaining strength and structural integrity.

Influence Of Size Effects On Surface Generation During Finish Machining And Surface Integrity In Ti-6al-4v, Ian S. Brown

Theses and Dissertations--Mechanical Engineering

Finish machining is an essential manufacturing process that is used to enhance the mechanical characteristics of critical components. The deformation that occurs at the tool and workpiece interface in finish machining significantly affects a host of component properties, commonly referred to as “surface integrity” properties. Surface roughness is a machining deformation-affected characteristic that is of high relevance in contemporary manufacturing. However, over recent decades it has been made clear that the material properties of the deformed surface layers are relevant to component performance as well. Predicting the overall surface quality of a machined component is of great relevance to the …