Manufacturing Commons^™

Noise Control In Sorting Conveyors, Eyra Herrera

Mechanical Engineering Undergraduate Honors Theses

E-commerce has increased the necessity of effective material handling equipment in warehouses and distribution centers. Sorter conveyors systems facilitate material handling by providing a reliable and automated system to classify and distribute products in a gentle and rapid manner. With the steady increase of speed in sorter conveyors to satisfy today’s industry demand, some systems have started to produce high noise levels that could potentially affect workers’ health. Since decreasing the speed of these conveyors is not a viable option to decrease noise in sorter equipment, industries have opted to find other ways to apply noise control to their equipment. …

Statistical Study Of The Effect Of Implementing An Airveyor System On The Warpage Of Injection Molded Closures, Charles Wesley Bozarth

Masters Theses & Specialist Projects

Berry Global in Bowling Green, Kentucky produces predominantly polypropylene container closures. One variant, the 83mm lined jar closure, is produced by first being injection molded, placed in work-in-progress (WIP) hold for 24 hours to cool, and then finished through the auxiliary liner operation into a final product. While this process is an effective method to produce a quality large-diameter closure and allows the polypropylene adequate time to cool without warping out of shape, the 24-hour WIP time and the manpower needed to accomplish this can negatively impact several business metrics as well as employee safety.

The purpose of this thesis …

Jcati Base Plate, Jacob Atamian

All Undergraduate Projects

Students of the Mechanical Engineering Technology (MET) program at Central Washington University have contributed to an ongoing Carbon Fiber Recycler project funded by the Joint Center for Aerospace Technology Innovation (JCATI). The goal of this project was to modify the existing recycling system to produce a higher success rate of recycled carbon composite material. This report focuses on increasing the rigidity of the crushing gears so that the deflection occurring among the components during operation was below 0.005 inches to ensure proper operating conditions. The operating speed of the crushing gears was 2.5 rpm with a crushing load of 10,500 …

Balsa Wood Bridge, Andrew Harris

All Undergraduate Projects

Faculty at Central Washington University proposed a challenge to mechanical engineering students that could be accomplished in an in-home setting. The goal was to create a balsa wood bridge, weighing no more than 85 grams, that can support a load over an open span and raise above its resting position by means of a mechanical system. To produce a successful solution to the problem, a vertical lift bridge was created consisting of two lifting towers and a load bearing bridge. Using equations of static equilibrium and strength of materials, the required width for each member was determined. Project requirements were …

Mini Rc Baja Car, Jason Schindler

All Undergraduate Projects

Incorporating each aspect of engineering incorporated into a senior project is difficult. That is why an RC Baja car is a great senior project for Mechanical Engineering students. The approach that students must take to design, construct, and test the car is to set parameters, and to make overall goals that can be easily measured. These goals include, but not limited to things like a $700 budget and the ability to withstand a 1-foot drop to a flat surface on all four wheels simultaneously. First, the design must meet the specifications and rules that are set previously. This ensures that …

Hydraulic Balsa Wood Rising Bridge, Kaitlyn Greenfield

All Undergraduate Projects

What is the solution to allowing tall vessels to navigate past a vehicle bridge that is less than 10 [ft] above the water? To answer this question, a balsa wood bridge was designed, constructed, and tested. The bridge needed to articulate by mechanical means, allow for travel through the bridge, and be able to withstand ample force while the main structure only being constructed of balsa wood and glue. The project was analyzed in sections. These sections include: the bridge structure and its members, the hydraulic lift, and the pins needed for the bridge and hydraulic lift to operate. The …

The Investigation Of The Underlying Microstructure Associated With Fracture Features In 6061 Cold Sprayed Aluminum, Justin White

UNF Graduate Theses and Dissertations

Cold gas dynamic spraying commonly known as cold spray is a process currently used for restoration, re-tolerancing, and application of coatings. With additional resources allocated towards the development of a through process model aimed at predicting the properties of bulk material produced via the Cold Spray process, more lab testing and investigation must be done to capture the effects of the varying microstructure in CS materials. The properties of ultra-fine-grained materials are derived from data collected from coarse grained materials and processes that do not accurately capture the effects as elevated strain rates and ultra-fine-grained materials. The lack of property …

Advance Metallic Reinforcement Of Vat Photo Polymerized Parts, Scott Zinn

UNF Graduate Theses and Dissertations

The metallization or metallic reinforcement of polymer parts has been widely used in industry for several decades. Polymer parts are classically metalized for aesthetics, chemical and thermal resistance, electrical conductivity, and mechanical strength. Metallization has been shown to increase strength of polymer parts when compared to the strength of the bulk material without metallization. Additive manufacturing (AM) techniques that have emerged in the last few decades produce parts with different surface features and chemistry than the typical polymer part produced through injection molding. AM parts are typically weaker than traditionally manufactured parts from the same material due to intrinsic details …

Tailoring Texture, Microstructure, And Shape Memory Behavior Of Niti Alloys Fabricated By L-Pbf-Am, Sayed Ehsan Saghaian N.E.

Theses and Dissertations--Mechanical and Aerospace Engineering

Laser Powder Bed Fusion (L-PBF) is one of the most promising Additive Manufacturing (AM) methods to fabricate near net-shape metallic materials for a wide range of applications such as patient-specific medical devices, functionally graded materials, and complex structures. NiTi shape memory alloys (SMAs) are of great interest due to a combination of unique features, such as superelasticity, shape memory effect, high ductility, work output, corrosion resistance, and biocompatibility that could be employed in many applications in automotive, aerospace, and biomedical industries. Due to the difficulties with traditional machining and forming of NiTi components, the ability to fabricate complex parts, tailor …

Thermomechanical Mechanisms That Cause Adhesion Of Aluminum High Pressure Die Castings To The Die, Alex Monroe

Dissertations, Master's Theses and Master's Reports

In high pressure die casting (HPDC) of aluminum, cast material adhering to die is a significant defect. Adhesion occurs in two primary ways. The casting may stick preventing its removal from the die. Aluminum can also adhere to the die and buildup in local areas on the die surface with additional casting cycles. This second form of adhesion is called soldering. Lubricant is the best technology to control all forms of adhesion, but it comes at the cost of casting porosity, blisters, reduced die life, and increased die casting machine wear. New strategies to prevent adhesion are desired to eliminate …

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 …

Viability Of A Proposed Transparent Fluid Model For Analog Metal Casting Filling Process, Andres Segura Irazoqui

Dissertations and Theses @ UNI

This research work was conducted to develop a proposed transparent fluid model to mimic dross formation and dispersion in metal castings during the mold filling process. The major cause for dross formation includes the air entrainment, surface turbulence, and bubbles, which create oxide films inside the molten metal. The oxide films are trapped inside the casting after solidification causing detrimental effects on the mechanical properties of the casting.

The objective of the investigation was to explore the feasibility using phenolic urethane as a transparent fluid material to investigate air entrainment mechanism. The experimentation consists of the following materials: the phenolic …

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

College of Graduate Studies: Theses & 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 …

The Development Of A Holistic Quality Score Using In-Situ Monitoring Of Laser Powder Bed Fusion, Ryan Daigneault

College of Graduate Studies: Theses & Dissertations

Additive manufacturing processes allow for a great degree of flexibility in terms of part production. The process is autonomous once the part has started printing in that the operator generally does not need to intervene until the part is finished. One issue that this introduces, however, is an inability to determine part quality during the printing process. Once a part has started printing, the operator must either wait until the part is finished or regularly check on the part during the print to determine the part quality. Using data gathered from multiple sensors, a quality score can be used to …

Reclamation Of Fused Silica From Investment Shells Used For Casting Steel, Samuel L. Holt

College of Graduate Studies: Theses & Dissertations

Fused silica is widely used for investment casting shell molds. Fused silica shells are discarded after being used for casting one time. This is due to the transformation of fused silica to beta cristobalite above 1652℉ (900℃). To reduce cost and waste of investment casting foundries, this study is exploring a method to inhibit transformation of fused silica and reclaim it from high temperature investment casting shells. This research has employed firing to minimalize fused silica transformation to cristobalite. The phase transformation is minimalized due to sintering and coarsening of the particles during firing. Coarsening reduces surface area to volume …

Modeling And Optimization Of Process Parameters In Face Milling Of Ti6al4v Alloy Using Taguchi And Grey Relational Analysis, Al Mazedur Rahman, S M Abdur Rob, Anil K. Srivastava

Manufacturing & Industrial Engineering Faculty Publications

Titanium alloys are extensively used in aerospace, missiles, rockets, naval ships, automotive, medical devices, and even the consumer electronics industry where a high strength to density ratio, lightweight, high corrosion resistance, and resistance to high temperatures are important. The machining of these alloys has always been challenging for manufacturers. This article investigates the combined effect of radial depth, cutting speed and feed rate on cutting forces, tool life, and surface roughness during face milling of Ti6Al4V alloy. This study focuses on the significance of radial depth of cut on cutting force, tool life and surface roughness compared to that of …

Dry Reforming Of Methane Using Microwave Irradiated Metal Oxide/Coal Char Catalysts, Anthony Carter

Graduate Theses, Dissertations, and Problem Reports (ETD)

This research focuses on the synthesis of both shaped and amorphous powder materials, the combination of these materials with dried Powder River Basin (PRB) coal char, and their reactionary properties with methane and carbon dioxide gasses with conventional and microwave (MW) heating. The first goal of this project was to synthesize shaped micro and nano sized particles with ideal dielectric properties for converting electromagnetic energy into heat and proven capabilities of activating methane. These particles were synthesized via solvothermal, hydrothermal, and co-preceptory treatments alone and onto the surface of dried PRB coal char. PRB is a sub-bituminous, low-ranking coal (LRC) …

Thermo-Fluid Characterizations Of The Powder-Bed Fusion Additive Manufacturing Processes Using Laser And Electron Beam, M Shafiqur Rahman

LSU New Orleans Theses and Dissertations

The powder-bed fusion (PBF) process is a subdivision of Additive Manufacturing (AM) technology where a heat source at a controlled speed selectively fuses regions of a powder-bed material to form three-dimensional (3-D) parts. Two of the most effective PBF processes are selective laser melting (SLM) and electron beam additive manufacturing (EBAM), which can fabricate full-density metallic parts in a layer-by-layer fashion. In this study, thermal behavior and melt-pool dynamics in the PBF process are investigated by developing 3-D multiphysics-based thermo-fluid models for both SLM and EBAM, containing Ti-6Al-4V alloy as a powder-bed material. The laser and electron beams are modeled …

Design, Fabrication, And Reliability Effects Of Additively Manufactured First Level Compliant Interconnects For Microelectronics Application, Tumininu David Olatunji

Graduate Theses and Dissertations

Semiconductor packaging and development is greatly dependent on the magnitude of interconnect and on-chip stress that ultimately limits the reliability of electronic components. Thermomechanical related strains occur because of the coefficient of thermal expansion mismatch from different conjoined materials being assembled to manufacture a device. To curb the effect of thermal expansion mismatch between conjoined parts, studies have been done in integrating compliant structures between dies, solder balls, and substrates. Initial studies have enabled the design and manufacturing of these structures using a photolithography approach which involves a high number of fabrication steps depending on the complexity of the structures …

Modeling And Analysis For Unit Cell Size, Material Anisotropy And Material Imperfection Effects Of Cellular Structures Fabricated By Powder Bed Fusion Additive Manufacturing., Yan Wu

Electronic Theses and Dissertations

Cellular structures are networks of interconnected struts or walls with porosities and are widely found in many natural load-bearing structures such as plants and bones. Cellular structures offer unique functional characteristics such as high stiffness to weight ratio, tailorable heat transfer coefficient, and enhanced mechanical energy absorption, which makes them highly attractive in various engineering disciplines such as biomedical implants, electrodes, heat exchangers, and lightweight structures. There exists an abundance of literatures that have investigated various mechanical properties of various cellular structures such as Poisson’s ratio, elastic modulus, ultimate strength, yield strength, and failure characteristics. Based on the classic cellular …

Study On The Viability Of Preparing Plaster Molds For Rapid Prototyping Of Complex Ceramic Parts Using The Lost Pla Method, Shelton F. Fowler Iv

Honors College Theses

In the field of metal casting, cast parts often require an internal cavity to be made to meet design requirements. Frequently, these interior surfaces are not manufacturable through standard machining processes, and even when possible, they would most likely involve expensive and time-consuming operations. In order to avoid these machining costs, expendable ceramic or sand cores are manufactured and placed into the mold to allow the direct casting of complex internal geometries. This research seeks to use relatively inexpensive plastic 3D printing technology and the lost PLA casting process for the production of low-cost and rapidly producible ceramic cores. A …

Formula Sae Monocoque Chassis Development, Kc Egger, Brian Ford, Kyle Nagao, Neal Sharma, Donovan Zusalim

Mechanical Engineering

Formula SAE is a collegiate competition hosted by SAE International with the primary goal being to design, manufacture, and race an open wheel race car. The Cal Poly Racing Formula SAE team strives for improvement every race season and has remained competitive as a result. The 2019-2020 management team determined that further research and development towards the chassis would yield the greatest performance benefit for future seasons, as the previous chassis platform limited packaging and mounting options for vehicle subsystems which interfaced with the chassis.

A redesign of the Cal Poly Racing Formula SAE team’s carbon fiber reinforced polymer monocoque …

Comparison Of Pressure-Assist Silver Sintering To Tin Silver Solder Alloy As Die Attach Material In High Power Semiconductor, Tolentino Erik Nino

Student Works (2020-2029)

The research is focused on pressure-assisted silver sintering material that is compared to tin silver solder alloy paste as used in power electronics. Material characterization, electrical tests, and reliability tests were conducted in the experiment. After drying process, it was observed that the Ag sintering paste height was reduced to approximately 40 percent. Die attach shear test showed that the average reading is about from 200 to 600 grams which are already enough to hold the dice before proceeding to the pressure sintering process. X-ray revealed that the void percent for SnAg paste sample is about 1.5 percent while pressure-assist …

Wavelength Decomposition Of Hybrid Additive Manufacturing Power Signals And Their Relationship With Surface Integrity, Xingtao Wang

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

Additive Manufacturing (AM) has been a promising manufacturing technology in industrial applications and gained a massive amount of attention from researchers all over the world. Directed Energy Deposition (DED) is an AM process in which focused thermal energy is used to fuse materials by melting as they are deposited. One of the most significant challenges involved in current metal AM processes is improving repeatability and consistency. Substantial effort has already been invested in this area of research.

In this dissertation, a milling tool not only played a role in subtractive manufacturing but also acted as a method of monitoring the …

Preventing Delayed Cracks In Sus304 Deep Drawn Cups Using Extreme Blank Holding Forces Aided By Nanolubrication, Ibrahim Muhammad Shafiq

Student Works (2020-2029)

This study was to investigate the formation and reformation of delayed cracks of SUS304 cylindrical drawn cups under elevated blank holding force (BHF) from 8~32 kN with 1~3 wt% SiO2 nanolubricants concentrations. The widest crack-free BHF range i.e. from 29 ~ 31 kN was determined for 2 wt% of SiO2 in the experiment. Delayed cracks were also observed below and beyond this BHF range. There was an increment of frictional force at the cup flange region when entering the crack-free BHF range, as proven by the rebound in sidewall thickness, relative intensity of α′-martensite, elongated height and drawing force beyond …

Microstructural Characteristics And Mechanical Properties Of Sn-Ag-Cu Solders With Minor Additions Of Al And Zn, Yee Mei Leong

Student Works (2020-2029)

Driven by the recent trend towards miniaturization of lead free electronic products, researchers are putting immense efforts to improve the properties and reliability of Sn based solders. Recently, much interest has been shown on low silver (Ag) content solder SAC 105 (Sn-1.0Ag-0.5Cu) solder because of economic reasons and improvement of impact resistance as compared to SAC387(Sn-3.8Ag-0.7Ag). The present work investigates the effect of minor (0.1-0.5wt.%) Aluminium (Al) and Zinc (Zn) addition to SAC105 on the bulk and interfacial structure between solder and copper substrate during reflow and after thermal aging , the mechanical properties of the solder joint and the …

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 …

Effects Of New And Recycle Flux On The Mechanical Properties Of Submerged Arc Welded (Saw) Line Pipe Grade X52m And X65m, Taib Meor Mohd Adli

Student Works (2020-2029)

Two line pipe grade X52M and X65M were manufactured using submerged arc welding process. For each grade, two different welding flux condition were simulated, i.e. 100% new flux and 100% recycle flux. The flux used was aluminate basic type trade name OP 132. The outside diameter and wall thickness for X52M was 610mm x 12.7mm and for X65M was 762mm x 14.3mm. Lower weld re-entrant angle and higher weld bead height were observed in recycle flux condition. Lower weld manganese content recorded in recycle flux condition. And lower mechanical tests (i.e. tensile, impact, and hardness) value reported for recycle flux …

Fly Ash Based Geopolymer For High Temperature And High Compressive Strength Applications In Aggressive Environment, Aaryan Manoj Nair, Akm S. Rahman

Publications and Research

Geopolymers are the results of geosynthetic reactions between aluminosilicates and strong bases. This results in chemical bonds between aluminum (Al), Silicon (Si)and oxygen (O) composing polymer rings in tetrahedral coordination. These bonds give them widespread useful applications such as high heat bearing ceramics, and base construction material whilst being far more environmentally conscious. The purpose of the experiment is to examine the effect of Silicon Carbide whisker and inorganic glass particles on thermal and mechanical properties of Geopolymers. This study will help understand the effect of various compositions and concentrations of SiO₂ in mechanical strength. In this experiment, the …

Comparative Analysis And Dynamic Response Of Garolites Under Temperature Spectrum Using Low Velocity Impact Test, Birendra Chaudhary

Honors Theses

The purpose of this study was to examine the dynamic response of three different grades of garolites under the temperature spectrum. High-Temperature G-11 Sheet (HTG), Impact Resistance Garolite E-glass (HIG), and Economical Garolite (EG) were tested using an Instron Dynatup 8250 impact tester. Three specimens were used for all three composites and were tested at 6 different temperatures, -10^oC, 25^oC, 50^oC, 100^oC, 150^oC and 200^oC using the Low-Velocity Impact Machine with 20 Kip punch shear load cell. The results showed that HIG had the highest resistance to punch …