Manufacturing Commons^™

Ua66/9/3 Ogden College Of Science & Engineering Engineering Student Organizations, Wku Archives

WKU Archives Collection Inventories

Records created by and about Engineering department student organizations.

An Energy Profile Model For Fused Deposition Modeling 3d Printing Process, Calvin Hawkins

Research Opportunities for Engineering Undergraduates (ROEU) Program 2018-19

This project develops a strategy to monitor and estimate the energy consumption of fused deposition modeling (FDM) additive manufacturing, which will benefit manufacturers and designers seeking to design and manufacture products with minimal energy consumption.

Enhanced Surface Integrity With Thermally Stable Residual Stress Fields And Nanostructures In Cryogenic Processing Of Titanium Alloy Ti-6al-4v, James R. Caudill

Theses and Dissertations--Mechanical and Aerospace Engineering

Burnishing is a chipless finishing process used to improve surface integrity by severe plastic deformation (SPD) of surface asperities. As surface integrity in large measure defines the functional performance and fatigue life of aerospace alloys, burnishing is thus a means of increasing the fatigue life of critical components, such as turbine and compressor blades in gas turbine engines. Therefore, the primary objective of this dissertation is to characterize the burnishing-induced surface integrity of Ti-6Al-4V alloy in terms of the implemented processing parameters. As the impact of cooling mechanisms on surface integrity from SPD processing is largely unexplored, a particular emphasis …

Transforming A Circular Economy Into A Helical Economy For Advancing Sustainable Manufacturing, Ryan T. Bradley

Theses and Dissertations--Mechanical and Aerospace Engineering

The U.N. projects the world population to reach nearly 10 billion people by 2050, which will cause demand for manufactured goods to reach unforeseen levels. In order for us to produce the goods to support an equitable future, the methods in which we manufacture those goods must radically change. The emerging Circular Economy (CE) concept for production systems has promised to drastically increase economic/business value by significantly reducing the world’s resource consumption and negative environmental impacts. However, CE is inherently limited because of its emphasis on recycling and reuse of materials. CE does not address the holistic changes needed across …

Trade-Off Balancing For Stable And Sustainable Operating Room Scheduling, Amin Abedini

Theses and Dissertations--Mechanical and Aerospace Engineering

The implementation of the mandatory alternative payment model (APM) guarantees savings for Medicare regardless of participant hospitals ability for reducing spending that shifts the cost minimization burden from insurers onto the hospital administrators. Surgical interventions account for more than 30% and 40% of hospitals total cost and total revenue, respectively, with a cost structure consisting of nearly 56% direct cost, thus, large cost reduction is possible through efficient operation management. However, optimizing operating rooms (ORs) schedules is extraordinarily challenging due to the complexities involved in the process. We present new algorithms and managerial guidelines to address the problem of OR …

Analysis Of Surface Integrity In Machining Of Cfrp Under Different Cooling Conditions, Arjun Nagaraj

Theses and Dissertations--Mechanical and Aerospace Engineering

Carbon Fiber Reinforced Polymers (CFRP) are a class of advanced materials widely used in versatile applications including aerospace and automotive industries due to their exceptional physical and mechanical properties. Owing to the heterogenous nature of the composites, it is often a challenging task to machine them unlike metals. Drilling in particular, the most commonly used process for component assembly is critical especially in the aerospace sector which demands parts of highest quality and surface integrity.

Conventionally, all composites are machined under dry conditions. While there are drawbacks related to dry drilling, for example, poor surface roughness, there is a need …

Design And Process Of 3d-Printed Parts Using Composite Theory, Jordan Garcia

Theses and Dissertations--Mechanical and Aerospace Engineering

3D printing is a revolutionary manufacturing method that allows the productions of engineering parts almost directly from modeling software on a computer. With 3D printing technology, future manufacturing could become vastly efficient. However, it is observed that the procedures used in 3D printing differ substantially among the printers and from those used in conventional manufacturing. In this thesis, the mechanical properties of engineering products fabricated by 3D printing were comprehensively evaluated and then compared with those made by conventional manufacturing. Three open-source 3D printers, i.e., the Flash Forge Dreamer, the Tevo Tornado, and the Prusa, were used to fabricate the …

Remotely Controlled Industrial Robotic Arm And Simulation Of Automated Thermal Furnace, Prince Mehandi Ratta

Dissertations, Master's Theses and Master's Reports

The right execution of controllers ensures the correct analysis of information, generating efficient results and better optimizing the system. In this report, two controllers were designed. Firstly, a remotely controlled robotic arm, since there are no such type commercially available controllers. Moreover, robotic platforms are costly, so students and researchers are often unable to learn the concepts of programming industrial robots. This project makes a non-destructive, remotely-controlled robotic arm to better teach students and researchers about programming and control of robotic arms. Secondly, simulation of an automated thermal furnace for ArcelorMittal on SIMULINK, which is used for the annealing process …

3d Printing In Low Resource Healthcare Settings: Analysis Of Potential Implementations, Alenna Beroza

Dissertations, Master's Theses and Master's Reports

3D printing has gained significant momentum in the past ten years, and its unique advantages make it especially ideal for use in low resource healthcare settings, where many designs have already been successfully implemented. Yet, little has been studied on how 3D printing can be sustainably and functionally implemented in low resource healthcare systems as a manufacturing practice. In this report, three business models are proposed for this implementation: In-House Operator, Independent Operator, and Print Farm. These models were then tested over four months in Kisumu county, Kenya, at two workshops and seven public hospitals. I worked with local medical …

Influence Of Micro-Nucleate Boiling On Annular Flow Regime Heat Transfer Coefficient Values And Flow Parameters – For High Heat-Flux Flow Boiling Of Water, Soroush Sepahyar

Dissertations, Master's Theses and Master's Reports

Analysis of results from steady and steady-in-the-mean high heat-flux (15 - 70 W/cm², with water as working fluid) shear driven annular flow-boiling experiments presented here - and low heat-flux (0.1- 1 W/cm², with FC-72 as working fluid) experiments presented elsewhere – together lead to a key conclusion. The conclusion is that heat carrying nucleation rates go often undetected by the typically used visualization approaches for flow boiling – as such flows often involve µm- to sub- µm scale bubble diameters in millimeter-scale ducts. These nucleation rates play a significant role in most of the so-called convective …

Multi-Scale, Capillary Assisted Copper Surfaces For Enhanced Pool Boiling Heat Transfer Processes, Chetan Agarwal

Dissertations, Master's Theses and Master's Reports

Phase-change heat transfer through pool boiling process offers a promising thermal management solution in applications wherein conventional air or single-phase liquid-based cooling methods prove inefficient such as for high-power electronics. Pool boiling process, which utilizes the latent heat of evaporation, provides a robust and efficient way to efficiently dissipate the excessive heat generated in a small footprint area in particular as seen in CPUs (Central Processing Units), GPUs (Graphics Processing Units), LEDs (Light Emitting Diodes), radars, and other demanding computing, sensing and surveillance electronics. Although boiling process has been studied for over five decades, it has not been yet adapted …

Space Dynamics Laboratory Payload Challenge: Autonomous Water Sampling Uav, Thomas Wheeler, Zachary Williams, Joseph Stack

Williams Honors College, Honors Research Projects

The following report has been completed over the course of the Fall 2018 and Spring 2019 semesters at The University of Akron by Joseph P. Stack (Aerospace Systems Engineering), Thomas J. Wheeler (Mechanical Engineering) and Zachary M. Williams (Mechanical Engineering). The purpose of this project was to create a payload system for the Akronauts Rocket Design Team to use at the Intercollegiate Rocket Engineering Competition (IREC) Spaceport America Cup. The Competition as a challenge that is sponsored by Space Dynamics Laboratory specifically regarding payload systems. The challenge in very open-ended and allows student to identify their own scientific experiment and …

Reactive Archey Target Design Team "Mimic", Brandon Croyle, Jacob Boss, David Rodgers, Austin Wivell

Williams Honors College, Honors Research Projects

This design project will aim to provide archery hunters with a platform to simulate shooting at string jumping deer. String jumping refers to a spooked deer hearing the snap of a bow string and instintivly ducking up to ten inches. This often results in wounded or missed deer. We will design and build a control system that uses the sound of a bow string as a trigger to operate a mechanical target system. A sound sensor will mimic a deer’s hearing in close range hunting and then send a signal to the mechanical system to replicate the dropping motion of …

Center Lift Trailer Support Structure, Carson Corle, Anthony M. Hayes, Bryan A. Truax

Williams Honors College, Honors Research Projects

Center lift pontoon trailers have a high center of gravity, therefore have the potential for the pontoon and trailer to tip while cornering. There is need for a component to stabilize the pontoon on the trailer while towing. Different concepts of a support system were sketched to determine the best option. The characteristics that were deemed important for the support system were narrowed down to determine the best concept and the connections of the best design were sketched in greater detail. The forces that the support system would have to withstand to stabilize the pontoon on the trailer were calculated. …

Design And Mechanical Characterization Of 3d Printed Gradient Porosity Poly(Propylene Fumarate) Scaffolds, Andrea Felicelli

Williams Honors College, Honors Research Projects

Worldwide incidence of bone disorders and conditions, an already prevalent problem, is expected to double by 2020 from the rate in 2013 due to factors such as higher life expectancies and lower levels of physical activity. Every year in the United States, over half a million patients receive bone defect repairs, with costs greater than $2.5 billion. Current repairs are typically done with bone grafts, which are often costly and can result in added complications in the donor surgical site. Tissue engineering, a growing field that seeks to assist and enhance tissue defect repairs through the use of synthetic materials, …

Carbon Fiber Racing Wheel, Megan Sanok, Melissa Furdak, Sydney Schipani

Williams Honors College, Honors Research Projects

Industry today thrives off of competition; everybody wants their product to be the best. Across almost every field of manufacturing and design, there is a pattern of factors that companies strive for when producing their specialized products. The most effective companies can create a commodity that is relatively inexpensive, easy to manufacture, and has the ability to meet high standards. As engineers, it is ingrained in us that there is always room for improvement, and that we have been given the tools to make it happen.

When evaluating what needed to be improved in our daily lives, the SAE Zips …

Sae Baja Custom Caliper And Upright Design, Katelynn R. Kise

Williams Honors College, Honors Research Projects

The Zips Baja Off-Road Racing team had a successful 2018 season however some aspects of the car needed to be updated and improved for the 2019 season. This reports captures the design cycle performed to improve the cost, integration, and reliability of the front braking caliper and upright.

Carbon Fiber Monocoque, Dan Brown, Leland Hoffman

Williams Honors College, Honors Research Projects

The University of Akron’s Human Powered Vehicle Team designed a high performing, fully functioning vehicle that is safe, efficient, and practical for the 2018-2019 season. These objectives were the main priorities when it came to the initial stages of designing the vehicle. In addition, the vehicle was designed in accordance with the ASME 2019 Human Powered Vehicle Challenge guidelines to satisfy all the rules and requirements. Additional priorities have been created to teach practical engineering skills and techniques to the students participating in the project through different points in the production process including research, vehicle design, construction, and testing.

The …

Metric Coil Car, Abigail Eberly

Williams Honors College, Honors Research Projects

Coil cars are a vital part of many steel mills. They allow mills to easily transfer a coil from one location to another without the use of a crane, manual labor, or other extraneous forces. Steel Equipment Specialists, or SES, gets multiple orders every year for coil cars. While the general functions and goals of the cars remains consistent, the details, such as the size of the car, the distance between rails, and the weight/ size of the coils differs between each place. Due to this variety, SES has requested a coil car that can easily be manipulated and produced …

Generator Design: A Study Of Optimized Airflow, Rachel Wattleworth

Williams Honors College, Honors Research Projects

The core goal of this project was to prototype, test, and evaluate a new type of fan for the Safran Electrical & Power air-cooled generators. The idea of a new fan being made for these two generators arose when they were not adhering to design requirements. A base mixed-flow fan was created to test on multiple generators. Upon creating a prototype, it will be tested to prove if it can increase the air flow, decrease temperatures, and increase power and life of the machines. They all proved to be successful and achieve the main objectives for this project. Data such …

Power Wheelchair Canopy, Mohamed F. Battah, Joshua D. Brown, Dujuan J. Mcclendon, Gavin M. Francisco

Williams Honors College, Honors Research Projects

Some power wheelchair users can not drive and independently hold an umbrella at the time because they do not have much upper body strength. Therefore, users are unprotected from the rain and are getting soaking wet. One of the members of this group is in a wheelchair and faces this problem. He has previously searched for something to protect him from rain, but could not found something he could independently use. What users need is a powered umbrella that attaches to their power wheelchair. There is no such umbrella available in the market. In this project, the solution to this …

Recumbent Bicycle Balancing Aid, James Hager

Williams Honors College, Honors Research Projects

For our senior design project, our team will be consulting to create a balancing aid system intended for the recumbent bicycle shown below in Figure 1. The owner of the bicycle is Robert Henderson, a former United States Navy sailor from Northeast Ohio who picked up biking and skiing while he was stationed in Maine in the late 80’s. While there, he took to the mountains on the rugged terrain and brought this passion of biking back home to share with his wife, Johanna once he completed his service to his country. Biking became an integral part of the …

Testing Of A Human Powered Vehicle, Bailey Conard, Marlee Reynolds

Williams Honors College, Honors Research Projects

The University of Akron’s Human Powered Vehicle Team designed a high performing, fully functioning vehicle that is safe, efficient, and practical for the 2018-2019 season. These objectives were the main priorities when it came to the initial stages of designing the vehicle. In addition, the vehicle was designed in accordance with the ASME 2019 Human Powered Vehicle Challenge guidelines to satisfy all the rules and requirements. Additional priorities have been created to teach practical engineering skills and techniques to the students participating in the project through different points in the production process including research, vehicle design, manufacturing, and testing.

The …

Developing A Commercial Product Using A Consumer Grade 3d Printer, Calvin Smith

All Graduate Theses, Dissertations, and Other Capstone Projects

The development of affordable, quality, consumer grade 3D printers has allowed entrepreneurs to develop new products and start small businesses. As the print quality of consumer grade printers has improved entrepreneurs have been able to develop consumer quality products without the traditional expense of mass manufacturing. This change from mass manufacturing to small scale and custom production has allowed for the growth of small businesses. Websites such as www.etsy.com show hundreds of small businesses based on 3D printing, these businesses showcase thousands of products ranging from useful household items to cosplay. This thesis covers the process of a small business …

Developing A Testing Instrument To Evaluate The Performance Of 3d-Printed Body-Powered Prosthetic Hands, Araz Al-Dawoodi

All Graduate Theses, Dissertations, and Other Capstone Projects

A 3D printed prosthetic hand is an open source technology that became a good substitution for many products in the market. For many reasons, Low-cost, easy made / easy build. As an open source product, 3D printed prosthetic designs are available to anyone around the world, a good option for young children because they need to have a new prosthetic more frequent until they reach the adulthood age. Most families cannot pay a thousand dollars technology. From the research, it found that that there are not enough studies cover the open source wrist body-powered prosthetic. Other studies covered products used …

Managing Variability In Assembly Lines, Sumanth Gokapai

All Graduate Theses, Dissertations, and Other Capstone Projects

Every successful company have a diversified product portfolio based on their customer demand. Though products are branded as different variants, versions etc. most of them are similar products with little variations in their features or functions they perform. With the traditional, product centric approach to handle variation, new techniques like Clone and own were implemented in which engineers pick the most similar one available, copy it, make changes to it and present it as a new variant. Even though this approach employs reuse, but the savings occur once and only once. This project discussed how companies can exploit the commonality …

Hydrogen Fuel Cell Gasket Handling And Sorting With Machine Vision Integrated Dual Arm Robot, Devin C. Fowler

College of Graduate Studies: Theses & Dissertations

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

Laser Machining Countersinks In Carbon Fiber Reinforced Polymer, Leon James Neely Hill

Masters Theses

“Laser machining countersinks with a frequency doubled Q-switched diode pumped Nd:YAG laser is demonstrated. Tests were conducted in 0.100" thick IM7 prepreg CFRP with [0,90]3S orientation. The HAZ is minimized to avoid stress concentrations in the epoxy matrix. A chamber and filtration system was designed and built to contain the byproducts produced in the machining process. The variables investigated are the number of repetitions in the offset path, the plunge rate, and the line energy. The research was performed over one baseline study, one parameter space exercise, two full factorial experiments, and one repeatability study. Assessment was done under an …

Differential Mobility Classifiers In The Non-Ideal Assembly, Thamir Alsharifi

Theses and Dissertations

The differential mobility classifier (DMC) is one of the core components in electrical mobility particle sizers for sizing sub-micrometer particles. Designing the DMC requires knowledge of the geometrical and constructional imperfection (or tolerance). Studying the effects of geometrical imperfection on the performance of the DMC is necessary to provide manufacturing tolerance and it helps to predict the performance of geometrically imperfect classifiers, as well as providing a calibration curve for the DMC. This thesis was accomplished via studying the cylindrical classifier and the parallel plate classifier. The numerical model was built using the most recent versions of COMSOL Multiphysics^{® …}

Material Interactions And Self-Assembly In Inkjet Printing, Karam Nashwan Al-Milaji

Theses and Dissertations

Inkjet printing has attracted much attention in recent years as a versatile manufacturing tool, suitable for printing functional materials. This facile, low-cost printing technique with high throughput and accuracy is considered promising for a wide range of applications including but not limited to optical and electronic devices, sensors, solar cells, biochips, and displays. The performance of such functional devices is significantly influenced by the deposit morphology and printing resolution. Therefore, fabrication functional devices with precise footprints by inkjet printing requires deep understanding of ink properties, material interactions, and material self-assembly.

In conventional inkjet printing process, where sessile droplets are directly …