Manufacturing Commons^™

Designing A Manufacturing System To Reduce Production Learning Curve, Nicholas Devin Kuhnsman

Industrial and Manufacturing Engineering

The goal of this project was to design a new manufacturing system for Patio Pacific that would reduce the learning curve and the skilled labor required in the production process. Multiple ideas to decrease the scrap rate in the vert manufacturing process were tested. It was determined that outsourcing the manufacturing of the vertical frame piece was the most optimal because it would reduce overall cost and increase product quality. A new facility and production layout were designed in order to accommodate the new pre-manufactured parts. The approved facility design included a new production flow that transitioned manufacturing from single …

Theatrical Turntable, Liam R. Martinez, Isaac Becker, Robert R. Reed, Caroline A. Whelan

Mechanical Engineering

No abstract provided.

Mechanical Characterization Of Selectively Laser Melted 316l Stainless Steel Body Centered Cubic Unit Cells And Lattice Of Varying Node Radii And Strut Angle, Christopher James Hornbeak

Master's Theses

An experimental study of several variants of radius and strut angle of the body centered cubic unit cell was performed to determine the mechanical properties and failure mechanisms of the mesostructure. Quasi static compression tests were performed on an Instron® universal testing machine with a 50kN load cell at 0.2mm/min. The test samples were built using a SLM Solutions 125 selective laser melting machine with 316L stainless steel. Test specimens were based on 5mm cubic unit cells, with a strut diameter 10% of the unit cell size, with skins on top and bottom to provide a cantilever boundary constraint. Specimens …

Defect Detection In Selective Laser Melting, Moira Foster

Master's Theses

Additively manufactured parts produced using selective laser melting (SLM) are prone to defects created during the build process due to part shrinkage while cooling. Currently defects are found only after the part is removed from the printer. To determine whether cracks can be detected before a print is completed, this project developed print parameters to print a test coupon with inherent defects – warpage and cracking. Data recorded during the build was then characterized to determine when the defects occurred.

The test coupon was printed using two sets of print parameters developed to control the severity of warpage and cracking. …

Farmbot Trackless Redesign, Cole Thomas, Cailey Kamm, Clayton Alderson, Otto Akerstrom

Industrial and Manufacturing Engineering

For this project the team PLANT3D worked along with Rory Aronson and FarmBot to generate a cheaper more user-friendly design for the FarmBot Genesis 1.3. Working with Rory and FarmBot, we as a team generated a list of design requirements and engineering specifications for the project. These requirements centered around creating a more accessible FarmBot model for the average person to be able to purchase and set up with ease. Much of this required taking the existing system and eliminating the most common problem areas. These were the track system, built using 1.5 meter aluminum extrusions and the complex interchangeable …

Solar Electric Immersion Heating Element Fabrication, Logan V. Kregness

Industrial and Manufacturing Engineering

Believing that cooking with flame is cheaper and more efficient than cooking with electricity, Ugandan citizens have exposed themselves to several health and safety risks, including major respiratory issues through harmful emissions, pollution, and the burning down of many homes. Even though solar electric cooking is cheaper and healthier than cooking with flames in the long run, many Ugandans lack the resources to invest in cooking with electricity.

The Solar Stove student research team, led by Dr. Pete Schwartz, partnered with Aid Africa to bring solar panels and prototype solar electric cooking units to villages in Uganda. Observing how their …

Improving Efficiencies For The Loading And Packaging Departments At San Luis Sourdough, Alexis Bergstrom, Isabella Pereira, Claudia Robinson

Industrial and Manufacturing Engineering

San Luis Sourdough, currently has issues with efficiency and standardization in their packaging department, ergonomics problems in the packaging department, shipment accuracy in their loading department, and lacks an organized layout design. As a result, four objectives were designed within a six month period. The first was to create standard operating procedures for the packaging department. To inform this decision time studies were performed before and after creating these SOPs. It was discovered that there was a clear need for the SOPs due to variation in packaging efficiency among new and experienced associates. The second set of time studies showed …

Slm Materials Development, Justin G. Reiner, Michael T. Schembri

Industrial and Manufacturing Engineering

The purpose of this project was to create a procedure to efficiently determine a “recipe” of parameter values that create a desired set of mechanical properties. Research was conducted into the laser powder bed fusion process with focus on underdeveloped materials. A design of experiment was used with a set of density correlated parameters to establish a method of producing nearly dense parts. Our methods include SLM printing, metrology, and statistical analysis. An experimental procedure for materials development was designed, but unable to be validated during the scope of this project, due to unforeseen safety issues (exposure to Chromium 6, …

Team Joseph's Bike Trailer, Keely Thompson, Curtis Wathne, Ryan Meinhardt

Mechanical Engineering

This final design report shows the results of this senior project’s design process of creating a custom bike trailer for Team Joseph. As done in the Scope of Work, Preliminary Design report, and Critical Design report, current products, relevant technologies, and American Society for Testing and Materials (ASTM) standards are fully researched and benchmarked to aid in the design selection process. Customer requirements are looked at and developed into engineering specifications. A detailed design was created for CDR to show to Team Joseph, and manufacturing and testing plans were laid out. This final design report adds the final design revisions …

Multi-Purpose Heart Valve Therapy Assembly Fixture, Alec John Foster, John Patrick Hofstetter, Emily Lim

Mechanical Engineering

STATEMENT OF CONFIDENTIALITY: The complete senior project report was submitted to the project advisor and sponsors. The results of this project are of a confidential nature and will not be published at this time.

Cal Poly Supermileage Drivetrain, Michael Bolton, Justin Miller, Heather Fields

Mechanical Engineering

The following report details the full design process used by the Cal Poly Supermileage Drivetrain (CPSMD) Senior Project team in designing a new drivetrain system for the Cal Poly Supermileage Vehicle (SMV) Team. Included is the development stages of each component, the manufacturing of our parts, the final solution’s assembly, the testing of the project, and the results from the 2018 Shell Eco-Marathon Competition. After collecting data from several tests, only the final drivetrain efficiency and final sprocket alignment remain unknown. Otherwise, the project came in under budget, within our weight tolerance, and met all the other design objectives. The …

Annuloplasty Mti: Improved Tooling For Annuloplasty Ring Manufacturing, Justin David Smith, Spencer Lee Combs, Luke Edward Maly

Mechanical Engineering

The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Identification System For Heart Valve Manufacturing, Nicholas Robert Jensen, Edgar Davis Nix, Judith Evelyn Gonzalez, Albert Austin Liddicoat

Mechanical Engineering

Abstract withheld due to NDA constraints

Transcatheter Heart Valve Leaflet Assembly Tooling Improvement Final Design Report, James Craig Sherman, Zachary Robert Dicks, Luke Edward Williams

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Composite Suspension For A Mass Market Vehicle, Sarah M. Chapiama, Brian Auyeung, Jose Guerrero, Ethan Lau

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Curb Navigation, Cole A. Tudor, Kaitlyn R. Adams, Robbie Huerta

Mechanical Engineering

The Curb Navigation senior project, proposed by the QL+ organization, was presented to find a solution to an issue a former veteran, Velette, is having. Velette has a difficult time maneuvering curbs when out doing day-to-day errands and activities. The goal of this project is to develop a solution that will give Velette the ability to traverse curbs without the assistance of others or the need to do a wheelie that can lead to an injury. The team has found that adapting and optimizing an anti-tipper design may be the best way to solve the proposed challenge. The team decided …

Dynamic Model For Simulating Motion Of The Right Ventricle, Brian Michael Larsen, Sam Koopman Porter, John Francis D'Ambrosio

Mechanical Engineering

This report documents all the research, ideation, and mockups used to determine right ventricle motion and develop a system capable of reproducing that motion on a tissue sample. The model is intended for evaluating anchoring systems being developed by Edwards Lifesciences for use with tricuspid valve therapies. Several design solutions were considered for the primary functions of recreating motion of the right ventricle and attaching tissue to the device. From these ideas a primary means of producing motion and attaching tissue was selected. These ideas were then developed over the course of a school year to become the final system …

Additive Manufacturing Powder Removal, Madison A. Lignell, Tyler W. Laird, Kurt K. Reed

Mechanical Engineering

Metal powder-bed fusion is an additive manufacturing process which enables the creation of unique shapes in metal parts that would otherwise be difficult, expensive, or impossible to machine. Metallic powder is melted and fused together by either a laser or electron beam to produce parts quickly. The excess powder covers newly printed parts and can be difficult to remove from small internal features. The scope of this project is to design a device that effectively removes the powder from newly printed parts safely, while reclaiming as much powder as possible for reuse. The solution for this project must be able …

Metal Foam Drying Process, Bryce Zander, Ethan Serpa, Daniel Moore, Michael Mullen

Mechanical Engineering

Design and construction of machine to increase the throughput of metal foam that ERG Aerospace produces.

Prove Endurance Car Front Suspension, Lauren A. Williams, Logan Simon, Justine G. Kwan

Mechanical Engineering

This document details the collaborative Mechanical Engineering Senior Project with Cal Poly PROVE Lab on PROVE Lab’s Project 2; an electric vehicle designed to travel 1000 miles on a single charge. Logan Simon, Justine Kwan, and Lauren Williams are given the challenge of designing an innovative proof of concept front suspension suspension for this vehicle.

After detailed research of new suspension systems, it was determined that the innovative nature could be in the form of unique manufacturing methods, materials use, or mechanical design. At this point in time, this vehicle is a purely conceptual design with no concrete requirements. Therefore …

Modeling Of Cloud-Based Digital Twins For Smart Manufacturing With Mt Connect, Liwen Hu, Ngoc-Tu Nguyen, Wenjin Tao, Ming-Chuan Leu, Xiaoqing Frank Liu, Rakib Shahriar, S M Nahian Al Sunny

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The common modeling of digital twins uses an information model to describe the physical machines. The integration of digital twins into productive cyber-physical cloud manufacturing (CPCM) systems imposes strong demands such as reducing overhead and saving resources. In this paper, we develop and investigate a new method for building cloud-based digital twins (CBDT), which can be adapted to the CPCM platform. Our method helps reduce computing resources in the information processing center for efficient interactions between human users and physical machines. We introduce a knowledge resource center (KRC) built on a cloud server for information intensive applications. An information model …

Foil-Based Additive Manufacturing System And Method, Hai-Lung Tsai, Yiyu Shen, Yingqi Li, Chen Chen

Mechanical and Aerospace Engineering Faculty Research & Creative Works

An additive manufacturing system, method of manufacturing, and fabricated part. The system uses a material joining laser system to join together foil sheets to form a metal part. The material joining laser system can be configured to join adjacent foil sheets together in a substantially uniform manner. The manufacturing system also includes a material removal system that removes material from selected locations of the foil sheets to shape the foil sheets to correspond with selective slices of the part. The material removal system can be a laser system, such as a laser system configured to remove material from a foil …

Analysis Of Surface Integrity In Machining Of Aisi 304 Stainless Steel Under Various Cooling And Cutting Conditions, F. Klocke, B. Döbbeler, S. Lung, S. Seelbach, Ibrahim S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Recent studies have shown that machining under specific cooling and cutting conditions can be used to induce a nanocrystalline surface layer in the workspiece. This layer has beneficial properties, such as improved fatigue strength, wear resistance and tribological behavior. In machining, a promising approach for achieving grain refinement in the surface layer is the application of cryogenic cooling. The aim is to use the last step of the machining operation to induce the desired surface quality to save time-consuming and expensive post machining surface treatments. The material used in this study was AISI 304 stainless steel. This austenitic steel suffers …

A Numerical Investigation Of Bio-Inspired Scaffolds And Surface Textures, Yucong Gu

Graduate Theses and Dissertations

Synthetic scaffolds are widely used as implants to repair bone fracture. Without a proper design, scaffolds could pose significant health risks to the patient and fail to heal the bone properly. A good synthetic scaffold needs to have high porosity and large pore size to allow new bone cells to form on it. However, a scaffold with higher porosity and larger pore size tends to have reduced mechanical strength. Thus, it is important to find a structural design which allows the implant to have a high porosity and large pore size while retaining high strength. In this research, a 3D-printable …

Phase Field Model Of Thermally Induced Phase Separation (Tips) For The Formation Of Porous Polymer Membranes, Ashley Green, Aria Green

Mechanical Engineering Undergraduate Honors Theses

Most membrane research and development has been done through experimental work, which can be costly and time consuming. An accurate computational model would greatly reduce the need for these experiments. The focus of the research presented in this paper is to create an accurate computational model for membrane formation using thermally induced phase separation (TIPS). A phase field model is employed to create this model including the Cahn Hilliard Equation and Flory Huggins Theory. This model produced computational results that correspond well with theoretical and experimental results. The model was then adapted to correspond to the PVDF/DPC polymer-solvent system by …

Influence Of Impact Conditions On Feedstock Deposition Behavior Of Cold-Sprayed Fe-Based Metallic Glass, Constance Ziemian, Wendelin Wright, David E. Cipoletti

Faculty Journal Articles

Cold spray is a promising method by which to deposit dense Fe-based metallic glass coatings on conventional metal substrates. Relatively low process temperatures offer the potential to prevent the crystallization of amorphous feedstock powders while still providing adequate particle softening for bonding and coating formation. In this study, Fe48 Mo14 Cr15 Y2 C15 B6 powder was sprayed onto a mild steel substrate, using a variety of process conditions, to investigate the feasibility of forming well-bonded amorphous Fe-based coatings. Particle splat adhesion was examined relative to impact conditions, and the limiting values of temperature and velocity associated with successful softening and …

Ultrasonic Nondestructive Evaluation Of Metal Additive Manufacturing., Venkata Karthik Nadimpalli

Electronic Theses and Dissertations

Metal Additive Manufacturing (AM) is increasingly being used to make functional components. One of the barriers for AM components to become mainstream is the difficulty to certify them. AM components can have widely different properties based on process parameters. Improving an AM processes requires an understanding of process-structure-property correlations, which can be gathered in-situ and post-process through nondestructive and destructive methods. In this study, two metal AM processes were studied, the first is Ultrasonic Additive Manufacturing (UAM) and the second is Laser Powder Bed Fusion (L-PBF). The typical problems with UAM components are inter-layer and inter-track defects. To improve the …

Design And Implementation Of A Virtual Reality Laboratory For Mechanical Maintenance, Adolfo Enrique Samudio Cano

Morehead State Theses and Dissertations

A thesis presented to the faculty of the College of the College of Business and Technology at Morehead State University in partial fulfillment of the requirements for the Degree Master of Science by Adolfo Enrique Samudio Cano on April 27, 2018.

Novelis Teaching Table, Phillip Laplante, Robert Hemker, Taylor Mcgriff, Juan Restrepo, Shelly Abraham

KSU Journey Honors College Capstones and Theses

Novelis is a company that specializes in metal casting, recycling, and rolling. They primarily focus on aluminum rolling for cans and car bodies but are an industry leader in numerous related areas. As the rolling process is not taught in most general engineering courses, Novelis periodically teaches new engineers and technicians about the specifics of this relatively mathematically complex process. Most of the current teaching methods are through PowerPoint presentations and group exercises, with minimal hands-on involvement. One of the most useful tools for teaching the rolling process is an actual jeweler’s rolling mill, which Novelis currently possesses, but is …

Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one …