Manufacturing Commons^™

An Experimental Evaluation Of Performance Variance For Internally Threaded Geometry Related To Extended Tap Wear In Low Carbon Steel, Todd E. Alberts

All-Inclusive List of Electronic Theses and Dissertations

The development of internal threads in a manufactured part is in many cases one of the final operations in the production workflow. Quality issues in thread form development can destroy a part that has previously undergone expensive machining. The issue of tap wear is one of the multi-faceted elements that have a direct correlation on the quality of threaded components. The purpose of this research centers on resultant mechanical pull performance for the stripping of internally threaded geometry in low carbon steel as measured over various increments of the tap cutting life cycle.

Iii Finishing, Lapping, Honing And Polishing: Processes, Characterisation And Novel Techniques-Experimental Research On Ultra-Smooth Surface Polishing Based On Two-Dimensional Vibration Of Liquid, Zhong Ning Guo, X. Z. Huang, Z. G. Huang, Z. Q. Yu, T. M. Yue, Wing Bun Lee

Faculty Publications

No abstract provided.

An Experimental Comparison Of Dimensional And Strength Characteristics Of American And Chinese Manufactured Fasteners, Michael Bailey Stroup

All-Inclusive List of Electronic Theses and Dissertations

This research investigated the quality and strength characteristics ofboth American and Chinese manufactured fasteners. The purpose of this research was to determine if there is a significant statistical difference between both manufacturers dimensional and tensile strength characteristics as to the American National Standards Institute's specified tolerances. The researcher selected the independent samples t-test to analyze the raw data collected from the experiment. SPSS 13.0 statistical analysis software was used to determine the degree of correlation between the independent variables: fastener dimensions, and ultimate tensile strengths. The researcher involved utilizing a calibrated micrometer that was capable to producing measurements to the …

Comparison Of Thermal Properties Of Laser Deposition And Traditional Welding Process Via Thermal Diffusivity Measurement, Yu Yang, Omoghene Osaze Obahor, Yaxin Bao, Todd E. Sparks, Jianzhong Ruan, Jacquelyn K. Stroble, Robert G. Landers, Joseph William Newkirk, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser deposition is an effective process for mold and die repair. In order to improve the part repair quality, the process impact on thermal diffusivity and thermal conductivity needs to be understood for laser deposited, welded and virgin H13. In this paper, H13 tool steel samples were made by laser deposition, welding and virgin H13 and then cut into pieces. Experiments were conducted to investigate the thermal diffusivity and conductivity. A laser flash method is used to test these samples. The future work and opportunities are also summarized.

Evaluation Of Mechanical Properties And Microstructure For Laser Deposition Process And Welding Process, Yaxin Bao, Jianzhong Ruan, Todd E. Sparks, Jambunathan Anand, Joseph William Newkirk, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Aided Manufacturing Process (LAMP) can be applied to repair steel die/molds which are currently repaired using traditional welding process in industry. In order to fully understand the advantages of laser deposition repair process over traditional welded-repair process, the mechanical properties such as tensile strength and hardness of H13 tool steel samples produced by these two processes were investigated. The microstructure and fracture surface of the samples were analyzed using optical microscope and SEM (Scanning Electron Microscope). Moreover, depositions on substrates with different shapes were studied to evaluate the performance of LAMP on damaged parts with complicated geometric shape.

Applications Of A Hybrid Manufacturing Process For Fabrication And Repair Of Metallic Structures, Frank W. Liou, Kevin P. Slattery, Mary Kinsella, Joseph William Newkirk, Hsin-Nan Chou, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Since its appearance, rapid prototyping technology has been of interest to various industries that are looking for a process to produce/build a part directly from a CAD model in a short time. Among them, the direct metal deposition process is the only process which directly manufactures a fully dense metal part without intermediate steps. However, challenges of the direct metal deposition process include building overhang structures, producing precision surfaces, and making parts with complex structures. Coupled between the additive and the subtractive processes into a single workstation, the integrated process, or hybrid process, can produce a metal part with machining …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part Ii: Extrusion Process Control, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Part I of this paper provided a detailed description of a novel fabrication machine for high solids loading ceramic slurry extrusion processes and presented an empirical model of the ceramic extrusion process, viewing ram velocity as the input and extrusion force as the output. A constant extrusion force is desirable as it correlates with a constant material deposition rate and, thus, good part quality. The experimental results used to construct the model demonstrated that a constant ram velocity will not necessarily produce a constant extrusion force. In some instances the extrusion force increased until ram motor skipping occurred, and process …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part I: Extrusion Process Modeling, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A novel, solid freeform fabrication method has been developed for the manufacture of ceramic-based components in an environmentally friendly fashion. The method is based on the extrusion of ceramic slurries using water as the binding media. Aluminum oxide (Al₂O₃) is currently being used as the part material and solids loading as high as 60 vol. % has been achieved. This paper describes a novel manufacturing machine that has been developed for the extrusion of high solids loading ceramic slurries. A critical component of the machine is the deposition system, which consists of a syringe, a plunger, …

Freeze-Spray Processing Of Layered Ceramic Composites, Qiang Fu, Oratai Jongprateep, Ashlee Abbott, Fatih Dogan

Materials Science and Engineering Faculty Research & Creative Works

Thermal gradients and associated stresses are critical in designing with ceramic composites having low thermal conductivity. In order to reduce the stresses from thermal gradients, compositional gradients are employed in designing of composite structures. This study addresses development of freeze-spray process to fabricate layered ceramic structures with controlled layer thickness and microstructural development. The composites were processed by spraying of ceramic slurries with low binder content and relatively high solids loadings (up to 40 vol%) on a cooled substrate. The frozen parts were freeze-dried and sintered at elevated temperatures. The relationship between microstructural development and thermal expansion behavior of Al …

Freeze-Form Extrusion Fabrication Of Ceramics, Tieshu Huang, Michael S. Mason, Greg Hilmas, Ming-Chuan Leu

Materials Science and Engineering Faculty Research & Creative Works

A novel, environmentally friendly solid freeform fabrication method called Freeze-form Extrusion Fabrication (FEF) has been developed for the fabrication of ceramic-based components. The method is based on deposition of ceramic pastes using water as the media. The ceramic solids loading can be 50 vol. % or higher and initial studies have focused on the use of aluminum oxide (Al₂O₃). The FEF system components and their interaction are examined, and the main process parameters affecting part geometry defined. 3-D shaped components have been fabricated by extrusion deposition of the ceramic paste in a layer-by-layer fashion. The feasibility …

Study Of Ceramic Slurries For Investment Casting With Ice Patterns, Qingbin Liu, Ming-Chuan Leu, Harish Jose, Von Richards

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Ice patterns generated by rapid freeze prototyping or a molding process can be used to make ceramic investment molds for metal castings. Due to the use of ice, the ceramic slurries must be poured around the pattern and cured at sub-freezing temperatures. Success of this process depends greatly on the mold strength after the gelation of the slurries. This paper describes the experimental results of the mold strength after the gelation of the slurries under different compositions. The parameters considered include mixing time, alumino-silicate vs. fused silica ratio, volume of binder, and volume of catalyst. The strength of the gelled …

Riser Design For Green Sand And Ductile Iron Castings, K. Michael Kuebler

Graduate Research Papers

Shrinkage defects in ductile iron riser contacts has long been one of the most frustrating defects to eliminate for the foundry engineer. While process variation can definitively contribute to the occurrence of these defects most can be prevented if the risers are properly designed and/or applied to the castings to be fed. There are several proven methods for the designing risers some of which go back over 40 years ago. There are also new methods available today with the advancements of simulation software. Four of these riser design methods were evaluated for their ability to produce an internally sound casting …

Comparison Study Of Cooling Fins And Chills Effectiveness In Aluminum Sand Mold Casting, Vladimir E. Kouznetsov

Graduate Research Papers

Besides proper design of gating and risering systems, there are several methods used to control and modify solidification behavior of cast alloys. Within these methods, the most widely used are local cooling aids employing cooling fins (thin segments attached to problematic areas of casting) or external chills (metal inserts placed into mold walls to accelerate heat withdrawing from potential hot spot). The later helps to promote directional solidification when traditional methods are not possible to use due to limitations related to the casting design. Despite relatively wide application in aluminum foundries, there are no specific recommendations on cooling aids parameters …

System Integration And Real-Time Control Architecture Of A Laser Aided Manufacturing Process, Mallikharjuna R. Boddu, Robert G. Landers, Srinivas Musti, Sanjeev Agarwal, Jianzhong Ruan, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper discusses a hybrid deposition–removal manufacturing system being developed at the University of Missouri--Rolla. The system consists of a laser system, five-axis CNC machining center, and powder feeder system. A description of the control software, real-time control architecture, and integration of various subsystems to build the hybrid system is given. The interaction of the real-time controller with various sensors and subsystems to monitor and regulate the process is presented. The communication between integrated process planning for the system and real–time control is also discussed in this paper.

Relationship Between Cost Of Technical Training And Cost Reduction Of Internal Defects At John Deere Waterloo Foundry, John Brackin

Graduate Research Papers

Can the cost of technical training at John Deere Waterloo Foundry pay for itself in the reduction of internal defects? This research compared training costs to the savings from reduced internal defects on Molding Unit 801 located in the John Deere Waterloo Foundry. Training was the independent variable of this research. The results of this research identified a correlation between training costs ( operational definition on page 10) and defect reduction costs. A correlation between these two established a break even point for training dollars spent.

The dependent variable was the dollar savings based on reduction of internal defects. There …

An Evaluation Of The Aws Entry Level Welder Training Program, John R. Rice

Dissertations and Theses @ UNI

The purpose of this study was to evaluate the effectiveness of a training program for Entry Level Welders and to provide this information to the American Welding Society (AWS), industry, and educators. The problem of this study was to evaluate the AWS Entry Level Welder Training Program (ELWTP) by obtaining the opinions of faculty members who taught the program and welders who had completed the program.

Two groups comprised the research population for this study. The first group consisted of faculty members who were actually involved in teaching the course at institutions accredited by the AWS to offer the curriculum. …

A Fluid Flow Analysis Of Aluminum 356.0 In The Vacuum Assisted Countergravity Method, John Launstein

Graduate Research Papers

The purpose of this study is to determine the fluid flow pattern obtained through the use of the countergravitaional process. The physical fluid flow model assists design engineers in their casting design of parts utilizing the LS-Vac technology thereby reducing tooling costs and time losses.

Recent Developments In Extrusion Freeform Fabrication (Eff) Utilizing Non-Aqueous Gel Casting Formulations, Greg Hilmas, John L. Lombardi, Robert A. Hoffman, Kevin Stuffle

Materials Science and Engineering Faculty Research & Creative Works

Extrusion Freeform Fabrication (EFF) was shown to be an extremely versatile method for fabricating Functionally Graded Materials (FGMs) The approach is inexpensive and potentially feasible for grading between any thermodynamically compatible ceramic-metal, ceramic-ceramic, or metal-metal material combination. Several material systems were investigated in this study including alumina-304 stainless steel, zirconia-304 stainless steel, alumina-Inconel 625, zirconiaInconel625, alumina-nickel aluminide, zirconia-nickel aluminide, titanium carbide-InconeI625, titanium diboride-nickel aluminide, and tungsten carbide-nickel aluminide. A controlled gradient was demonstrated between the end members for all of the above compositions. The FGMs were hot pressed to achieve near theoretical densities, providing flexural strengths as high as 1000 …

An Investigation Into The Use Of Expanded Polystyrene Patterns With The Loose-Sand, Vacuum Assisted Counter Gravitational Casting Process, John B. Vandersall

Graduate Research Papers

"Considered for years as a metal casting renegade, Expendable Pattern Casting (EPC) is believed by some to be tomorrows long-term casting future. Others, however, see it as an unproven headache-ridden process that makes the simple art of metal casting unnecessarily complex." (Lessiter, 1994, p. 36). The complexity of this process has been largely due to the lack of knowledge surrounding the interaction of the metal front and the dissipating polystyrene pattern.

Since the discovery of EPS as a pattern material, numerous applied research projects have been performed to gain a better understanding of the thermal breakdown characteristics of the material. …

An Analysis Of The Disposition Of Used Foundry Sand With Thermal Reclamation, Douglas Miller

Graduate Research Papers

The purpose of this study was to identify the economic and environmental concerns for the disposal, reuse, or reclamation of used foundry sand and show how foundries have developed options to landfills. The sand type and the reclamation processes available are the factors to use in determining whether disposal, reuse, or reclamation is appropriate. The continued use of landfills for disposal of used sand strongly indicates that reclamation and reuse techniques were either not understood or not as economical as disposal. Public concerns and new environmental laws demand that alternate means of disposal for used foundry sand should be developed …

Superplastic Forming System Design, Keith Bain

Honors Capstone Projects and Theses

No abstract provided.

A Technical Paper On Automated Pouring And The Selection Process Used By One North American Foundry, R. Stanley Weaver

Graduate Research Papers

This report on automated pouring focuses on the selection process used by one North American iron foundry. The problem facing this facility and any operation wishing to implement this technology lies in the number of variables which must be addressed in their quest for a suitable system.

Desirable Combinations Of Electrode And Flux For Submerged Arc Welding Of Low Carbon Steel, James A. Husmann

Graduate Research Papers

The major purpose of this study was to provide information about desirable combinations of welding electrode and appropriate fluxes for submerged arc welding of low carbon steel. Other purposes were to:

1. Test a variety of combinations of available submerged arc welding electrodes and fluxes in welding low carbon steel.

a. Prepare specimens for tensile tests.

b. Conduct tensile tests.

c. Calculate tensile strength, yield point, break point, percent of elongation, and percent reduction of area.

2. Determine the most desirable combinations of electrode and flux for companies presently using or planning to use submerged arc welding for low carbon …

Wood Finishing For Tree Samples Of Five Honduran Species, Amilcar A. Cruz

Graduate Research Papers

This research report will study the application of four wood finishing techniques to samples of each of five species of Honduran hardwood.

These four wood finishing methods are: The varnish-method, the lacquer method, the antiquing method and the oil-rub method. The researcher will attempt to determine which is the best method for each of the five species.

Photo Chemical Milling, Terry R. Smith

Graduate Research Papers

This study is concerned with the techniques used in the production of metal parts by the use of photofabrication. Included will be a research of the historical background of the industry, and the production processes used by the photofabrication industry that apply to this project. Information will include careers, education, current status of the industry, as well as methods for implementing the processes into the industrial arts curriculum.

Electrostatic Fluidized Bed Plastic Powder Coating Process, Richard H. Florer

Graduate Research Papers

The overall objective is the fabrication of a functional electrostatic fluidized bed dry plastic powder coating apparatus which can be utilized in an Industrial Arts laboratory.