Manufacturing Commons^™

Model-Based Predictive Controller Design, Soheil Sadeghi

Graduate Research Papers

Process control in industries is becoming more critical due to demands on reducing consumed energy, reducing cost, and improving system efficiency and performance. In this work, a well-developed, model-based controller is introduced and implemented in one of the most common processes in the industry. Model Predictive Controller (MPC) has been studied for ten years, but recently has emerged into small industries as the number of current applications grows. These controllers need a process model in the forms of transfer functions, step response, or state-space. Although obtaining a process model can be a cumbersome task, it is worth having it (the …

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 …

Investigating The Production Of Cores By Using Reclaimed Foundry Green Sand, Kristopher Lee Boss

Dissertations and Theses @ UNI

Increasing environmental regulations, transportation cost, delivery interruptions leading to production concerns, disposal cost, and demand from other industries have influenced the way foundry’s view used sand. The purpose of this research was to determine a beneficial reuse of overflow-green sand that would normally be disposed. The reclamation process used is a combination of mechanical and wet reclamation. The focus was on the production of foundry cold box cores and if using this reclamation process could create a core with a similar quality performance compared to new sand. Research in reclamation could pave the way for a closed loop sand system, …

How Quality Management Has Been Impacted In The Face Of Covid-19, Eldina Siljkovic

Dissertations and Theses @ UNI

The Coronavirus pandemic has impacted many facets of the United States. This study focuses on its magnitude in comparison to prior pandemics such as Anthrax, SARS, and Ebola. In addition to this comparison its impact on Quality Management within the agricultural sector and food supply chain was also assessed. The results of these studies showcase that COVID-19 has grown exponentially in comparison to prior pandemics and will continue to do so as we enter the winter season. Agricultural equipment manufacturing companies saw a drastic decline in quarterly revenues within 2020 in comparison to 2019. Millions in net sales were lost …

Development Of A Hydraulic Component Leakage Detecting System Using Pressure Decay Signal, Xuanju Shang

Dissertations and Theses @ UNI

It is preferable to detect leakage at the earliest phase in the manufacturing process, and then further assembly of hydraulic components with leakage problems can be avoided. Integrating a USB based microcontroller and a pressure sensor; this study developed a hydraulic leakage detection system in using air instead of hydraulic oil as medium, through measuring pressure decay signals captured by a real time data acquisition system. Compared with the conventional hydraulic system using oils, this system shows advantages in safety operation and little environmental concerns due to use a lower pressure clean air.

The low-cost hydraulic leakage detection system was …

Management Theories In Manufacturing, James Nathan Webster

Graduate Research Papers

The principles and ideology of management have been around for thousands of years. "Before industrialization, organizations were primarily the household, the tribe, the church, the military, and government" (Wren, 1987, p. 13). It was very rare for people to gather and organize outside of these structures prior to the industrial revolution. As mankind and civilization have progressed, the power of organizations has shifted throughout time. In the time of Confucius, government positions were of the utmost respect, and Confucius taught that positions of power "should go to men of proven merit and ability" (Wren, 1987, p. 14). The ancient Egyptians …

Manufacturing Companies And The Information Age In The U.S., Marcos Reynero

Graduate Research Papers

The purpose of this research paper is to analyze the relationship between the amount of indirect labor and value added in manufacturing companies. Companies are moving manufacturing sites overseas in order to reduce cost. The cost of direct labor in countries like China is relatively lower in comparison to the cost of labor in the U.S. Edward Hill, professor at Cleveland State University's College of Urban Affairs, states that an hour of a manufacturing plant in the U.S. costs $150 versus $1 in China (Scherer, 2005). Companies are making strategic decisions based on reducing cost in order to improve profits. …

Automated Casting Cleaning, Chris Anderson

Graduate Research Papers

The dilemma facing all foundries today is finding a cost effective, efficient, and safe manner in which to clean castings. At the same time produce a cleaned casting that meets consistent quality and delivery expectations. Today nearly 90% of all casting produced are cleaned by the use of manual labor via chipping an grinding. This manual method has proved to be very labor intensive, costly, lacking consistent quality, and carry high rates of injuries. The use of automation to clean castings is in its embryo stage in the foundry industry. The use of automation in the foundry industry, products currently …

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 …

Universal Mounting Bracket For Laser Targeting And Feedback System, Richard J. Kelin Ii

Patents (University of Northern Iowa)

A support bracket for mounting a device such as a laser targeting and feedback system to a spray gun. The bracket includes a bolt having a threaded end, a first collar disposed on the bolt opposite the threaded end and a second collar threadably engaged with the threaded end of the bolt. A compressible member is disposed on the bolt between the collars. Opposite the compressible member, a support arm used to support the device is attached to the second collar. The bracket is engageable with a portion of the spray gun body and is engaged therewith by deflecting the …

The Design And Evaluation Of A Plc-Based Model Predictive Controller For Application In Industrial Food Processes, Bryan T. Griffen

Dissertations and Theses @ UNI

Model Predictive Control (MPC) is a viable control strategy for industrial processes that display relatively large variations in the process variable, have complex process variable interactions, or display a large amount of process deadtime. The objective of using MPC in manufacturing is to reduce overall process variability, the result being an increase in process accuracy, precision and efficiency. This study focused on the implementation of model predictive control techniques on an industrial sugar cooking process. The goal was to implement a successful MPC solution directly on a programmable logic controller (PLC) rather than on a personal computer (PC). Although there …

The Effects Of An Interactive Computerized Multimedia Tutorial On Knowledge Gain In Modular Fixturing Design Concepts, Veekit O'Charoen

Dissertations and Theses @ UNI

This study was designed to compare student knowledge gain from learning modular fixturing design concepts by computer tutorial versus traditional lecture. The use of computer tutorial to support engineering and technology classroom instructions has been a major issue for many studies. The undergraduate curricula in engineering and technology are becoming increasingly complex due to the today's modern wide variety of manufacturing processes. The concept of modular fixturing in tool design course is one of the technical competencies which most industries would like graduates to be able to apply their knowledge to real-world problems and situations.

An interactive computerized multimedia tutorial …

A Leadership Model And Supervisory Skills Perceived By Production Employees, Supervisors, And Managers As Important To The Improvement Of Employee Performance In Manufacturing, Douglas R. Hotek

Dissertations and Theses @ UNI

The purpose of this research was to provide to industry and education a better understanding of what makes a supervisor a good supervisor of today's educated and technically skilled work force. Manufacturing firms that depend on advanced technologies and employee-technology relationships have made an impact on the role of supervision. The modern supervisor has a new role in managing production operations. The role has changed from that of directing and controlling employees to that of effectively leading the improvement of employee performance. This study builds upon previous research in an effort to further identify and authenticate a leadership model with …

The Effect Of Heat On Fingertip Sensitivity Of Meat Processing Workers, Brian James Finder

Dissertations and Theses @ UNI

Current research indicates that acute non-freezing cold exposure elicits short-term performance problems; namely reduced upper extremity temperature, blood flow, tactile sensitivity, and dexterity. However, various animal-related studies indicate that humans are at increased risk of incurring semi-permanent upper extremity nervous system dysfunction as a result of repeated cold exposure.

The purpose of this research was to examine various factors that may contribute to hand/arm nervous system impairment of individuals who work in a refrigerated meat-processing environment. The methodology used was primarily the Experimental Method and from studies conducted by other researchers, was driven by the following questions:

(1) How would …

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 Introduction To Web-Based Training For Statistical Process Control (Spc), Richard A. Juel

Graduate Research Papers

John Deere Waterloo Works had been using statistical process control in its manufacturing and assembly operations since the mid-nineteen seventies. Over the years this process had evolved from using hand-written paper control charts to using computer devices to collect data and generate charts. A variety of computer hardware and software products were being used. Training on statistical concepts and use of the various devices had deteriorated to the point that it was no longer a formal process. SPC training passed from one employee to another in the course of break-in to perform a specific job.

A team had been formed …

An Evaluation Of John Deere Waterloo Works Internal Quality System Audit Process With Recommendations For Improving Its Effectiveness, Karl J. Bultsma Sr.

Graduate Research Papers

The objective of this paper is to evaluate the internal quality system audit process at the John Deere Waterloo Works. This evaluation is necessary to identify improvements to ensure continued quality system registration and make the auditing process as efficient and effective as possible for improved business performance.

Investigation Of Torque Control Systems For Pump Assembly, Donald E. Lynch

Graduate Research Papers

The purpose of the study was to determine which of three types of torque systems would best meet the torque specifications required in the assembly of hydraulic pump outlet valve plugs. Each torque system was evaluated in regards to expense, reliability, and effectiveness.

Degree Of Manufacturer Readiness For Skill-Based Pay Programs, Michael R. Willett

Graduate Research Papers

The purpose of this study is to determine the degree of readiness of manufacturing companies in Black Hawk County, Iowa, to adopt a skill-based pay plan. Readiness, or change orientation, will be determined by comparing current characteristics of companies in this sample to those characteristics of American companies that have already implemented successful skill-based pay plans.

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.

Development Of A Simple, Analytical Method To Optimize Machining Cycles For Non-Cnc Gear Hobbing Machines, Steven M. Klabunde

Graduate Research Papers

The purpose of this research project was to develop a simple, analytical method for the optimization of hobbing cycles on non-CNC gear hobbing machines. Such a method would allow manufacturers to optimize hobbing cycle times, reduce part costs, and improve productivity. There have been many advances in gear cutting tool technology. Because of these advances, the capabilities of modern cutting tools are beyond the capabilities of non-CNC machines designed more than fifteen years ago. The majority of the machines used today in gear manufacturing are of this vintage. The cycles on these machine tools are machine-limited, which is much more …

An Investigation Of Diameter Measurement Repeatability Using A Coordinate Measuring Machine And A Multi-Baseline Repeatability Assessment Methodology, Bruce Marsh

Dissertations and Theses @ UNI

The need for reliable and consistent measurement has become more acute with the use of statistical process control (SPC), gage repeatability and reproducibility (Gage R&R) assessment, and high precision, computer-controlled gaging systems. Although it is often overlooked, the inspection methodology under which various features are inspected has an impact on Gage R&R results. This notion was confirmed when a 1993 thesis study substantiated inspection methodology as a source of measurement variability in direct computer-controlled, coordinate measuring machines (DCC/CMMs). Although this study explored a methodology to bring measurement variability under statistical control, the tested assessment methodology--single baseline repeatability assessment--was not validated. …

The Characteristics Of Agile Manufacturing That Can Be Implemented In The Manufacture Of Agricultural Equipment, Irvin L. Wilhelms

Graduate Research Papers

The problem of this study was to determine the characteristics of agile manufacturing and their applicability to a manufacturer of heavy agricultural equipment.

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. …

First Line Supervisor Perceptions: The Effectiveness Of Specific Safety Training Materials, Cynthia Houlson

Graduate Research Papers

The problem of this study was to determine whether first line supervisors, who have been exposed specifically to Safety Focus Topics, perceived them as an effective tool in filling their role as a safety trainer.

Comparison Of Rapid Prototyping Systems For Implementation Into The Product Development Cycle, Daniel S. Koenig

Graduate Research Papers

The problems with the implementation and use of RP technology is choosing the best system from the fifteen or more RP systems commercially available and more than 20 other systems under development throughout the world (Wohlers, 1993). The problem of this study was to evaluate each of six preselected RP systems based on key characteristics. This study provides pertinent data so that those teams and individuals involved in the implementation and the use of a RP process can make sound decisions.

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 …

A Market Profile Of Epc Foundries In North America, Jennifer D. Ballacchino

Graduate Research Papers

The purpose of this study is to discover what successes foundries are having with the EPC process and promote these successes. The EPC casting industry can use this information to encourage adoption of the process and thereby stimulate component conversion and application. Information gathered during this study will be consolidated into promotional materials about the EPC process. The materials will provide information to individuals in the industry, including foundries, suppliers and, most importantly, designers. Through sharing of information about the process, it can be better understood and acceptance may increase.