Manufacturing Commons^™

Smart Factories, Dumb Policy? Managing Cybersecurity And Data Privacy Risks In The Industrial Internet Of Things, Scott J. Shackelford

Minnesota Journal of Law, Science & Technology

No abstract provided.

Enhanced Heat Transfer Performance By Shape Optimization Of A Non-Axisymmetric Droplet Evaporating On A Heated Micropillar, Haotian Wu

McKelvey School of Engineering Theses & Dissertations

Abstract

Enhanced Heat Transfer Performance by Shape Optimization of a Non-axisymmetric Droplet Evaporating on a Heated Micropillar

By

Haotian Wu

Department of Mechanical Engineering and Materials Science

Washington University in St. Louis, 2019

Research Advisor: Professor Damena Agonafer

The stacked multilayer 3D IC structure used in next generation high-powered electronics poses great challenges in dissipating their large heat flux, which causes extreme difficulties for traditional cooling technologies. In response, more advanced two-phase liquid cooling technologies, such as droplet evaporation, which utilizes the latent heat of vaporization to remove excessive heat, have been widely investigated. Compared to traditional single-phase cooling techniques, …

Fiberglass Mat-Roll Carryover, Bryce Youngson, Aaliyah Ramos, Johann Cayaban, Tony Ledesma

Mechanical Engineering

The asphalt shingle is a type of roof shingle that uses asphalt for waterproofing. Its low cost and easy installation make it one of the most common roof covers in North America. General Aniline and Film (GAF) is one of the nation’s largest manufacturers of roofing materials and produces asphalt shingles at their Shafter, California manufacturing facility. To manufacture asphalt shingles, a base material of fiberglass passes through a series of processes that sequentially add asphalt, ceramic-coated mineral granules, and thermoplastic adhesive. The fiberglass base-material arrives at the manufacturing facility in large rolls that workers must periodically splice together in …

Critical Radius Of Insulation, Maria N. Ambrose, Samuel J. Sayre, Travis W. Martin, Matt T. Sterling

Mechanical Engineering

The critical radius of insulation is a counterintuitive concept within the study of heat transfer. The theory states that adding insulation to a cylindrical or spherical object will increase the rate of heat loss rather than decrease it, if the radius (thickness) of the insulation is at its “critical” value. The Critical Radius of Insulation Senior Project is designed to demonstrate this phenomenon to Heat Transfer students via a portable apparatus. The concept will be demonstrated with a cylindrical object which is heated by way of a separate voltage source. Thermocouples will display the temperature of the cylinder while insulation …

Process Improvement And Lift Design For The Installation Of A Metrology Machine Assembly, Dalt J. Lasell, James Mitchell O'Meara, Matthew Steensma

Industrial and Manufacturing Engineering

The objective is to work with Onto Innovations, a leading provider of semiconductor metrology and manufacturing solutions, to develop a system that safely installs a 250lb optics plate into the Atlas III: one of their metrology machines. Based in Milpitas, CA, Onto Innovations utilizes a variety of operations to create different products and assembles each product on site. The 250lb optics plates are WIP that are transferred between fixtures and the Atlas III using a combination of lifts and human workers. The WIP have long lead times, high tolerances, and large costs associated with their manufacturing process.

Onto Innovations identified …

Automation Of Data Analysis In Formula 1, Adam Joseph Mourad, Prescott Jeanne Delzell, Patrick Conner Mccabe

Industrial and Manufacturing Engineering

This paper explores economic solutions for Formula 1 racing companies who are interested in data visualization tools. The research was conducted on the current development of data gathering, data visualization, and data interpretation in Formula 1 racing. It was found that a large chunk of racing companies within the league needs an affordable, effective, and automated visualization tool for data interpretation. As data collection in Formula 1 arises, the need for faster and more powerful software increases. Racing companies profit off-brand exposure and the more a racing team wins, the more exposure they receive. The goal of the paper focuses …

Katie's Jogger, Megan Guillermo, Erin Wint, Abdullah Sulaiman, Kathryn Mangiaracina

Mechanical Engineering

Edward Robinson is an avid runner who would like to take his daughter on runs. His daughter, Katie, is 100% wheelchair bound and currently does not fit in any commercial joggers on the market. The project team was expected to design, build, and test a custom working prototype of a jogger that the sponsor can use to take his daughter on runs. This entire project was performed over a span of three quarters.

Mad Jack Alpine Touring Model Design, Austin Gasbarra, Gillian Stargensky, Madeleine Mccool, Brannon Smudz

Mechanical Engineering

Skiing is a sport enjoyed by millions of people every year, yet ski boots are very uncomfortable and cost- prohibitive, resulting in a low conversion rate of first-time skiers to lifetime skiers. Additionally, Alpine Touring (AT) is seeing a surge in popularity as ski resorts become more expensive, but few companies are developing affordable products in this realm. Mad Jack Snow Sports has developed a product that they believe addresses some of the main issues associated with skiing, but they want to develop their product line further. The problem statement and scope state that the purpose of this project is …

Design And Testing Of A Modular Laser System With Laser Machining And Bioprinting Capabilities, Jesus Gonzalez

Theses and Dissertations

This thesis introduces the applications of ultrafast lasers while focusing on their bioprinting capabilities. A custom system was designed to utilize a femtosecond laser for 2D and 3D applications. The characteristics of lasers allow them to be efficiently used in machining, 3D printing, research, and more. Their power and precision allow them to be used for delicate work such as bioprinting. Bioprinting is a field holding great potential to benefit society. Studies conducted over the years prove its usefulness in printing cells and biomaterials, while showing there is still much to improve upon before being able to print fully functioning …

Evaluation Of The Most Significant Factors Influencing The Production Rates Of Highway Construction Activities, Angelica M. Neira

Theses and Dissertations

The utilization of realistic production rates is key for the accurate estimation of the contract time in highway projects. Several factors have an impact on production rates and change the total duration of construction projects. To organize and complete projects in a timely, quality and financially responsible manner, projects need to be scheduled carefully. Schedulers and planners of the Texas Department of Transportation (TxDOT) have been noticing that the estimated timelines are far from the reality and want to investigate if external factors can be the cause of this discrepancy. Some of the factors considered in this study are the …

Exploring Convergence Of Snake Skin-Inspired Texture Designs And Additive Manufacturing For Mechanical Traction, Catherine Sue Tiner

Graduate Theses and Dissertations

This research focuses on the understanding, development, and additive manufacture of a 3D printed snake skin-inspired texture pattern. The design functionalities of snake skin were determined through the study of the snake species Python Regius otherwise known as the ball python. Each scale of a snake has hierarchical texture with hexagonal macro-patterns aligned on the ventral surface of the skin with overriding anisotropic micro textured patterns such as denticulations and fibrils. Using a laser-powder bed fusion (L-PBF) process, 420 stainless steel samples were 3D printed which closely resemble the above described directional texture of natural snake skin. This printed surface …

The High Rise Storage System, Justin H. Harmon

Chancellor’s Honors Program Projects

No abstract provided.

An Investigation Of High-Speed Consolidation And Repair Of Carbon Fiber - Epoxy Composites Through Ultrasonic Welding, David A. Hoskins

LSU Master's Theses

Adhesive repair of carbon fiber composite structures is commonly done on damaged structures to extend the service life. This method requires careful preparation of the damaged surface with intricate steps to ensure good bonding between the repair patch and the parent structure by means of an adhesive film. As with many forms of composite manufacturing, it is required to perform vacuum bagging, debulking, and a heated cure depending on the resin. All these steps make the repair process costly and time consuming.

In this present work, an alternative method of repair is investigated which explores the experimental feasibility of using …

Three Essays On Data-Driven Optimization For Scheduling In Manufacturing And Healthcare, Ekin Koker

Doctoral Dissertations

This dissertation consists of three essays on data-driven optimization for scheduling in manufacturing and healthcare. In Chapter 1, we briefly introduce the optimization problems tackled in these essays. The first of these essays deals with machine scheduling problems. In Chapter 2, we compare the effectiveness of direct positional variables against relative positional variables computationally in a variety of machine scheduling problems and we present our results. The second essay deals with a scheduling problem in healthcare: the team primary care practice. In Chapter 3, we build upon the two-stage stochastic integer programming model introduced by Alvarez Oh (2015) to solve …

The Business Case For Industrial Safety: Revealing The Comprehensive Value Of Ergonomic Investments For Manufacturing Enterprises In Industry 4.0, Shane Stan

Honors Theses

How can today’s manufacturing enterprises construct, implement, and optimize modern safety initiatives in a manner that will present maximum return on investment and facilitate enterprise growth? Furthermore, how can these manufacturers assure individual ergonomic investments become part of a larger strategy to facilitate organizational change in safety? This work addresses these questions by placing industrial ergonomics in a business improvement context which comprehensively presents the financial returns and growth opportunities poised by modern safety initiatives. Additionally, to further strengthen the business case for industrial safety, an ergonomic action planning framework is established to guide the creation of holistic safety programs …

Development Of A Robotized Laser Directed Energy Deposition System And Process Challenges, Meysam Akbari

Mechanical Engineering Research Theses and Dissertations

Metal additive manufacturing (AM) is a disruptive technology, enabling fabrication of complex and near net shaped parts by adding material in a layer-wise fashion. It offers reduced lead production time, decreased buy-to-fly ratio, and repair and remanufacturing of high value components. AM processes are finding applications in many industrial sectors such as aerospace, automotive, biomedical and mold tooling. However, beside tremendous advantages of AM, there are still some challenges that prevent the adoption of this technology into high standard applications. Anisotropy and inhomogeneity in mechanical properties of the as-built parts and existence of pores and lack-of-fusion defects are considered as …

Adhesion Testing Of Printed Inks While Varying The Surface Treatment Of Polymer Substrates, Clayton Neff, Edwin Elston, Amanda Schrand, Nathan B. Crane

Faculty Publications

Additive manufacturing with conductive materials enables new approaches to printed electronics that are unachievable by standard electronics manufacturing processes. In particular, electronics can be embedded directly into structural components in nearly arbitrary 3D space. While these methods incorporate many of the same materials, the new processing methods require standard test methods to compare materials, processing conditions, and determine design limits. This work demonstrates a test method to quantitatively measure the adhesion failure of printed inks deposited on a substrate without changing the ink printing conditions. The proposed method is an adaption of single lap shear testing in which the lap …

Bridging The Gap Between Automated Manufacturing Of Fuel Cell Components And Robotic Assembly Of Fuel Cell Stacks, Devin C. Fowler, Vladimir Gurau, Daniel Cox

Department of Manufacturing Engineering Faculty Research and Publications

Recently demonstrated robotic assembling technologies for fuel cell stacks used fuel cell components manually pre-arranged in stacks (presenters). Identifying the original orientation of fuel cell components and loading them in presenters for a subsequent automated assembly process is a difficult, repetitive work cycle which if done manually, deceives the advantages offered by either the automated fabrication technologies for fuel cell components or by the robotic assembly processes. We present for the first time a robotic technology which enables the integration of automated fabrication processes for fuel cell components with a robotic assembly process of fuel cell stacks into a fully …

Materials Selection Of 3d Printing Filament And Utilization Of Recycled Polyethylene Terephthalate (Pet) In A Redesigned Breadboard, Mark Keanu James E. Exconde, Julie Anne A. Co, Jill Z. Manapat, Eduardo R. Magdaluyo Jr.

Goal 12: Responsible Consumption and Production

The demand for a novel and sustainable alternative materials for 3D printer filaments has been knowingly increasing. One alternative source for the filament is to reuse and recycle post-consumer plastic products, which is also a compelling approach to conserve energy and sustain the environment. Thus, this study is focused on the materials selection of virgin polymer resins and recycled post-consumer plastics for use in 3D printer filaments. A multi-criteria decision method of Elimination and Choice Expressing the Reality (ELECTRE) was utilized to determine the best materials for 3D printer filaments. The study has shown that the virgin low-density polyethylene (LDPE) …

Mechanical And Temperature Resilience Of Multi-Material Systems For Printed Electronics Packaging, Clayton Neff, Justin Nussbaum, Chris Gardiner, Nathan B. Crane, James L. Zunino, Mike Newton

Faculty Publications

In this work, two AM technologies were utilized to compare the effectiveness of fabricating a simple electronic device with a conductive trace and hollow cylinder representative of ‘printed packaging’ that would survive harsh environmental conditions. The printed packaging cylinder delineates printed potting for electronics packaging. An nScrypt direct write (DW) system was the primary manufacturing system but a developing technology—coined large area projection sintering (LAPS)—manufactured a subset of samples for comparison. The tests follow Military Standard (MIL STD) 883K and include resiliency evaluation for die shear strength, temperature cycling, thermal shock, and high G loading by mechanical shock. Results indicate …

Applications Of Laser Machining For Fiber Optic Sensor Development, Lauren Sailor

The Journal of Purdue Undergraduate Research

No abstract provided.

Frequency Inspection Of Additively Manufactured Parts For Layer Defect Identification, Aimee Allen, Kevin Johnson, Jason R. Blough, Andrew Barnard, Troy Hartwig, Ben Brown, David Soine, Tristan Cullom, Douglas A. Bristow, Robert G. Landers, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufactured (AM) parts are produced at low volume or with complex geometries. Identifying internal defects is difficult as current testing techniques are not optimized for AM processes. The goal of this paper is to evaluate defects on multiple parts printed on the same build plate. The technique used was resonant frequency testing with the results verified through Finite Element Analysis. From these tests, it was found that the natural frequencies needed to detect the defects were higher than the excitation provided by a modal hammer. The deficiencies in this range led to the development of other excitation methods. Based …

Effective Elastic Properties Of Additively Manufactured Metallic Lattice Structures: Unit-Cell Modeling, Okanmisope Fashanu, David Murphy, Myranda Spratt, Joseph William Newkirk, K. Chandrashekhara, Ben Brown, John Porter

Materials Science and Engineering Faculty Research & Creative Works

Lattice structures are lightweight materials, which exhibit a unique combination of properties such as air and water permeability, energy and acoustic absorption, low thermal conductivity, and electrical insulation. In this work, unit-cell homogenization was used to predict the effective elastic moduli of octet-truss (OT) lattice structures manufactured using selective laser melting (SLM). OT structures were manufactured using a Renishaw AM 250 SLM machine with various relative densities. Compression test was carried out at strain rate 5 x 10^-3 m^-1 using an MTS frame. Finite element analysis was used in the determination of the OT’s effective elastic properties. Results …

In-Situ Local Part Qualification Of Slm 304l Stainless Steel Through Voxel Based Processing Of Swir Imaging Data, Cody S. Lough, Xin Wang, Robert G. Landers, Douglas A. Bristow, James A. Drallmeier, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper demonstrates the potential for qualification through local part property prediction of 304L stainless steel parts manufactured by Selective Laser Melting (SLM). This is accomplished through voxel based processing of SWIR imaging data measured in-situ. Thermal features are extracted from time-series SWIR imaging data recorded from layer-to-layer to generate 3D point cloud reconstructions of parts. The voxel based data is indexed with localized measurements of SLM part properties (light-to-dark microstructural feature ratio, microhardness, μCT data) to demonstrate the correlations. Various features are extracted from the thermal history for comparison of their respective abilities to predict the resulting local part …

Comparison Of Fatigue Performance Between Additively Manufactured And Wrought 304l Stainless Steel Using A Novel Fatigue Test Setup, M. M. Parvez, Y. Chen, Joseph William Newkirk, Frank W. Liou

Materials Science and Engineering Faculty Research & Creative Works

In this research, a novel adaptive controlled fatigue testing machine was designed for bending type high cycle fatigue test. A unique dual gauge section Krouse type mini specimen was designed for simply supported transverse bending. Displacement controlled fatigue tests were implemented using an electromechanical actuator. The variation in the control signal and load observed during the test provides unique insights into realizing the deterioration of the specimen due to fatigue. These analyses were utilized to compare the fatigue performance of wrought and additively manufactured 304L stainless steel. The influence of the build direction on fatigue performance was also investigated by …

Frequency Domain Measurements Of Melt Pool Recoil Pressure Using Modal Analysis And Prospects For In-Situ Non-Destructive Testing, Tristan Cullom, Nicholas Altese, Douglas A. Bristow, Robert G. Landers, Ben Brown, Troy Hartwig, David Soine, Aimee Allen, Andrew Barnard, Jason Blough, Kevin Johnson, Edward C. Kinzel

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Fielding Additively Manufactured (AM) parts requires evaluating both the part’s geometry and material state. This includes geometry that may be optically hidden. Both the geometry and material state affect the vibration response of the parts and modal analysis (identifying natural frequencies) has been shown to be effective for at least simple geometries using ex-situ methods (shaker table and impact hammer excitations). This paper investigates evaluation of the frequency response of metal parts inside the build chamber using the process laser to excite the parts during printing (Renishaw AM250). Vibrations in the part are measured with accelerometers connected to the build …

Joining Of Copper And Stainless Steel 304l Using Direct Metal Deposition, Xinchang Zhang, Yitao Chen, Tan Pan, Wenyuan Cui, Lan Li, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In the current study, the feasibility of joining pure copper (Cu) and stainless steel 304L (SS304L) through direct metal deposition process was investigated by material characterization. Samples were analyzed in terms of microstructure, elemental distribution, and tensile testing. Direct depositing pure copper on SS304L shows copper was mechanically rather than metallurgical bonded with SS304L due to the poor dissolubility of iron in copper. Iron was diffused into copper with a diluted distance of 1.5 mm and above that, pure copper deposits were obtained. Columnar structure was observed at the copper region near the interface while the columnar grains became finer …

Application Of Schlieren Technique In Additive Manufacturing: A Review, R. Bharadwaja, Aravind Murugan, Yitao Chen, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive manufacturing has gained a lot of attention in the past few decades due to its significant advantages in terms of design freedom, lower lead time, and ability to produce complex shapes. One of the pivotal factors affecting the process stability and hence the part quality is the shielding gas flow in additive manufacturing. As extremely beneficial for the process, the shielding gas flow is often set at maximum supply to achieve enough gas cover over the substrate. This causes excessive quantity of shielding gas to be unutilized. Realizing the importance of shielding gas, various studies have been carried out …

Applications Of Supervised Machine Learning Algorithms In Additive Manufacturing: A Review, M. S. Joshi, Aaron Flood, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Additive Manufacturing (AM) simplifies the fabrication of complex geometries. Its scope has rapidly expanded from the fabrication of pre-production visualization models to the manufacturing of end use parts driving the need for better part quality assurance in the additively manufactured parts. Machine learning (ML) is one of the promising techniques that can be used to achieve this goal. Current research in this field includes the use of supervised and unsupervised ML algorithms for quality control and prediction of mechanical properties of AM parts. This paper explores the applications of supervised learning algorithms - Support Vector Machines and Random Forests. Support …

Simulated Effect Of Laser Beam Quality On The Robustness Of Laser-Based Am System, Aaron Flood, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In many metal AM techniques, a laser is used as the heat source and in some applications, it can be advantageous to work off of the focal plane. When operating outside of focus, the beam quality of the laser can have drastic impacts on the ability to manufacture quality parts. This study investigates the effect of the beam quality and distance from the focal plan on the ability to deposit Ti-64, aluminum, and steel through the simulation of the blown powder process.