Manufacturing Commons^™

A Case Study Of Multiple-Use Finish Electrodes For Die-Sinking Edm, Troy A. Robertson

Masters Theses & Specialist Projects

This study examines the use of one finishing electrode to finish multiple dies without remachining the electrode. The multiple-use electrode finishing experiment in this study addresses technology in the die-forging industry. Methods of manufacturing spherical straight bevel forge gear dies have relied on die-sinking Electrical Discharge Machining (EDM) practices that showed great potential for advancement. The focus of this study is solely on the improvements of electrode use in EDM finishing-processes. The surface finish quality itself is not an area of concern other than maintaining that it does not diminish. The focused concern is maximizing the process by using one …

Fusion Of Short-Mid Wavelength Infrared Image And Long Wavelength Image Using Discrete Wavelet Transform For Image Quality Enhancement, Rocky Hedrick

Electrical Engineering Undergraduate Honors Theses

Infrared technology advancements have led to an expansive set of infrared applications in both the private and public sectors. New materials and manufacturing techniques have continued to reduce the cost while improving the quality of infrared cameras, but the cost is still high when compared to the cost versus quality of visible light spectrum cameras. Innovative image processing techniques can be implemented to help bridge this gap between the cost and quality of infrared cameras. The goal of this research is to improve the overall quality of infrared imaging by fusing short-mid wavelength infrared images and long wavelength images of …

Loss On Ignition Using Infrared Heating, Benjamin J. Binoniemi

Masters Theses

The focus of this study is a proof of concept that infrared heating can be used to produce a reliable and rapid method of performing the loss on ignition test. The loss on ignition test is a foundry industry standard test that requires all moisture and volatile organic compounds be vaporized from a sample of foundry sand. The standard test as recommended by the American Foundry Society uses a muffle oven and requires nearly four hours to perform. This new concept performs the same test in approximately ten minutes. The biggest issues with the loss on ignition test are time …

Manipulating The Mass Distribution Of A Golf Putter, Paul J. Hessler Jr.

Senior Honors Projects

Putting may appear to be the easiest but is actually the most technically challenging part of the game of golf. The ideal putting stroke will remain parallel to its desired trajectory both in the reverse and forward direction when the putter head is within six inches of the ball. Deviation from this concept will cause a cut or sidespin on the ball that will affect the path the ball will travel.

Club design plays a large part in how well a player will be able to achieve a straight back and straight through club head path near impact; specifically the …

Parker Hannifin Chainless Challenge 2014-15 Senior Design Project, Matt Pallotta, Nathan Klammer, Kemper Whaley, Jack Rechtin

Mechanical Engineering

California Polytechnic State University has been invited to compete in the Parker Hannifin Chainless Challenge Competition in 2014-15. Cal Poly has chosen a team of mechanical engineering students to take part. We have named our team “Bike Under Pressure” and all references as such refer to the team.

The challenge is to build a bicycle which does not have a solid mechanical connection between the power input of the rider to the power output of the wheel(s). After conducting research into different previous designs and brainstorming designs of their own, Bike Under Pressure developed two conceptual designs. One design featured …

Mechatronics Design Process With Energy Optimization For Industrial Machines, Aderiano Medeiros Da Silva

Dissertations (1934 -)

The need for designing industrial machines with higher energy efficiency, reliability, flexibility, and accuracy has increased to satisfy market demand for higher productivity at reduced costs in a sustainable manner. As machines become more complex, model-based design is essential to overcome the challenges in mechatronic system design. However, a well-designed mechanical system with a well-designed and tuned control system are not sufficient for machines to operate at high-performance conditions; this also heavily depends on trajectory planning and the appropriate selection of the motors controlling the axes of the machine. In this work, a model-based design approach to properly select motors …

The Design For Manufacturing And Assembly Analysis And Redesign Of An Aircraft Refueling Door Hinge Utilizing Additive Manufacturing, Kurt A. Schwarz

Doctoral Dissertations and Master's Theses

In this thesis, an aircraft door hinge assembly provided by Gulfstream Aerospace was analyzed following an established process called DFMA. The hinge was then redesigned to be additively manufactured, which is uncommon currently in industry for load bearing components. It was shown that the Design for Manufacturing (DFM) guidelines were inadequate when applied to the new technology of additive manufacturing (AM). This was primarily due to AM's unique and unprecedented manufacturing capabilities.

A conservative redesign approach was followed due to a limitation in current AM material properties and time available for analysis. Despite this, a significant improvement in weight reduction …

Creating A User-Friendly Personal Wine Collection Inventory Management System, Peter Loddengaard

Industrial and Manufacturing Engineering

This project set out to create a user-friendly wine collection management software. Existing systems were reviewed and discussions with collectors took place to establish the user requirements for this type of inventory management system. This led to the scope of the project being narrowed to making a wine bottle entry form that was quick and easy to use. The programming language, Ruby on Rails, was used to design this system, and learning the software was a large part of the project itself. It was established that four forms would be designed using combinations of two ergonomic factors: an “F” shaped …

Wasco Environmental Chamber System Manifold, Steve Mark Yatco

Industrial and Manufacturing Engineering

This report details the process of designing and producing a manifold that connects ultra-high purity (UHP) pressure and vacuum switches to an air supply so that the parts may be tested in an environmental chamber. Using the DMAIC (define, measure, analyze, improve, and control) methodology of problem solving, progress on the project includes thorough research about the problem, preliminary design solutions, iterative prototyping, and testing specific functionalities. Manufacturing engineering topics of tooling, fixturing, metrology, quality, and machining with manual and computer numerical control (CNC) varieties of both mills and lathes are applied during the course of the project. The report …

Frito-Lay - Supply Chain Impact Analysis, Kerri Blosch, Vincent Phua, Jeffrey Silva

Industrial and Manufacturing Engineering

The snack food company Frito-Lay relies on Route Sales Representatives (RSRs) to stock and maintain shelves of snack foods in every store. Frito-Lay currently does not have a system which can accurately predict cannibalization, or the effects of a store opening or closing on other stores of the same chain in the area. The goal is to sort through 1900 stores in a given metropolitan area to see the effects of cannibalization. In order to tackle the problem, a Microsoft Access program was created to filter stores based on location or whether the store was open for the full three-year …

Process Testing And Improvement Of Tapping Machinery At Lisi Aerospace, Michael James Hester

Industrial and Manufacturing Engineering

This report documents my senior project for California Polytechnic State University San Luis Obispo. I have chosen to do a senior project with Lisi Aerospace. Lisi would like to compare the manufacturer rated cycle count of taps versus an experimental one based on our machines in house. My goal for this project would be to run an experiment on one tapping machine and report on the achievable cycle count for the taps. I plan to do this in several ways including:

• Running extra cycle counts above tap manufacturer recommendations

• Documenting machine failure modes

• Create a process document to be repeated …

  ---

  Go to article

Improving Advertisement Recognition And User Interface Of Gameofwarrealtips.Com, Chad Kihm, Alexander Meyer

Industrial and Manufacturing Engineering

The purpose of this experiment was to determine which location of advertisement would be the most recognized on the Game of War Real Tips website and to improve the website’s user interface by using both quantitative and qualitative data. To accomplish this, two experiments were created. The first experiment was designed to determine which location of advertisement would be recognized most by users. A screen would flash for 0.5 seconds and the subjects would mark where they believed they recognized an advertisement. A statistical analysis was completed to determine whether the location of the advertisement had an effect on the …

Wine Club Shipment Package Redesign, Emily E. Prescott

Industrial and Manufacturing Engineering

This report shows the design, manufacturing, and testing process for the product development of a wine club shipment package for Niner Wine Estates. Niner has two different shipment sizes, 4 bottles and 6 bottles, and wishes to improve their current package by giving it a more “high-class” feel. After the new package was designed and prototyped, it went through standardized quality testing to be cleared for commercial use. This testing is intended to simulate the distribution cycle the package will experience and subject it to potential hazards such as being dropped and vehicle vibration during transportation.

After the package passed …

Methods Of Extrusion On Demand For High Solids Loading Ceramic Paste In Freeform Extrusion Fabrication, Wenbin Li, Amir Ghazanfari, Ming Leu, Robert Landers

Faculty Publications, Mechanical Engineering

Fabrication of highly dense parts with complex geometry by paste-extrusion-based solid freeform fabrication processes requires a precise control of the extrusion flow rate to dispense material on demand, which is often referred as Extrusion-On-Demand (EOD). The extrusion process for aqueous ceramic pastes is complex and difficult to control due to their non-Newtonian behavior, compressibility and inhomogeneity. In this study, three methods of EOD (based on ram extruder, needle valve, and auger valve) are introduced and investigated for the extrusion of high solids loading (i.e., >50%, volumetric) aqueous alumina paste. Optimal extrusion process parameters for these methods are determined through printing …

Optimal Rastering Orientation In Freeform Extrusion Fabrication Processes, Amir Ghazanfari, Wenbin Li, Ming Leu, Robert Landers

Faculty Publications, Mechanical Engineering

Many researchers have tried to optimize the build direction of additively manufactured parts to minimize the vertical staircase effect. However, the horizontal staircase effect should also be considered when fully dense parts are to be fabricated. In this paper, part inaccuracy due to the horizontal staircase effect is considered in order to determine the optimal rastering orientation in building the part. An algorithm is developed to estimate this inaccuracy and a technique is proposed to minimize it. The effect of rastering orientation on staircase errors is examined, and the particle swarm optimization method is used to determine the optimum rastering …

Addressing New Skills Needed For The Automotive Industry Through A Motorsports Educational Pathway, Vukica M. Jovanovic, Mileta M. Tomovic, Alok K. Verma, Nathan Luetke, Steve Branch

Engineering Technology Faculty Publications

The automotive industry has higher-skilled positions available that need engineers and engineering technologists qualified and capable to work in a high-paced, advanced manufacturing sector. Various educational programs across the country offer programs related to the motorsports area at the Associate of Science level. There are also various articu-lation agreements that enable students to continue their education to the baccalaureate level. These programs try to fill in the gap related to the skills shortage in systems and new design methods and processes. The main strength of such educational pathways is that students, who are trained to work as technicians with an …

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 …

Stress-Limiting Test Structures For Rapid Low-Cost Strength And Stiffness Assessment, Andrew Katz, Craig P. Lusk, Nathan B. Crane

Faculty Publications

Purpose: Evaluate the use of a simple printed geometry to estimate mechanical properties (elastic modulus, yield strength) with inexpensive test equipment.

Design Methodology/Approach: Test geometry is presented that enables controlled strains with manual deformation and repeatable measurement of vibrational frequencies. This is tested with multiple FDM machines to assess measurement accuracy and repeatability. Printing orientation and some printing parameters are varied to assess the measurement sensitivity.

Findings: The test methods show good correlation with manufacturer material specifications in the X-Y plane and reported elastic strain limits. It is also sensitive to printing orientation and printing parameters.

Research Limitations/Implications: Further work …

Binder Jet Additive Manufacturing Of Stainless Steel-Hydroxyapatite Bio-Composite, Don Suranga Dhanushka Uduwage

All Graduate Theses, Dissertations, and Other Capstone Projects

This study was conducted to create a bio-composite with a porous structure using the binder-jet printing additive manufacturing process. The samples were printed by changing the parameters such as layer thickness, roller speed, sintering time and sintering temperature of the X1-Lab binder jet additive manufacturing printer. The samples were printed 80% stainless steel 316 mixed with 20% Calcium Phosphate Tribasic by volume. Eight experiments were attempted to print according to the fractional factorial design of experiment. The effects of changing parameters on the mechanical properties of the new bio-composite was tested using ASTM E-09 compressive strength standards. The compression testing …

A Simulation-Based Approach To Risk Assessment And Mitigation In Supply Chain Networks, Mamadou Seck, Ghaith Rabadi, Christian Koestler

Engineering Management & Systems Engineering Faculty Publications

We present in this paper a simulation-based approach to evaluate the risk associated with supply chain disruptions caused by failures in some supply chains nodes and measure the impact of such disruptions on supply chain key performance measures (KPIs) of interest. The proposed framework enables analysts and managers to repeatedly assess the risk to their supply chains based on various simulated scenarios and identify the most critical nodes whose disruption will have the highest impact on the KPIs of interest. As a result, companies can focus on the most critical supply chain assets and develop targeted mitigation plans that minimize …

Effect Of Heating And Ionization Of Four Atomizing Gases On The Spray Characteristics Of A High Volume Low Pressure Spray Atomizer, Anthony V. Adornato

Theses and Dissertations--Mechanical and Aerospace Engineering

The disintegration of a liquid jet emerging from a nozzle by a high speed gas stream has been under investigation of several decades. A result of the liquid jet disintegration is droplet formation. This process is referred to as atomization. Industrial applications use atomization as a method for applying coatings to substrates. It has been reported that the use of other atomizing gases instead of compressed plant air will positively affect paint droplet size distributions, spray patterns and finish qualities; furthermore, the ionization and heating of the atomizing gas was reported to positively affect finish qualities. Although ionization techniques have …

A Framework For Sustainable Material Selection For Multi-Generational Components, Ryan T. Bradley

Theses and Dissertations--Mechanical and Aerospace Engineering

The early stages of a product’s design are a critical time for decisions that impact the entire life-cycle cost. Product designers have mastered the first generation; however, they currently do not have the ability to know the impact of their decisions on the multi-generational view. This thesis aims at closing the gap between total life-cycle information and the traditional design process in order to harbor sustainable value creation among all stakeholders involved. A framework is presented that uses a combination of a life-cycle costing methodology and an evolutionary algorithm in order to achieve a sustainability assessment for a true multi-generational …

Joint Formation Under Severely Altered Background Atmosphere In Controlled Atmosphere Brazing Of Aluminum, Cheng-Nien Yu

Theses and Dissertations--Mechanical and Aerospace Engineering

Adverse changes of background atmosphere in a brazing chamber cause qualitative and quantitative deterioration of joint formation in an aluminum brazing process. This study offers an insight into the adverse effects with gradually adjusted atmospheric conditions in terms of oxygen and humidity levels. Corresponding responses of the molten clad flow and the joint formation upon resolidification vs. atmospheric conditions are documented by comparative tests involving self-fluxing and surface-fluxing brazing sheets: 1) in situ and in real time study of the onset of melting, clad flow, and joint formation, and 2) inclined wedge-tee mating tests for brazeability assessment. The surface-fluxing brazing …

Thermographic Investigation Of Laser Metal Deposition, Sreekar Karnati

Masters Theses

"Laser metal deposition as an additive manufacturing technique has been proven to possess the capability for fabricating complex, intricate geometries and excellent material properties through material deposition. Accurate manufacture of such geometric features would require precise control over the material deposition process. The need of the hour are process monitoring and analyses mechanisms that are crucial in ascertaining the occurrence of the intended actions during deposition while also serving as effective learning tools. The current work involved developing and incorporating an Infra-Red (IR) camera as a process monitoring tool for laser metal deposition. Using the IR camera the thermal dynamics …

Swagelok Probing Station Tester Improvement Project, Ross Crocker

Williams Honors College, Honors Research Projects

A step in the inspection process for the Swagelok ends is performed using Probing Station testing. This testing process involves fitting a cylindrical probe into the open end of the fittings. Contact between the probe and the fitting causes the probe to wear. Spare probes are kept at each inspection machine to replace a probe that becomes too worn to function. These spare probes occasionally fall out of their storage location and break without ever being used in inspection. This project seeks to reduce the wear on the probes in service and reduce the number of dropped spare probes that …

2015 Zips Sae Baja Brakes And Throttle System, Philip A. Bennett

Williams Honors College, Honors Research Projects

The SAE Baja student design team at The University of Akron is one of the longest-standing design teams at the university. The purpose of this team is to design, manufacture, test, and race an off-road vehicle within the guidelines of competition established by the Society of Automotive Engineers. The vehicle is made up of a small number of subsystems including frame, drivetrain, suspension, steering, and braking. The following will discuss all aspects of the design process of the braking and throttle system of the 2015 Zips Baja car. This process includes several steps and considerations such as design goals, system …

Senior Design: Kong Toy Instruction-Manual Insertion, Rachael L. Innocenzi, Ashley N. Cuthbert, Marianna R. Smith

Williams Honors College, Honors Research Projects

The team’s goal is to design and test a prototype and procedure that will automate the insertion of the Kong toy instructions into the cardboard packaging. This automation will increase the speed at which the product is packaged and will serve as an aid to workers with limited dexterity who find the task cumbersome.

Senior Design:Kong Toy Instruction-Manual Insertion, Ashley N. Cuthbert, Rachael L. Innocenzi, Marianna R. Smith

Williams Honors College, Honors Research Projects

The team’s goal is to design and test a prototype and procedure that will automate the insertion of the Kong toy instructions into the cardboard packaging. This automation will increase the speed at which the product is packaged and will serve as an aid to workers with limited dexterity who find the task cumbersome.

Design Of An Sae Baja Racing Off-Road Vehicle Powertrain, Eric T. Payne

Williams Honors College, Honors Research Projects

No abstract provided.

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 …