Manufacturing Commons^™

Cam And Design For Manufacturing: Developing A Project-Based Learning Course, Stephen Pierson

Mechanical Engineering Undergraduate Honors Theses

To effectively serve student career success, mechanical engineering programs must teach students how to account for manufacturing considerations in design. Despite this, manufacturing education is a glaring area of need in current engineering curricula. In fact, basic manufacturing knowledge is one of the only hard skills consistently ranked as one of the greatest weaknesses of mechanical engineering hires in surveys of industrial employers over the last few decades. Without radically changing departmental curriculum to include more emphasis on design-build projects, one solution to combat this is to incubate a lab course in mechanical engineering programs in which undergraduates would practice …

Effects Of Machining Parameters Of C45 Steel Applying Vegetable Lubricant With Minimum Quantity Cooling Lubrication (Mqcl), Mayur A. Makhesana, Prashant J. Bagga, Kaushik M. Patel, Jaime Taha-Tijerina

Informatics and Engineering Systems Faculty Publications and Presentations

One of the most significant performance indicators for measuring the machinability of materials is tool wear and surface roughness. Choosing the best combination of cutting parameters can help reduce production costs, which is what the manufacturing industry is interested in. At the same time, industries are always looking for an alternative to conventional flood cooling since its use creates an environmental burden and health concerns for the operators. Therefore, vegetable oil-based minimum quantity cooling lubrication (MQCL) is considered a cutting environment. Sunflower oil is utilized as base fluid in MQCL and applied to the cutting zone through a nozzle. The …

Path Planning For Additive Manufacturing Of Wire Arc Additive Manufacturing And Blue Light Fringe Projection Scanning, Tiffany Patricia Quigley

Masters Theses

Current methods of manufacturing large scale parts can take up to six months to generate the objective product. The objective of the wire arc additive manufacturing (WAAM) hybrid cell is to significantly reduce lead time associated with large scale parts. The WAAM process utilizes a 6 degree-of-freedom (DOF) robot manipulator in addition to a 2 DOF part positioner. 5 degrees of freedom are necessary for an effective WAAM process, leaving 3 DOF as redundant in this cell. This thesis serves to prove successful implementation of redundant kinematics on a WAAM robotic system. This is accomplished by maintaining a gravity aligned …

In-Situ Characterization Of Surface Quality In Γ-Tial Aerospace Alloy Machining, David Adeniji

Theses and Dissertations--Mechanical Engineering

The functional performance of critical aerospace components such as low-pressure turbine blades is highly dependent on both the material property and machining induced surface integrity. Many resources have been invested in developing novel metallic, ceramic, and composite materials, such as gamma-titanium aluminide (γ-TiAl), capable of improved product and process performance. However, while γ-TiAl is known for its excellent performance in high-temperature operating environments, it lacks the manufacturing science necessary to process them efficiently under manufacturing-specific thermomechanical regimes. Current finish machining efforts have resulted in poor surface integrity of the machined component with defects such as surface cracks, …

Displacement-Based Dynamometer For Milling Force Measurement, Michael F. Gomez

Doctoral Dissertations

This project will study the design and testing of a low-cost dynamometer for milling dynamic force measurement. The monolithic design is based on constrained-motion/flexure-based kinematics, where force is inferred from displacement measured using a low-cost optical interrupter (i.e., a knife edge that partially interrupts the light beam in an emitter-detector pair). The time-dependent displacement of the dynamometer’s moving platform caused by the milling force is converted to the frequency domain, multiplied by the inverse of the dynamometer’s ideally single degree of freedom (SDOF) frequency response function (FRF), and converted back into the time-domain to obtain the time-dependent cutting force. The …

Design And Fabrication Of Invar Layup Tool Molds Using Additive And Subtractive Manufacturing, Matthew Lamsey

Masters Theses

The development of novel additive manufacturing technologies, such as Wire Arc Additive Manufacturing (WAAM), has opened the door for the fabrication of complex part geometries that could not be achieved with traditional manufacturing methods. Best practices for designing parts for fabrication with WAAM are still in their infancy. This thesis presents a novel design and fabrication framework for parts created using WAAM, which was realized through the fabrication of two demonstration composite layup tool molds. The framework includes design principles for WAAM, finite element simulation of part performance, metrological analysis of printed preforms, and considerations for closely integrating the WAAM …

C6 Wheels, Samuel L. Pizot, Luke Martin, Josh Warner, Jonah Levis

Mechanical Engineering

This document details the C6 Wheels project being undertaken for senior design. The objective is to design and manufacture carbon fiber reinforced polymer wheels for the Cal Poly Formula Society of Automotive Engineers (FSAE) team. The wheel shells will be used on FSAE’s competition vehicles. FSAE requested the wheels to improve the handling characteristics of their vehicles by reducing the unsprung and rotational mass. They have attempted carbon fiber wheels previously but have not yet run any on their vehicles. FSAE specifically proposed the design of carbon fiber shells with an aluminum center as opposed to full carbon fiber wheels …

Custom Designed Wall Mounted Shop Crane, Bradley Lewis

All Undergraduate Projects

The objective of this project was to design and fabricate a custom wall mounted jib crane to specific, non-standard dimensions. The crane was designed to be industry rated for 2000 pounds, rotate at least 180 degrees, and be designed to have a maximum boom length tailored to the specific installation site. Two potential installation sites and purposes were selected for construction: inside the bay doors of a fabrication shop, intended to transfer large pieces of material to and from a plasma table, and inside a car maintenance garage, intended to lift and remove engines and transmissions from cars.

Design of …

Investigation Of Chip-Form And Tool-Wear In Turning Of Hardened Af9628 Alloy Under Various Cooling And Lubrication Conditions, Jason Wolf

Theses and Dissertations--Manufacturing Systems Engineering

Next generation defense and commercial applications for structural steels require new alloys that eliminate or reduce critical elements from their composition to lower cost and improve manufacturability, while maintaining or exceeding high strength and toughness requirements. A new alloy, denoted as AF9628, has recently been developed for this purpose and its manufacturing characteristics and the material response in component manufacturing must be fully understood.

In the present study, hardened AF9628 alloy was turned with a coated carbide cutting tool under fixed cutting speed, feed rate, and depth of cut parameters. This work focuses on chip-form and tool-wear analysis to understand, …

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 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 …

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

Mechanical Engineering

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

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

Institute for Sustainable Manufacturing Faculty Publications

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

Cwu Bottle Opener Manufacturing, Austin Sanford

All Undergraduate Projects

Previous students from the Mechanical Engineering Technology program came up with a method to help raise funds and awareness for the program. The idea was to manufacture and sell CWU bottle openers. However, a more efficient manufacturing method was needed. The aspect of the process that would have the most impact on the manufacturing time and material efficiency was the CNC machining of the parts. There were many potential variables to change to improve the process, but the main changes were to the cutter speeds and stock material size. Consequently, the changes made to stock material size reduced the number …

Multi-Axis Machining Project Development, Ryan Patrick Blodgett, Andre Peter Rivera

Industrial and Manufacturing Engineering

Multi-axis milling is a manufacturing material removal process in which computer numerically controlled (CNC) tools cut away excess material through movement in four or more axes. Compared to traditional three-axis machining, multi-axis machining greatly increases the capability and accuracy of the CNC machining processes by reducing the amount of operations required to completely machine a part. Currently, the Industrial and Manufacturing Engineering Department at Cal Poly lacks an advanced CNC class that incorporates fourth and fifth axis CNC machining in the curriculum. This report describes the process behind creating a project for such a class. The class will demonstrate the …

Multi-Use Fireline Handtool, Bruce W. Bernard Jr

All Undergraduate Projects

A wildland firefighter is a valuable resource to protecting public lands and managing fuels. The many hand tools used by firefighters aid in their ability to complete any required tasks effectively. Several of the tools available are specially purposed for individually grubbing, scraping, or liming. A small squad of firefighters could become a more effective resource if the tools they carried could perform several of these purposes as one single tool. To improve the effectiveness of an individual on the fireline a multi-use hand tool was designed to include an axe for liming and a heavy duty scraper for grubbing …

Met 314 Torque Measurement, Jose Bejar

All Undergraduate Projects

As part of the Mechanical Engineering Technology program, students are required to take a Thermodynamics class. In this class one of the labs they do consists of an air motor running a water pump. The professor teaching that class wanted a device that would fit within the lab rig which would calculate the torque produced by the motor. Therefore this project consists of building a device that will allow the case (body) of the air motor to fully rotate opposite to the rotation of the shaft in order to measure the torque the motor produces at certain revolutions per minute. …

A Simplified Model For Ploughing Forces In Turning, Daniel Waldorf

Industrial and Manufacturing Engineering

This paper aims to provide experimental data in support of a modified theoretical model for quantifying the effect of cutting tool edge geometry on machining forces. A previously published slip-line model is simplified and extended to the case of turning. Several sets of machining experiments were run with custom-fabricated cutting inserts of varying edge hone radius and chamfer geometry. Cutting forces were measured using a dynamometer during cutting. Results show that varying edge geometry can have a major effect on cutting forces. The developed model effectively captures the edge phenomenon and its effect on cutting forces and also offers a …