Manufacturing Commons^™

Carbon Fiber Cv Tripod Axle Design: Husker Motorsports Formula Sae, Taylor D. Boudreaux

Honors Program: Senior Projects (Public)

The 2024–2025 HMS Formula SAE senior design team successfully reduced axle system weight, cost, and improved manufacturability using a bonded tripod joint and ±45° intermediate modulus carbon fiber tube. The final design was validated on HMS 25, with no failures under rigorous testing.

Budget:
/="/"> Total project cost was $1,165.64, exceeding the initial $1,000 target due to unanticipated test rig expenses. However, per-axle production cost was reduced from $525.31 to $383.37 through in-house manufacturing, use of on-hand epoxy (DP460), and switching to cost-effective 7068 aluminum. The axle-specific cost was $766.74.

Timeline:
/="/"> Despite early delays from building a torsional testing …

Design And Fabrication Of A Carbon Fiber Wheel For The Husker Motorsports Club, Benjamin Bashtovoi, Jordan Chapin, Michael Pineda, Caden Lind, Thomas Crum

Honors Program: Senior Projects (Public)

Every year, the Husker Motorsports team participates in a Formula SAE competition that challenges students to design and manufacture a Formula-style vehicle to compete against colleges from around the world. The Husker Motorsports club has sponsored this senior capstone project to improve the vehicle’s performance by reducing unsprung mass. Unsprung mass reduction has numerous benefits on vehicle dynamics, including improved acceleration, handling, and braking. To achieve these performance improvements, the team developed carbon-fiber composite wheels that weigh less than the current wheel solution and provide better rigidity. The team designed and modeled the wheel according to the 2023-2024 competition car …

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 …

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 …

The Business Case For Industrial Safety: Revealing The Comprehensive Value Of Ergonomic Investments For Manufacturing Enterprises In Industry 4.0, Shane Stan

Honors Program: Senior Projects (Public)

How can today’s manufacturing enterprises construct, implement, and optimize modern safety initiatives in a manner that will present maximum return on investment and facilitate enterprise growth? Furthermore, how can these manufacturers assure individual ergonomic investments become part of a larger strategy to facilitate organizational change in safety? This work addresses these questions by placing industrial ergonomics in a business improvement context which comprehensively presents the financial returns and growth opportunities poised by modern safety initiatives. Additionally, to further strengthen the business case for industrial safety, an ergonomic action planning framework is established to guide the creation of holistic safety programs …

Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy

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

The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one …

Effect Of Shot Peening On Stress Corrosion Behavior Of Biodegradable Magnesium We43, Tejaswita Patil

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

Conventionally used metals for orthopedic devices made of titanium, stainless steel, and Co-Cr alloys are designed to be permanently implanted. However, long-term complications arise and a secondary implant removal surgery is often necessary. A mismatch in stiffness between the bone and implant results in stress shielding that negatively affects bone density. To overcome these problems, magnesium alloys (e.g., WE34) are favored due to a lower Young’s modulus (45 GPa) and biodegradability. The critical technical barrier with magnesium alloys is their high corrosion rate in physiological (salt-based) environments. One solution is to use surface treatments, such as shot peening (SP), to …

Microstructure And Properties Of Spark Plasma Sintered Moalb Ceramics, Ting Lou

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

Molybdenum aluminum boride (MoAlB) is a ternary transition metal boride which has promising aeronautic and nuclear applications. It inheres excellent properties of the binary transitional metal borides (e.g., MoB, ZrB₂) such as high melting temperature, high hardness, and thermal conductivity. Besides, MoAlB is superior to MoB because: (1) the Al element provides an oxidation resistance at high temperatures; (2) its nanolaminated structure consisting of M-B layers with alternating Al layers results in a unique damage tolerance property. In this research, polycrystalline MoAlB have been successfully synthesized and simultaneously sintered using spark plasma sintering (SPS) from molybdenum boride (MoB) …

Modeling And Simulation Of Micro Electrical Discharge Machining Process, Bai Shao

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

Micro parts and systems are playing crucial roles in the area of semiconductor, biomedical device, micro fluid devices, automotive, aerospace and so forth. Micro manufacturing is one of the most important technologies in realizing miniaturization. Compared to other micro manufacturing methods, micro-EDM is drawing lots of attention due to its ability to machine complex 3D parts regardless of the hardness of the workpiece material.

Micro-EDM is the cumulative result of numerous single discharges; therefore, it is crucial to understand the single discharge material removal process in micro-EDM. However, due to the stochastic nature and complex process mechanism, micro-EDM, including its …

Size Effects In Human Visual Inspection For Micro/Meso Scale Parts, Sri Harsha Kavuri

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

Visual inspection has been a major method of quality control in conventional manufacturing processes for the last fifty years. Utilizing trained human inspectors to perform this visual inspection has been the most effective means of maintaining quality control. Extensive research has been performed to understand the factors that influence the human inspection process.

In the recent years, there has been a significant emphasis on manufacturing at the smaller end of the size-spectrum such as Micro and Meso scale manufacturing. Quality control at becomes a challenging task due to the extremely small sizes. Several automated visual inspection techniques have been proposed …

Sustainability For Die Manufacturing: Comparative Study Of Wedm And Milling, Matthew S. Kalus

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

Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society. Concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries are the most well known industries that machine harder materials using mills and WEDM. The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute to …

Study Of Grinding Burn Using Design Of Experiments Approach And Advanced Kaizen Methodology, Kiruthika Devi Sundarrajan

Department of Industrial and Management Systems Engineering: Dissertations, Theses, and Student Research

Grinding burn has been one of the re-occurring issues at a leading automotive manufacturer. Historically when grinding burn occurred, trial and error was used to delicately find a set up process settings that provided good-enough-to-get-by results, but not optimal. Some changes include changing the coolant manifold to improve the coolant flow and rate, changing the grinding wheel, changing the type of coolant. The experiments have proved to introduce some improvements, however the occurrence of grinding burns have not been reduced or quantified and the cause of the grinding burn has not been identified or quantified. Grinding is a complex phenomenon …

A Shock Tube Technique For Blast Wave Simulation And Studies Of Flow Structure Interactions In Shock Tube Blast Experiments, Nicholas N. Kleinschmit

Department of Engineering Mechanics: Dissertations, Theses, and Student Research

Improvised explosive devices (IED’s) are widely used against US and allied forces fighting in Iraq and Afghanistan. Exposure to IED blast may cause blast-induced traumatic brain injury (bTBI). The injury mechanisms are however not well understood. A critical need in bTBI-related research is the ability to replicate the loading conditions of IED blast waves in a laboratory environment. In this work, experimental studies have been carried out to explore the use of the shock tube technique for generating air shock waves that mimic the temporal and spatial characteristics of free-field blast waves and to investigate the blast wave-test sample interactions …

Adaptive Cutting Force Control For Process Stability Of Micro Ultrasonic Machining, Ala'a M. Al-Okaily

Department of Industrial and Management Systems Engineering: Dissertations, Theses, and Student Research

The growing demand for miniaturized products motivates the advancement in micromanufacturing processes research and development. Micro Ultrasonic Machining (Micro USM) is a downscaled version of a macro USM process that is developed to fabricate complex features in chemically inert, nonconductive, hard, brittle materials such as quartz, glass, and ceramics. These materials have many applications in various fields such as optics, electronics, MEMS, and biotechnology. The micro USM process stability is hard to accomplish, because it is highly influenced by the accuracy of the machining system and the variation of the process control parameters. The repeatability of micro USM machined features …

An Integrated Approach To Simulation And Activity-Based Costing For Evaluating Alternative Manufacturing Cell Designs, Robert Williams, Paul Savory, Rodney Rasmussen

Department of Industrial and Management Systems Engineering: Faculty Publications

One effective technique for improving manufacturing efficiency involves the application of group technology part families and manufacturing cells. Selection of the best or optimum configuration of the manufacturing cell relies on the experience and judgment of the cell designer. This paper describes how activity-based costing (ABC) concepts can be integrated into a discrete-event simulation model and be used to evaluate manufacturing cell configurations. The output of the combined ABC simulation model provides a detailed “Bill of Activity” which allows the cell designer to consider costs as a critical factor in the cell design problem. Alternative cell configurations studied in this …