Manufacturing Commons^™

E-Design Tools For Friction Stir Welding: Cost Estimation Tool, Pradeep Kumar Tipaji

Masters Theses

"A cost model is an important tool for product design and material selection. An efficient and effective cost estimation tool is necessary for early design evaluation. In this paper, cost estimation models that estimate the production cost for Metal Inert Gas (MIG), Friction Stir (FS), and Friction Stir Spot (FSS) welded joints are presented. These models determine the cost incurred to fabricate each joint along with a detailed explanation of each cost component. Each cost component has been closely analyzed and major cost components have been included in the cost model"--Abstract, page iv.

Towards A Methodology For Integrated Freeform Manufacturing Systems Development With A Control Systems Emphasis, Jacquelyn K. Stroble

Masters Theses

"A variety of fully integrated Freeform Fabrication (FFF) systems have been developed, a selected group for research and several for commercialization. The design methodology behind most of them is not documented, standardized, or rational. It is important to understand that the final product from any integrated system is affected not only by the unit manufacturing processes themselves, but also by the extent the individual units are assimilated into an integrated process. Thus, a scheme consisting of eight steps and the salient five elements necessary to create or retrofit an existing system to achieve an Integrated Freeform Manufacturing System (FFMS) is …

Mechanical Properties And Microstructure Study For Direct Metal Deposition Of Titanium Alloy And Tool Steel, Yaxin Bao

Masters Theses

"This thesis is focused on the research about DMD (Direct Metal Deposition) which is an additive manufacturing process and used in various engineering applications such as producing fully dense and net shape productions in difficult-to-machine materials. In this study, the microstructure was analyzed through optical microscopy and some mechanical properties were tested with different equipments such as SEM (Scanning Electron Microscopy) and micro-hardness tester...In summary, this thesis validated that DMD process can be improved through surface treatments and is capable of repairing molds for die casting industry"--Introduction, page 1.

Optimal Formation Of Supplier Networks For Product Design And Production Phases To Realize An Evolving Product Family, Padmavathi K. Pakala

Masters Theses

"Due to rapid changes in customer requirements and vast improvements in technology, many product development companies have identified strategies like time-to-market (TTM) compression and product family development as critical for attaining success in today's hyper-competitive markets. Compressing the TTM, to a large extent, is dependent on the suppliers and the project execution skills of the integrator companies. This study presents a methodology for selecting suppliers for two significant phases of the product realization process, namely, product design and production. The proposed methodology uses a two-stage approach for supplier selection where suppliers for product design are selected in the first stage …

On-Line Inspection And Thermal Properties Comparison For Laser Deposition Process, Yu Yang

Masters Theses

"This thesis is focused on comparing the laser deposition cladding with intended design model and comparing the effect of laser deposition process on thermal properties with traditional welding process. It is research on two aspects of laser deposition cladding. The first part of the thesis is aimed at solving the geometric inspection of laser deposition cladding, and the second part is for comparing the thermal properties of laser deposition cladding to samples of conventional welding process"--Introduction, page 1.

Development Of A Statistical Model For Process Control To Eliminate Sink Marks In Injection Molded Products, Kurt Frederick Hayden

Masters Theses

Customer demands for high-quality, defect-free injection-molded products are ever increasing. In order to satisfy these quality requirements, much effort is spent monitoring and controlling variable data such as cycle time, part weight, and dimensions. Attribute defects such as sink or splay are often overlooked in the development of process control systems. However, customers reject products because of these attribute defects. Industrial control systems based upon process variables and product design variables can detect conditions that may result in the molding of products with attribute defects. The systems can then correct the process prior to the molding of these defective products. …

Investment Casting Using Ice Patterns -- Solid Mold And Shell Mold Methods, Harish Jose

Masters Theses

"This thesis focuses on the development and implementation of the investment casting process using ice patterns. The traditional method of the investment casting process involves using wax patterns. Wax patterns tend to expand during the dewaxing process, and this causes stress on the shell wall which can eventually lead to the breaking of the wall. Ice patterns on the other hand shrink when heated. This is a very desirable property for the investment casting process. The process of dewaxing (dewatering) of ice patterns can be achieved by keeping the shells at room temperature, instead of heating the shell in an …

Application Of Laser Aided Manufacturing Process For Functionally Graded Thermal Barrier Coatings, Yashodhan Joshi

Masters Theses

"Laser Aided Manufacturing Process (LAMP) is a rapid prototyping process used to build three dimensional functional metal and ceramic parts. The process developed in the LAMP laboratory at University of Missouri-Rolla uses a 5-axis fadal CNC machine and a 2.5 KW Nd:YAG (TEM₀₀) Rofin Sinar laser. The laser power and metal/ceramic powder are the input along with auxiliary systems such as shielding gas delivery, RT data acquisition, coolant system. The hybrid process makes use of metal deposition and machining to obtain parts meeting design tolerances.

LAMP is used to improve upon the process of Thermal Barrier Coating (TBC) …

Using Stiffeners For Improved Geometric Fidelity Of Flexible Elements, Ankit Kapoor

Masters Theses

Flexible hoses play an important role in safe operation of a transportation vehicle in automotive and aerospace field. Due to lack of accurate and efficient modeling techniques for such flexible elements with large deformation, most Computer Aided Engineering system do not address the problem in their solution methods.

In this thesis a method is presented to improve the geometric fidelity of flexible element models by using off-axis bi-linear stiffeners (spring) into a discrete linear beam model. Resulting deflection of a hose were compared with the digital scans of an actual deflection of the hose. Though the method is computationally expensive, …

Comparing Refractory Coatings On Shell Sand Utilizing Elevated Temperature And Collapsibility Testing, Suet Fong Cheah

Masters Theses

This research study examines the effects of refractory coatings on a shell sand using laboratory testing equipment as opposed to the more laborious and time consuming processes of molding, melting, filling, shakeout, and obtaining dimensions of actual castings. As of today, there have not been any such laboratory test methods. This research project focused on quantifying distortion, mass change, and impact strength found in refractory coated shell sand. The equipment used was the thermal distortion tester (TDT) and a modified impact tester. The thermal distortion curves (TDC), mass change, and impact strength are provided and compared for all systems studied. …

Tool Management In Flexible Manufacturing Systems, Ahmet Soylemezoglu

Masters Theses

"In this study, impact of cutting tool life and tool slot size on tool management in Flexible Manufacturing Systems (FMS) is investigated. A conceptual tool management framework, which has been proposed by Buyurgan, Saygin, and Kilic (2003), is modified and implemented in a simulation environment in order to assess its performance. This model, namely LS Model (LS stands for Life and Size), makes decisions by considering both tool life and tool slot size. An alternative tool management model that makes decisions based only on tool life, namely LO Model (LO stands for Life Only), is developed in order to make …

A Comparison Of The Level Of Maturity Of Manufacturers In The Lake Land College School District In Lean Manufacturing Techniques As Compared To Goodson's Survey Data, Mark W. Henderson

Masters Theses

The purpose of this study was to determine if manufacturers in the Lake Land College School District have implemented Lean Manufacturing techniques and score as high as the manufacturers in Goodson's Michigan study. Lean Manufacturing techniques have revolutionized the auto industry, with the Toyota Production system the benchmark in Lean Manufacturing techniques. A survey using Goodson's Rapid Plant Assessment compares the level of maturity in the utilization of the Lean Manufacturing techniques with the manufacturers in the Lake Land College School District and Goodson's survey of manufacturers in Michigan. The mean score of 57.67 for the manufacturers in the Lake …

A Study Of Kanban Based Production System In Cellular Manufacturing Environment, Sanjay Bhargava

Masters Theses

The study of effects of production data variabilities on Kanban based cellular manufacturing system is vital before its design and implementation because it would give better understanding of their uncertain behavior.

In this research, a detailed analysis of a Kanban system, with subcell scenario, under dynamic operating conditions is performed. The Control variables considered were number of Kanbans, processing time variability, demand variability and machine breakdown. The performance parameters considered were profit, production lead time, machine utilization and material processing lead time.

Approximately 200 simulation runs were made with 3 replications each by varying one control variable at a time. …

An Empirical Study Of Just-In-Time And Total Quality Management Principles Implementation In Manufacturing Firms In The U.S., Loknath Sriparavastu

Masters Theses

Literature in vogue points out that, in the last decade, American manufacturing companies came a long way in their renewed emphasis on the quality process. Justin- Time (JIT) and Total Quality Management (TQM) are the two magical phrases that are being frequently used in almost all the articles published on quality and productivity. Nevertheless, the literature does not provide any satisfactory explanation as to how JIT and TQM principles are implemented in the manufacturing industries.

This research, through a nationwide empirical survey, analyzed the effects of JIT and TQM strategies implementation. Survey results showed that implementing both JIT and TQM …

An Empirical Investigation Of Quality And Productivity Management Practices In Manufacturing Firms, Kiran Vuppalapati

Masters Theses

A growing number of firms are implementing the concept of Just In Time (JlT) manufacturing and Total Quality Management (TQM). This research examines the impact of these management philosophies in manufacturing firms.

This research identifies a set of critical organizational variables necessary for a successful . implementation and the organizational problems faced during their implementation. The major object is to test the performance of firms implementing both JlT and TQM against firms implementing none of these philosophies. Results show that JIT-TQM firms are more customer focused and have better employee relations than traditional firms. This study also compares the performance …

An Experimental Study Into The Role Of Routing Flexibility In The Justification Of Advanced Manufacturing Systems, Sanjay Pathak

Masters Theses

Increased competition in manufacturing has focused attention on advanced technologies. These costly technologies lead to difficulty in purchase justification using traditional methods. New methods quantify attributes relating to the flexibility of advanced systems. One such attribute is routing flexibility.

This thesis presents results of experiments into evaluation of routing flexibility. The performance of conventional dedicated machinery when compared with that of machines having routing flexibility indicates an advantage of flexible machinery. The thesis indicates a procedure for evaluation of different flexibilities and their comparison with conventional machinery in reality.

An empirical formula is developed that helps in quantifying routing flexibility …