Manufacturing Commons^™

Grey-Taguchi Approach To Optimize Fused Deposition Modeling Process In Terms Of Mechanical Properties And Dimensional Accuracy, Md Asif Bin Syed, Qausar Rhaman, Hasan Md Shahriar, Mohammad Muhshin Aziz Khan

Graduate Student Scholarship

Fused Deposition Modeling (FDM) is a process that allows for the rapid production of functional parts through the deposition of fused material layers in a sequential manner. FDM has flexibility and the potential to create complicated parts. This study aims to optimize the FDM process parameters in terms of tensile strength, flexural strength, and longitudinal shrinkage using the Grey-Taguchi approach. The input parameters chosen to study the effects on dimension and mechanical properties are layer thickness, the raster angle, fill density, the number of contours, printing temperature, and printing speed. The Taguchi L27 orthogonal array is used as the statistical …

The Effect Of Surface Gas/Liquid Entrapment On Drag Reduction, Haosen Tan

Mechanical Engineering Research Theses and Dissertations

Economic globalization has made today’s world more closely linked, where transportation (e.g. shipping, pipeline) has played an important role. Approximately over 60% (in air), 80% (underwater), and 100% (in pipeline) propulsive power is used to overcome surface drag, so reducing surface drag will have a substantial impact economically and environmentally.

To develop a surface that has lower drag, the intuitive idea is to convert no-slip boundary conditions to slip or partial slip ones. To achieve that, the most promising approach is to replace the solid-liquid boundaries completely or partially with gas-liquid or liquid-liquid boundaries, because the shear stress is much …

Center For Manufacturing Excellence Capstone Project: Sec Rivals Checkers, Ward Winstead

Honors Theses

Each year, the seniors in the Haley Barbour Center for Manufacturing Excellence complete a capstone project. A team comprised of seniors in varying disciplines work to develop a business model focused on producing a specific product. This team, SEC Rivals Checkers, chose to produce wooden checker boards where each half of a board is custom to a specific SEC school. These halves were designed to be interchangeable, so a variety of different combination could be created when utilizing the product. Through initial marketing analysis, cost estimation, prototyping, and process development, the original SEC Rivals Checkers idea was developed into a …

Customized Sidearm Case: Leading A Cme Capstone Team From Concept To Production, Robert B. Sharp

Honors Theses

The goal behind this thesis is to document and analyze my performance as the project manager for the Customized Sidearm Case capstone team during the Center for Manufacturing Excellence’s senior capstone experience. The capstone experience begins the fall of students senior year where a select number of product ideas submitted by the students are chosen, and teams are built around these projects. The objective of the project is to walk a product from the concept phase through the entire design process resulting in a full-scale production run during the spring semester. My product pitch of a wooden sidearm case, customized …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …

Ambient Temperature Phase Change Launcher, Johnny Molloy

Senior Honors Projects

JOHNNY MOLLOY (Mechanical Engineering) Ambient Temperature Phase Change Launcher Sponsor: Bahram Nassersharif (Mechanical Engineering)

Deployment of payloads stored in watertight cylindrical bodies in underwater environmental conditions are of interest to the marine and naval community. The proposed work will investigate the possibility of using inert carbon dioxide gas compressed into its liquid state and stored under pressure to launch payloads by means of expansion from a cylindrical tube. To suit the needs of the Naval Undersea Warfare Center (NUWC), this launching system must fire from up to 14 ft underwater, have two degrees of freedom, and the payload must not …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

LSU New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Properties Of 25cr7ni Stainless Steel Fabricated Through Laser-Powder Bed Fusion., Arulselvan Arumugham Akilan

Electronic Theses and Dissertations

Stainless steel is a low carbon high alloyed system with higher concentrations of Cr& Ni, which impart high corrosion resistance to them. Alloys with approximately 25% Cr & 7% Ni in their chemical composition are commercially referred to as ‘Super Duplex Stainless Steel’. They have a unique phase composition of approximately 50% ferrite & 50% austenite, yielding a robust combination of high mechanical strength & corrosion resistance. They find extensive interest & application in the fields which demand a longer service life under intense mechanical / corrosive environment such as offshore oil rigs & pipelines in nuclear power plants. Traditional …

Autonomous Material Refill For Swarm 3d Printing, William C. Jones

Mechanical Engineering Undergraduate Honors Theses

3D printing currently offers robust and cheap rapid prototyping solutions. While standard 3D printing remains at the periphery of mass production, the technology serves as a starting point for the development of swarm manufacturing. Since swarm manufacturing is predicated upon autonomy, swarm technology companies such as AMBOTS are seeking to minimize human involvement in the swarm’s functions. At present, the 3D printing swarm consists of the printers, a transporter which can take them between job sites, and the floor tiles which provide power and support the build surfaces. To add to this ecosystem, this project is focused on the design …

Multistage Modeling Of Fatigue Of Ti-6al-4v Fabricated By Different Additive Manufacturing Techniques, Lionardo Lado, Saeed Ataollahi, Mohammad J. Mahtabi

Honors Theses

Thanks to its high strength-to-weight ratio and corrosion resistance, Ti-6Al-4V has gained a lot of attention in additive manufacturing (AM) of complex parts with aerospace and medical applications. The realistic loading condition in these applications is mostly cyclic. However, the main challenge with AM of this alloy - and in general AM of metallic parts - is fatigue resistance and durability of the part, which has been reported to be much lower than the conventional materials. In this study, fatigue life performance of three additive manufacturing methods was compared using the Multistage Fatigue model (MSF). MSF model predicts the fatigue …

Triggering Thermal Runaway In Lithium-Ion Batteries, Chris John

Honors Scholar Theses

The proliferation of lithium-ion batteries enables electric devices such as cell phones to electric vehicles to become a reality. A latent danger, however, exists in these batteries. Mechanical, thermal, or electrical damage can initiate a phenomenon known as thermal runaway (TR). This damage causes internal short circuits within the battery, releasing heat and triggering exothermic decomposition reactions. The battery will catch fire if rapid cooling is not present. While experimental designs exist for evaluating TR, significant safety hazards and impracticality may impede testing efforts. Finite element analysis, therefore, becomes a vital tool in modeling TR and mitigation techniques. However, there …

Machine Learning Tools In The Predictive Analysis Of Ercot Load Demand Data, Md Riyad Hossain

Theses and Dissertations

The electric load industry has seen a significant transformation over the last few decades, culminating in the establishment and implementation of electricity markets. This transition separates electric generation services into a distinct, more competitive sector of the industry, allowing for the introduction of greater unpredictability into the system. Forecasting power system load has developed into a core research area in power and energy demand engineering in order to maintain a constant balance between electricity supply and demand. The purpose of this thesis dissertation is to reduce power system uncertainty by improving forecasting accuracy through the use of sophisticated machine …

Monitoring Of Tool Wear And Surface Roughness Using Anfis Method During Cnc Turning Of Cfrp Composite, Md Mofakkirul Islam

Theses and Dissertations

Carbon fiber-reinforced plastic (CFRP) is gaining wide acceptance in areas including sports, aerospace and automobile industry . Because of its superior mechanical qualities and lower weight than metals, it needs effective and efficient machining methods. In this study, the relationship between the cutting parameters (Speed, Feed, Depth of Cut) and response parameters (Vibration, Surface Finish, Cutting Force and Tool Wear) are investigated for CFRP composite. For machining of CFRP, CNC turning operation with coated carbide tool is used. An ANFIS model with two MISO system has been developed to predict the tool wear and surface finish. Speed, feed, depth of …

The Grate Solution: Simplifying Viking Oven Packaging Processes, Megan Jansen

Honors Theses

The following report details work completed to improve the Viking Oven Corporation’s gas oven assembly line. The current state of the line hosts an unreliable system for packaging oven grates. Viking manufactures two types of gas ovens on the same line: open burner and closed burner. These different types require different prepackaged grates to be included in the final assembly area. Viking estimates that the wrong grates are sent to the customer ten percent of the time. The following report presents research, brainstorming, problem-solving techniques, and proposed solutions to the problem. The proposed solution would solve the problem at little …

Characterization Of Friction Element Welding Using Finite Element Modeling, Ankit Varma

All Dissertations

Friction element welding (FEW) has been advocated as a solution to weld different materials together, with the ability to join high-strength materials for a range of thicknesses with low input energy and a short processing time. This work develops a coupled thermal-mechanical finite element model to better understand the physical mechanisms involved in the process and to predict temperature and material flow during the process. Furthermore, microstructural analysis is performed for the steel layer using a scanning electron microscope and Vickers microhardness tester to understand the variation in its grain structure and hardness. Results from the finite element model and …

An Experimental Analysis Of Thin Sheet Metal Bending By Ultrafast Laser Peen Forming, Bryce J. Tessmann

All Theses

This study demonstrates the viability of femtosecond laser peen forming for bidirectional sheet metal bending. Ultrafast laser forming is a valuable method thanks to its flexibility, negation of springback, no need for a confining or protective layer, and minimalization of thermal degradation in comparison to other forming processes. However, femtosecond lasers have traditionally been believed to be unsuitable for laser forming in comparison to nanosecond lasers, particularly bidirectional bending, because the induced shock waves were expected to be weak. Conversely, in this study it is elucidated that the femtosecond laser-induced shock waves are extremely strong (several hundred GPa) but the …

Examining The Different Snap-Through Characteristics Of Bistable Cfrp Composite Laminates, Vishrut Deshpande

All Theses

Bistable carbon fiber composites, whose bistability arises from having asymmetric fiber layouts in different layers, have shown immense potential for use in shape morphing and adaptive structure applications. While many studies in this field focus on these composite laminates’ external shapes at the two stable states, their snap-through behavior of shifting from one stable shape to the other remains a critical aspect to be investigated in complete detail. Moreover, symmetric loading conditions have been extensively studied based on the classical lamination theory, but the asymmetric loading conditions received far less attention. Therefore, this study examines an asymmetric, localized point load …

Understanding Processing And Mechanics Of Extrusion-Based Additive Manufacturing For Multi-Material Parts, Jafar N/A Ghorbani

Mechanical Engineering ETDs

Despite the design freedom that additive manufacturing (AM) processes provide, there are still challenges in using some AM processes for end-use products. Fused filament fabrication (FFF), also known as material extrusion, is one of the AM technologies that has been used mainly for prototyping due to the low cost of machines, raw material, and ease of operation. Another advantage of FFF is its ease of integration with other additive or subtractive technologies. However, some disadvantages such as relatively poor and anisotropic mechanical properties have hindered FFF for end-use engineering components. The first chapter of this dissertation is a brief review …

Application Of Phased Array Eddy Current (Paec) Nondestructive Technology For Stress Corrosion Cracking (Scc), Cameron A. Jones

GS4 Student Scholars Symposium

Stress Corrosion Cracking (SCC) is the constant growth of a crack or fault due to the tensile and corrosive stresses in a given environment. These cracks can potentially progress to sudden and catastrophic failures in metals exposed to tensile stress and corrosive environment. The over-whelming cost and damage caused by Stress Corrosion Cracking (SCC) is an immense amount of cost in many industries considering that SCC happens to produce a spontaneous failure due to overload stress. The topic of stress corrosion cracking has drastically changed the movement and progression of the production of better-quality products and engineering design such as, …

Carbon Nanotori Reinforced Lubricants In Plastic Deformation Processes, Jaime Taha-Tijerina, Juan Manuel Martinez, Daniel Euresti, Patsy Yessenia Arquieta-Guillen

Manufacturing & Industrial Engineering Faculty Publications

This research presents the effects of carbon nanotori structures (CNst) dispersed as reinforcement for metal-working and metal-forming lubricants. Synthetic (SL) and deep drawing (DD) nanolubricants were prepared following a two-step method at 0.01 wt.%, 0.05 wt.%, and 0.10 wt.% filler fractions. Slight increases in viscosity (oz) increased by 16% and 22% at merely 0.01 wt.% CNst reinforcement and up to 73% and 107% at 0.10 wt.% filler fraction for SL and DD nanolubricants, respectively, compared to conventional materials. Additionally, at 0.10 wt.% wear scar evaluations showed a highest benefit of 16% and 24%, for SL and DD nanolubricants, respectively. This …

Digital Transformation: Implementing 3d Printing Activities Into Core Business Classes, Shota Yasuda, Rohit Gibson, Will Smith, Beau Wilkins, Blair Dilbeck, Jamari Baker

Symposium of Student Scholars

The business college’s new 3D lab, launched in August 2021, has been providing 3D design and 3D printing workshops for core business classes, specifically IS 2200 and IS 3100, to allow students to experiment with additive manufacturing, more commonly known as 3D printing. In the age of digital transformation, it is more important than ever that business school graduates are exposed to these emerging technologies, learn from experimentation, and develop a foundational understanding of these technologies so that they are better prepared to innovate and lead once they have graduated.

The idea of the 3D printing workshops is that a …

Effects Of Varied Oxygen Levels, Laser Powers, And Scanning Speeds On Manufactured Components By Laser-Based Powder Bed Fusion, Amelia Mcnamee

Honors College Theses

This project addresses the effects of oxygen concentration, laser power, and scanning speed on the melt pool geometry of laser-based powder bed fusion (L-PBF) additively manufactured components. A parametric analysis using the substrate alone was conducted to determine a range of desirable laser powers and scanning speeds. The parameter with the more significant effect will be decided upon based on the depth-to-width ratios (D/W) of the resultant laser weld bead. A range of oxygen levels and scan speeds was selected for the next phase. These samples were then be analyzed for depth-to-width ratios. It was expected that higher oxygen concentrations …

A Low-Cost And Low-Tech Solution To Test For Variations Between Multiple Offline Programming Software Packages., Steffen Wendell Bolz

Masters Theses & Specialist Projects

This research paper chronicles the attempt to bring forth a low-cost and low-tech testing methodology whereby multiple offline programming (OLP) software packages’ generated programs may be compared when run on industrial robots. This research was initiated by the discovery that no real research exists to test between iterations of OLP software packages and that most research for positional accuracy and/or repeatability on industrial robots is expensive and technologically intensive. Despite this, many countries’ leaders are pushing for intensive digitalization of manufacturing and Small and Mediumsized Enterprises (SMEs) are noted to be lagging in adoption of such technologies. The research consisted …

Evaluation Of Microstructural And Mechanical Behavior Of Ahss Cp780 Steel Welded By Gmaw-Pulsed And Gmaw-Pulsed-Brazing Processes, Alan Jadir Romero-Orozco, Jaime Taha-Tijerina, Rene De Luna-Alanis, Victor Hugo Lopez-Morelos, Maria Del Carmen Ramirez, Melchor Salazar-Martinez, Francisco Fernando Curiel-Lopez

Manufacturing & Industrial Engineering Faculty Publications

Joints of complex phase 780 (CP-780) advanced high strength steel (AHSS) were carried out by using an ER-CuAl-A2 filler metal for the gas metal arc welding pulsed brazing (GMAW-P- brazing) process and the ER-80S-D2 for the GMAW-P process employing two levels of heat input. The phases in the weld bead and HAZ were analyzed, and the evaporation of zinc by means of scanning electron microscopy (SEM) was also monitored. The mechanical properties of the welded joints were evaluated by tension, microhardness and vertical impact tests. It was found that there was greater surface Zn evaporation in the joints welded with …

A Deep Learning-Based Approach To Extraction Of Filler Morphology In Sem Images With The Application Of Automated Quality Inspection, Md. Fashiar Rahman, Tzu-Liang Bill Tseng, Jianguo Wu, Yuxin Wen, Yirong Lin

Engineering Faculty Articles and Research

Automatic extraction of filler morphology (size, orientation, and spatial distribution) in Scanning Electron Microscopic (SEM) images is essential in many applications such as automatic quality inspection in composite manufacturing. Extraction of filler morphology greatly depends on accurate segmentation of fillers (fibers and particles), which is a challenging task due to the overlap of fibers and particles and their obscure presence in SEM images. Convolution Neural Networks (CNNs) have been shown to be very effective at object recognition in digital images. This paper proposes an automatic filler detection system in SEM images, utilizing a Mask Region-based CNN architecture. The proposed system …

Utilization Of Resin-Based Additive Manufacturing For Investment Casting, Matthew Frost, Isaiah Hong

Mechanical Engineering

Dr. Xuan Wang, an Industrial & Manufacturing Engineering (IME) professor at California Polytechnic State University, San Luis Obispo, has sponsored the resin-based 3D printing investment cast senior project. The objective of the project was to thoroughly research the process and document the findings of using a resin-based 3D printed part as the pattern for investment casting. While this manufacturing process is not necessarily a new idea, the lack of technical research and documentation limits its ability to be reproducible. The research portion of the senior project included analyzing the limitations to the printing/casting manufacturing process. Measurements of part thicknesses, hole …

Effects Of A Nitrogen And Hydrogen Build Atmosphere On The Properties Of Additively Manufactured Tungsten, Dana C. Madsen

Theses and Dissertations

Additively manufactured tungsten was printed in pure nitrogen, nitrogen-2.5% hydrogen, and nitrogen-5% hydrogen atmospheres as part of a 2^3 full factorial designed experiment and subjected to room temperature and high-temperature three-point-bend testing, chemical analysis, hardness testing, and microstructural imaging techniques. The pure nitrogen specimens exhibited the highest strength and ductility at both high temperature and room temperature. Chemical analysis showed a 2-8x reduction in compositional oxygen relative to unprocessed powder. Hardness values for all samples was between 306.8 and 361.5 HV1. It is proposed that adding hydrogen into the build atmosphere reduced the available energy density for tungsten melting by …

Investigation Of Additively Manufactured Molybdenum-Tungsten-Rhenium Alloys, Randolph T. Abaya

Theses and Dissertations

The process of creating metal components through additive manufacturing is changing the way different industries can avoid the shortcomings of traditional metal production. Metals such as tungsten, molybdenum, and rhenium have many advantages for different applications, especially when alloyed together. In this study, an additively manufactured alloy containing 70% molybdenum, 25% tungsten, and 5% rhenium (70Mo-25W-5Re) is tested for its strength, ductility, hardness, and porosity. The 70Mo-25W-5Re alloy is printed through Laser Powder Bed Fusion (LPBF) under different conditions such as printing speed and printing atmosphere. Additionally, the effects of post printing heat treatment are conducted to understand the advantages …

Computational Based Investigation Of Lattice Cell Optimization Under Uniaxial Compression Load, Derek G. Spear, Jeremiah S. Lane, Anthony N. Palazotto, Ryan A. Kemnitz

Faculty Publications

Structural optimization is a methodology used to generate novel structures within a design space by finding a maximum or minimum point within a set of constraints. Topology optimization, as a subset of structural optimization, is often used as a means for light-weighting a structure while maintaining mechanical performance. This article presents the mathematical basis for topology optimization, focused primarily on the Bi-directional Evolutionary Structural Optimization (BESO) and Solid Isotropic Material with Penalization (SIMP) methodologies, then applying the SIMP methodology to a case study of additively manufactured lattice cells. Three lattice designs were used: the Diamond, I-WP, and Primitive cells. These …

Comparative Study Of Decision Tree Models For Bearing Fault Detection And Classification, Armin Moghadam, Fatemeh Davoudi Kakhki

Faculty Research, Scholarly, and Creative Activity

Fault diagnosis of bearings is essential in reducing failures and improving functionality and reliability of rotating machines. As vibration signals are non-linear and non-stationary, extracting features for dimension reduction and efficient fault detection is challenging. This study aims at evaluating performance of decision tree-based machine learning models in detection and classification of bearing fault data. A machine learning approach combining the tree-based classifiers with de-rived statistical features is proposed for localized fault classification. Statistical features are extracted from normal and faulty vibration signals though time do-main analysis to develop tree-based models of AdaBoost (AD), classification and regression trees (CART), LogitBoost …