Manufacturing Commons^™

Binder-Jet Printing Of Fine Stainless Steel Powder With Varied Final Density, Mohsen Ziaee, Eric M. Tridas, Nathan B. Crane

Faculty Publications

Binder jetting is an additive manufacturing process that produces relatively weak porous parts that are strengthened through sintering and/or infiltration. This paper reports on two different methods of preparing fine 316 stainless steel powder and their impact on the final sintered density and dimensions relative to direct printing into -22 micron powder. The first method uses agglomerates of fine powder. In the second, nylon 12 powders are mixed with the steel powder as a fugitive space holder to increase porosity. Sintered density and sintering shrinkage of agglomerate material are shown to vary with the density of the spread powder bed. …

Advances In Composite Manufacturing Of Helicopter Parts, Tobias A. Weber, Hans-Joachim K. Ruff-Stahl

International Journal of Aviation, Aeronautics, and Aerospace

This study investigates and compares different methods for improving standard autoclave composite manufacturing in order to find suitable approaches to a more efficient composite production. The goal is not only a reduction in manufacturing times and costs but also quality enhancement. Improved part quality while decreasing costs enables a manufacturer of composite parts to expand its market share, especially in the helicopter market, which has been constantly shrinking over the last two years. Various approaches such as improved tooling technology, the use of automated systems for lamination as well as outsourcing are examined to provide an overview of possible advancements …

Quality Improvement In Drilling Silicon By Using Micro Laser Assisted Drilling, Barkin Bakir

The Hilltop Review

The micro-laser assisted drilling (µ-LAD) of monocrystalline silicon (100), using a diamond cutting tool coupled with a laser, was tested in order to improve the cutting edge quality of a drilled samples. The laser beam is transmitted through an optically transparent diamond drill bit and focused precisely at the tool-workpiece interface, where the material is under high pressure induced by the diamond tool. The influence of the laser power on the quality and the inner surface finish of the drilled materials is investigated. Different laser powers were used to carry out the experiments. The experimental results indicated that the µ-LAD …

Design And Validation Of Novel Potential High Entropy Alloys, Boliang Zhang

LSU Doctoral Dissertations

The design approach and validation of single phase senary refractory high entropy alloys (HEAs) MoNbTaTiVW and HfNbTaTiVZr were presented in first part of this dissertation. The design approach was to combine phase diagram inspection of available binary and ternary systems and Calculation of Phase Diagrams (CALPHAD) prediction. Experiments using X-ray diffraction and scanning electron microscopy techniques verified single phase microstructure in body centered cubic lattice for both alloys. The observed elemental segregation agrees well with the solidification prediction using Scheil model. The lattice constant, density and microhardness were measured to be 0.3216 nm, 4.954 GPa and 11.70 g/cm³ for …

Tensile Specimen Punch, John Allen

All Undergraduate Projects

This project comes from a need to have tensile specimens made for the MET 351, Metallurgy/Materials and Processes, and 426, Applied Strengths of Materials, labs. This punch is designed to be used with an arbor press to create the desired tensile specimen shape out of plastic blanks. The initial concept was suggested by Dr. Craig Johnson. The designs went through many changes, for example getting rid of the sides originally proposed to hold the specimen in place, and modifications to other parts to make them more efficient. Additional parts were also added to the design with the help and advice …

High Accessibility Cabinet Insert, Matthew Leal

All Undergraduate Projects

Watching grandparents and parents get older, the struggle of day-to-day activities generally increases. One of the most recurring issues the older generation experiences nearly daily is their inability to reach dishes, glassware, and other things on the topmost shelves of a kitchen. Not only is it difficult for them to use things such as stepstools, it also becomes increasingly dangerous. With age, a fall from any height could be catastrophic. With this scenario in mind, a user-friendly cabinet insert would be a very effective way to combat this issue. However, many existing models of cabinet designed to fit these requirements …

Composite Cold Expansion Tooling, Andrew Amos

All Undergraduate Projects

In the world of aircraft manufacturing, cold expansion products literally hold these aircraft together. The problem faced today is that the Little Brute Hydraulic Puller designed and built by Fatigue Technology Inc. is a handheld steel hydraulic cylinder that is heavy and expensive to produce. In a market that demands continuous improvement, there is a constant push to make the product cheaper, better and lighter. In order to accomplish this demand a composite tube will be substituted in the design as the primary pressure cylinder instead of the traditional steel pressure cylinder in order to create a lighter and cheaper …

Beer Rack On Demand Water Heater, Jason Warenski

All Undergraduate Projects

On-Demand Water Heater (for homebrewing systems)

By Jason Warenski (Engineering Technologies)

The on-demand water heater is being built for a home brewing system. The is intended to improve brewing process efficiency while reducing the footprint of the brewing equipment. The device contains a coil made from 3/8” soft copper tubing. The coil is inserted into a housing which is constructed of two 22-gauge stainless steel cylinders and a layer of ceramic insulation. Attached to the inlet and outlet of the coil are monitoring and control devices. On the inlet is a water flow meter which allows the user to monitor …

Directional Rope Capture Device, Seaver Philipp

All Undergraduate Projects

The current market for rope capture devices shows a trend of using toothed devices as the method of creating a rope capture system. These systems are effective for a variety of applications but in any scenario in which a high load is encountered there is a large amount of damage done by the teeth to the rope. The objective of this project was to create a rope capture device that did not utilize teeth in order to create a safer loading condition on the rope. The method used for this project was application of equiangular spirals, this is the same …

Portable Snow-Bike, Tiago Sousa

All Undergraduate Projects

The world of extreme sports and more specifically the world of snow sports is changing by the minute. At the forefront of these new changes is the snow bike. The bike allows you to ride the mountain like you were riding a mountain-bike on skies, but it comes with challenges. The biggest of them being portability. The bike is restricted to certain types of lifts within the mountain and that restricts the user of its potential. This report will show that it is possible to “fold” both the frame and the handlebars to make the bike portable and therefore opening …

Modeling Of Selective Laser Sintering/ Selective Laser Melting, Xuan Wang, Connor West

Industrial and Manufacturing Engineering

Selective laser sintering and selective laser melting are powder based additive manufacturing (AM) process that can rapidly manufacture parts with comparable mechanical properties to conventional manufacturing methods directly from digital files. However, the processing recipe development and design optimization of AM parts are often based on trial and error which erodes the benefit of AM. Modeling is a powerful tool to enable faster development cycle by significantly reducing the experimental efforts. In this paper we discussed the current status of selective laser sintering/melting modeling, in which the laser and powder interaction was studied to understand and predict the process and …

Weather Balloon Payload Box, Shellbie Liberty

All Undergraduate Projects

A payload box holding a self-rotating camera was constructed to go on a weather balloon that will document the upcoming solar eclipse on August 21, 2017. A group of physics students, and the paper’s author, are working under Dr. Darci Snowden on the CWU Near Space Observation Team for research dedicated to the eclipse in Oregon. Various projects, including the payload box, are being designed to go up on a high altitude weather balloon. The payload box was designed and constructed to withstand the impact force of falling from 120,000 ft. This was done so the box could be reusable …

Pin Router Duplicator Base, Matthew Tebo

All Undergraduate Projects

The idea for the following project came from the Lean Manufacturing class that is offered at Central Washington University. In this class the manufacturing processes is demonstrated through the production of guitar kits. A problem with the class is that the CNC machine gets backed up causing a bottleneck in the production line. The solution to this problem was to make a pin router duplicator. A pin router duplicator is a device that allows the operator to trace a finished part with a pin while a router mimics its movements, cutting a new part. The component that is looked into …

Fabricating Zirconia Parts With Organic Support Material By The Ceramic On-Demand Extrusion Process, Wenbin Li, Amir Ghazanfari, Devin Mcmillen, Andrew Scherff, Ming Leu, Gregory Hilmas

Faculty Publications, Mechanical Engineering

Ceramic On-Demand Extrusion (CODE) is an extrusion-based additive manufacturing process recently developed for fabricating dense, functional ceramic components. This paper presents a further development of this process and focuses on fabricating 3 mol% yttria-stabilized zirconia (3YSZ) components that cannot be fabricated without using support structures. The 3YSZ paste is deposited through the main nozzle, and a polycaprolactone (PCL) pellet feedstock is melted and deposited through an auxiliary nozzle to build support structures. After a green part is printed and dried, the support structures are removed by heating the part to ~70°C to melt the PCL. The part is then sintered …

Built-In Bicycle Rack For Cars, Scott A. Hansberry

All Undergraduate Projects

Transporting a bicycle after riding somewhere and then needing to be pickup can be problematic. Bicycles will not fit in most vehicles without removing components. There is also the risk of damaging the inside of the vehicle. Expecting everyone to have a bike rack for their vehicle is unrealistic because the bike rack could be considered unappealing visually, take up to much space in the trunk, or limit the vehicle owner’s access to the trunk. The solution to this problem is a bike rack that mounts onto your car and then mounts your bike onto the rack. Most people don’t …

Pin Router Duplicator, Daniel Phan

All Undergraduate Projects

The purpose of this project is to develop a pin router duplicator to accurately produce guitar bodies, necks, and fret boards. The pin router duplicator is designed to speed up the production process for the class Lean Manufacturing (MET 345), offered at Central Washington University. In the class, students learn how to work as a team to improve the way a woodshop is ran. In Lean Manufacturing, guitar bodies, necks, and fret boards are produced by using a CNC router. For this project, the motivation is to increase production by reducing production time. Accuracy and repeatability is also taken into …

H.F. Hauff Outrigger: Vertical Arm, Juan Tovar

All Undergraduate Projects

H.F. Hauff is a company based out of Yakima which specializes in farming equipment. One of their products is a trailer which has a wind machine attached to it. In order to keep the fan’s thrust from tipping the trailer over, the trailer needs outriggers to extend out. The outriggers also serve as a way to level out the trailer in uneven surfaces. The outriggers are what needed to be designed. This portion of the project was the vertical arm which extends from the horizontal arm, and goes towards the ground to raise the trailer. The project consisted of three …

Eliminating The Illusion Of Learning From Engineering Courses, Jason Weaver

Faculty Publications

This paper describes the efforts of the author to incorporate tools into an undergraduate engineering course to help facilitate better learning and assess proficiency more effectively by avoiding the illusion of learning. Several techniques are used, including suggestions from the recent book Make It Stick by Brown, Roediger, and McDaniel. Student feedback and instructor observations are discussed, and future recommendations for the course are given

Lean Implementation Through Process Automation, Olusola Onadipe Jr.

All Graduate Theses, Dissertations, and Other Capstone Projects

As lean manufacturing is increasingly becoming a common practice today in an effort to keep companies competitive, new and innovative processes are becoming the norm. Part of that innovation includes the development of automated machinery that can help alleviate some struggles with lead times and reduce overall labor. It is all in keeping with the trend of building products cheaper and faster to gain that edge. Company X has been focusing their efforts on lean manufacturing for years now. This paper covers an important project that involves the implementation of a complex mechanical system in an effort to build products …

Condition Assessment Of End-Of-Use Products For Remanufacturing, Jovan Morgan

Research Opportunities for Engineering Undergraduates (ROEU) Program 2016-17

The goal of the project is to use the automated 3-D laser scanner using a Capnut as a test object to detect surface defects, corrosion and calculation error through offline quality inspection. potentially reducing labor time and cost for both consumers and manufacturers.

Nanotextured Titanium Surfaces For Implants: Manufacturing And Packaging Aspects, Sachin Bhosle

Dissertations, Master's Theses and Master's Reports

It has been shown that nanotexturing the surface of otherwise smooth titanium orthopedic materials increases osteoblast proliferation in vitro, and the bone-implant contact area and pullout force in vivo. However, this prior work has not focused on the requirements for scale-up to industrial processes. This dissertation reports on titanium surface modifications by electrochemical anodization using a benign NH₄F electrolyte, and a hybrid electrolyte also containing AgF, rather than hazardous hydrofluoric acid used elsewhere. Nanotube fabrication of Ti6Al4V foils, rods, thermal plasma sprayed commercial implants, and laser and e-beam melted powder materials was demonstrated.

It was found …

Thermal Analysis Of 3d Printed 420 Stainless Steel, Adithya Pothuri

All Graduate Theses, Dissertations, and Other Capstone Projects

Additive manufacturing opens new possibilities in the manufacturing industry. 3D printing is a form of additive manufacturing. 3D printers will have a significant influence over the industrial market, with extremely positive effects in no time. The main aim of this research is to determine the effect of process parameters of Binder Jet manufactured 420 Stainless Steel (420SS) parts on thermal properties such as thermal conductivity. Different parameters, such as layer thickness, sintering time and sintering temperature were varied. A full factorial design of experiment matrix was made by varying these parameters using two levels. Testing showed that different parameters affected …

Pore Formation In Aluminum Castings: Theoretical Calculations And The Extrinsic Effect Of Entrained Surface Oxide Films, Pedram Yousefian

UNF Graduate Theses and Dissertations

Aluminum alloy castings are being integrated increasingly into automotive and aerospace assemblies due to their extraordinary properties, especially high strength-to-density ratio. To produce high quality castings, it is necessary to understand the mechanisms of the formation of defects, specifically pores and inclusion, in aluminum. There have been numerous studies on pore formation during solidification which lead to hot tearing and/or reduction in mechanical properties. However, a comprehensive study that correlates pore formation theory with in situ observations and modeling assumptions from the literature as well as experimental observations in not available. The present study is motivated to fill this gap. …

Enhanced Handheld Engine Ethanol Study, Charindu Kariyawasan Jalath Thanthree

All Graduate Theses, Dissertations, and Other Capstone Projects

This study examined consumer and professional grade handheld engines. Twenty-four consumer grade 50 hour Emissions Determination Period (EDP) trimmers and 24 professional grade 300 hour EDP backpack leaf blowers were run on four different ethanol fuel concentrations; E0, E10, E15, and E20. Six engines of each type were run on each of the fuel blends through their full EDP.

All engines were broken-in and adjusted to manufacturer specifications on E0. Then engines were emissions tested on E0 to provide a baseline and to determine the rich to lean order of the engines. Next, the leanest operating engine received E20 and …

Trustworthiness Requirements For Manufacturing Cyber-Physical Systems, Radu F. Babiceanu, Remzi Seker

Publications

Distributed manufacturing operations include cyber-physical systems vulnerable to cyber-attacks. Long time not considered a priority, cybersecurity jumped to the forefront of manufacturing concerns due to the need to network together legacy, newer equipment, and entire operation centers. This paper proposes trustworthiness solutions for integrated manufacturing physical-cyber worlds, where trustworthiness is defined to complement system dependability requirements with cybersecurity requirements, such that the resulting manufacturing cyber-physical system delivers services that can justifiably be trusted. Acknowledging the inevitability of cyber-attacks, the paper models the cybersecurity component using the resilient systems framework, where system resilience is viewed as preservation of a required state …

Adaptive Scheduling For Operating Room Management, Honghan Ye

Theses and Dissertations--Mechanical and Aerospace Engineering

The perioperative process in hospitals can be modelled as a 3-stage no-wait flow shop. The utilization of OR units and the average waiting time of patients are related to makespan and total completion time, respectively. However, minimizations of makespan and total completion time are NP-hard and NP-complete. Consequently, achieving good effectiveness and efficiency is a challenge in no-wait flow shop scheduling. The average idle time (AIT) and current and future idle time (CFI) heuristics are proposed to minimize makespan and total completion time, respectively. To improve effectiveness, current idle times and future idle times are taken into consideration …

The Limits & Effects Of Draw On Properties And Morphology Of Pan-Based Precursor And The Resultant Carbon Fibers, Sarah Edrington

Theses and Dissertations--Mechanical and Aerospace Engineering

The process, structure, and property relationship of PAN fiber as a precursor to carbon fiber was studied. The limitations of stable spinning and property improvement associated with hot draw in solution spinning were found and quantified. Conditions were varied to generated precursor fiber up to the limit of draw, from which actual samples were collected for thermal conversion to carbon fiber. Samples of PAN and subsequent carbon fiber were characterized using tensile testing and x-ray analysis. The effects of draw on modulus and break stress, as well as the orientation of the crystalline structure of both parent precursor and resultant …

Shape Memory Behavior Of Dense And Porous Niti Alloys Fabricated By Selective Laser Melting, Soheil Saedi

Theses and Dissertations--Mechanical and Aerospace Engineering

Selective Laser Melting (SLM) of Additive Manufacturing is an attractive fabrication method that employs CAD data to selectively melt the metal powder layer by layer via a laser beam and produce a 3D part. This method not only opens a new window in overcoming traditional NiTi fabrication problems but also for producing porous or complex shaped structures. The combination of SLM fabrication advantages with the unique properties of NiTi alloys, such as shape memory effect, superelasticity, high ductility, work output, corrosion, biocompatibility, etc. makes SLM NiTi alloys extremely promising for numerous applications.

The SLM process parameters such as laser power, …

Torque Response Of Thin-Film Ferromagnetic Prisms In Uniform Magnetic Fields At Macro And Micro Scales, Soroosh Torabi

Theses and Dissertations--Mechanical and Aerospace Engineering

The non-contact nature of magnetic actuation makes it useful in a variety of microscale applications, from microfluidics and lab-on-a-chip devices to classical MEMS or even microrobotics. Ferromagnetic materials like nickel are particularly attractive, because they can be easily deposited and patterned using traditional lithography-based microscale fabrication methods. However, the response of ferromagnetic materials in a magnetic field can be difficult to predict. When placed in a magnetic field, high magnetization is induced in these ferromagnetic materials, which in turn generates force and/or torque on the ferromagnetic bodies. The magnitude and direction of these forces are highly dependent on the type …

A Framework And Metrics For Sustainable Manufacturing Performance Evaluation At The Production Line, Plant And Enterprise Levels, Aihua Huang

Theses and Dissertations--Mechanical and Aerospace Engineering

Sustainable manufacturing is becoming increasingly important due to scarcity of natural resources, stricter regulations and increasing customer demand for sustainable products. Sustainable manufacturing involves the use of sustainable processes and systems to produce more sustainable products. In order to meet these demands for sustainable products, manufacturing companies have to adopt numerous strategies to achieve sustainable manufacturing. The approach for evaluating sustainable products and processes have been investigated in previous work where product/process sustainability indices were proposed. However, no comprehensive methods are available for sustainable manufacturing performance evaluation at the system level. This work aims to develop two alternate methods for …