Manufacturing Commons^™

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

All Theses

Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

Jack And Alex Rc-Baja, Alex Vornbrock

All Undergraduate Projects

Teams of two mechanical engineering students were tasked with the construction of an RC Baja car qualified by the rules and regulations of the Baja competition as well as specifications set by the individual team member for their portion of the vehicle. This proposal focuses on the Chassis and Drivetrain of the vehicle while team member Jack Stutz oversaw the steering and suspension. Teams will compete against each other in various modes to determine the best vehicles of the competitors. The chassis was made of standard aluminum, the remaining parts made by the students were made with PLA; both materials …

Rc Baja Suspension And Steering, Garrett Bailey

All Undergraduate Projects

The RC Baja team set out to engineer and construct a working remote-control device that can compete in the ASME Baja Competition. The students have a focus on either suspension and steering or drivetrain and chassis. This report is centered on the suspension and steering. First, multiple analyses were completed using engineering methods such as mechanical design, statics, strengths of materials, and dynamics for parts of the device. The calculations found in the analysis are then used to create designs for the parts so that they will meet the requirements and be successful in the competition. After the parts are …

Baja Bug Suspension, James Ankers, Rebecca Hansen, Dakota Robert Hollingsworth, Thomas Alfred Spycher

Mechanical Engineering

The goal of this senior project was to design and build a long travel front suspension system for a VW Bug. This started by defining the scope of the project and performing preliminary research. In this step, similar products were investigated, and research was done on stakeholders and customers. Next, concept development, design, and evaluation were performed. With this, the first iteration of our CAD model was designed, and physical prototypes were made. Using all this information, and feedback from advisors and sponsors, multiple iterations of our CAD were performed until the design was ready to manufacture. Drawings were taken …

Human Powered Vehicle Team Challenge, Sydney Nedlik, Spencer Brodie, Maria Griffin, William Schell, Ryan Serraglio

Williams Honors College, Honors Research Projects

Design and build a Human Powered Vehicle in a team of five. Compete at the ASME HPVC competition in March of 2022. Re-establish the Human Powered Vehicle Team at the University of Akron.

Integration Of Blockchain Technology Into Automobiles To Prevent And Study The Causes Of Accidents, John Kim

Electronic Theses, Projects, and Dissertations

Automobile collisions occur daily. We now live in an information-driven world, one where technology is quickly evolving. Blockchain technology can change the automotive industry, the safety of the motoring public and its surrounding environment by incorporating this vast array of information. It can place safety and efficiency at the forefront to pedestrians, public establishments, and provide public agencies with pertinent information securely and efficiently. Other industries where Blockchain technology has been effective in are as follows: supply chain management, logistics, and banking. This paper reviews some statistical information regarding automobile collisions, Blockchain technology, Smart Contracts, Smart Cities; assesses the feasibility …

Design And Analysis Of One-Piece 10” Carbon Fiber Wheels For Zips Racing Zr20 Formula Sae Racecar, Patrick Kruse, Henry J. Wathen, Jordan J. Hyde, Nicholas D. Dobben, Jordan D. Blake

Williams Honors College, Honors Research Projects

Reducing the weight of a vehicle in racing can substantially improve the vehicle dynamics and general performance capabilities. More specifically, the reduction of the unsprung corner weight can provide noticeable performance gains in handling and responsiveness, leading to a quicker, more agile car due to a lower yawing moment of inertia. Unsprung weight reduction also improves the car’s ability to maintain contact between the tires and the road surface for a more consistent grip. In this project we identified the loads that act on the wheel rims according to the data collected from the sensors in the car’s suspension, and …

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 …

Numerical Analyses And Integration Of Split Lot Sizing Using Lean Benchmark Model For Small Lot Manufacturing In High Mix Low Volume Production, Omkar Bhosale

Theses and Dissertations--Manufacturing Systems Engineering

As the global demand for automobiles has increased rapidly over the last fifty years, customers have become more particular about the characteristics of the autos they want. This change in demand, in part has pushed manufacturing to become more flexible and created a demand for alternative, more efficient processes like the High Mix Low Volume (HMLV) production of vehicles. During HMLV, manufacturers create production lot sizes and schedule to synchronize the production processes to meet customer demand on time. The demand for the automobile parts may not be uniform or parts may not be consumed by the customer immediately, Due …

Torsional Stiffness Of A Race Car, Reiley A. Schraeger, Cameron Kao, Raymond Deng, Omar Roman

Mechanical Engineering

Torsional stiffness plays a major role in any road vehicle. To understand torsional stiffness of a vehicle and make future iterations and improvements, a proper torsional stiffness jig is required to prove accurate and useful data. This report encompasses the new and improved testing jig and potential improvement ideas for more accurate results. With real data result relating to FEA calculations, designers can be confident in the FEA changes to torsional stiffness is accurate and will yield the probably results they desired. This report shows the methodology, manufacturing process and testing procedure to use on any Baja or SAE vehicle …

Autojack - Hydraulic Powertrain System, Tyce Vu

All Undergraduate Projects

A primary problem for mechanics and automotive enthusiasts is the risk associated with lifting and securing a vehicle with conventional jack stands. Often times, improper jack-stand installation results in the vehicle collapsing unexpectedly, causing injury and/or death. This problem can be minimized through the application of a newly re-designed vehicle lifting system. The conventional method for lifting cars is time consuming and can be unsafe in many circumstances. A better, safer, and more efficient lift design was needed; the AutoJack. The approach of the AutoJack design was entirely focused on the safety of lifting a vehicle. Safety was improved by …

An Analysis Of Resistance Spot Weld Quality Based On Acoustic And Electrical Signatures, Ivan Charles Butler

Theses and Dissertations--Manufacturing Systems Engineering

The union of a set of materials by way of Resistance Spot Welding is designed so that once fused together, a substantial amount of intentional, external force must be applied to separate the contents. Therefore, Resistance Spot Welding is often the preferred fusion method in high-volume manufacturing processes. The result of Resistance Spot Welding however is the formation of a weld nugget which is not visible to the naked eye. Destructive and/or ultrasonic methods applied off-line must be used to determine the quality of each weld; both inefficient and expensive processes. The following research analyzes the data fed back during …

Carbon Fiber Racing Wheel, Megan Sanok, Melissa Furdak, Sydney Schipani

Williams Honors College, Honors Research Projects

Industry today thrives off of competition; everybody wants their product to be the best. Across almost every field of manufacturing and design, there is a pattern of factors that companies strive for when producing their specialized products. The most effective companies can create a commodity that is relatively inexpensive, easy to manufacture, and has the ability to meet high standards. As engineers, it is ingrained in us that there is always room for improvement, and that we have been given the tools to make it happen.

When evaluating what needed to be improved in our daily lives, the SAE Zips …

Sae Baja Custom Caliper And Upright Design, Katelynn R. Kise

Williams Honors College, Honors Research Projects

The Zips Baja Off-Road Racing team had a successful 2018 season however some aspects of the car needed to be updated and improved for the 2019 season. This reports captures the design cycle performed to improve the cost, integration, and reliability of the front braking caliper and upright.

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

Daimscale — 1:14th Tractor-Trailer For Testing Driver Assistance Technology, Christopher Marrale, Jase Sasaki, Devin Bodmer

Mechanical Engineering

Active driver assistance systems are becoming increasingly wide-spread throughout the automotive industry due to their potential for safer roads and decreased costs of transportation, but testing these systems on real trucks can be time consuming, dangerous, and costly. Testing these systems on a small-scale tractor-trailer combination will lead to faster and more efficient development of driver assistance systems and can be used by both engineers and students, leading to a larger field of experienced developers to improve these systems.

Our goal will be to design, manufacture, and build a scale 6x2 model of the tractor portion of a Daimler semi-truck …

Composite Suspension For A Mass Market Vehicle, Sarah M. Chapiama, Brian Auyeung, Jose Guerrero, Ethan Lau

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Development Of A Laser-Based Technique For The Assessment Of High Quality Automotive Surfaces, Navraj Heer

Electronic Thesis and Dissertation Repository

The quality of painted surfaces plays an important role in the overall aesthetics of the automotive products. Although a number of quantitative techniques have been developed for this particular type of quality assessment, the solutions proposed so far remain costly and proprietary such that industry continues to rely primarily on qualitative, error-prone human evaluations. To address this, the primary objective of this thesis was to explore the possibility to develop a laser-based technique for the non-tactile quantification of defects in reflective painted surfaces. For this purpose, analytical solutions were formulated to predict the reflection of a laser beam from a …

Asme Rc Baja Challenge: Suspension And Steering, Hunter W. Jacobson

All Undergraduate Projects

The American Society of Mechanical Engineers (ASME) usually hosts an RC Baja challenge each year, testing a RC car in three events: slalom, acceleration and Baja. Although ASME will not be holding an event this year, CWU will be holding a similar event with three RC Baja car teams from CWU. The RC car that is tested in these events is designed and manufactured typically in teams of two. The RC car that each team submits must be able to complete these events while also remaining competitive. One part of great importance for the RC car is the suspension and …

Built-In Bicycle Rack For Cars, Scott A. Hansberry

All Undergraduate Projects

Transporting a bicycle after riding somewhere and then needing to be pickup can be problematic. Bicycles will not fit in most vehicles without removing components. There is also the risk of damaging the inside of the vehicle. Expecting everyone to have a bike rack for their vehicle is unrealistic because the bike rack could be considered unappealing visually, take up to much space in the trunk, or limit the vehicle owner’s access to the trunk. The solution to this problem is a bike rack that mounts onto your car and then mounts your bike onto the rack. Most people don’t …

Parametric Design, Modeling, And Optical Evaluation Of Retroreflective Prismatic Structures, Sama Hussein

Electronic Thesis and Dissertation Repository

Retroreflectors (RR) are defined as passive optical structures that redirect incident light to its originating source. Specific types of retroreflectors called inverted cubes (ICs) function through total internal reflection (TIR) and are used in various applications such as measurement tools, traffic signs and automotive rear and side lighting. This thesis aims to model, analyze, fabricate and study a novel type of IC retroreflectors called right triangular prism (RTP). A parametric approach is used to model existing IC geometries from a generic unit cube and is then implemented to model the novel RTP geometry. Those elements are then tested by optical …

Hydraulic Sprayer Boom Upgrade, Chad R. Omlin

All Undergraduate Projects

Title and Author: Agriculture sprayer hydraulic boom upgrade by Chad Omlin (engineering Technologies, Safety, and Construction)

Abstract: Today’s agriculture industry is all about being the most efficient with your time, land, employees, and machinery. One thing that has made farming more efficient has been the use of hydraulics. Having a sprayer unit with manual booms is not being efficient with your time and/or employees. To make the sprayer unit more efficient, hydraulic cylinders were added. Sketched solutions were analyzed using statics and mechanics of materials principles. Drawings were completed for the successful analysis solutions. Solid works software was used to …

Design, Fabrication And Analysis Of An Auxiliary Power Unit On A Heavy-Duty Truck To Power The Hvac Systems Of The Truck During Driver Off-Duty Conditions, Rohan Milind Kalurkar

Dissertations, Master's Theses and Master's Reports

Currently, one of the biggest challenges the world is facing is energy insufficiency. One of the contributors to energy consumption in United States are the idling semi-trailer trucks. In May 2001, President Bush issued The National Energy Policy in which he directed The Environmental Protection Agency (EPA) and Department of Transportation (DOT) to reduce the idling of trucks. This was done in order to reduce energy consumption by lowering fuel consumption and emissions coming out of semi-trailer trucks in the United States of America.

This project deals with the efforts of installing an Auxiliary Power Unit (APU) as a device …

Design And Fabrication Of A Suspension Rig, Abhijith Geo Philip

Dissertations, Master's Theses and Master's Reports

Owing to its placement under the vehicle body, the suspension system is one of the parts of the vehicle which are difficult to comprehend completely, albeit being a vital component. For demonstrating the working of a suspension system, a physical model in which one can actually see the movement of all the components would be a great tool. A Mustang II independent front suspension system was purchased from Heidts Engineering Performance and a rig that can emulate some of the real world situations of vehicle suspension action was designed and fabricated. All the components are accessible and conditions like bounce, …

The Effect Of Cutting Blade Geometry And Material On Carbon Fiber Severing As Used In High-Volume Production Of Composites, Michael Francis Anthony Adamovsky

Electronic Thesis and Dissertation Repository

Automotive manufacturers have started to actively look into weight savings options for mass production of vehicles that meet new government regulations. Falling prices of carbon fibers have made carbon fiber composites a promising material to be used. The study has focused on the fiber-severing unit incorporated in a high-volume composite production line in an attempt to better define the impact of blade geometry and material on the wear as experienced while cutting carbon fiber. A method to quantify the effect of usage on the cutting ability of a blade has been developed, as well as methods to measure blade wear. …

Binder Jet Additive Manufacturing Of Stainless Steel-Hydroxyapatite Bio-Composite, Don Suranga Dhanushka Uduwage

All Graduate Theses, Dissertations, and Other Capstone Projects

This study was conducted to create a bio-composite with a porous structure using the binder-jet printing additive manufacturing process. The samples were printed by changing the parameters such as layer thickness, roller speed, sintering time and sintering temperature of the X1-Lab binder jet additive manufacturing printer. The samples were printed 80% stainless steel 316 mixed with 20% Calcium Phosphate Tribasic by volume. Eight experiments were attempted to print according to the fractional factorial design of experiment. The effects of changing parameters on the mechanical properties of the new bio-composite was tested using ASTM E-09 compressive strength standards. The compression testing …

An Analysis Of The Manufacturing Process As Related To The Camber Requirement For Brake Pads, Daniel Patrick Midden

Morehead State Theses and Dissertations

A thesis presented to the faculty of the College of Science and Technology at Morehead State University in partial fulfillment of the requirements for the Degree of Master of Science by Daniel Patrick Midden on November 30, 2010.