Manufacturing Commons^™

Advancing The Use Of Quality Control Tools For High-Density Data In Modern Manufacturing, Romina Dastoorian

Dissertations

In modern manufacturing, advanced metrology systems are continually being incorporated into quality control (QC) systems to provide high-density (HD) datasets. These datasets can contain millions of measurements that can be used to represent a part’s whole geometry. While integrating HD datasets into QC systems has brought several opportunities to enhance the performance of QC systems, it has resulted in new challenges in this area as well. While significant amounts of research have been performed in this area, the QC research community still strives to tackle these challenges. This study identifies key challenges regarding incorporating HD datasets into QC systems. Specifically, …

Parametric Design Of Flywheel For An Electric Punch Press, Prashant Dhakal

Honors Theses

Almost all designs start with a design requirement. These may be weight, volume, clearance, and even custom calculations. Finding a solution that meets these requirements often involves tedious and time-consuming iterations. Once the solution has been found, the design must be optimized to find the best possible solution. Finding the ‘best possible design’ requires substantial time and effort dedicated to iterating and analyzing the potential model solutions. This is where Parametric design comes into play. The Parametric design aids in specifying the key parameters of the design and makes changes interactively, with the model updating automatically. The purpose of this …

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 …

A Dynamic Programming Approach To Determine Optimum Modularity Level In Industrial Packaging, Marshal Louie, Kumar B

Journal of Applied Packaging Research

Modular packaging facilitate customization for accommodating variable product sizes in a product family. When determining package sizes for product variability, packaging engineers does not find difficulty to determine package dimension for less product variety whereas if the product variety is more, then determining the dimension of modular package involves complex decision-making and time-consuming process to find the optimal solution. This in turn directly impacts the overall lead time of the supply chain. Thus, in this paper a dynamic programming is developed to determine the quantity and dimension of modular packages for every demand of assorted products sizes. The program helps …

Energy Consumption And Lifecycle Assessment Comparison Of Cutting Fluids For Drilling Titanium Alloy, Navneet Khanna, Prassan Shah, Jwalant Wadhwa, Anjali Pitroda, Julius M. Schoop, Franci Pusavec

Institute for Sustainable Manufacturing Faculty Publications

This study analyzes four cutting conditions (dry, flood, Liquid CO 2 (LCO2), and Liquid N2 (LN 2)) based on energy consumption and ecological impacts for drilling VT-20, a Titanium alloy. The lower cutting and total energy have been consumed for LCO2 as compared to others. The Life Cycle Assessment (LCA) analysis has been performed using ReCiPe 2016 midpoint (H) to identify the impact of cutting conditions on ecosystem, human health, and natural resources. Cryogenic environment with LN 2 has been found as the most ecological cutting condition next to dry machining, while flood coolant has 94-99% of total impact considering …

Generic Design Methodology For Smart Manufacturing Systems From A Practical Perspective, Part I—Digital Triad Concept And Its Application As A System Reference Model, Zhuming Bi, Wen-Jun Zhang, Chong Wu, Chaomin Luo, Lida Xu

Information Technology & Decision Sciences Faculty Publications

Rapidly developed information technologies (IT) have continuously empowered manufacturing systems and accelerated the evolution of manufacturing system paradigms, and smart manufacturing (SM) has become one of the most promising paradigms. The study of SM has attracted a great deal of attention for researchers in academia and practitioners in industry. However, an obvious fact is that people with different backgrounds have different expectations for SM, and this has led to high diversity, ambiguity, and inconsistency in terms of definitions, reference models, performance matrices, and system design methodologies. It has been found that the state of the art SM research is limited …

Sustainability Assessment Of Direct Energy Deposition (Ded) Based Hybrid Manufacturing Using Life Cycle Assessment (Lca) Method, Faujia Islam

Graduate Theses, Dissertations, and Problem Reports (ETD)

As sustainability has emerged as a highlight for almost every field over the last few decades, the manufacturing field is no exception. Generally, additive manufacturing performs better than traditional manufacturing in terms of sustainability because of its lean energy- and material usage. Previous studies have compared the sustainability performance between traditional and additive manufacturing, but hybrid manufacturing was not focused upon much. In this paper, the life cycle assessment method is used to analyze and compare the energy consumption and environmental impact of direct energy deposition (DED) based hybrid manufacturing and traditional manufacturing “CNC milling” process for a turbine blade. …

Predictive Maintenance Of Bearing Machinery Using Simulation- A Bibliometric Study, Karan Gulati Mr., Keshav Basandrai Mr., Shubham Tiwari Mr., Pooja Kamat Prof., Satish Kumar Dr.

Library Philosophy and Practice (e-journal)

Modelling is a way of constructing a virtual representation of software and hardware that involves a real-world device. We will discover the behaviour of the system if the software elements of this model are guided by mathematical relationships. For testing conditions that may be difficult to replicate with hardware prototypes alone, modelling and simulation are particularly useful, especially in the early phase of the design process when hardware might not be available. Model-based approach in MATLAB-Simulink can be useful for predictive maintenance of machines as it can reduce unplanned downtimes and maintenance costs when industrial equipment breaks. Through this bibliometric …

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 …

Data Analysis To Evaluate The Performance Of Breathing Masks Used For Filtering Nano-Level Particles At Manufacturing Sites, Gracia M. Dardano

Honors College Theses

The work performed in this research aims to evaluate the performance of commercially available breathing masks in filtering airborne nanoparticles at manufacturing sites. Nanoparticles are found virtually anywhere, from dust in a worksite to a simple sneeze. Therefore, they pose a substantial threat to human health as their velocity and volatility are high. This research analyzes if current efforts of breathing masks to hinder nanoparticles are effective, especially at manufacturing sites. Data has been collected in order to analyze the behavior of nanoparticles and to measure nanoparticle levels at manufacturing sites and its working environment. Data is statistical in nature …

Fusion-Features And Visual-Dictionary Image Recognition Methods For Apple Classification In Smart Manufacturing, Ahsiah Ismail

Student Works (2020-2029)

Smart manufacturing enables an efficient manufacturing process to optimize production. The optimization is performed through data analytics that requires reliable and informative data as input. Therefore, in this research, two image recognition feature extraction methods namely Curvelet Wavelet-Gray Level Co-occurrence Matrix (CWGLCM) and Fuzzy-Spatial Pyramid Matching (F-SPM) are proposed to provide reliable inputs for vision-based apple classification in smart manufacturing. Feature extraction is one of the major steps that could influent the efficiency of the manufacturing process. The CW-GLCM method is a feature extraction of fusion-features with Decision Tree classifier, while the F-SPM method uses a visual-dictionary based method to …

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 …

Feasibility Of Electric Field Assisted Clogging Reduction In Cold Gas Spraying Nozzle, Hendric Tronsson

ENGS 88 Honors Thesis (AB Students)

The relatively novel cold spraying process expands its range of applications constantly. In order to continue this trend, this process still has various hurdles that need to be overcome such as clogging. Clogging within the cold gas spraying process causes porous coatings with less material properties and lower durability; a solution is needed in order to reduce the clogging and so expand the cold gas spraying applications. This study aimed to explore the feasibility of using an electric field to reduce clogging. To do so a simplified channel was used to simulate charged particle trajectory shifts under the influence of …

Virginia Digital Shipbuilding Program (Vdsp): Building An Agile Modern Workforce To Improve Performance In The Shipbuilding And Ship Repair Industry, Joseph Peter Kosteczko, Katherine Smith, Jessica Johnson, Rafael Diaz

VMASC Publications

Industry 4.0 is the latest stage in the Industrial Revolution and is reflected in the digital transformation and use of emergent technologies including the Internet of Things, Big Data, Robotic automation of processes, 3D printing and additive manufacturing, drones and Artificial Intelligence (AI) in the manufacturing industry. The implementation of these technologies in the Shipbuilding and Ship Repair Industry is currently in a nascent stage. Considering this, there is huge potential to increase cost savings, decrease production timelines, and drive down inefficiencies in Lifecyle management of ships. However, the implementation of these Industry 4.0 technologies is hindered by a noticeable …

Utilization Of Recycled Filament For 3d Printing For Consumer Goods, Alexa Peterson

Apparel Merchandising and Product Development Undergraduate Honors Theses

The 3D printing market has been used in a wide variety of manufacturing industries including textile and apparel. Many consumers can now own a personal 3D printer at home for recreational printing. There are even websites dedicated to 3D printing patterns made by consumers. However, the materials used in the 3D printing process pose a problem for the environment due to their plastic-based nature. 3D printing is a layered process with each layer being printed depending on the layer below it for strength and stability. During the 3D printing process, great amounts of waste are produced as a result of …

Machine Learning In Manufacturing: Review, Synthesis, And Theoretical Framework, Ajit Sharma, Zhibo Zhang, Rahul Rai

Business Administration Faculty Research Publications

There has been a paradigmatic shift in manufacturing as computing has transitioned from the programmable to the cognitive computing era. In this paper we present a theoretical framework for understanding this paradigmatic shift in manufacturing and the fast evolving role of artificial intelligence. Policy, Strategic and Operational implications are discussed. Implications for the future of strategy and operations in manufacturing are also discussed. Future research directions are presented.

Ideal Lacrosse Stick, Josh Beck, Tyler Skoloda, Noah Reed, Stanley Dembosky

Williams Honors College, Honors Research Projects

This project is focused on the design of a new and innovative lacrosse stick. Our main points of focus will be the strength and durability of the head. As well as solving some of the problems that exist in existing equipment. These problems were identified by interviewing experienced players at the college level. Benefits would include a stronger head that is easier to use for a player on the field to do things like pass, catch, shoot, and field ground balls in an optimal manner. Normally players will have to purchase new heads every season as a result of warping …

Smart Factories, Dumb Policy? Managing Cybersecurity And Data Privacy Risks In The Industrial Internet Of Things, Scott J. Shackelford

Minnesota Journal of Law, Science & Technology

No abstract provided.

Maquiladoras In Central America: An Analysis Of Workforce Schedule, Productivity And Fatigue., Jose L. Barahona

Masters Theses & Specialist Projects

Textile factories or Maquiladoras are very abundant and predominant in Central American economies. However, they all do not have the same standardized work schedule or routines. Most of the Maquiladoras only follow schedules and regulations established by the current labor laws without taking into consideration many variables within their organization that could affect their overall performance. As a result, the purpose of the study is to analyze the current working structure of a textile Maquiladora and determine the most suitable schedule that will abide with the current working structure but also increase production levels, employee morale and decrease employee fatigue. …

Nano Fab Lab 63, Brian K. Deemer, Josh Clemons, Nick Brodine, Delaney Fitzsimmons

Mechanical Engineering

Lawrence Livermore National Laboratories (LLNL) has several steps in the production process for ceramic nanofiber tubes that they would like to improve - electrospinning, cutting, rolling, sealing and heat treating. We undertook the challenge to deliver LLNL with a semi-automated process that efficiently integrates the steps of cutting, rolling, and sealing to save time and improve control over end dimensions. In this document, we discuss the technical background of the manufacturing steps currently followed to create nanofiber tubes, identify which steps are incorporated in our prototype and explain how they will interface with one another, define the design requirements, present …

Fault Adaptive Workload Allocation For Complex Manufacturing Systems, Charlie B. Destefano

Graduate Theses and Dissertations

This research proposes novel fault adaptive workload allocation (FAWA) strategies for the health management of complex manufacturing systems. The primary goal of these strategies is to minimize maintenance costs and maximize production by strategically controlling when and where failures occur through condition-based workload allocation.

For complex systems that are capable of performing tasks a variety of different ways, such as an industrial robot arm that can move between locations using different joint angle configurations and path trajectories, each option, i.e. mission plan, will result in different degradation rates and life-expectancies. Consequently, this can make it difficult to predict when a …

Fracture Toughness And Fatigue Crack Growth Rate Characterization Of Inconel 718 Formed By Laser Powder Bed Fusion, Charles C. Hohnbaum

Theses and Dissertations

Continuing improvement in the field of AM of metals provides the opportunity for direct fabrication of aerospace parts. AM was once used in large part for rapid prototyping but improvements in technology and increases in the knowledge base of AM materials has provided the opportunity for manufacture of AM parts for operational use. The ability to create low numbers of unique parts without having to invest in expensive tooling provides great economic incentive to utilize this technique. IN718 is the most common high temperature alloy used in the aerospace industry and lends itself readily to formation by LPBF. The superior …

Process Parameter Development Of Additively Manufactured Af9628 Weapons Steel, Erin M. Hager

Theses and Dissertations

The manufacture of components in Additive Manufacturing processes is limited by the range of materials available. Qualification of materials for Additive Manufacturing is time intensive, and is often specific to a single type of machine. In this study, an approach to selecting power, speed, and hatch spacing values for a newly powderized material, AF9628 weapons steel, is described that results in highly dense (>99.9%) parts on an MLab 200R Cusing. Initial power and speed values used in a weld track study were selected based on a survey of parameters used on similar materials, with a focus on the energy …

Stair Climbing Hand Truck, James Mcpherson

All Undergraduate Projects

Abstract

Getting a heavy object up a flight of stairs usually requires a team of two or more people. Even with a team of people, the task is often still difficult, dangerous, and possibly insurmountable by one person. This problem is especially prevalent in for those who are moving into apartment complexes. Most apartment complexes have many buildings with two or more floors of living quarters, and elevators are often missing. This project sought to offer a solution to this problem. The solution in question; a motorized hand-truck with 2, trigonal planar pinwheels in place of the stock wheels. The …

Process Sustainability Evaluation For Manufacturing Of A Component With The 6r Application, Ana E. Bonilla Hernández, Tao Lu, Tomas Beno, Claes Fredriksson, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Sustainability in manufacturing can be evaluated at product, process and system levels. The 6R methodology for sustainability enhancement in manufacturing processes includes: reduced use of materials, energy, water and other resources; reusing of products/components; recovery and recycling of materials/components; remanufacturing of products; and redesigning of products to utilize recovered materials/resources. Although manufacturing processes can be evaluated by their productivity, quality and cost, process sustainability assessment makes it a complete evaluation. This paper presents a 6R-based evaluation method for sustainable manufacturing in terms of specific metrics within six major metrics clusters: environmental impact, energy consumption, waste management, cost, resource utilization and …

Ua66/1/5 Ogden College Of Science & Engineering Dean's Office Centers, Wku Archives

WKU Archives Collection Inventories

Records created by and about centers associated with the Dean's office in the Ogden College of Science & Engineering.

A Total Life Cycle Approach For Developing Predictive Design Methodologies To Optimize Product Performance, Buddhika M. Hapuwatte, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Sustainable products must be designed by considering how design decisions impact their total life cycle (TLC) sustainability content. Even more so important when designing products to incorporate the technological elements of sustainable manufacturing, the 6Rs (Reduce, Reuse, Recycle, Recover, Redesign and Remanufacture), to achieve Circular Economy (CE). This paper presents the preliminary work of an ongoing research project on developing a novel framework incorporating predictive models with TLC considerations. This unique approach develops and integrates models with associated risks, and optimizes for maximizing the sustainability benefits due to design decisions. Such predictive capability is extremely useful for process planning, where …

Designing And Redesigning Products, Processes, And Systems For A Helical Economy, Ryan Bradley, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

The Circular Economy (CE) concept has promised to unlock trillions of dollars in business value while driving a significant reduction in the world’s resource consumption and anthropogenic emissions. However, CE mainly lives in ambiguity in the manufacturing domain because CE does not address the changes needed across all of the fundamental elements of manufacturing: products, processes, and systems. Conceptually, CE is grounded in the concept of closed-loop material flows that fit within ecological limits. This grounding translates into a steady state economy, a result that is not an option for the significant portion of the world living in poverty. Therefore, …

Transforming A Circular Economy Into A Helical Economy For Advancing Sustainable Manufacturing, Ryan T. Bradley

Theses and Dissertations--Mechanical and Aerospace Engineering

The U.N. projects the world population to reach nearly 10 billion people by 2050, which will cause demand for manufactured goods to reach unforeseen levels. In order for us to produce the goods to support an equitable future, the methods in which we manufacture those goods must radically change. The emerging Circular Economy (CE) concept for production systems has promised to drastically increase economic/business value by significantly reducing the world’s resource consumption and negative environmental impacts. However, CE is inherently limited because of its emphasis on recycling and reuse of materials. CE does not address the holistic changes needed across …

Modeling Of Cloud-Based Digital Twins For Smart Manufacturing With Mt Connect, Liwen Hu, Ngoc-Tu Nguyen, Wenjin Tao, Ming-Chuan Leu, Xiaoqing Frank Liu, Rakib Shahriar, S M Nahian Al Sunny

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The common modeling of digital twins uses an information model to describe the physical machines. The integration of digital twins into productive cyber-physical cloud manufacturing (CPCM) systems imposes strong demands such as reducing overhead and saving resources. In this paper, we develop and investigate a new method for building cloud-based digital twins (CBDT), which can be adapted to the CPCM platform. Our method helps reduce computing resources in the information processing center for efficient interactions between human users and physical machines. We introduce a knowledge resource center (KRC) built on a cloud server for information intensive applications. An information model …