Manufacturing Commons^™

Methods For Fabricating Printed Electronics With High Conductivity And High Resolution, Tengyuan Zhang

Electronic Thesis and Dissertation Repository

Flexible and printable electronics are attractive techniques which are believed to be widespread and occupy huge market. However, low conductivity, nozzle clog because of the accumulation of nano-particles and relative high cost (expensive silver/copper nanoparticle inks) limit its appeal. In this thesis, two new effective and convenient methods of fabricating copper patterns with high conductivity and strong adhesion on flexible photopaper and polymer substrates (PET) are demonstrated, solving all those problems. Functional photopaper and PET substrate was prepared with inkjet printing of a palladium salt solution and hyperthermal hydrogen induced cross-linking (HHIC) polyelectrolytes onto its surface respectively, followed by electroless …

Equipment Maintenance And Replacement Decision Making Processes, Michael W. Gage

Industrial and Manufacturing Engineering

This project contains recommendations for the decision making processes for support and production equipment maintenance and replacement for a large defense contractor. Recent literature has been reviewed to provide perspective on current trends in the field. A complete evaluation of their current processes and systems is included with recommendations on areas for improvement. A decision support system is also proposed to supplement their existing decision making.

S1nn Gmbh & Co. Kg (Automobile Connectivity Module 1.1), Tyler Alexander Ball

Industrial and Manufacturing Engineering

The results of this report show how when diagnostics were run on the Connectivity Module 1.1, the problems discovered such as potential short-circuiting, 90-degree copper tracing angles, and components overheating/tombstoning were addressed. By using the method of “DMAIC,” which stands for Design, Measure, Analyze, Implement, Control, successful corrections were made. In the first design of the Printed Circuit Board (PCB), 1454 critical issues were found. With the newly designed PCB’s modifications being implemented, only 12 critical issues remained, which were later addressed and corrected. The results from this report are a functional Automobile Connectivity Module 1.1.

Project Management Of High School Shadow And Building An Engineer Day, Andrea M. Carroll

Industrial and Manufacturing Engineering

Building an Engineer Day and High School Shadow are semi-annual outreach events hosted by Cal Poly’s Society of Women Engineers section during fall and spring quarters. The events focus on encouraging women and minorities to take an interest in engineering. These events are the two largest outreach events hosted by The Society of Women Engineers and need to run smoothly in order to provide student attendees with a meaningful experience.

Building an Engineer Day and High School Shadow are currently un-organized and un-planned, which leads to problems with officer retention, increase in expediting process and a low attendance rate at …

Fixture For Carbon Fiber Spar Of Human Powered Helicopter, David John Ikeda, Luis Gonzalez

Industrial and Manufacturing Engineering

The following report describes our contribution to Cal Poly Human Powered Helicopter for the 2012 competition for the Sikorsky Prize offered by the American Helicopter Society. In order to win this prize the team needs to build and fly a human powered helicopter for more than 60 seconds reaching and altitude of 3 meters while staying in a 10 meter square box. Our team was created to support the integration of Carbon Fiber parts, specifically the carbon fiber spars with rotor and landing gears. Precise cutting and accurate drilling was needed and our team was tasked with creating a fixture …

Design Of An Automatic Wood Trimming Machine, Van Ho, Nicholas Maskal, Andrew Rutland

Mechanical Engineering

This final design report, prepared for Sunrise Arts by the Cal Poly design team Mahogany Automation, details the year-long process in which the team of three engineering students designed and built an automated wooden -plank edge trimming machine that incorporates anti-jamming and continuous loading features. The team has examined current woodworking machines and features available on the industrial and commercial market, and used these as guides along with device requirements set by the project sponsor, Bruce Palmer. The focus has been on designing the simplest and most cost effective device that allows operators to make production runs of wooden slats …

The Collapsible Trailer: Design And Manufacture, Robert Hobson

Biomedical Engineering

No abstract provided.

Investigation Of Thermal Cycle And Hardness Distribution In The Laser Cladding Of Aisi H13 Tool Steel Produced By A High Power Direct Diode Laser, Parisa Farahmand, Prabu Balu, Fanrong Kong, Radovan Kovacevic

Mechanical Engineering Research

Laser cladding (LC) of tool steel has significant application in rapid tooling, and surface coating for worn-out components in different industries. During the LC process, several phase transformations influence the microstructural and mechanical properties of the deposited layer. In order to successfully implement the LC process, it is essential to understand the relationship between the thermal cycle (heating and cooling), phase transformations, and the output quantities of the deposited layer. In this study a direct diode laser with a power of up to 8 kW was used to deposit AISI H13 tool steel on mild steel grade A36 substrate to …

Implementing The Surface Response To Excitation Method (Sure) With Non-Contact Sensors, Sergio R. Gonzalez Jr.

FIU Electronic Theses and Dissertations

Structural health monitoring (SHM) systems generally install low cost excitation component and/or sensors to the machines or buildings permanently to monitor the health of it. Non Destructive Evaluation (NDE) systems use high cost sensors to perform the inspection of structures. It would be advantageous to inspect the some aerospace structures and parts in vacuum environment by using the remotely monitoring systems such as laser vibrometer. In this study, a scanning laser vibrometer is used to detect the location of the problem at the structure. For data collection and analysis recently, developed surface response to excitation (SuRE) method was used.

First …

Nasa Msfc Summer Internship 2013 5.5m Composite Cryotank Sump Door Fabrication, Markus Murdy

Von Braun Symposium Student Posters

No abstract provided.

Effects Of Bit Type On Maximum Torque And Axial Force Using Manual Screwdrivers, Mark Hickok

Master's Theses (2009 -)

The screwdriver is a tool that has been among the most widely used hand tools for decades and continues to be used in the workplace to perform a variety of fastening tasks. Advancements in fastener technology have been complemented by the development of new types of screwdriver bits. While designs may vary, so do the force application requirements placed on the tool user. The primary objective of this experiment is to analyze the relationship between user torque and screwdriver bit design. A further objective is to utilize the results to develop an effort metric by which bits of different designs …

Merging Creative Design And Cad Learning Activities In A Product Design Programme, Pearl O'Rourke, Colm O'Kane, Leslie Smith, Michael Ring

Conference Papers

Traditional learning and teaching methods for creativity differ from those used in a scientific context. Although the creative process can benefit from a certain level of prescription and structural constraint - with time allocated to research, problem definition, conceptualisation and idea development - flexibility and fluidity are necessary for creative innovation. In contrast, the more linear and rigid pedagogies associated with science and engineering education facilitate efficient learning of subjects such as those based on software packages, manufacturing and materials theory or mechanics. This paper describes the development of a project which aims to establish constructive links between the learning …

Do Middle Managers Contribute To Their Organisation's Strategy?, Tony Kealy

Conference Papers

This paper presents an empirical study on the contribution made by middle managers to the development of strategy in an organisation. The data was collected using semi-structured interviews with four managers in randomly-chosen companies. Two of the participant managers held senior management positions while the other two held middle manager positions. The data was analysed using a qualitative approach. Previous studies in this field were found to be wide and varied. An early study by Mintzberg (1978) found that strategy mainly forms from emergent influences at middle and lower levels of the organisation, as well as from deliberate influences emanating …

Small-Scale Wind Turbines: An Appraisal, Tony Kealy

Conference Papers

This research seeks to evaluate the economic benefits to be gained by installing a small-scale wind turbine for a customer with a three-phase electrical supply requirement. The evidence for the claims made in this paper is obtained by using actual data obtained from the installed equipment over a three year period. The objective is to accurately appraise the financial investment using real data. There appears to be limited studies conducted into this type of research, possibly because the renewable energy sector is in the infancy stage in the host country, Ireland. There are some wind energy installations with financial appraisal …

Numerical Modeling Of Solidification Process And Prediction Of Mechanical Properties In Magnesium Alloys, Mehdi Farrokhnejad

Electronic Thesis and Dissertation Repository

A formulation used to simulate the solidification process of magnesium alloys is developed based upon the volume averaged finite volume method on unstructured collocated grids. To derive equations, a non-zero volume fraction gradient has been considered and resulting additional terms are well reasoned. For discretization the most modern approximations for gradient and hessians are used and novelties outlined. Structure-properties correlations are incorporated into the in-house code and the proposed formulation is tested for a wedge-shaped magnesium alloy casting. While the results of this study show a good agreement with the experimental data, it was concluded that a better understanding of …

Additive Manufacturing Laser Deposition Of Ti‐6al‐4v For Aerospace Repair Applications, Nanda Kumar Dey, Frank W. Liou, C. Nedic

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Parts or products from high performance metal are very expensive, partly due to the processing complexities during manufacturing. The purpose of this project is to use additive laser deposition and machining processes to repair titanium parts, thus extending the service life of these parts. The study broadly included preparing the defects, laser deposition, machining, sample preparation and mechanical tests. Comparative study of mechanical properties (UTS, YS, percentage elongation) of the repaired samples to the ideal conditions was undertaken. The research throws up interesting facts where the data from the test sample shows enhancement of properties of the repaired part.

Development Of Freeze-Form Extrusion Fabrication With Use Of Sacrificial Material, Ming-Chuan Leu, Diego A. Garcia

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The development of Freeze-form Extrusion Fabrication (FEF) process to fabricate three-dimensional (3D) ceramic parts with use of sacrificial material to build support sections during the fabrication process is presented in this paper. FEF is an environmentally friendly, additive manufacturing process that builds 3D parts in a freezing environment layer-by-layer by computer controlled extrusion and deposition of aqueous colloidal pastes based on computer-aided design (CAD) models. Methyl cellulose was identified as the support material, and alumina was used as the main material in this study. After characterizing the dynamics of extruding alumina and methyl cellulose pastes, a general tracking controller was …

Probabilistic Simulation Of Solidification Microstructure Evolution During Laser-Based Metal Deposition, Jingwei Zhang, Frank W. Liou, William Seufzer, Joseph William Newkirk, Zhiqiang Fan, Heng Liu, Todd E. Sparks

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A predictive model, based on a Cellular Automaton (CA) - Finite Element (FE) method, has been developed to simulate microstructure evolution during metal solidification for a laser based additive manufacturing process. The macroscopic FE calculation was designed to update the temperature field and simulate a high cooling rate. In the microscopic CA model, heterogeneous nucleation sites, preferential growth orientation and dendritic grain growth kinetics were simulated. The CA model was able to show the entrapment of neighboring cells and the relationship between undercooling and the grain growth rate. The model predicted the dendritic grain size, structure, and morphological evolution during …

Numerical Analysis Of Thermal Stress And Deformation In Multi-Layer Laser Metal Deposition Processes, Heng Liu, Todd E. Sparks, Frank W. Liou, David M. Dietrich

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Direct metal deposition (DMD) has gained increasing attention in the area of rapid manucooling rate, resulting in residual stresses and distortion. This paper presents a 3D sequentially coupled thermo-mechanical finite element model to predict residual stresses and deformations. The temperature distribution, thermal stress field and geometry deformation across domain are illustrated. The effect of deposition parameters on residual stress and deflections are also explored. A set of validation experiments for mechanical effects were conducted using laser displacement sensor. The comparisons between the simulated and experimental results show good agreement

Vision-Based Process Monitoring For Laser Metal Deposition Processes, Sreekar Karnati, Niroop Matta, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Metal deposition is a process with immense scope and promise for becoming a robust manufacturing technology in the near future. Monitoring process variables is very instrumental in process planning and output monitoring. The current work deals with realizing the effect of power modulation on size of the high temperature region during deposition with varying powder feed. A thermal camera was used to visualize and analyze the deposition process. The area of the high temperature region through the deposition was identified and compared to realize the effect of each variable parameter during deposition. The power modulation was fruitful in modulating …

Effect Of Architecture And Porosity On Mechanical Properties Of Borate Glass Scaffolds Made By Selective Laser Sintering, Krishna C. R. Kolan, Ming-Chuan Leu, Greg Hilmas, Taylor Comte

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The porosity and architecture of bone scaffolds, intended for use in bone repair or replacement, are two of the most important parameters in the field of bone tissue engineering. The two parameters not only affect the mechanical properties of the scaffolds but also aid in determining the amount of bone regeneration after implantation. Scaffolds with five different architectures and four porosity levels were fabricated using borate bioactive glass (13-93B3) using the selective laser sintering (SLS) process. The pore size of the scaffolds varied from 400 to 1300 μm. The compressive strength of the scaffolds varied from 1.7 to 15.5 MPa …

Experimental Investigation Of Different Cellular Lattice Structures Manufactured By Fused Deposition Modeling, Osman Iyibilgin, Cemil Yigit, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Experimental tests were conducted to evaluate the compressive properties (yield strength and compressive modulus) and build time for five different cellular lattice structures fabricated by the Fused Deposition Modeling (FDM) process. The lattice structures had repeating unit cells, and the shapes of the unit cell under study included honeycomb, square, diamond, triangle, and circle. Test specimens were manufactured by a Stratasys Fortus 400mc machine using ABS (Acrylonitrile Butadiene Styrene) as the part material. The five different lattice structures were compared with each other and also with the sparse and sparse-double dense build styles that are directly available from the Fortus …

Development Of Hydrodynamic Channel Routing Model Of The Lower Rio Grande River To Assist In Flood And Stormwater Management, Andrew W. Leeper

Theses and Dissertations - UTB/UTPA

Flooding and stormwater management of the Lower Rio Grande River (LRG) has become a major issue throughout the years with local entities along the river. The purpose of this study is to develop a hydrodynamic channel routing model to predict water surface elevation changes due to flooding. The study area consists of the LRG from Los Ebanos to Brownsville, Texas. This hydrodynamic model displays the hydraulics of the water flow through the LRG and determines where potential flood hazards exist. To verify the accuracy of the model a series of calculated output hydrographs were established at the Progreso Bridge and …

A Comparative Analysis Of Energy Modelingmethods For Commercial Buildings, Spencer Mark Salmon

Theses and Dissertations

This thesis researched the accuracy of measured energy data in comparison to estimated hand calculation data and estimated building energy performance simulation data. In the facility management industry, there is minimal evidence that building energy performance software is being used as a benchmark against measured energy usage within a building. Research was conducted to find examples of measured energy data compared to simulated data. The study examined the accuracy of a simulation software and hand calculations to measured energy data. Data suggests that comparisons may be made between building energy performance simulated data and measured data, though comparisons are solely …

The Sustainability Of Lean Manufacturing As A Competitive Advantage, Louis G. Jones

Theses and Dissertations

Since the early 1990s lean manufacturing has been employed by companies looking to reduce costs, increase efficiencies and improve quality. Academic studies of the financial benefits of lean manufacturing are mixed in their results, where some show benefit and others do not. The objective of the current work was to confirm a financial benefit of lean manufacturing, while also establishing whether such a financial advantage was sustainable. Financial data was collected for a large number of companies in the manufacturing sector, over the period from 1990 to 2010. The data were used to show correlation between inventory turns and return …

Project Based Learning In Engineering Economics: Teaching Advanced Topics Using A Stock Price Prediction Model, Lizabeth Schlemer

Industrial and Manufacturing Engineering

A graduate level advanced engineering economics class taught at California Polytechnic State University, San Luis Obispo, includes a thorough review of time value of money, investment evaluation, inflation, risk and return, financing decisions, corporate investment strategies, risk analysis and decisions incorporating non-monetary considerations. Historically this course was taught using an advanced text where the topics were covered sequentially. A redesign of the course now includes the construction of a stock price prediction model for a company of the student’s choice. Through the model, the topics are covered and discussed in the context of the large model-building project. For instance, inflation …

Human Powered Hydrofoil Bike Pontoon Floatation, Shelley Dangoor, Tyler Brennent

Mechanical Engineering

This report documents the brainstorming and design development of the hydrofoil bike floatation device. This project is in conjunction with senior project team MobyBike. MobyBike’s focus is in the development of the bike actuation system, as our team’s focus is on designing and developing the floatation device to be incorporated in the final hydrofoil bike design.

Loaded Shift Tester Sram, Nick Cox, Sam Shaffer, Michael Polka

Mechanical Engineering

This report details the design, manufacturing, and testing of a loaded shift tester for the SRAM Bicycle Corporation. The machine is used to perform developmental and qualification tests on various bicycle drivetrain components. Using SolidWorks, the design team created a solid model of the machine on the computer, then ordered and manufactured the parts required to build it. The machine was tested to ensure that all the parts worked together, and was finally delivered to SRAM when it was deemed ready.

Beach Wheelchair Project, Rory Aronson, Joshua Marcum, Samuel Coyne, Alex Hayes, Alexa Colburn, Max Hessel, Benedikt Strauss, Marvin Rimmele, Marco Pietsch

Mechanical Engineering

The Beach Wheelchair, Sandcrawler, is a machine intended to help give people with disabilities the full beach experience. The non-profit organization Bridge II Sports sponsored this project, and tasked us with developing the design and fabricating a prototype. This chair has several features including a linkage mechanism that raises and lowers a chair relative to an external frame, hand crank drive with Gates Carbondrive belt and sprockets, buoyant Wheeleez balloon tires, and much more.

Hoist To Transfer Athletes From Wheelchair Into A Kayak, Jennifer Batryn, Javier Mendez, Kyle Mooney

Mechanical Engineering

No abstract provided.