Manufacturing Commons^™

Generalizable Fugitive Carrier Method For 3d Printing Of Hydrogels, Hakan Arslan

Mechanical and Aerospace Engineering Dissertations - Archive

Hydrogels, with physical characteristics resembling biological soft tissues, hold great potential for bioinspired and biomedical applications. However, using them in additive manufacturing systems has challenges because of their poor mechanical and rheological properties. In response to these challenges, we introduce a fugitive carrier method, a novel and generalizable approach for materials incompatible with pneumatic-based extrusion three-dimensional (3D) printers. Our developed fugitive carrier method allows the 3D printing of a broad spectrum of hydrogel precursors with low viscosity while retaining their inherent properties. This technique has been successfully demonstrated by creating biomimetic structures with anisotropic and programmable systems utilizing temperature-sensitive hydrogel …

Rc Baja: Drivetrain And Chassis, Caden Harris

All Undergraduate Projects

The engineers in the CWU Mechanical Engineering Technology program were asked to design and manufacture a remote-controlled Baja car to compete in several different events. The car was required to compete in a drag race, slalom event, and Baja event against other cars created by engineering students. To compete at the highest level, the cars needed to finely balance ruggedness, weight, torque, and top speed.

This report is dedicated to the designing, manufacturing, and testing of the drivetrain and chassis that supported the RC car as it competed in the school-sanctioned competition; a partner was responsible for the steering and …

Articulating Balsa Wood Bridge, Nate Harris

All Undergraduate Projects

This report describes the design, construction, and testing of a small-scale articulating balsa wood bridge that allowed passage over normally impassable terrain. The bridge was required to span a 400mm gap, while also articulating the midpoint of the bridge 140mm above its resting position. The bridge also needed to support a 20kg (44 lbs.) point load in the center of the bridge, and the bridge and articulation tower together needed to weigh less than 85 (0.19 lbs.) grams.

To construct the bridge, statics and mechanics of materials was used to design a truss that was calculated to support the load …

Navigating The Complexities Of Engineering Management: Insights Into Metrics, Measurements, And Pitfalls, Charles Daniels

Engineering Management & Systems Engineering Faculty Publications

In the realm of Engineering Management, the reliance on metrics and measurements stands as a cornerstone for effective decision-making processes. These quantitative tools offer insights into performance dynamics and facilitate informed strategic choices. However, the uncritical application of metrics devoid of profound domain expertise presents significant challenges. This abstract explores the pitfalls inherent in utilizing metrics and measurements within Engineering Management without comprehensive understanding, emphasizing the potential consequences and proposing strategies for navigating this complex terrain.

Energy Efficiency In Additive Manufacturing: Condensed Review, Ismail Fidan, Vivekanand Naikwadi, Suhas Alkunte, Roshan Mishra, Khalid Tantawi

Engineering Technology Faculty Publications

Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly …

Processing Of Niti Sma For High Reflectivity Applications, Nicholas Dean Asbury

UNF Graduate Theses and Dissertations

Nickel Titanium (NiTi) is a shape memory alloy (SMA) that is capable of being deformed and subsequently returned to the original shape through heating. This unique property makes NiTi a prime material for potential applications in the aerospace industry. As manufacturing capabilities advance, the ability to produce and implement advanced materials, such as shape memory alloys like NiTi, becomes more feasible. One such application being studied is deployable mirrors for imaging satellites. Reflector and mirror surfaces for imaging in the visible and infra-red range of the light spectrum require low surface roughness across the largest allowable area for the collection …

Effect Of Resin Bleed Out On Compaction Behavior Of The Fiber Tow Gap Region During Automated Fiber Placement Manufacturing, Von Clyde Jamora, Virginia Rauch, Sergii G. Kravchenko, Oleksandr G. Kravchenko

Mechanical & Aerospace Engineering Faculty Publications

Automated fiber placement is a state-of-the-art manufacturing method which allows for precise control over layup design. However, AFP results in irregular morphology due to fiber tow deposition induced features such as tow gaps and overlaps. Factors such as the squeeze flow and resin bleed out, combined with large non-linear deformation, lead to morphological variability. To understand these complex interacting phenomena, a coupled multiphysics finite element framework was developed to simulate the compaction behavior around fiber tow gap regions, which consists of coupled chemo-rheological and flow-compaction analysis. The compaction analysis incorporated a visco-hyperelastic constitutive model with anisotropic tensorial prepreg viscosity, which …

Artificial Intelligence Enabled Machinery Fault Detection And Diagnosis Using Vibro-Acoustic Signals, Srinivasa Rao Ippili

Theses and Dissertations--Mechanical and Aerospace Engineering

In various industries, the early detection of faults in rotating machinery is crucial to prevent system failures and ensure customer satisfaction. Typically, vibration measurement and diagnosis are employed for fault detection, but this process faces challenges in automation due to the complexity of installing and maintaining accelerometers, particularly in end-of-line quality control or pre-installed machinery health assessments. Acoustic signals, as a form of mechanical wave, offer an alternative for monitoring machinery while in operation. Unlike accelerometers, acoustic transducers are non-contact and easy to set up, enabling real-time data collection without interrupting equipment operation. However, utilizing acoustic signals in manufacturing poses …

Fatigue Resistant Cast Steel Railcar Couplers Produced By Wire-Arc Additive Manufacturing (Waam), Samuel Vellequette

Dissertations, Master's Theses and Master's Reports

Every year, approximately 90,000 cast steel railcar coupler knuckles are replaced preemptively to avoid fatigue failure. The coupler geometry has been in service since the early 1930s, so geometry changes are restricted to maintain compatibility with the existing fleet. Defects from the casting process, decarburization during heat treatment, and in-service exposure to corrosive environments combine to promote fatigue crack nucleation in high-stress regions of the knuckle. Wire-arc additive manufacturing (WAAM), which uses traditional welding techniques to build material to near-net shapes, was employed to deposit higher-strength materials in critical regions. By replacing the cast steel in the high-stress region of …

High Temperature Strength Reduces Soldering In Aluminum High Pressure Die Casting, Jacob A. Belke

Dissertations, Master's Theses and Master's Reports

Die soldering, an adhesion defect in high pressure die casting (HPDC), is a symptom of localized sticking where a localized portion of the cast material is adhered to the tooling surface causing build up over time. This requires the tooling to be serviced which incurs additional costs to the process that gets passed on to the parts. Historically, soldering has been mitigated using lubricants, coatings, and alloy chemistry modifications but solder persists.

The Tresca friction thermomechanical model suggests soldering occurs when the local interfacial shear stress between the casting and die surface exceeds the local shear strength of the casting. …

Materials Testing For Large Format 3d Printing, William Jenkins

Williams Honors College, Honors Research Projects

An ABS Carbon Fiber blend was printed into single walled hexagons at a variety of settings on a Cincinnati BAAM large format 3D printer. These hexagons were then cut down into sheets and had tensile and flexural test samples cut out of them, in order for materials testing to be performed. Tensile strength, tensile strain, young’s modulus, flexural strength, deflection and elastic modulus were all determined. A desktop CNC machine and a planer were purchased for the manufacturing of these samples, and an efficient cutting procedure was designed and optimized. After all data collection concluded, this data was thoroughly analyzed, …

Stanley Black And Decker Slag Removal Design Project, Colt Hemphill, Kyle Stober, Andrew Raymond, Robert Artrip

Williams Honors College, Honors Research Projects

My group given the task of designing a system to remove the slag of large metal plates. Removing this slag is an important step in creating the final assembly of a model. Currently we the operators are flipping the plates using a large magnet and crane. The issue that we see with the current method is the risk of injury while having the plate suspended in the air. These plates can reach upwards of 600lbs and poses a serious threat to the operators if the magnet is not secured correctly. Our new system for removing the slag is designed to …

Yankee Manufacturing Multi-Assembly Pvc-Gasket Assembly Mechanism, Lily Coss, Jessica Kun, Dana Chapin, Jenan Hasan

Williams Honors College, Honors Research Projects

This project focuses on designing and implementing an efficient mechanism to connect PVC and gasket pieces in the door assembly process at Yankee Manufacturing. The aim is to improve process efficiency and productivity by increasing the assembly rate from 130 to 195 assemblies per hour, a 38% improvement. The project involved research, design iterations, performance evaluations, and adherence to engineering codes and standards, particularly focused on safety, ergonomics, and sustainability. The design process includes addressing challenges from a previous attempt, redefining project scope, and incorporating new elements such as transitioning to the packaging process seamlessly. Ethical considerations include promoting operator …

Short Strand Carbon Fiber Reinforced Polylactic Acid Filament For Additive Manufacturing, Dale Chenoweth, Lukas Seggi, Luke Phillips

Williams Honors College, Honors Research Projects

In this design project, the additive manufacturing filament of short strand carbon fiber (SSCF) reinforced polylactic acid (PLA) composite was developed. The micro-size, precision cut SSCFs were mixed with the PLA pellets through a melting homogenization process. Through this process the composite material block is cut and divided into pieces for ease of pelletizing. The material block pieces are then pelletized to be fed through the single screw extruder to develop the SSCF-PLA composite filament. The SSCF-PLA filaments were manufactured with a varying amount of SSCF ranging from 0.5% to 10% of the material block's weight. Development of a 1% …

Battery Dunnage, Paul Hirsch, Alex Cox, Ben Strubbe

Williams Honors College, Honors Research Projects

Schaeffler is launching a new assembly line for a battery in 2025. As part of the project, it is necessary to design and fabricate a reusable dunnage (packaging) specialized for the battery, meant for safe domestic transportation in the United States. Through an iterative process, the team developed a final dunnage design out of steel components that had a maximum footprint of 62 in X 43.5 in X 29.25 in and a weight of 821.682 lbs. The dunnage is stackable on itself up to two high, weighing a total of 4,918.724 lbs. when loaded with four batteries. The design was …

3d Printed Drone (Body And Controls), Michael Dick, Hayden Pinkelman, Tanner Henderson, Logan Prince

Williams Honors College, Honors Research Projects

The objective is to build a scaled down model of a 3D printed drone capable of carrying a payload scalable to 50 lbs. for a wide array of applications. Some applications of the drone could include delivering support materials during natural disasters, such as foam to put out fire or medical aid packs to provide aid to injured people, food or package delivery, or military applications. The project has been split up into two groups. One group will be focusing on the propulsion aspect of the project, such as the electric motors and airfoil. Simultaneously, this group will design the …

Zips Racing Electric Brakes Design, Zachary Koneval, Andrew Thompson, Cory Baczkowski

Williams Honors College, Honors Research Projects

The Zips electric racing team is a collegiate team full of engineering students to make a formula electric car that competes against other universities and their cars. But before the cars make it to competition they go through a series of tests to make sure the car is able to perform in all of the actual competition stages. One of the tests for the cars is the brakes test. Where the car has to lock up all four wheels at once and stop in a square that is on the ground. So in this report we have detailed out our …

Application Of Conductivity Techniques For Interlayer Discontinuity Detection In Additively Manufactured Metal Materials, Joshua D. Newell, Riley R. Myers

Williams Honors College, Honors Research Projects

Additive manufacturing is becoming increasingly more popular and efficient. One drawback is the possibility of interlayer discontinuities forming in the material. A non-destructive technique utilizing the changing resistivity of the material as discontinuities appear was used to detect those discontinuities and was verified through additional testing of manually added through-thickness discontinuities. This technique has been proven to be useful in understanding fatigue crack growth of conventional metal and composite structures. Experimental investigation of fatigue in steel with an edge notch has been performed using these techniques to understand source and location of crack formation and growth in conventional material. Application …

A Decision-Making Approach To Reduce The Risk Of Measurement Uncertainty For Product Size, Mostafa Awadalla Sedeek, Fatma Abdallah Elerian, Ossama Badie Abouelatta, Mona. A. Aboueleaz

Mansoura Engineering Journal

The measurement uncertainty has a significant impact on quality control processes. This is particularly true of standards that are assessed to determine if a product is compliant. This ambiguity introduces two potential risks of decision-making: accepting a non-conventional product (the consumer's risk) or rejecting a conventional product (the producer's risk). This investigation explores the potential for false decisions caused by measurement errors in product assessments. By studying data near the control limits, a greater understanding of the manufacturing process is intended to facilitate informed decision-making, and guide the implementation of effective quality control methods. The investigation highlights the importance of …

Minimizing The Production Cost Of The Cam-Follower Profile Using Shape Optimization Techniques, Khaled Ahmed, Magdy Samuel, Rania Mostafa

Mansoura Engineering Journal

The study of shape optimization techniques in structural products helps in reducing mechanical stresses and vibrations in related mechanical elements, such as cam follower mechanisms. This, in turn, has a positive impact on cost savings in the manufacturing process and enhances production quality and reliability. The point of view in this research depends on the idea of minimizing the total production cost while ensuring good functional performance of the cam profile during the shape-manufacturing optimization problem-solving process. The investigation of the impact of changing the motion type of a cam, such as Uniform Velocity Motion (UVM) and Simple Harmonic Motion …

Schaeffler E-Axle Value Engineering, Andrew Powers

Williams Honors College, Honors Research Projects

This project aims to design a manufacturable E-Axle end housing that improves system performance while reducing cost. The project is focused on utilizing Schaeffler's manufacturing competencies to achieve a simple assembly with a significant reduction in cost per part, while using existing machines or processes within the company. The design development process will follow the conceptual design stage through Finite Element Analysis and classical engineering calculations. Cross-functional design reviews will be conducted to ensure that agreement can be reached on the manufacturing feasibility of the design. Concepts will be entered in a decision analysis sheet to identify the best one …

Extending Trailer, Alex Grove

Williams Honors College, Honors Research Projects

The goal of this research project is to revolutionize the convenience in towable transportation. This innovative design aims to enhance the versatility of pull-behind trailers by incorporating an extendable feature, allowing users to effortlessly adjust the length according to their specific needs. Whether navigating tight spaces or accommodating extra cargo, our trailer adapts to diverse situations, providing unmatched flexibility. In addition to its adjustable length, the trailer is engineered to be compactable, addressing the storage constraints often faced by users with limited space. The collapsible design ensures easy storage without compromising on functionality, making it an ideal solution for individuals …

Yankee Feedstock Project, Nathan Mcanany, Richard Gualtiere

Williams Honors College, Honors Research Projects

This report details the design process, application, considerations, costs, and functionality of an automated tape “feedstock” machine. Yankee Insulation Products will use this project to create rolls of Aluminum foil tape that are included in their Therma-Dome assembly kit. The goal of this design will aid in the streamlining and effectiveness of the current process. When designing the automated process, the current process was evaluated for areas of improvement. Design parameters were also given to the project by the sponsoring company that were to be considered and incorporated.

Shape Inverse Prediction Of Magnetic Field-Actuated Soft Robots By Neural Network Machine Learning, Lineth J. Perez Monsalve

Theses and Dissertations

Soft robotics has drawn tremendous interest in recent years because the compliance and motion of soft robotics enable biocompatibility and versatility for many applications, such as human-machine interaction, wearable and assistive devices, and health monitoring. This study introduces a novel predictive modeling approach using neural networks for shape control of magnetic soft robots. The robots are made of silicone materials embedded with hard magnetic particles, which respond to the external magnetic field provided by a ring-type of permanent magnet. These robots, free from physical connections to external devices, i.e., non-tethered actuation, hold significant potential for applications in healthcare, such as …

Assessment Of Surface Waviness In A Wire Arc Additive Manufacturing Process, Shammas Mahmood Shafi

Dissertations, Master's Theses and Master's Reports

Wire Arc Additive Manufacturing (WAAM) is increasingly recognized for its ability to produce metal components with high deposition rates and efficiency, particularly in the aerospace and automotive sectors. However, one significant challenge that WAAM faces is achieving surface quality that complies with industry standards, as well as creating geometries that closely resemble the initial design. A crucial factor contributing to this challenge is surface waviness, which is an inherent characteristic of the WAAM process. This waviness arises from the geometry of the weld beads and the overlap distance between them. It can adversely affect the fusion quality of successive layers, …

Functional Verification Of Additively Manufactured Metallopolymer Structures For Structural Electronics Design, Nathan D. Singhal

Honors Undergraduate Theses

As an attempt to improve the overall cost-effectiveness and ease of structural electronics manufacturing, this study characterizes the mechanical and electrical responses of structures which are fabricated from a novel metallopolymer composite material by fused deposition modeling as they are subjected to quasi-static, uniaxial mechanical tension. Baseline values of tensile properties and electrical resistivity were first obtained via ASTM D638-22 standard testing procedures and linear sweep voltammetry (LSV), respectively. A hybrid procedure to measure in-situ mechanically dependent electrical behavior was subsequently developed and implemented. The mechanical and electromechanical testing was followed by the derivation of stochastic values for several mechanical …

Using Tensile And Compressive Stress Superposition During Incremental Forming To Manipulate Martensitic Transformation In Ss304, Elizabeth M. Mamros, Fabian Maaß, A. Erman Tekkaya, Brad L. Kinsey, Jinjin Ha

Faculty Conference Papers and Presentations

Single point incremental forming (SPIF) is a flexible manufacturing process that has applications in industries ranging from biomedical to automotive. In addition to rapid prototyping, which requires easy adaptations in geometry or material for design changes, control of the final part properties is desired. One strategy that can be implemented is stress superposition, which is the application of additional stresses during an existing manufacturing process. Tensile and compressive stresses applied during SPIF showed significant effects on the resulting microstructure in stainless steel 304 truncated square pyramids. Specifically, the amount of martensitic transformation was increased through stress superposed incremental forming. Finite …

Thermomechanical Process Simulation And Quantification Of Nanoscale Precipitation Influencing Ductility And Strength During Alloy Processing, Alyssa Stubbers

Theses and Dissertations--Chemical and Materials Engineering

Experimental process simulation and quantification of microstructure development during processing are challenging due to limitations with machinery temperature capability, inadequate resolution and sampling volume of currently available characterization techniques, and difficulty characterizing material microstructures as close to processing-relevant conditions as possible. This dissertation addresses how process simulation can be performed using Gleeble thermomechanical technologies and how microstructure development during these processing simulations can be quantified both in-situ and ex-situ.

The first portion of this dissertation demonstrates how Gleeble technologies can be applied to simulate complex material processing conditions in order to produce process-property profiles that can be used to inform …

Towards The Automation Of Post-Processing Of Additive Manufacturing Using Collaborative Robots, Logan Schorr

Theses and Dissertations

Despite the incredible potential that collaborative robots have, they are underutilized in several industries that could benefit greatly. These specialized fields, such as additive manufacturing, face challenges that can be solved with the use of robotics, including advanced computer vision, end-effector tooling, and process refinement. My research aims to utilize collaborative robots in an effort to solve the above stated problems, for the specific fields of additive manufacturing. Specifically within this field is the automation of post-processing; this is normally completely manual, as the tools for automation are not sufficiently developed to handle the flexibility required for additive manufacturing. This …

Resonant Ultrasound Spectroscopy(Rus) For Material Characterization Of Metal Am Parts, Malik Marks

College of Graduate Studies: Theses & Dissertations

Additive manufacturing (AM) has revolutionized the manufacturing industry by offering flexibility, customization, and rapid prototyping capabilities. However, ensuring the quality and reliability of AM parts remains a significant challenge due to variations in material properties and process parameters. The NDE method used in this study is Resonant Ultrasound Spectroscopy (RUS). This method was used to evaluate and understand its ability to detect internal voids and defects. Dog-bone samples were made using the 316L stainless steel alloy which were fabricated by powder bed fusion (PBF) AM technique at different processing conditions and post processing conditions. These samples were tested to find …