Manufacturing Commons^™

Natural Fibers And Fiberglass: A Technical And Economic Comparison, Justin Andrew Zsiros

Theses and Dissertations

Natural fibers have received attention in recent years because of their minimal environmental impact, reasonably good properties, and low cost. There is a wide variety of natural fibers suitable for composite applications, the most common of which is flax. Flax has advantages in tensile strength, light weight, and low cost over other natural fibers. As with other natural and synthetic fibers, flax is used to reinforce both thermoset and thermoplastic matrices. When flax is used in thermoplastic matrices, polypropylene and polyethylene are the main resins used. Although at first glance flax may seem to be a cheaper alternative to fiberglass, …

Testing Guidelines For New Product Development, Derek W. Egbert

Theses and Dissertations

While many literary sources outline the product development process, few make mention of the prototyping and testing stage. This thesis suggests that because of its importance in the product development process, "Testing" should be documented as a major step and not just listed as a side note. As part of the testing step, it is suggested that standardized, in-use, and market tests be used to properly evaluate a product. While many rely solely on standardized tests to validate their products, effective in-use tests can be another vital tool that can prove the performance of the product in more specific and …

Investigation Of Rf Curing Parameters In Resin Infusion Molding, Christopher K. Love

Theses and Dissertations

The purpose of this study is to investigate RF or Radio Frequency energy as a viable alternative to traditional heating methods for the purpose of curing resins used in resin infusion molding, a molding system for polymeric composites. Traditional heating/curing methods include technologies such as room temperature, oven, microwave, infrared, and ultraviolet. Although RF curing provides far more advantages than disadvantages, its implementation into a manufacturing process can be challenging. Specifically, three critical elements must be present in order for RF to function in a manner that is profitable to the manufacturer. Those elements are: (1) the proper generator (voltage …

The Effect Of Liquid Hot Filling Temperature On Blow-Molded Hdpe Bottle Properties, Benjamin S. Hudson

Theses and Dissertations

The occurrence of deformation in plastic bottles is a common problem in the bottling industry where bottles are blow molded, hot filled at high temperatures and sealed. Plastics have unique properties that make it difficult to predict when and why such changes may occur. The root cause of such deformation is unknown by many bottle producers and recent attempts have been made to minimize the occurrence of such defects. The purpose of this research is to determine which variables involved in the bottle production process influence bottle shape. Earlier variables that were tested included both blow molding resin and total …

Lean Six Sigma As A Source Of Competitive Advantage, Alessandro Giorgio Cavallini

Theses and Dissertations

Anecdotal data affirms that companies applying Lean Six Sigma in their operations not only deliver higher quality products and services, but also obtain superior financial results. The goal of this research was to empirically verify anecdotal data. The study proposed to analyze a group of publicly traded manufacturing companies with the intent of verifying if a correlation exists between companies being lean and the attainment of superior returns on investments. The researcher performed a series of statistical tests comparing key Financial Performance Indicators (FPI) extracted from annual reports (10-K) from a large pool of companies. The outcome of this study …

Predicting The Longevity Of Dvdr Media By Periodic Analysis Of Parity, Jitter, And Ecc Performance Parameters, Daniel Patrick Wells

Theses and Dissertations

For the last ten years, DVD-R media have played an important role in the storage of large amounts of digital data throughout the world. During this time it was assumed that the DVD-R was as long-lasting and stable as its predecessor, the CD-R. Several reports have surfaced over the last few years questioning the DVD-R's ability to maintain many of its claims regarding archival quality life spans. These reports have shown a wide range of longevity between the different brands. While some DVD-Rs may last a while, others may result in an early and unexpected failure. Compounding this problem is …

Development Of A Particle Flow Test For Rotational Molding, Russell B. Whatcott

Theses and Dissertations

One of the current testing method (the Dry Flow test) to qualify resin for use in production in the rotomolding process has been shown to have many flaws in both equipment and procedure. Research was done here to investigate a possible alternative that could eliminate some of these testing deficiencies. By reducing equipment and operator errors, the testing of materials becomes more valuable of an exercise. The Angular Flow test developed in this research can increase repeatability. By coming to understand the rotational molding process better, an evaluation that can give more valid information was devised.

Development Of A Quality Improvement Method For International Manufacturing, Andrew J. Strong

Theses and Dissertations

Many companies are entering the international manufacturing arena. The continued expansion of the global market suggests that international manufacturing will grow. Among other concerns, the difficulty of producing high quality in some countries suggests that it is critical that companies using international locations for manufacturing find methods to better monitor and improve quality. The purpose of this research was to develop and test a method for quality improvement in an offshore environment. This method would be specifically applicable to a third-party logistics company (3PL), where the 3PL is a United States company that brokers manufacturing in China, networks to multiple …

Comparing The Feasibility Of Cutting Thin-Walled Sections From Five Commonly Used Metals Utilizing Wire Electric Discharge Machining, Richard C. Stephenson

Theses and Dissertations

Wire Electric Discharge Machining (wire-EDM) is a non-traditional machining process. Controlled electric sparks are successively used to vaporize part of a workpiece along a programmed path in order to machine a desired part. Because there is no tool that comes in direct contact with the workpiece, it is possible to machine thin, delicate parts. This thesis was designed to observe and analyze the differences in cutting capabilities for a conventional wire-EDM machine when cutting thin-walled sections from five commonly used metals utilizing a variation of roughing and finishing passes. The five metals that were used in this study are: Aluminum …

Friction Stir Welding Of High-Strength Automotive Steel, Eric Michael Olsen

Theses and Dissertations

The following thesis is a study on the ability to create acceptable welds in thin-plate, ultra-high-strength steels (UHSS) by way of friction stir welding (FSW). Steels are welded together to create tailor-welded blanks (TWB) for use in the automotive industry. Dual Phase (DP) 590, 780, and 980 steel as well as Transformation-Induced Plasticity (TRIP) 590 steel with thicknesses ranging from 1.2 mm to 1.8 mm were welded using friction stir welding under a variety of processing conditions, including experiments with dissimilar thicknesses. Samples were tested under tensile loads for initial determination if an acceptable weld had been created. Acceptable welds …

Objective Test Methods For Waveguide Audio Synthesis, Steven Gregory Wood

Theses and Dissertations

Acoustic Physical Modeling has emerged as a newer musical synthesis technique. The most common form of physical modeling synthesis in both industry and academia is digital waveguide synthesis. Commercially available for the past thirteen years, the top synthesizer manufacturers have chosen to include physical modeling synthesis in their top of the line models. In the area of audio quality testing, the most common tests have traditionally been group listening tests. While these tests are subjective and can be expensive and time-consuming, the results are validated by the groups' proper quality standards. Research has been conducted to evaluate objective testing procedures …

An Evaluation Of American Companies That Outsource Manufacturing To China: Decision-Making And Performance, Michael Kenyon Favreau

Theses and Dissertations

The topic of outsourcing ranks at the top of business issues for a wide variety of companies (Wery, 2004; Ezrati, 2004). The majority of American companies believe that offshore-related matters rank as the most strategic decisions that management is expected to make in the next 12 months (Wery, 2004). “Outsourcing in China can help many companies save money, but it can be very frustrating if not done right" (Ting, 2004). The perceived benefits of outsourcing production to China are tremendously enticing, but a lack of understanding of the total costs involved lures many companies into outsourcing when it is not …

Lifetime Testing Of Wire-Grid Polarizers With Selected Over-Coatings, Steven J. Malone

Theses and Dissertations

Wire-grid polarizers (WGPs) offer superior extinction, durability, angle of incidence, and heat resistance when compared to traditional organic polarizers. WGPs are found in applications such as high lumen lighting, laser devices, high lumen digital cinema projectors, LED packaging, and other integrated optical applications and are driving the need for over-coatings. Over-coating a WGP has been found to increase lifetime and durability. This research provides lifetime data on coated and uncoated WGPs. WGPs over-coated with 100nm of SiO2, 300nm of MgF2, and with no over-coating were heated to temperatures of 450 ºC, 500 ºC, and 550 ºC and timed until they …

A Qualitative Study Of Selected Quality Knowledge And Practices In Guangdong Province, China, Tyler R. Thomas

Theses and Dissertations

The manufacturing industry has become very competitive in today's global market environment. Many US companies are faced with the choice of keeping their manufacturing domestic or looking to low cost off-shore countries to take advantage of the labor costs differences. To gain an understanding of the state of manufacturing in China, a major focus in the manufacturing world today, this thesis was undertaken. This thesis presents the findings of research conducted in Guangdong Province, China in June - July, 2005. This research addressed customer focus, leadership and general manufacturing and quality knowledge and practices of small, medium and large sized …

Spot Friction Welding Of Ultra High-Strength Automotive Sheet Steel, Jack H. Sederstrom

Theses and Dissertations

Spot friction welding (SFW) was performed on ultra high strength steel (UHSS) steel sheet commonly used in automobile manufacturing. Alloys studied included DP780, DP780EG, DP980, and DF140T sheet steel of varying thickness from 1.2 mm to 1.4 mm. Welding was accomplished using a PCBN standard tool. Weld strengths were then compared to a proposed AWS standard. Initial hardness readings were taken in cross sectioned samples. Grain structure in a SFW is presented. Resistance spot welds were created in three steels. This study focuses on the strength of SFW joints as compared to traditional resistance spot welding (RSW) in welding like …

An Evaluation Of Attributes And Competencies For Manufacturing Engineering Technology Graduates, Loni S. Williamson

Theses and Dissertations

The purpose of this study is to determine the required attributes and competencies required for a graduate from a manufacturing engineering technology baccalaureate program. A document called “Competencies of Manufacturing Engineering Technology Graduates” was compiled in October 2004. This document lists twelve attributes thought to be important for MET graduates: Leadership, Professionalism, Creativity and Problem Solving, Management, Materials, Processes, Quality, Systems, Design, Communication, Safety and Environmental Issues, and Global Awareness. Under each attribute is a list of five to seven competencies creating a total of seventy-three competencies for graduates of an MET baccalaureate program. This list of attributes and competencies …

Contractor Variability In Construction Of Cement Treated Base Layers, Maile Anne Rogers

Theses and Dissertations

The primary purposes of this research were to identify construction factors most correlated to specific mechanical properties of cement-treated base (CTB) layers and to determine which construction factors exhibit comparatively high variability within individual construction sections of the two pavement reconstruction projects included in this study. In addition, differences between construction sections tested in this research were evaluated. The research focused on the construction of CTB layers in two pavement reconstruction projects in northern Utah, one along Interstate 84 (I-84) near Morgan and one along U.S. Highway 91 (US-91) near Richmond. The significant predictor variables associated with California bearing ratio …

A Solution For Commodity Field Hauling With Self-Unloading Semi-Trailers, Lee Pagens Wilkerson

Theses and Dissertations

Commodity hauling of bulk goods is a growing enterprise that has expanded from hauling agricultural products to hauling many other bulk products. Commodity trailers are used to haul agricultural products from storage facilities to processing plants. These trailers are designed for highway use but are frequently required to work in field conditions as well. In many cases this environment overstresses these trailers and results in permanent irreparable damage. In addition to the structural problems of these trailers, the current systems for unloading the bulk produce from these trailers have serious inadequacies. While functional, the currently used chain and non-chain driven …

Automated Manipulation For The Lotus Filament Winding Process, Jeffrey V. Anderson

Theses and Dissertations

The filament-winding process produces quality consistent composite parts for many industries. Filament winding allows for consistent quality parts by automating the winding process. A recent development of filament winding is the Lotus process. The Lotus process reverses conventional filament winding by leaving the mandrel stationary and winding composite fiber around the mandrel. The automated Lotus filament-winding machine is controlled by four-axis control manipulating the Lotus ring around a fixed mandrel. This allows Lotus filament winding to wind parts that do not have a linear axis. Lotus filament winding is in its early stages of development. As a second step in …

A Gasless Method Of Spraying Thermoplastic Resin, Dan T. Rogers

Theses and Dissertations

This spraying method for thermoplastic resins is a new manufacturing process for applying thermoplastics to a mold or surface in an efficient way that has the potential of reducing cycle time. Spraying thermoplastic resins is similar to spraying other polymers, such as paint, with the differences being higher pressure and temperature. This method uses an injection molding machine with a modified nozzle to spray the plastic material. In this study, temperature, pressure, and nozzle size were factors that influenced the success of this spraying method. The method of spraying in this study proved spraying without a gas is possible, a …

Development Of Commercial Applications For Recycled Plastics Using Finite Element Analysis, Nanjunda Narasimhamurthy

Theses and Dissertations

This thesis investigates the suitability of thermo-kinetically recycled plastics for use in commercial product applications using finite element analysis and statistics. Different recycled material blends were tested and evaluated for their use in commercial product applications. There are six different blends of thermo-kinetically recycled plastics used for testing and CATIA is used for finite element analysis. The different types of thermo-kinetically recycled plastics blends are: pop bottles made of PolyethyleneTeraphthalate (PET), milk jugs made of High-Density Polyethylene (HDPE), Vinyl seats made of Poly Vinyl Chloride (PVC) and small amount of Polypropylene (PP) and Urethane, electronic scrap made of engineering resins …

Integrating Value Stream Mapping And Simulation, Michelle E. Scullin

Theses and Dissertations

An important principle in Lean manufacturing, value stream mapping (VSM) can be helpful in understanding how process flow and information flow affect each other. A VSM is a static picture of a process that allows the user to see where value is added into the value stream. Simulation is used to evaluate the behavioral issues of processes. In a manufacturing realm this means simulation shows how each operation affects other operations so determinations can be made about where bottlenecks or other problems exist in the process. Theoretically, the integration of VSM and Simulation can aide in process improvement by showing …

Determination Of Wall Thickness And Height When Cutting Various Materials With Wire Electric Discharge Machining Processes, Sangseop Kim

Theses and Dissertations

This thesis looks at the capabilities of cutting thin webs on Wire EDM machines that are difficult or impossible to machine using conventional methods. Covered is an investigation of how different material and web thickness affect the capability of machining thin-walled parts.

Five different metals are used for the test; Aluminum 6061 T6, Yellow Brass SS360, 420 Stainless Steel, D2 unheat-treated tool steel 25-30 RC, and D2 heat-treated tool steel 60-65 RC. The small parts were cut to a 6mm (0.2362 inch) height with six different wall thicknesses: 0.30mm (0.0118 inch), 0.25mm (0.0098 inch), 0.20mm (0.0078 inch), 0.15mm (0.0059 inch), …

A Tool Wear Comparative Study In Turning Versus Computer Simulation In 1018 Steel, Woodrow D. Miner

Theses and Dissertations

The material removal process uses cutting tools in order to produce the desired shape of the workpiece. Tool wear has been a problem for cutting tools, since cutting tools wear and break. Research has been accomplished in the tool wear field for tool life and more recently tool wear. The computer generation has created a method to simulate the material removal process. These computer simulations model the cutting tool reaction with the workpiece. Many of the simulation models use finite element analysis to calculate the reaction of the cutting tool. Different finite element models are being used throughout the world …

The Purposes And Evaluation Methods For State Residential General Contractor Licensing, James Ellis Fenn

Theses and Dissertations

The main topic in the licensing debate is whether licensing affects construction quality. Available literature and previous studies indicate that it does not. The real question is not whether licensing improves quality, but whether the improving quality is the actual purpose of licensing. There is little information available on the purpose of licensing as defined by state licensing departments as well as a general lack of information on how states evaluate whether licensing is fulfilling the intended purpose. In order to effectively resolve some of the issues surrounding the construction licensing debate, the true purpose of licensing and the methods …

New Product Launch Decisions Under Competition And Uncertainty: A Real Options And Game-Theoretic Approach To New Product Development, James O. Ostler

Theses and Dissertations

New product development is central to many firms' future success. Not only as a means to continue to maintain their piece of the market, but product development can also be a strategic means for a company to diversify, and/or alter focus to adapt to changing market conditions.

Most of the research in new product development has been on how to do it cheaper and faster than the next guy. However, early commercialization does not guarantee a position of strength in the market. Failures of EMI in CT scanners and Xerox in personal computers illustrate that being first to market does …

A Finite Element Simulation Of Temperature And Material Flow In Fricton Stir Welding, Mark J. Lasley

Theses and Dissertations

The purpose of this research was to use the Transvalor S.A. product, Forge3, to develop a finite element simulation of the friction stir welding process that improves the predictability of temperature evolution and material flow within the plunge portion of the process. Previous modeling created more heating within the billet than experimental results, probably due to the simplification of the simulation with adiabatic boundary conditions. More realistic tooling temperatures were included in this model as these affect heat evolution which is a determining factor in microcrystalline growth. These results were validated by experimental efforts using a billet and tooling instrumented …

A Method For Winding Advanced Composites Of Unconventional Shapes Using Continuous And Aligned Fibers, Abraham K. Allen

Theses and Dissertations

Advanced composites are extremely strong, rigid, and light, even when compared with advanced metals. Advanced composites are replacing high-tech metals as the material of choice for aerospace engineering. However, the processes used to manufacture advanced composites generally lose some of the properties of the materials by their process limitations.

One process that keeps the theoretically awesome qualities of the composite materials in tact is filament winding. Filament wound parts are used as rocket shells, bicycle frame tubes, drive shafts, pressure vessels, etc. Filament winding is an automated process and makes reliable parts to close tolerances. If a straight tube were …

The Effectiveness Of Computer-Based Tutorials In Learning Computer-Aided Design Methods For Tool Design Procedures, Andrew Moroni Hall

Theses and Dissertations

Throughout the past twenty-five years the process of designing and manufacturing a product has been revolutionized by the integration of Computer Aided Design (CAD). Although three-dimensional solid modeling, or 3-D CAD offers a better representation of the product in a virtual environment, it can be complicated and difficult to learn. Tutorials have been developed to assist manufacturing tool design student in the learning of 3-D CAD principles as they apply to tool design. This study seeks to test the effectiveness of those tutorials. A BYU tool design class was divided into two groups according to their assigned laboratory time. The …

The Benefit Of Using Simulation To Improve The Implementation Of Lean Manufacturing Case Study: Quick Changeovers To Allow Level Loading Of The Assembly Line, Jack J. Mcclellan

Theses and Dissertations

In today's competitive manufacturing environment, companies are constantly looking for ways to improve. Because of this, many companies are striving to become "lean" by implementing lean manufacturing, which is a difficult process. To aid in the implementation of lean manufacturing, simulation was used to reduce the trial-and-error period of lean manufacturing and find to optimum approach to implement the lean manufacturing principle. In this research, a case study of implementing level loading of the production schedule for BullFrog International, L.C. will be examined. To make it possible to implement level loading, the thermo-former machine at the beginning of the operations …