The Design, Testing, And Manufacturing Of A Pin Fin Extrusion Heat Sink, Arash Michael Mira

Industrial and Manufacturing Engineering

My senior project focuses on the design, testing, and manufacturing of pin fin extrusion heat sinks that are you used to cool simple electronic applications across a multitude of markets. Without the modern day heat sink, electronics that we have become familiar with throughout our everyday lives will cease to exist. I will design these heat sinks using Solid Works 3D CAD. I will then test the heat sinks using ICEPAK CFD software, where I will model the heat sink against a 5 watt application, inside of a cabinet that models the chassis of a computer. After receiving these results, …

Evaluation And Design Of Potting Production Process Improvements For The Non-Profit Organization, Growing Grounds Farm, Maiya Avalon Bourland, Precilla Tang

Industrial and Manufacturing Engineering

This report focuses on the potting production process for the non-profit organization (NPO) Growing Grounds Farm (GGF), and aims to promote a standardized workflow system to enhance the working experience for Transitions‐Mental Health Association employees and volunteers. This project takes careful consideration into the process improvements proposed so to support the double bottom line of economic and social objectives. To address the equally important objectives, the Human Centered Design toolkit created by IDEO, specifically for third sector organizations, was integrated with the traditional Industrial Engineering design process methodology. Feasible alternatives were developed and evaluated based on the objectives. The selected …

Design Of An Automated Employee Scheduling System, Matthew Cameron, Yuriy Goldman

Industrial and Manufacturing Engineering

Many retail stores, as well as other organizations that employ a multitude of part-time employees, rely on developing schedules frequently, since the availabilities of the employees as well as the needs of the business change often. This process is often performed on a weekly basis, and is complex and time-consuming. The schedule must typically satisfy numerous requirements, including business needs, legal restrictions, and employee availability constraints. As a result, errors are common, and employee time that could have been spent on improving sales or operations is instead consumed by the scheduling task.

This project explores two solution methods for this …

Atk's Radial Airframe Forming Process Assessment, Andres Martinez

Industrial and Manufacturing Engineering

The purpose of this project was to provide ATK with a solution to increase efficiency in the R-02 radial forming center so that it could meet the increase in demand projected for the next 5 years. In addition, give ATK projected dates of when new machines would need to be implemented to be able to keep up with the demand. The system was analyzed through time studies to identify areas of possible improvement and eliminate any non-value added activities. Cycle times of each activity were used to simulate the current state of the system using ProModel software. Changes in operations …

Restaurant Design: An Industrial Engineering Perspective, Joseph Travis Spanu

Industrial and Manufacturing Engineering

The objective of this paper is to design a health food restaurant using current industrial engineering tools and practices. This includes creating a menu, determining the average gross profit per customer, determining the location, designing a 3-d layout, simulating service, and analyzing local food supply chains. Using a simplified menu and pricing quotes from a food distributor, the average gross profit per customer is estimated to be $3.50. Location is determined by comparing the predicted number of customers and the cost to rent at two different areas. A downtown location is determined to gross approximately $5,200 per month over a …

Women's High Heel Discomfort Analysis And Prototype Solution, Kevin Blakley, Annamarie Kepple

Industrial and Manufacturing Engineering

ABSTRACT

WOMEN’S HIGH HEEL DISCOMFORT ANALYSIS AND SOLUTION

Kevin Blakley and Annamarie Kepple

Women love high heeled shoes, but this love comes at the cost of comfort. Wearing high heels causes a lot of pain and, in the long term, health complications. This project tries to overcome the problem by ultimately making high heels more comfortable. In order to do this, one must first understand the reasons that high heels are uncomfortable, such as arch angle, heel height, and the changes in walking motion. Once there is a true understanding of the factors that contribute to high heel discomfort, the …

Design And Optimization Of A Keycard Encoding Machine, Elliott Oberg

Biomedical Engineering

Security on college campuses is a good thing, especially when it comes to your dorm room or apartment building. But due to high initial cost, the Housing and Business Department at Cal Poly, San Luis Obispo, has opted for a proprietary door lock system which requires encoding new keycards manually for every resident, every year. The goal of this project is to offset this labor cost and drain on resources by automating the keycard encoding process. This project will address the design specifications and economic advantages of automation while also exploring and comparing alternative solutions.

Material Characterization And The Effects Of Moisture And Drying On Injection Molded Torlon 5030, Michael R. Di Re

Master's Theses

The effects of water absorption and drying were studied on injection molded Torlon 5030, a high performance thermoplastic fabricated by Solvay Specialty Polymers. Torlon 5030 contains 30% by weight glass fibers in a polyamide-imide base resin. The objective behind this work was to test and better define relevant properties for industrial applications using this material. While the material design guide offers information on many mechanical properties including tensile, fatigue, and creep data; there is little to no publicly published data on the effects of water absorption and any subsequent drying of Torlon 5030. Blistering was also studied. With exposure to …

Effect Of Process Parameters On The Weld Quality In Laser Welding Of Az31b Magnesium Alloy In Lap Joint Configuration, Masoud Harooni, Blair Carlson, Radovan Kovacevic

Mechanical Engineering Research

Magnesium is the lightest structural metal; therefore it has been used in a variety of industries such as automotive, aerospace, electronics and defense. Among different joining processes, laser welding is advantageous due to its low heat input, high depth-to-width weld ratio and good mechanical properties. In this study, a fiber laser is used to weld AZ31B magnesium alloy in a lap joint configuration. Pores were formed in the weld bead that are caused by a thick oxide layer existing on the surface of as-received AZ31B samples. Process parameters including laser power and welding speed are studied to determine their effects …

Supplier Sustainability Evaluation Utilizing Multi Attribute Utility Modeling, Scott E. Ladd

Theses and Dissertations--Manufacturing Systems Engineering

Conventionally, the focus during supplier evaluation has been to assess cost, quality and delivery effectiveness due to their impact on profitability. In recent years, there has been increased emphasis on promoting more sustainable business practices that focus on reducing environmental impact and improve societal well-being, in addition to economic benefits. However, most of the existing supplier evaluation methods in literature as well as those used by leading companies fall short of comprehensively assessing suppliers from a Triple Bottom Line (TBL) perspective. TBL defined as holistically looking at the economic, environmental, and societal aspects of an entity. This paper presents a …

An Observational Study Of The Methods And Progress In Enterprise Lean Transformation At A Learning Health Care Organization, Christopher Michael Rosenbaum

Theses and Dissertations--Manufacturing Systems Engineering

The health care industry in the United States is increasingly pressured to improve safety and quality performance and increase revenue. In response, many health care institutions are moving to redesign their processes and practices in an effort to decrease costs and provide safer, higher quality, and more efficient care. The purpose of this paper is to document the Lean implementation strategy and progress in implementation at a large teaching health care organization undergoing Lean transformation in order to understand enterprise transformation strategies and the impact of leadership involvement on culture development and Lean implementation. Through direct observations and involvement and …

Paste Development And Co-Sintering Test Of Zirconium Carbide And Tungsten In Freeze-Form Extrusion Fabrication, Ang Li

Masters Theses

"Ultra-high temperature ceramics are being investigated for future use in aerospace applications due to their superior thermo-mechanical properties, as well as oxidation resistance, at temperatures above 2000°C. However, their brittle properties make them susceptible to thermal shock failure. Components fabricated as functionally graded materials (FGMs) can combine the superior properties of ceramics with the toughness of an underlying refractory metal by fabricating graded composites. This paper discusses the grading of two materials through the use of a Freeze-form Extrusion Fabrication (FEF) system to build FGMs parts consisting of zirconium carbide (ZrC) and tungsten (W). Aqueous-based colloidal suspensions of ZrC and …

Development Of A New Temporary Fastener For Aerospace Automation, Xiangwen Zhang

Masters Theses

"Temporary fasteners are required in aircraft assembly, especially in the assembly of wings, fuselage, and aircraft skin's substructure prior to drilling holes for permanent fasteners by automated drilling machines. The objective was to develop a temporary fastener that can be installed, clamped, loosened, and removed from one side with a short head length. Published papers, web pages and patents relating to temporary fasteners were reviewed. Then by considering the ability to meet the operation requirements and concerns, a temporary fastener was designed with the following advantages:

• a simple structure that can be easily fabricated
• a short head length to save …

Development Of A Postprocessor For A Multi-Axis Cnc Milling Center, Mihir Satish Adivarekar

Masters Theses

"Most of the current college design and manufacturing curricula are primarily focused on computer aided design (CAD), while less emphasis is given to computer aided manufacturing (CAM). A great opportunity has been missed as the benefits of CAD/CAM cannot then be fully learned. Postprocessor plays a vital role in integration of CAD//CAM with computer numerically controlled (CNC) machines. Hence, postprocessor must be developed accurately. This thesis is composed of one paper. Paper I proposes a novel methodology to determine compensation vectors for the post processor of multi-axis milling center. The new approach that has been implemented in Paper I involves …

Kinetics Of Wedge-Tee Joint Formation During Brazing Of An Aluminum Alloy Under Controlled Atmosphere, Fangxiao Dong

Theses and Dissertations--Mechanical and Aerospace Engineering

This work involves investigation of the kinetics data of a joint formation during aluminum alloy brazing. Data was generated by several groups of experiments conducted under conditions of a controlled oxygen level of the background brazing atmosphere. Generated data are examined to identify the phases of the joint formation and the time frame of its evolution. Specifically, the triple line kinetics data are analyzed to verify whether a power law between (1) the triple line of the molten metal preceding joint formation and (2) the formation time can be established for each formation phase. In addition, both initial and residual …

Experimental Investigation To Inform Optimal Configurations For Dynamic Near-Field Passive Uhf Rfid Systems, Donnie E. Proffitt Ii

Theses and Dissertations--Mechanical and Aerospace Engineering

RFID has been characterized as a “disruptive technology” that has the potential to revolutionize numerous key sectors. A key advantage of passive RFID applications is the ability to wirelessly transmit automatic identification and related information using very little power. This paper presents an experimental investigation to inform the optimal configuration for programming passive ultra-high frequency (UHF) RFID media in dynamic applications. Dynamic programming solutions must be designed around the tag’s functionality, the physical programming configuration and environment. In this investigation, we present a methodology to determine an optimal configuration to maximize the systems programming efficiency for dynamic applications.

Process-Induced Surface Integrity In Machining Of Niti Shape Memory Alloys, Yusuf Kaynak

Theses and Dissertations--Mechanical and Aerospace Engineering

NiTi alloys have been the focus of Shape Memory Alloys (SMA) research and applications due their excellent ductility and shape memory properties, and these alloys have been extensively used in automotive, aerospace, and in biomedical applications.

The effects of machining on the surface integrity and the corresponding material and mechanical properties of alloys can be best studied by utilizing NiTi alloys as workpiece material since their physical and mechanical properties are highly microstructure dependent. However, due to very poor machining performance of NiTi shape memory alloys, no comprehensive or systematic investigation on this topic has been conducted by researchers as …

Parameter Optimization For Controlling Aluminum Loss When Laser Depositing Ti-6al-4v, Richard Charles Barclay

Masters Theses

"The ability to predict the mechanical properties of engineering materials is crucial to the manufacturing of advanced products. In the aerospace industry, Ti-6Al-4V is commonly used to build structures. Any deviation from the alloy's standard properties can prove detrimental. Thus, the compositional integrity of the material must be controlled. The ability to directly build and repair large, complicated structures directly from CAD files is highly sought after. Laser Metal Deposition (LMD) technology has the potential to deliver that ability. Before this process can gain widespread acceptance, however, a set of process parameters must be established that yield finished parts of …

Part Height Control Of Laser Metal Additive Manufacturing Process, Yu-Herng Pan

Masters Theses

"Laser Metal Deposition (LMD) has been used to not only make but also repair damaged parts in a layer-by-layer fashion. Parts made in this manner may produce less waste than those made through conventional machining processes. However, a common issue of LMD involves controlling the deposition's layer thickness. Accuracy is important, and as it increases, both the time required to produce the part and the material wasted during the material removal process (e.g., milling, lathe) decrease. The deposition rate is affected by multiple parameters, such as the powder feed rate, laser input power, axis feed rate, material type, and part …

Web-Based Virtual Learning For Digital Manufacturing Fundamentals For Automotive Workforce Training, Vukica Jovanovic, Nathan W. Hartman

Engineering Technology Faculty Publications

Automotive manufacturers are experiencing difficulties in hiring highly qualified workers with ability to adopt new technologies fast. This kind of ongoing need for training is slowing innovation. This problem is related to the difficulty in obtaining consistent training resources and services especially with lack of training for advanced manufacturing practices for specialised industry sectors. More and more occupations require degrees higher than secondary education because of the global need for so called ‘knowledge workers’. An example of an interactive learning programme, developed with the support of narrated presentation technology, podcasts and online access has been shown in this paper. Sixty …

Production Of A Banjo: Development Of Manufacturing Processes For Banjo Resonators,Rims, And Necks., Kevin N. Zollinger

Undergraduate Honors Theses

This body of research focused on the development of prototype tooling and manufacturing processes to produce resonators, rims, and necks for building banjos. The resulting fixtures and manufacturing processes were designed for ease of use by a single employee in a small shop environment. This research required proficiency in interdisciplinary mediums (ie. 2D modeling, 3D modeling, centerline tool path program generation, 2D modeling, 3D modeling, rendering, design, and woodworking).

The resonator required development of a matching set of forming surfaces, a bending/gluing fixture, a work-holding fixture for utilizing a wood lathe, and a steam chamber required for bending strips of …

Best Practices Using Building Information Modeling In Commercial Construction, Simon Beveridge

Theses and Dissertations

There has been an increase in adoption of building information modeling (BIM) by commercial contractors over the past few years but there is not a clear indication of current application or the frequency of each use. This research was undertaken to determine the frequency and best practices of using BIM in commercial construction. Leading commercial contracting firms were contacted and employees were selected to complete a telephone survey that was designed to determine how they are using BIM. It was found that BIM is being used with more frequency on projects, with plans to continue to implement it even further …

Strider: Manufacturing Processes, Michael Warren-Angelucci

Industrial and Manufacturing Engineering

The goal of the Strider Project is to create a mobility device that can support a person with weakened leg strength and enable them to be supported and maintain a standing position. A prototype of the Strider was created by three Mechanical Engineering students as their senior project. The topic of this senior project was to analyze and create a manufacturing process for the manufacture of the Strider that will be ergonomic and cost effective.

There were many things that needed to be accomplished in order to create the manufacturing process. The first step was to verify that the prototype …

Solar Turbines Creep Test Fixture, Rene Maciel, Eric Nelson, Chris Ewald

Mechanical Engineering

No abstract provided.

Sustainability For Die Manufacturing: Comparative Study Of Wedm And Milling, Matthew S. Kalus

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

Sustainability is more important in today's culture due to the increasing demand for a more eco-friendly society. Concentrations in minimizing and reducing environmental impacts, energy and natural resources have been forthcoming in industry. The tool, mold and die industries are the most well known industries that machine harder materials using mills and WEDM. The objective of this thesis was to compare the sustainability differences in both of these machines utilizing the accepted standards for evaluating the manufacturing process performance for sustainability. These standards include the evaluation of the process parameters, raw materials, power, tools and fluids which all contribute to …

Handitrike - Recumbent Tricycle, Sean Higginson, Kevin Howie, Vinay Patel

Mechanical Engineering

This report covers the design and construction of the recumbent racing tricycle for Mr. Robert T. Kelly, a disabled veteran. Unfortunately Rob’s right leg is five inches shorter than his left one and therefore is unable to properly operate standard cranks. Our team HandiTrike is composed of Sean Higginson, Kevin Howie, and Vinay Patel and our project requires us to come up with a design that is feasible to complete within the given three quarters, as well as allow Rob to gain full use of his tricycle. Currently Rob ‘s trike uses the standard crank set up found on most …

Formula Sae Turbocharger Engine Development, Eric Griess, Kevin Mccutcheon, Matthew Roberts, William Chan

Mechanical Engineering

This project, Formula SAE Turbocharger System Development, was sponsored by the Cal Poly, San Luis Obispo Formula SAE team. The team proposed this project in order to have a powerful yet lightweight engine so they can be extremely competitive at their competition. The baseline output of the single cylinder 450cc engine (2006 Yamaha WR450F) was 46 horsepower and 27 ft-lb of torque. The goal of this project was to increase the output of that engine to 60 horsepower and 35 ft-lb through the use of a turbocharger.

Process Improvements For Establishing Cmmi Certification At Company Xyz, Megan Farrell

Industrial and Manufacturing Engineering

CMMI stands for Capability Maturity Model Integration and is an enterprise-wide Process-Improvement model that provides a set of best practices that addresses productivity, performance, costs, and stakeholder satisfaction. This improvement model is generally used in computer software companied and not only does it improve their processes, but many contracts will only be awarded with those companies who are CMMI certified, so it is very important for Company XYZ. This goal of this project was to help improve the CMMI efforts at Company XYZ in 4 of the 20 distinct processes areas to attain a CMMI Maturity Level of 3. Improvement …

Design And Manufacture Of Natural Composite Canoe, Derek Baptista

Industrial and Manufacturing Engineering

Abstract

This report looks into the application and feasibility of manufacturing natural composite canoes. The main fabrics that were analyzed are flax, hemp, and jute. These were then compared to carbon fiber and fiberglass to see the difference in mechanical properties. It was found that the natural fibers have lower mechanical properties but that this could be overcome by designing a balsa wood core with ribs running up the walls. After manufacturing a hemp canoe, many lesson were learned and areas of interest were further explored. With the use of different natural fibers, these canoes can greatly reduce the carbon …

Chsr Clothing: How To Start A Small Business Clothing Line To Be Run Efficiently With Minimum Capital And Maximum Profit, Kayvon Banisalam

Industrial and Manufacturing Engineering

Executive Summary

Many clothing brands have failed because they did not design marketable products with a suitable business plan. Often times, clothing brand owners do not use the capital they possess in efficient ways. They can get caught off guard with unexpected costs and are not running the business in the most resourceful and professional way.

The goal of this project is to create a clothing brand that portrays distinctive designs to go along with an effective business model. This includes implementing decision analysis at several points of the planning phase, along with quality and cost controls. Creating quality products …