Manufacturing Commons^™

Comparative Analysis And Dynamic Response Of Garolites Under Temperature Spectrum Using Low Velocity Impact Test, Birendra Chaudhary

Honors Theses

The purpose of this study was to examine the dynamic response of three different grades of garolites under the temperature spectrum. High-Temperature G-11 Sheet (HTG), Impact Resistance Garolite E-glass (HIG), and Economical Garolite (EG) were tested using an Instron Dynatup 8250 impact tester. Three specimens were used for all three composites and were tested at 6 different temperatures, -10^oC, 25^oC, 50^oC, 100^oC, 150^oC and 200^oC using the Low-Velocity Impact Machine with 20 Kip punch shear load cell. The results showed that HIG had the highest resistance to punch …

Product Realization Capstone: Using Project Management To Optimize Manufacturing Of Charcuterie Boards, Megan Staffieri

Honors Theses

The purpose of this project was to successfully create 36 charcuterie boards with varying designs during a two-week production period using principles of project management and manufacturing. In the initiation phase, the needs and requirements were assessed according to the project definition. During the planning phase, a work breakdown structure was created, material was researched, a budget was developed, and an initial risk assessment was performed. During the executing phase, the initial designs were prototyped before production began. The controlling phase was done in conjunction with the executing phase. The controlling phase monitored the project management plan and recorded the …

Utilizing The Product Development Process To Bring An Idea From Concept To Production, Sydney Ferguson, Jackson Sneed

Honors Theses

The purpose of this thesis is to document and discuss the five-stage product development process starting with defining a problem and resulting in manufacturing a final product for sale as it was implemented in the Portable Fire Pit Center for Manufacturing Excellence Senior Capstone Project. This project was carried out over the course of the Fall 2019 and Spring 2020 semesters by a team consisting of three Undergraduate Mechanical Engineering majors and two Undergraduate Accountancy majors. The ultimate goal of the project was to carry out a full production run of the Portable Fire Pit outputting fifteen units meeting retail …

Experimental And Numerical Study Of Process Parameters Effects Towards Part Quality And Porosity During Powder Bed Additive Manufacturing Processes., Subin Shrestha

Electronic Theses and Dissertations

Powder bed additive manufacturing (PB-AM) process utilizes an electron beam or a laser as a heat source to melt the metallic powder particles. These processes have the capability of freeform fabrication, however certain defects such as porosity, high surface roughness, etc. would hinder its application. It is important to understand the effect of the process parameters and the underlying physical phenomena, which lead to the formation of such defects. In this regard, a three-dimensional (3D) thermo-fluid model is developed to study the effect of beam speed on the surface morphology during powder bed electron beam additive fabrication (PB-EBAF). Besides, the …

Impact Of Magnetocaloric Material Properties On Performance Of A Magnetocaloric Heat Pump., Michael G. Schroeder

Electronic Theses and Dissertations

In the field of magnetocaloric heat pumps much research has been performed around machine design and theoretical machines, but little has been researched around practical problems such as variability in material properties. The present work defines a simulation tool that has been proven with experimental data. Magnetocaloric material cascades were statistically analyzed and parameterized, such that they could be recreated parametrically using a split Lorentz function with normally distributed parameters. Correlated curve-defining values with standard deviations were used as input into the simulation tool to determine the effect of variation on cooling heat pump performance for a household refrigerator application. …

Service Dog Ramp, Matthew Lundgren, Ariel Tolentino, Dallas Rocha, Adam Mayeda

Mechanical Engineering

This project involves designing a device to help a service dog easily get into and out of a truck. It details the design and manufacturing process. The project was interrupted due to the COVID-19 pandemic, so detailed instructions are provided for whoever takes on the project in the future.

Utilization Of Recycled Filament For 3d Printing For Consumer Goods, Alexa Peterson

Apparel Merchandising and Product Development Undergraduate Honors Theses

The 3D printing market has been used in a wide variety of manufacturing industries including textile and apparel. Many consumers can now own a personal 3D printer at home for recreational printing. There are even websites dedicated to 3D printing patterns made by consumers. However, the materials used in the 3D printing process pose a problem for the environment due to their plastic-based nature. 3D printing is a layered process with each layer being printed depending on the layer below it for strength and stability. During the 3D printing process, great amounts of waste are produced as a result of …

Materials-Processing Relationships For Metal Fused Filament Fabrication Of Ti-6al-4v Alloy., Paramjot Singh

Electronic Theses and Dissertations

Additive manufacturing (AM) is at the mainstream to cater the needs for rapid tooling and small-scale part production. The metal AM of complex geometries is widely accepted and promoted in the industry. While several metal AM technologies exist and are matured to a level where expectation in terms of design and properties are possible to realize. But the metal AM suffers from the heavy expense to acquire equipment, isotropic property challenges, and potential hazards to work with loose reactive metal powder. With this motivation, the dissertation aims to develop the fundamental aspects to print metal parts with bound Ti-6Al-4V powder …

Selective Laser Melting 17-4 Ph Stainless Steel And The Effect Of Varied Thermal Treatments On Fatigue Behavior., Sean Daniel Dobson

Electronic Theses and Dissertations

Fatigue failure is the leading source of loss in industry. In order for new means of manufacturing to move towards mainstream use a complete understanding of material and mechanical behavior must be gained. This endeavor seeks to aide in that task by observing the fatigue behavior of selective laser melting (SLM) additive manufacturing (AM) specimens and the effect of differing thermal treatment conditions for an optimized AM process. Stainless steel 17-4 PH specimens were fabricated using SLM AM and thermally treated to three conditions: as-built, solutionized and hardened, and direct hardened. These specimens were characterized for material (powder quality, density, …

Investigating The Production Of Cores By Using Reclaimed Foundry Green Sand, Kristopher Lee Boss

Dissertations and Theses @ UNI

Increasing environmental regulations, transportation cost, delivery interruptions leading to production concerns, disposal cost, and demand from other industries have influenced the way foundry’s view used sand. The purpose of this research was to determine a beneficial reuse of overflow-green sand that would normally be disposed. The reclamation process used is a combination of mechanical and wet reclamation. The focus was on the production of foundry cold box cores and if using this reclamation process could create a core with a similar quality performance compared to new sand. Research in reclamation could pave the way for a closed loop sand system, …

Design And Demonstration Of Automated Technologies For The Fabrication And Testing Of Pem Fuel Cell Systems, Vladimir Gurau, Daniel Cox, Devin C. Fowler, Matthew Carter, Adedayo Ogunleke

Manufacturing Engineering: Faculty Publications (2015-2023)

This paper describes the research efforts at Georgia Southern University to develop robotic technologies for the fabrication of fuel cell components and stacks, as well as the design and fabrication of a High Temperature Proton Exchange Membrane Fuel Cell (HT-PEMFC) power system to be used as motive power and auxiliary power unit (APU) for a long range, unmanned, fully autonomous forest rover. The paper describes a manufacturing workcell consisting of a Yaskawa Motoman SDA5F dual arm robot with machine vision used for sorting, reorientation and stacking fuel cell components in presenters in preparation for their subsequent robotic assembly in fuel …

Impact Of Part Thickness And Drying Conditions On Saturation Limits In Binder Jet Additive Manufacturing, Nathan B. Crane

Faculty Publications

Binder jetting (BJ) is a high build-rate additive manufacturing process with growing commercial interest. Growth in BJ applications is driven by the use of finer powders and improved post-processing methods that can produce dense, homogenous final parts. However, understanding of the basic droplet/powder interaction is relatively limited. This paper considers the impact of in-process drying, part geometry, and droplet size on a key printing parameter: binder saturation. Parts of varying thicknesses are printed with a range of saturation levels under various heating conditions. The ratio of the printed part mass to the theoretical part mass is used to detect bleeding. …

Spherical Cavity Expansion Approach For The Study Of Rigid-Penetrator’S Impact Problems, Mario Buchely, Alejandro Marañon

Materials Science and Engineering Faculty Research & Creative Works

In recent years, Spherical Cavity Expansion (SCE) theory has been extensively utilized to model dynamic deformation processes related to indentation and penetration problems in many fields. In this review, the SCE theory is introduced by explaining the different mathematical features of this theory, its solution, and a potential application to model the penetration of a rigid penetrator into a deformable target. First, a chronologically literature review of the most common models used to study this kind of penetration problems is introduced, focusing on the SCE theory. Then, the engineering model of penetration is presented using the SCE approach. The model …

3d-Printed Biomimetic Bioactive Glass Scaffolds For Bone Regeneration In Rat Calvarial Defects, Krishna C. R. Kolan, Yue-Wern Huang, Julie A. Semon, Ming-Chuan Leu

Biological Sciences Faculty Research & Creative Works

The pore geometry of scaffold intended for the use in the bone repair or replacement is one of the most important parameters in bone tissue engineering. It affects not only the mechanical properties of the scaffold but also the amount of bone regeneration after implantation. Scaffolds with five different architectures (cubic, spherical, x, gyroid, and diamond) at different porosities were fabricated with bioactive borate glass using the selective laser sintering (SLS) process. The compressive strength of scaffolds with porosities ranging from 60% to 30% varied from 1.7 to 15.5 MPa. The scaffold's compressive strength decreased significantly (up to 90%) after …

A Study Of The Design And Manufacturing Of An Elevated Dog Feeder, Lena Turner

Honors Theses

ABSTRACT

The senior capstone which students in the Center for Manufacturing Excellence program partake in was the basis for project. The Dog Box is an elevated dog feeder with an internal food storage compartment. It was designed for medium to large dogs, and can hold over 40 lbs of dog food. The internal storage compartment has drawer access and contains a plastic tote that will hold the food. The purpose of the design was to create an aesthetically pleasing elevated dog feeder that would double as a storage device, and elevated feeding can help prevent health issues in large dog …

Faculty Instruction Face Shield Project, David Holden, John Schneiderhan

Michigan Tech 3D Designs

Early in the spring of 2020 project contributors David Holden and John Schneiderhan began test printing a variety of open source Personal Protective Equipment (PPE)/Covid related items that could help protect or prevent the spread of the emerging virus. With assistance from Pete Baril of the Western Upper Peninsula Health Department (WUPHD) approval was obtained for the face shields to be used in the health care and nursing homes in the area. With the support and approval from university and library administration efforts were coordinated with Dr. Joshua Pearce and the students from the MOST lab to concentrate on the …

Thermal Modeling Of Additive Manufacturing Using Graph Theory: Validation With Directed Energy Deposition, Jordan Severson

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

Metal additive manufacturing (AM/3D printing) offers unparalleled advantages over conventional manufacturing, including greater design freedom and a lower lead time. However, the use of AM parts in safety-critical industries, such as aerospace and biomedical, is limited by the tendency of the process to create flaws that can lead to sudden failure during use. The root cause of flaw formation in metal AM parts, such as porosity and deformation, is linked to the temperature inside the part during the process, called the thermal history. The thermal history is a function of the process parameters and part design.

Consequently, the first step …

Advanced Mechatronics, Hao Su

Open Educational Resources

Project-based course on the design of mechatronic devices to address needs identified by hospital-based clinicians and industry. Students work in teams to develop a mechatronic prototype. The lectures will cover the design of medical devices and robotics including sensors, actuators, and robots. The students will communicate with customers to understand design needs, then conduct study on prior art, intellectual property, due diligence, and idea conceptualization. Students will present ideas in class and to a broad audience from local industry. Students will also write a publication-quality final report, which they will be encouraged for publication submission.

Development Of A Finite Element Model Of The Stamping Process To Predict The Natural Frequencies Of Dimpled Beams, Varad Vasudeo Pendse

Masters Theses

Creating dimples on beams has been proven to be an effective way of altering their vibrational behavior. The objective of this research is to simulate the process of stamping using the finite element (FE) method to create a model of a dimpled beam. This dimple has non-uniform thickness, so it shows close agreement with its real-life counterpart.

ANSYS® Parametric Design Language (APDL) is used to build a three-dimensional (3-D) finite element model and simulate the process of stamping used to create the dimple. The structural simulation is validated by calculating the thickness and width of the deformed geometry of the …

Investigation Of Manual Material Handling On Musculoskeletal Disorder At Computer Numerical Control Workstation, Abdullah Nor Suliani

Student Works (2020-2029)

Manual Material Handling (MMH) tasks have been recognized among the major source of work-related musculoskeletal disorder (WMSD) in automotive industry and they are commonly practiced at Computer Numerical Control (CNC) workstation. At this workstation, workers act as a material transfer device in the process of loading and unloading products from pallets to machines. The physical interaction of workers to machine is not self-chosen and workers are forced to follow the pace of running CNC machine. The worst situation happens when workers are required to operate more than one machine concurrently. The mismatch interaction between workers and machine exposes workers to …

Novel Methods For Composites Recycling Via Pyrolysis, Matt Jacobs

Undergraduate Honors Theses

Composites are unique materials in many respects. When fabric woven from carbon fibers is joined with a thermoset resin in a controlled environment, it results in a very strong material, especially evaluated on a pound-for-pound basis against metals and ceramics. One aspect of this construction that provides great strength lies in the fiber-matrix adhesion which facilitates load transfer to the reinforcement of the composite. This fiber-matrix adhesion is promoted by the polarity of the usual thermoset matrices, and properly designed sizing materials coating the fibers. It’s a two-edged sword, though. Although the resin and the fibers are quite strong together, …

Cal Poly Supermileage Dynamometer, Jacob Randall, Nate Deffenbaugh, Kyle Milgram

Mechanical Engineering

Our senior project involves designing a chassis dynamometer capable of simulating variable loads for the Cal Poly Supermileage Vehicle (SMV) team. The chassis dynamometer we are developing uses an alternator to develop additional resistance that the vehicle will have to overcome while testing. To implement a control system for the variable load, we use an Arduino Nano paired with multiple sensors and drivers. This control system allows the user to select different levels of resistance that correlate with different road grades. We designed a custom Printed Circuit Board (PCB) that will contain all the electrical components needed for the control …

Utilization And Standardization Of Beverage Based Containers, Michael T. Bobke, Jack C. Maughan, Kenia Vargas

Industrial and Manufacturing Engineering

The purpose of this document is to formally describe and explain all of the decisions associated with the data collection and analysis for this Cal Poly Senior Project. Throughout the project, we will utilize and hone the skills that each team member has developed during our time in Cal Poly's Engineering program. In addition, this document will briefly describe some of Blue Diamond’s history as one of the biggest almond companies in the world. The statement of work will introduce and describe the current status of the beverage base container process and international beverage container design. Next it will discuss …

Rebar Impalement Safety, Spencer C. Nefores, Steven M. Hoover

Industrial and Manufacturing Engineering

This project is sponsored by Webcor with the purpose of finding a better solution to rebar impalement safety. The current rebar impalement safety caps being used by Webcor were found to frequently fall off after being installed. This results in workers being exposed to the hazard for longer than desired. The research that has been done by the team showed that rebar impalement is a serious hazard and results in injury or death every year. Site visits and interviews were performed to aid in understanding the problem and designing solutions. The customer needs, current state of the problem, existing solutions, …

Parklets San Luis, Owen Kenny, Preston Jag Stebel, Leonidas Goodman, Lukas Braun

Industrial and Manufacturing Engineering

Downtown San Luis Obispo has been a popular destination for tourists, students, families, and roadtrippers. However, according to Ryan Betz, Interim Assistant to the City Manager, foot traffic and retail business revenue has been decreasing. Downtown SLO does not have enough free public spaces. Recent projects such as sidewalk bump outs and lighted crosswalks have aimed at making SLO more pedestrian accessible, but they have not actually made downtown more pleasurable. These projects have not seemed to drive any more business or traffic downtown. There are a myriad of ways to rectify this; studies show that having a free place …

Development And Experimental Investigation Of Modular Crates For Industrial Packaging Applications, Marshal Louie, Kumar B

Journal of Applied Packaging Research

For the increased product varieties, engineered plywood crate production technique could not facilitate box size optimization. This paper investigates the implementation of modularity function onto the plywood crate to resize the pack cube volume on customer requirement and to reduce space wastage inside the box. This is achieved by using a new joint technique called “Flat- Post Tongue Joint”. The full-sized experimental work is carried out comprising Flexural test analysis on Flat-Post Tongue joint, Tensile test analysis on tongue joint and Box Compression Test analysis on the two developed models of modular crates namely Modifiable Reinforced Plywood Crate (MRPC) and …

Asts Frame, Dustin Braun

All Undergraduate Projects

The automotive industry has been an industry of many breakthroughs in technology and mechanical systems over the course of its history. But in one area, its innovation has slowed. That is in the area of the short throw shifter. All aftermarket short throw shifters are currently one dimensional. No adjustability, no ability to finetune to one’s personal desire. The goal of this project is to create a short throw shifter frame that is easier/faster to install, as well as allow for full adjustability of the shifter from inside the car. This frame design uses mostly 6061-T6 aluminum, along with some …

Speed Bump Power Generator, Sultan Alanazi, Osamah Abulgaith

All Undergraduate Projects

A large amount of energy is wasted by the vehicles on the speed breakers through friction. Energy can be produced by using the vehicle weight and speed. The team proposes a smart speed breaker that generates power (Speed bump power generator). The device allows vehicles to pass from both sides. The system makes use of mechanical assembly with metal sheets with linkages that press down with spring arrangement. Using the motion and weight of vehicles was the method that the team relied on to design the device. The mass of the vehicles allows the top plate to move the rack …

Machine Learning In Manufacturing: Review, Synthesis, And Theoretical Framework, Ajit Sharma, Zhibo Zhang, Rahul Rai

Business Administration Faculty Research Publications

There has been a paradigmatic shift in manufacturing as computing has transitioned from the programmable to the cognitive computing era. In this paper we present a theoretical framework for understanding this paradigmatic shift in manufacturing and the fast evolving role of artificial intelligence. Policy, Strategic and Operational implications are discussed. Implications for the future of strategy and operations in manufacturing are also discussed. Future research directions are presented.

Composite Guitar, Ryn Rollins

All Undergraduate Projects

Traditional wood-bodied products such as boats, hockey sticks, and guitars can be easily chipped or cracked if not properly taken care of. The wood can absorb moisture and deteriorate over time. If that wood is replaced with composite materials, those products can become stronger, more lightweight, and resistant to temperature and corrosion. Two of the most popular composite materials are carbon fiber and fiberglass. Because these composite materials have such a high strength, the core of a guitar body can also be replaced with a lighter material such as Styrofoam which makes for a lighter and more durable guitar. The …