Manufacturing Commons^™

Direct 3d Layer Metal Deposition, Jianzhong Ruan, Lie Tang, Todd E. Sparks, Robert G. Landers, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Multi-axis slicing for solid freeform fabrication (SFF) manufacturing processes can yield non-uniform thickness layers, or 3D layers. Using the traditional parallel layer construction approach to build such a layer leads to a staircase which requires machining or other post processing to form the desired shape. This paper presents a direct 3D layer deposition approach. This approach uses an empirical model to predict the layer thickness based on experimental data. The toolpath between layers is not parallel; instead, it follows the final shape of the designed geometry and the distance between the toolpath in the adjacent layers varies at different locations. …

Direct-To-Part Machining Waste Recycling Using Laser Metal Deposition, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser metal deposition typically uses metal powders as the build material of choice. The ability to reprocess waste materials using this technology would significantly reduce the material cost and cradle-to-grave energy content of parts produced using these methods. This capability will also greatly increase the utility of laser deposition, to potential industrial uses. This paper explores the usage of machining chips as an alternate source of build material. Topics covered include material handling, material preprocessing, and comparison to powder- based deposition.

Layer-To-Layer Height Control For Laser Metal Deposition Processes, Lie Tang, Jianzhong Ruan, Todd E. Sparks, Robert G. Landers, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A Laser Metal Deposition (LMD) height controller design methodology is presented in this paper. The height controller utilizes the Particle Swarm Optimization (PSO) algorithm to estimate model parameters between layers using measured temperature and track height profiles. The process model parameters for the next layer are then predicted using Exponentially Weighted Moving Average (EWMA). Using the predicted model, the powder flow rate reference profile, which will produce the desired layer height reference, is then generated using Iterative Learning Control (ILC). The model parameter estimation capability is tested using a four-layer deposition. The results demonstrate the simulation based upon estimated process …

Microstructural Characterization Of Diode Laser Deposited Ti-6al-4v, Tian Fu, Zhiqiang Fan, Syamala R. Pulugurtha, Todd E. Sparks, Jianzhong Ruan, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Direct Metal Deposition (DMD) is an effective approach to manufacturing or repairing a range of metal components. The process is a layer-by-layer approach to building up a three dimensional solid object. The microstructure influences mechanical properties of the deposited parts. Thus, it is important to understand the microstructural features of diode laser deposited parts. This paper presents a microstructure analysis of a diode laser deposited Ti-6Al-4V onto a Ti-6Al-4V substrate. laser deposited parts. This paper presents a microstructure analysis of a diode laser deposited Ti-6Al-4V onto a Ti-6Al-4V substrate.

Product Focused Freeform Fabrication Education, Frank W. Liou, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Presented in this paper is our experience of teaching freeform fabrication to students at the Missouri University of Science and Technology, and to high school students and teachers. The emphasis of the curriculum is exposing students to rapid product development technologies with the goal of creating awareness to emerging career opportunities in CAD/CAM. Starting from solid modeling, principles of freeform fabrication, to applications of rapid prototyping and manufacturing in industry sponsored product development projects, students can learn in-depth freeform fabrication technologies. Interactive course content with hands-on experience for product development is the key towards the success of the program.

Freeform Fabrication Of Zirconium Diboride Parts Using Selective Laser Sintering, Ming-Chuan Leu, Erik B. Adamek, Tieshu Huang, Greg Hilmas, Fatih Dogan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Using the Selective Laser Sintering (SLS) process, both flexural test bars and 3D fuel injector components have been fabricated with zirconium diboride (ZrB₂) powder. Stearic acid was selected as the binder. Values of SLS process parameters were chosen such that the green parts could be built with sharp geometrical features and that the sintered parts could have good mechanical properties. After binder burnout and sintering, the SLS fabricated ZrB₂ test bars achieved 80% theoretical density, and the average flexural strength of the sintered samples was 195 MPa. These values demonstrate the feasibility of the SLS process for …

Predicting The Longevity Of Dvdr Media By Periodic Analysis Of Parity, Jitter, And Ecc Performance Parameters, Daniel Patrick Wells

Theses and Dissertations

For the last ten years, DVD-R media have played an important role in the storage of large amounts of digital data throughout the world. During this time it was assumed that the DVD-R was as long-lasting and stable as its predecessor, the CD-R. Several reports have surfaced over the last few years questioning the DVD-R's ability to maintain many of its claims regarding archival quality life spans. These reports have shown a wide range of longevity between the different brands. While some DVD-Rs may last a while, others may result in an early and unexpected failure. Compounding this problem is …

Development Of A Particle Flow Test For Rotational Molding, Russell B. Whatcott

Theses and Dissertations

One of the current testing method (the Dry Flow test) to qualify resin for use in production in the rotomolding process has been shown to have many flaws in both equipment and procedure. Research was done here to investigate a possible alternative that could eliminate some of these testing deficiencies. By reducing equipment and operator errors, the testing of materials becomes more valuable of an exercise. The Angular Flow test developed in this research can increase repeatability. By coming to understand the rotational molding process better, an evaluation that can give more valid information was devised.

A Project-Based Electronics Manufacturing Laboratory Course For Lower-Division Engineering Students, Jianbiao Pan, Albert Liddicoat, James G. Harris, Dominic Dal Bello

Industrial and Manufacturing Engineering

This paper presents a project-based laboratory course on electronics design and manufacturing. The goal of this course is to provide lower-division engineering students a hands-on experience involving actual printed circuit board (PCB) design, layout, fabrication, assembly, and testing. Through project-based learning, students not only learn technical skills in designing and manufacturing an electronic device, but also develop their project management and communication skills early in their course of study at the university. The course outline and examples of the student projects are presented in this paper as well as project evaluations and students’ feedback. This paper also presents the selection …

Curricular Enhancement To Support Project-Based Learning In Computer And Electrical Engineering, Albert Liddicoat, Jianbiao Pan, James G. Harris, Lynne A. Slivovsky

Industrial and Manufacturing Engineering

Undergraduate computer and electrical engineering programs often partition the curriculum into several courses based on related topics taught in isolation. Students are expected to synthesize their knowledge in a senior design project. It is the authors’ experience that students often struggle during their senior design project since they have not gained the appropriate knowledge or mastered necessary skills needed to work on a significant or team-based engineering design project. Specifically, students need to be able to define system requirements, partition the design into subcomponents, design, build, test, and verify that the system requirements have been met. The authors have enhanced …

Enhancing Student Learning Through State-Of-The-Art Systems Level Design And Implementation: The Development Of A Lower Division Learning Module, James G. Harris, Dominic Dal Bello, Jianbiao Pan, Albert Liddicoat

Industrial and Manufacturing Engineering

The Cal Poly/Allan Hancock team is developing a learning module that will allow all lower division engineering students to design, fabricate, assemble, and test an electronic system implemented on a printed circuit board (PCB). All the services necessary to perform this laboratory experiment will be provided with low-cost vendors available on the . The learning module is being developed so that it can be integrated into the existing electrical engineering lower division courses that are required by all engineering students. The laboratory learning module will use operational amplifiers (op amp), resistors, capacitors and other common electronic components to study the …

Techniques For Developing Large Scale Fuzzy Logic Systems, Jon C. Ervin, Sema E. Alptekin

Industrial and Manufacturing Engineering

In this paper, we describe various techniques used to make Intuitionistic Fuzzy Logic Systems amenable to operating on applications with large numbers of inputs. A rule reduction technique known as Combs method is combined with an automated tuning process based on Particle Swarm Optimization. A second stage of tuning on rule weights results in improved performance and further reduction in the size of the rule-base. The entire process has been developed to operate within the Matlab software environment. The technique is tested against the Wisconsin Breast Cancer Database. The use of these tools shows great promise in significantly expanding the …

Drop Test Reliability Of Lead-Free Chip Scale Packages, Andrew Farris, Jianbiao Pan, Albert Liddicoat, Brian J. Toleno, Dan Maslyk, Dongkai Shangguan, Jasbir Bath, Dennis Willie, David A. Geiger

Industrial and Manufacturing Engineering

This paper presents the drop test reliability of 0.5 mm pitch lead-free chip scale packages (CSPs). Fifteen 0.5 mm pitch CSPs were assembled on a standard JEDEC drop reliability test board with Sn3.0Ag0.5Cu lead-free solder. Eight boards were edge-bonded with a UV-cured acrylic; eight boards were edge- bonded with a thermal-cured epoxy; and twelve boards were assembled without edge bonding. Half of the edge-bonded test boards were subjected to drop tests at a peak acceleration of 1500 G with a pulse duration of 0.5 ms, and the other half subjected to drop tests at a peak acceleration of 2900 G …

Development Of A Quality Improvement Method For International Manufacturing, Andrew J. Strong

Theses and Dissertations

Many companies are entering the international manufacturing arena. The continued expansion of the global market suggests that international manufacturing will grow. Among other concerns, the difficulty of producing high quality in some countries suggests that it is critical that companies using international locations for manufacturing find methods to better monitor and improve quality. The purpose of this research was to develop and test a method for quality improvement in an offshore environment. This method would be specifically applicable to a third-party logistics company (3PL), where the 3PL is a United States company that brokers manufacturing in China, networks to multiple …

Force Measurement And Evaluation For Surgical Cutting Applications: Development Of An Effective Characterisation Testbed, Dean Callaghan

Conference Papers

Sensorized instruments that cater for accurate measurement of the interaction forces (between biological tissue and instrument end-effector) during surgical procedures offer surgeons a greater sense of immersion during minimally invasive robotic surgery (MIRS). There is much ongoing research into force measurement/evaluation involving surgical graspers. However, comparatively little corresponding effort has been expended in the measurement and subsequent evaluation of forces between scissor blades and tissue. This paper presents the design and development of a force/strain measurement test apparatus, which will ultimately serve as an effective sensor characterisation and evaluation platform. Data acquired from the testing platform can be used to …

Design For Manufacturing For Friction Stir Welding, Harish Bagaitkar

Masters Theses

"This thesis is divided in two parts. In the first part, technical feasibility of implementing Friction Stir Welding (FSW) for automobile chassis fabrication is discussed using a case study. In the case study, Design for Manufacturing (DFM) principles are applied to manufacture an aluminum automobile chassis. Various DFM issues such as Tool Accessibility Issue, Joint Configuration Issue, and Fixture Support Issue along with relevant guidelines such as component geometry change and component elimination are discussed in the first section. Results show that more than 50% of the chassis joints can be welded using FSW technique. The second part of the …

Precision Coil Inspection, Karol Murphy

Theses

Boston Scientific produces the Guglielmi Detachable Coil in their Cork based facility. These are used in a surgical procedure to eliminate aneurysms. The first step in the process is to form a coil by wrapping a platinum wire around a mandrel. These coils have outer diameters ranging from 190 pm to 520pm. This is called the primary wind and is inspected to find any defects introduced into the coil from the winding process. These defects may be the result of wire defects in the raw material or possibly poor handling by the operators. These primary winds are processed further to …

Sorting Automated Concept Generator Results Based On Manufacture And Assembly Concerns, Kerry Ryan Poppa

Masters Theses

"Early in the design process, it is desirable to produce a large number of potential solutions. Completely exploring a problem's solution space is an unreasonable expectation for an unaided designer or design team. Computational tools have emerged to help designers more fully explore possible solutions. These automated concept generators use knowledge from existing designs and the desired functionality of the new product to suggest solutions. Existing automated concept generation methods produce many candidate solutions, but produce unmanageably large sets of solutions. Techniques are needed to organize the set of concepts into smaller groups, more easily parsed by the human designer. …

Design Issues For Therapeutic Ultrasound Angioplasty Waveguides, Declan Noone, Graham Gavin, Garrett Mcguinness

Conference Papers

Therapeutic ultrasound angioplasty is a new minimally invasive cardiovascular procedure for disrupting atherosclerotic lesions. Mechanical energy is transmitted in the form of ultrasound waves via long, flexible wire waveguides navigated to the lesion site through the vascular system. The underpinning principle of this technology is that plaque may be disrupted through a combination of direct contact ablation, pressure waves, cavitation and acoustic streaming, which all depend on the amplitude and frequency of displacements at the distal tip of the wire waveguide. This study identifies a number of key design issues for clinical devices of this type, and describes testing procedures …

Preparation And Accreditation Of Level 7 Engineering Programmes, Mark Mcgrath

Conference Papers

Accreditation of 3^rd level educational programmes by a suitably recognised professional body is of particular relevance in relation to engineering. The completion of a sequence of modules which leads to the attainment of this professionally recognised award is viewed as integral to the undertaking. The engineering technology fields are developing and expanding rapidly and the third level sector must keep abreast of these changes. This is essential if the third level institutions wish to continue delivering programmes which produce graduates who can successfully complete the transition from 3rd. Level to the various engineering sectors.

This paper outlines various aspects …

Treatment Of Aqueous Waste Streams At Eli Lilly - Alternatives To Incineration, Barry Hennessy

Theses

The aim of this project was to investigate the potential to treat liquid waste (secondary) from production processes at Eli Lilly with the emphasis on minimising the volume of waste sent for thermal oxidation. In addition, the project aimed to investigate if the chosen technology was diverse and potentially capable of handling waste streams from different processes. Membrane technology was identified as one of the most suitable technologies and trials were carried out on secondary waste from three production processes. The literature review and practical thrials aswell as assessment of trial results ran from October 2003 to June 2005.

All …

A Practical Guideline For Establishing Non-Return Valve Specification And Performance Criteria, Eric W. Dawkins

Masters Theses

The non-return valve has been a standard piece of equipment in the injection molding industry since the reciprocating screw was developed. Most molders understand the role of the non-return valve in the molding process. But few understand the functional problems of the non-return valve. Because of this, the non-return valve has been considered a nuisance item for injection molders.

Wear of the non-return valve is another problem that molders are faced with. The factors contributing toward wear are not entirely understood. Material, temperatures, hours and machine size, etc., all effect the life of a valve. Consequently, most worn valves are …

Designing And Manufacturing Microelectronic Packages For High-Power Light-Emitting Diodes, Brian Wright, Jianbiao Pan, Richard Savage

Industrial and Manufacturing Engineering

A new microelectronic package was designed for a high-power light-emitting diode (LED). The objective was to build a package that enables the LED to operate with currents as high as 2 Amps. An innovative thin-film interface has been developed to electrically connect the cathode of the LED die to a 22AWG Cu wire. This thin-film interface is wirebondable and solderable, and consists of three layers: Au, Ni93/V7, and Si. Four 1 mil Au wirebonds, supporting 2A of maximum current, connect the Au thin-film to the LED die cathode. Sn96Ag4 solder is used for connecting the Ni93/V7 thin-film to the 22AWG …

In-House Development Of Scheduling Decision Support Systems: Case Study For Scheduling Semiconductor Device Test Operations, Tali Freed, K. H. Doerr, T. Chang

Industrial and Manufacturing Engineering

Most manufacturing processes can benefit from an automated scheduling system. However;: the design of a fast, computerised scheduling system that achieves high-quality results and requires minimal resources is a difficult undertaking. Efficient .. scheduling of a semiconductor device test facility requires an information system that provides good schedules quickly. Semiconductor device testing-is the last stage of the long semiconductor manufacturing process, and therefore. is subjected to customer service pressures. The cost of an off-the-shelf computerised scheduling system may he prohibitive for many companies. In addition, many companies are taken aback by other characteristics of off-the-shelf scheduling systems, such as code …

Fabrication Of Functionally Graded 3a/5a Zeolites By Electrophoretic Deposition, X. Wang, E. A. Olevsky, E. Bruce, M. B. Stern, D. T. Hayhurst

Industrial and Manufacturing Engineering

Functionally graded zeolites of molecular sieve type 3A and 5A are deposited by electrophoretic deposition (EPD) from acetone suspension with 8% volume concentration of n-butylamine as particle charging agent. The EPD characteristics of both 3A and 5A suspensions are studied. Functionally graded zeolite 3A/5A deposits are obtained at 200 V DC. Energy dispersive X-ray dispersion (EDX) analysis results confirm the graded structure. The deposited zeolites are also analysed by scanning electron microscopy (SEM). The factors influencing the deposition process are discussed.

The Benefits Of Automatic Data Collection In The Fresh Produce Supply Chain, Ryan Charles Panos, Tali Freed

Industrial and Manufacturing Engineering

The potential for RFID based systems to improve the safety and efficiency of a supply chain with rapidly decaying products and strict health standards is creating pressure to adopt RFID in several agricultural industries. A handful of fresh produce industry leaders currently participate in mandated pilot projects, while the industry as a whole is still intimidated by the perceived cost of RFID. Therefore in this study we attempt to validate the correlation between performance and automated data collection, paving the way to economic justification of investment in data collection technologies, such as barcode and RFID.

The majority of product in …

Design Of Embedded Resistance Heating Element Using Rapid Manufacturing Process, Ravi Philip, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper discusses the design of heating element suitable for embedding in a rapid manufacturing process. A specific pattern is built using the laser deposition Process available at the University of Missouri--Rolla. A resistance heating element which is then cast into place using a castable refractory material, which acts as an electrical insulator. An application of this technology is for preheating the substrate before direct metal deposition.

Modeling And Validation Of Temperature And Concentration For Rapid Freeze Prototyping, Frances D. Bryant, Ming-Chuan Leu

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Rapid Freeze Prototyping is a solid freeform fabrication process that uses water as the main build material in a cold environment to create three-dimensional parts. A eutectic sugar-water solution (C₆H₁₂O₆ – H₂O) has been used as a sacrificial material in order to create complex 3D parts with features such as overhangs. A study of the interaction of the build and support materials is presented in this paper. The temperature of both materials during deposition and subsequent cooling is modeled using a semi-empirical model and a theoretical model. A concentration model is used to …

Thermocouple Embedding For The Production Of A Substrate For Rapid Manufacturing, Rana Gunaratnam, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This paper reports the results of a set of experiments testing methods to embed thermocouples during laser deposition. Various operating settings and shielding materials are explored. Temperature readings of the embedded thermocouples are compared with surface temperature readings taken by a non-contact digital pyrometer during the deposition process. Also, possibilities of using this information for system control are discussed.

Laser Deposition Cladding On-Line Inspection Using 3-D Scanner, Yu Yang, Todd E. Sparks, Jianzhong Ruan, Lan Ren, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser deposition directly deposits metal cladding to fabricate and repair components. In order to finish the fabrication or repair, 3-D shape of the deposition needs to be inspected, and thus it can be determined if it has sufficient cladding to fabricate a part after deposition process. In the present hybrid system in the Laser Aided Manufacturing Lab (LAMP) at the University of Missouri - Rolla, a CMM system is used to do the inspection. A CMM requires point-by-point contact, which is time consuming and difficult to plan for an irregular deposition geometry. Also, the CMM is a separate device, which …