Manufacturing Commons^™

Three Dimensional Die Repair Using A Hybrid Manufacturing System, Lan Ren, Ajay Panackal Padathu, Jianzhong Ruan, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A dramatic reduction in the cost, energy and time can be achieved by pursuing part repairing especially for die industry. In this paper, repairing process development was carried out by a hybrid manufacturing system aiming at the prevalent kinds of die core damages which is worn-out or corroded surface. Surface patches pattern is used for generating tool path to repair the damaged faces. A user-friendly software tool was developed to facilitate the users. 3D repairing technology was also integrated which ensures the alignment when more than one damages need to be repaired without reloading the part. Realization of 3D surface …

A Review Of Layer Based Manufacturing Processes For Metals, Jianzhong Ruan, Todd E. Sparks, Zhiqiang Fan, Jacquelyn K. Stroble, Ajay Panackal, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The metal layered manufacturing processes have provided industries with a fast method to build functional parts directly from CAD models. This paper compares current metal layered manufacturing technologies from including powder based metal deposition, selective laser sinstering (SLS), wire feed deposition etc. The characteristics of each process, including its industrial applications, advantages/disadvantages, costs etc are discussed. In addition, the comparison between each process in terms of build rate, suitable metal etc. is presented in this paper.

Applications Of A Hybrid Manufacturing Process For Fabrication And Repair Of Metallic Structures, Frank W. Liou, Kevin P. Slattery, Mary Kinsella, Joseph William Newkirk, Hsin-Nan Chou, Robert G. Landers

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Since its appearance, rapid prototyping technology has been of interest to various industries that are looking for a process to produce/build a part directly from a CAD model in a short time. Among them, the direct metal deposition process is the only process which directly manufactures a fully dense metal part without intermediate steps. However, challenges of the direct metal deposition process include building overhang structures, producing precision surfaces, and making parts with complex structures. Coupled between the additive and the subtractive processes into a single workstation, the integrated process, or hybrid process, can produce a metal part with machining …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part I: Extrusion Process Modeling, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A novel, solid freeform fabrication method has been developed for the manufacture of ceramic-based components in an environmentally friendly fashion. The method is based on the extrusion of ceramic slurries using water as the binding media. Aluminum oxide (Al₂O₃) is currently being used as the part material and solids loading as high as 60 vol. % has been achieved. This paper describes a novel manufacturing machine that has been developed for the extrusion of high solids loading ceramic slurries. A critical component of the machine is the deposition system, which consists of a syringe, a plunger, …

Determination Of Transformation Matrix In A Hybrid Multi-Axis Laser-Aided Manufacturing System And Its Practical Implementation, Ajay Panackal Padathu Vijayan, Todd E. Sparks, Jianzhong Ruan, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The Laser Aided Manufacturing Process (LAMP) is a multi-axis hybrid manufacturing process comprised of both an additive process, laser deposition, and a subtractive process, CNC machining. Determination of transformation matrix is one of the most important tasks to bridge the gap between process planning (software) and real deposition/machining process. The first part of the paper discusses an algorithm for computing the position of point/points in three-dimensional space, using homogenous transformation matrices. The second part of the paper discusses about how the algorithm was used in practice to build 3-D parts and part-repair using hybrid manufacturing process.

Freeze-Spray Processing Of Layered Ceramic Composites, Qiang Fu, Oratai Jongprateep, Ashlee Abbott, Fatih Dogan

Materials Science and Engineering Faculty Research & Creative Works

Thermal gradients and associated stresses are critical in designing with ceramic composites having low thermal conductivity. In order to reduce the stresses from thermal gradients, compositional gradients are employed in designing of composite structures. This study addresses development of freeze-spray process to fabricate layered ceramic structures with controlled layer thickness and microstructural development. The composites were processed by spraying of ceramic slurries with low binder content and relatively high solids loadings (up to 40 vol%) on a cooled substrate. The frozen parts were freeze-dried and sintered at elevated temperatures. The relationship between microstructural development and thermal expansion behavior of Al …

Effect Of Structured Laser Pulses On Grain Growth In H13 Tool Steel, Todd E. Sparks, Jianzhong Ruan, Zhiqiang Fan, Yaxin Bao, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In metal solidification. the cooling rate is an important factor in determining the resultant grain structure of the material. The paper discusses the results of a feasibility study done to determine whether a laser pulse scheme can be designed to affect, and eventually control, the resultant microstructure of the deposited material. A factorial experimental approach is applied to determine the significant parameters affecting grain size and orientation. Parameters investigated include maximum pulse power, pulse frequency, pulse shape, and material feed rate. Particular attention is given to parameter combinations that can cause grain growth through the layer boundaries of the deposited …

Freeform Extrusion Of High Solids Loading Ceramic Slurries, Part Ii: Extrusion Process Control, Michael S. Mason, Tieshu Huang, Robert G. Landers, Ming-Chuan Leu, Greg Hilmas

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Part I of this paper provided a detailed description of a novel fabrication machine for high solids loading ceramic slurry extrusion processes and presented an empirical model of the ceramic extrusion process, viewing ram velocity as the input and extrusion force as the output. A constant extrusion force is desirable as it correlates with a constant material deposition rate and, thus, good part quality. The experimental results used to construct the model demonstrated that a constant ram velocity will not necessarily produce a constant extrusion force. In some instances the extrusion force increased until ram motor skipping occurred, and process …

Contractor Variability In Construction Of Cement Treated Base Layers, Maile Anne Rogers

Theses and Dissertations

The primary purposes of this research were to identify construction factors most correlated to specific mechanical properties of cement-treated base (CTB) layers and to determine which construction factors exhibit comparatively high variability within individual construction sections of the two pavement reconstruction projects included in this study. In addition, differences between construction sections tested in this research were evaluated. The research focused on the construction of CTB layers in two pavement reconstruction projects in northern Utah, one along Interstate 84 (I-84) near Morgan and one along U.S. Highway 91 (US-91) near Richmond. The significant predictor variables associated with California bearing ratio …

A Solution For Commodity Field Hauling With Self-Unloading Semi-Trailers, Lee Pagens Wilkerson

Theses and Dissertations

Commodity hauling of bulk goods is a growing enterprise that has expanded from hauling agricultural products to hauling many other bulk products. Commodity trailers are used to haul agricultural products from storage facilities to processing plants. These trailers are designed for highway use but are frequently required to work in field conditions as well. In many cases this environment overstresses these trailers and results in permanent irreparable damage. In addition to the structural problems of these trailers, the current systems for unloading the bulk produce from these trailers have serious inadequacies. While functional, the currently used chain and non-chain driven …

A Stochastic Production Cost Model For Remanufacturing Systems, Gaurang S. Patel

Theses and Dissertations - UTB/UTPA

Growing environmental concern throughout this decade coupled with enforced legislation, customer expectations and economic incentives have forced increasing number of manufacturers to take back their products from end user. Managing this reverse flow of products is called reverse logistics. The stochastic nature of returned products complicates the production planning for remanufacturing systems in reverse logistics. In this thesis a stochastic production cost model, considering various costs associated under different situations for remanufacturing systems of returned products is developed. A search algorithm method is recommended to determine optimal production run size, production rate and space for remanufacturing systems in reverse logistics. …

A Comparative Study Of Various Loss Functions In The Economic Tolerance Design, Jehnan Pan, Jianbiao Pan

Industrial and Manufacturing Engineering

Engineering tolerance design plays an important role in modern manufacturing. In this paper, the Kapur's model was modified so that the economic specification limits for both symmetric and asymmetric losses can be established. Three different loss functions: (1) Taguchi's quadratic loss function; (2) Inverted Normal Loss Function; (3) Revised Inverted Normal Loss Function are compared in the economic tolerance design. The relationships between the three loss functions and process capability indices for symmetric tolerance are established. The results suggest that the revised inverted normal loss function be used in determination of economic specification limits.

Exchange Faculty Perspectives On International Collaborations, Donal Mchale

Conference Papers

The main purpose of the paper is to document key issues in developing successful transatlantic faculty exchanges and to document perspectives and key learnings’ emanating from the development and implementation of an international exchange process.

Plotting A Bright Future For Manufacturing Education: Results Of A Brainstorming Session, Daniel Waldorf, Sema E. Alptekin, Robert Bjurman

Industrial and Manufacturing Engineering

Manufacturing industries worldwide have undergone dramatic changes in recent years and now demand more from graduating manufacturing engineers. The effects of globalization have forever changed the parameters for success in manufacturing. Our educational institutions must respond to these changes with innovation. That agenda formed the basis for a special SME/CIRP international conference on manufacturing engineering education called “Looking Forward: Innovations in Manufacturing Engineering Education,” held in San Luis Obispo, California, June 22-25, 2005. At the meeting, manufacturing education professionals from around the world came together to share their own innovative ideas and to brainstorm ways to shape the future of …

Fixture Design For Load Measurement In Friction Stir Welding, Shekhar S. Kulkarni

Mechanical & Aerospace Engineering Theses & Dissertations

In the Friction Stir Welding Process a vertical force is required for plunging the pin or probe of the tool into the workpiece specimen material, and maintaining contact between the shoulder and the substrate. In addition to the vertical force, Friction Stir Welding Process also involves a horizontal force, which is instrumental for the advancement of the tool as the weld progresses. The essential objective of the thesis was to design, manufacture and test a fixture that can be utilized to measure the vertical force as well as the horizontal force. The designing of the fixture was concerned with various …

Process And Product Optimization Techniques - A Comparative Analysis Using Optimization Of Surface Roughness, Amol Suresh Sonje

Mechanical & Aerospace Engineering Theses & Dissertations

Robust design improves the fundamental function of the product or process considering noise factors in DOE. G. Taguchi has made significant advances in the use of experimental design. Taguchi methods are criticized on the basis of failure to deal with interactions, use of SIN ratio and lack of sequential nature of investigation. Response Surface Methodology deals with designing models that represents response in terms of various factors affecting it. Optimization of surface finish is achieved using both Taguchi Methods and Response Surface Methodology.

Dual response approach is a combination of Taguchi methods and RSM techniques in which primary response is …

Automated Manipulation For The Lotus Filament Winding Process, Jeffrey V. Anderson

Theses and Dissertations

The filament-winding process produces quality consistent composite parts for many industries. Filament winding allows for consistent quality parts by automating the winding process. A recent development of filament winding is the Lotus process. The Lotus process reverses conventional filament winding by leaving the mandrel stationary and winding composite fiber around the mandrel. The automated Lotus filament-winding machine is controlled by four-axis control manipulating the Lotus ring around a fixed mandrel. This allows Lotus filament winding to wind parts that do not have a linear axis. Lotus filament winding is in its early stages of development. As a second step in …

Processing Model For Tungsten Powders And Extention To Nanoscale Size Range, Randall M. German, J. Ma, X. Wang, E. Olevsky

Industrial and Manufacturing Engineering

Nanoscale tungsten powders promise access to very hard, strong and wear resistant materials via the press–sinter route. A small particle size changes the response during sintering, requiring lower temperatures and shorter times to attain dense but small grain size structures. On the other hand, oxide reduction and impurity evaporation favour high sintering temperatures and long hold times. Accordingly, press–sinter processing encounters conflicting constraints when applied to small particles. Presented here is an analysis of press–sinter tungsten particle processing to isolate conditions that balance the temperature and size dependent effects. The calculations are pinned by existing data. Opportunities are identified for …

The Effect Of Reflow Profile On Snpb And Snagcu Solder Joint Shear Strength, Jianbiao Pan, Brian J. Toleno, Tzu-Chien Chou, Wesley J. Dee

Industrial and Manufacturing Engineering

Purpose –The purpose of this work is to study the effect of the reflow peak temperature and time above liquidus on both SnPb and SnAgCu solder joint shear strength.

Design/methodology/approach –Nine reflow profiles for Sn3.0Ag0.5Cu and nine reflow profiles for Sn37Pb have been developed with three levels of peak temperature (230°C, 240°C, and 250°C for Sn3.0Ag0.5Cu; and 195°C, 205°C, and 215°C for Sn37Pb) and three levels of time above solder liquidus temperature (30, 60, and 90 s). The shear force data of four different sizes of chip resistors (1206, 0805, 0603, and 0402) are compared across the different …

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 …

Rfid Technology Use In Assembly And Disassembly Processes, Gordana Ostojić, Milovan Lazarević, Vukica Jovanović, Stevan Stankovski, Ilija Ćosić

Engineering Technology Faculty Publications

Modern production conditions demand the application of the concept of distributed production. Today companies are specialized for partial technology processes. Hundreds, sometimes even thousands, of collaborative processes depend on workers’ interaction and communication in product assembly and disassembly phases. RFID technologies can be really helpful in identifying objects in terms of sustainable development, regarding disassembly, recycling and reuse. In this paper we presented VCDE system architecture and the realization method of RFID technology as well as the data acquisition using RFID technology during the product lifecycle from the design process, production, assembly, usage, and an special example is given regard- …

Using Rfid Technology In Collaborative Design Of The Assembly Systems, Stevan Stankovski, Gordana Ostojić, Vukica Jovanović, Branislav Stevanov

Engineering Technology Faculty Publications

Modern production conditions require the application of the concept of distributing production. This approach means coordinative production in a number of small and middle size companies. Multiplex products, consisting of a number of parts, components, and modules are assembled in one function unit in one company, but they may not be manufactured in one place. Huge factory and production complex, which existed in our country, comprised all phases of product lifecycle, from the development of a concept solution to the assembly. Technology of product manufacturing, resource logistics, quality control, product testing and verification of product function characteristics all represented activities …

A Numerical Acoustic Fluid-Structure Simulation Of Therapeutic Ultrasound Angioplasty, Graham Gavin, Finbar Dolan, M.S J. Hashmi, Garrett Mcguinness

Conference Papers

INTRODUCTION Therapeutic ultrasound angioplasty is the delivery of high amplitude ultrasonic displacements to the distal-tip of small diameter wire waveguides with the goal of disrupting atherosclerotic plaques. This is a minimally invasive procedure that may have potential' in the treatment of complicated chronic total occlusions. The disruption of plaque is due to direct contact ablation and also cavitation, pressure waves and acoustic streaming in the fluid surrounding the vibrating waveguide distal-tip [1]. Cavitation appears to play a major role and some authors have suggested that plaque ablation is only evident above the cavitation threshold [2]. Makin and Everbach [3] performed …

A Numerical Acoustic Fluid-Structure Model Of A Therapeutic Ultrasound Angioplasty Device, Graham Gavin, M.S. J. Hashmi, Finbar Dolan, Garrett Mcguinness

Conference Papers

Ultrasonic angioplasty involves the use of ultrasonic vibrations delivered to the distal-tip of small diameter wire waveguides and is an emerging technology the may have potential use in the treatment of complicated atherosclerotic plaques during cardiovascular surgery. Complicated plaques, including chronic total occlusions and calcified lesions, seriously reduce success rates during standard intervention involving guidewire access, followed by balloon dilation or stent delivery. The large amplitude (0-150 μm) wire waveguide distal-tip displacements in the low-frequency ultrasonic (18-45 kHz) range have been shown to disrupt plaque material by direct contact ablation and cavitation, acoustic streaming and pressure wave components in adjacent …

A Gasless Method Of Spraying Thermoplastic Resin, Dan T. Rogers

Theses and Dissertations

This spraying method for thermoplastic resins is a new manufacturing process for applying thermoplastics to a mold or surface in an efficient way that has the potential of reducing cycle time. Spraying thermoplastic resins is similar to spraying other polymers, such as paint, with the differences being higher pressure and temperature. This method uses an injection molding machine with a modified nozzle to spray the plastic material. In this study, temperature, pressure, and nozzle size were factors that influenced the success of this spraying method. The method of spraying in this study proved spraying without a gas is possible, a …

Development Of Commercial Applications For Recycled Plastics Using Finite Element Analysis, Nanjunda Narasimhamurthy

Theses and Dissertations

This thesis investigates the suitability of thermo-kinetically recycled plastics for use in commercial product applications using finite element analysis and statistics. Different recycled material blends were tested and evaluated for their use in commercial product applications. There are six different blends of thermo-kinetically recycled plastics used for testing and CATIA is used for finite element analysis. The different types of thermo-kinetically recycled plastics blends are: pop bottles made of PolyethyleneTeraphthalate (PET), milk jugs made of High-Density Polyethylene (HDPE), Vinyl seats made of Poly Vinyl Chloride (PVC) and small amount of Polypropylene (PP) and Urethane, electronic scrap made of engineering resins …

Optimization Of The Fuzzy Logic Controller For An Autonomous Uav, Jon C. Ervin, Sema E. Alptekin, Dianne J. Deturris

Industrial and Manufacturing Engineering

In this paper, we describe the optimization of membership functions in an application employing a hierarchical Fuzzy Logic Controller. The size of the rule base is made manageable by using a unique formulation, known as Combs method, to help control the problem of ‘exponential rule expansion’. The optimization is performed using a steady state genetic algorithm with a dynamic fitness function. The controller being developed is designed to fly a small, autonomous parafoil, suitable for short-range reconnaissance and land survey applications. The optimization process is performed in the Matlab/Simulink software environment and incorporates fuzzy logic modules developed in the Matlab …

Manufacturing Companies And The Information Age In The U.S., Marcos Reynero

Graduate Research Papers

The purpose of this research paper is to analyze the relationship between the amount of indirect labor and value added in manufacturing companies. Companies are moving manufacturing sites overseas in order to reduce cost. The cost of direct labor in countries like China is relatively lower in comparison to the cost of labor in the U.S. Edward Hill, professor at Cleveland State University's College of Urban Affairs, states that an hour of a manufacturing plant in the U.S. costs $150 versus $1 in China (Scherer, 2005). Companies are making strategic decisions based on reducing cost in order to improve profits. …

Part Repair Using A Hybrid Manufacturing System, Kunnayut Eiamsa-Ard, Hari Janardanan Nair, Lan Ren, Jianzhong Ruan, Todd E. Sparks, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Nowadays, part repair technology is gaining more interest from military and industries due to the benefit of cost reducing as well as time and energy saving. Traditionally, part repair is done in the repair department using welding process. The limitations of the traditional welding process are becoming more and more noticeable when the accuracy and reliability are required. Part repair process has been developed utilizing a hybrid manufacturing system, in which the laser aided deposition and CNC cutting processes are integrated. Part repair software is developed in order to facilitate the users. The system and the software elevate the repair …

Sensitivity Analysis Of Process Parameters In Laser Deposition, Zhiqiang Fan, Kaushik Phatak, Frank W. Liou

Mechanical and Aerospace Engineering Faculty Research & Creative Works

In laser cladding with powder injection process, process output parameters, including melt pool temperature and melt pool dimensions, are critical for part quality. This paper uses simulation and experiments to investigate the effect of the process input parameters: laser power, powder mass flow rate, and scanning speed on the output parameters. Numerical simulations and experiments are conducted using a factorial design. The results are statistically analyzed to determine the significant factors and their interactions. The simulation results are compared to experimental results. The quantitative agreement/disagreement is discussed and further research is outlined.