Manufacturing Commons^™

Development Of Novel Turbomachinery Manufacturing Methods, Timothy P. Winkler

Theses and Dissertations

Compact turbine engines are of increasing interest as a means of propulsion for small, lightweight, low cost, unmanned aerial systems. This study looks to leverage advancements in novel manufacturing technology to produce turbomachinery components while simultaneously reducing costs and manufacturing time. To determine the feasibility of drop-in replacements for stock components this study focused on several research areas. This included materials research on both polymer-reinforced and ceramic materials, specimen tensile testing to determine temperature-dependent material properties, finite element analysis of multiple candidate materials, design and fabrication of a spin test rig, and physical spin testing of manufactured components to predict …

Creativity, Craftsmanship, And Connection: Large-Format Sculpture Design, Jacqueline L. Puga, Gordon Hoople

The Transdisciplinary STEAM+ Journal

Artistry is a concept that is not usually explored in engineering yet is an invaluable skill that touches everything from product design to systems thinking. This past summer I developed conceptual designs for a large format sculpture that required connecting engineering knowledge with artistic vision. The initial phase required constant inspiration and creativity. The first step was to look at previous sculptures showcased throughout the world, such as at venues like “Burning Man,” to understand the possibilities or limitations of the space provided. Sketching varied and numerous ideas was essential in our design process. Next, we took our favorite ideas …

Study Of The Graphene Energy Absorbing Layer And The Viscosity Of Sodium Alginate In Laser-Induced- Forward-Transfer (Lift) Bioprinting, Shuqi Zhou, Jianzhi Li, Ben Xu

Manufacturing & Industrial Engineering Faculty Publications

Laser induced forward transfer (LIFT) bioprinting has been viewed as a new and actively developed three-dimensional bioprinting technology due to its high accuracy and good cell viability. The printing quality is highly dependent on the jet formation and its stability in the LIFT bioprinting process. The objective of this study is to investigate the effect of a graphene Energy Absorbing Layer (EAL) and alginate hydrogel (SA) (w.t. 1% and 2%) viscosity on jet generation in the LIFT bioprinting process. Since SA exhibits a shear-thinning behavior, it is a non-Newtonian fluid. The effect of EAL thickness and SA’s viscosity were addressed …

Application Of Gaussian Mixture Models To Simulated Additive Manufacturing, Jason Hasse, Semhar Michael, Anamika Prasad

SDSU Data Science Symposium

Additive manufacturing (AM) is the process of building components through an iterative process of adding material in specific designs. AM has a wide range of process parameters that influence the quality of the component. This work applies Gaussian mixture models to detect clusters of similar stress values within and across components manufactured with varying process parameters. Further, a mixture of regression models is considered to simultaneously find groups and also fit regression within each group. The results are compared with a previous naive approach.

Launching A 3d Printing Program For Students: Recommendations And Best Practices For Libraries, Wilhelmina Randtke, Lee Bareford

Georgia Library Quarterly

The Georgia Southern University Libraries launched a 3D printing program for students in July 2022. Prior to launch, library employees at two of Georgia Southern University’s campuses investigated options for implementing safe, affordable, and sustainable 3D printing in existing academic libraries without retrofitting costly ventilation systems into existing facilities. This article describes the reasons why the Georgia Southern University Libraries thought that a 3D printing program could fulfill a service need for students across university colleges and departments and outlines some of the challenges, best practices, and unique innovations that the library’s employees experienced throughout the program launch process. The …

Lignin Derived Hydrophobic Deep Eutectic Solvents As Sustainable Extractants, Yuxuan Zhang, Qi Qiao, Usman Lame Abbas, Jun Liu, Yi Zheng, Christopher Jones, Qing Shao, Jian Shi

Markey Cancer Center Faculty Publications

Solvent innovation has become a central task for improving the sustainability of chemical processes1. Deep eutectic solvents (DESs) emerge as environmentally friendly alternatives to toxic and volatile organic solvents. One appealing aspect for DESs is that they can be synthesized using naturally occurring compounds from biomass. Herein, we prepared novel hydrophobic DESs based on lignin derivatives and characterized their physicochemical properties including density, viscosity, and thermal behavior. The results showed that five lignin-derived hydrophobic DESs made from menthol, thymol, and 2,6-dimethoxyphenol were promising as green solvents due to their low viscosities and environmentally friendly constituents. To evaluate the potential application …

Effect Of Austenization And Repeated Quenching On The Microstructures And Mechanical Properties Of Wear-Resistant Steel, Yanuar Nugraha, Myrna Ariati Mochtar

Journal of Materials Exploration and Findings

This study was focused on determining the effect of repeated austenitization and quenching on mechanical properties and microstructure. The experiment was carried out in a rolled quencher facility with a heat treatment process of one to two times, with parameters of an austenizing temperature of 9500C and quenching at a temperature of 8500C with pressurized water media. Testing of specimens, including microstructure observations and hardness testing. The repeated heat treatment process showed an increase in hardness of 0.79% on one-time repeated heat treatment and 1.65% on two repeated heat treatments. This occurs due to the presence accompanied by refinement of …

Combat Robot, Riley Buxton

All Undergraduate Projects

In the sport of combat robotics, the goal is to build a robot that can incapacitate an opposing robot before it becomes incapacitated itself. For this project, a combat robot was designed and tested to compete in Western Allied Robotics’ first competition at Central Washington University. The robot was built to compete in the beetle weight class which means the entire robot had to weigh less than 3 lbs.

To ensure the robot was competitive, a number of important design choices were made. Firstly, an effort was made to ensure that the design was simple and easy to take apart …

Jack And Alex Rc-Baja, Alex Vornbrock

All Undergraduate Projects

Teams of two mechanical engineering students were tasked with the construction of an RC Baja car qualified by the rules and regulations of the Baja competition as well as specifications set by the individual team member for their portion of the vehicle. This proposal focuses on the Chassis and Drivetrain of the vehicle while team member Jack Stutz oversaw the steering and suspension. Teams will compete against each other in various modes to determine the best vehicles of the competitors. The chassis was made of standard aluminum, the remaining parts made by the students were made with PLA; both materials …

Rc Baja Suspension And Steering, Garrett Bailey

All Undergraduate Projects

The RC Baja team set out to engineer and construct a working remote-control device that can compete in the ASME Baja Competition. The students have a focus on either suspension and steering or drivetrain and chassis. This report is centered on the suspension and steering. First, multiple analyses were completed using engineering methods such as mechanical design, statics, strengths of materials, and dynamics for parts of the device. The calculations found in the analysis are then used to create designs for the parts so that they will meet the requirements and be successful in the competition. After the parts are …

Rc Baja 2023 Drivetrain And Chassis, Nathan Norby

All Undergraduate Projects

Students’ objective this quarter was to design a remote-controlled vehicle that utilizes a 4-link rear suspension, an I-beam front suspension, the ability to withstand a substantial front impact and several gearing options. The team also used several agreed upon design requirements to quantify the results of the objective.

To meet these objectives students followed a strict engineering method. Students split into a team’s divided the work into two sections. Max was responsible for the suspension and steering and Nathan was responsible for the chassis and drivetrain. Methods included engineering analysis which used mechanics of materials, static analysis, dynamic analysis, and …

Advanced Microstructural Characterization Of Functionally Graded Dental Ceramic Material For Materials-Informed Finishing, Angani Vigneswaran

Theses and Dissertations--Manufacturing Systems Engineering

Yttria-stabilized tetragonal zirconia polycrystal (Y-TZP) has gained popularity as the choice of material for dental prosthetics. Ivoclar Vivadent’s IPS e.max ZirCAD Prime dental ceramic incorporates a unique gradient technology that varies the yttria content over the thickness of the material. The top layer is composed of 5Y-TZP which is desired for its optical properties while the bottom layer is composed of a much stronger 3Y-TZP. In between the two layers, 5Y-TZP and 3Y-TZP are mixed to form a transition layer. Varying the amount of yttria allows for more esthetically pleasing translucency in the visible areas of the restoration without compromising …

Rc Baja Project: Suspension And Steering, Chance Hills

All Undergraduate Projects

Students designed and manufactured an RC Baja car to compete in the ASME RC Baja competition. The goal of this section of the project was to create a steering system and suspension system that work together properly with a partner’s chassis/drive train systems during tests and competitions. The car needed to be able to complete in the three events, which are a drag race, a solemn course, and the Baja event. The RC will also be evaluated on the ability to climb inclines, top speed, and withstand the drop test. This proposal will explain all the details and effort that …

Evaluating The Sustainability Of Paper And Plastic Substitute Material Limex, E.-Lexus Thornton, Avery Hartley, Daniel Caudill, Martin Gamesu, Julius M. Schoop, Fazleena Badurdeen

Mechanical Engineering Faculty Publications

With the increasing decline in the environment and natural resources it is important to find new ways in which manufacturing can increase the sustainability of the world. This study seeks to compare LimeX, a state-of-the-art paper and plastic alternative primarily made of limestone, with conventional paper and plastic materials. For a better understanding of LimeX as a material, a brief investigation of the mechanical and chemical properties will be performed through experimentation and analysis. In addition, this paper aims to evaluate the sustainability of LimeX through the analysis of metrics relating to the triple bottom line (environmental impacts, economic impacts …

Jcati Carbon Fiber Recycler: Crusher System, Devin Riley

All Undergraduate Projects

With a substantial rise in Carbon Fiber use across all industries, the need for a way to recycle the waste has grown as well. A group of Mechanical Engineering Technology students at Central Washington University funded by the Joint Center for Aerospace Technology (JCATI) have created a machine to recycle waste wing trimmings from the Boeing company’s airplanes. This machine consists of 5 different sub-assemblies being the oven, crusher, gear train, conveyor, and shredder. The purpose of this project was to decrease the deflection in the crusher caused by bulging in the housing and movement of the bearings. To decrease …

A Conceptual Model For Quality 4.0 Deployment In U.S. Based Manufacturing Firms, Thomas Jones

Electronic Theses and Dissertations, 2020-2023

Manufacturing is currently undergoing a fourth industrial revolution, referred to as Industry 4.0, enabled by digital technologies and advances in our ability to collect and use data. Quality 4.0 is the application of Industry 4.0 to enhance the quality function within an organization. Quality practitioners are uniquely positioned within organizations and already possess data application skillsets. Despite a perception that Quality 4.0 will be critical to future success shared by a majority of industry, most companies have not attempted to implement Quality 4.0 strategy, and those that have report very low rates of success. The goal of this study was …

Machine Learning Applications In Advanced Additive Manufacturing: Process Modeling, Microstructure Analysis, And Defect Detection, Peter Warren

Electronic Theses and Dissertations, 2020-2023

Non-destructive evaluation (NDE) techniques are critical for assessing the integrity, health, and mechanical properties of materials manufactured from various methods. High fidelity NDE techniques are essential for quality control but often lead to massive data generation. Such a vast data load cannot be manually processed, this leads to a severe bottleneck for process engineers. Machine learning (ML) offers a solution to this problem by providing powerful and adaptable algorithms capable of learning patterns, identifying features, and finding hidden relationships in large sets of data. Various ML models are used in this work to improve predictions, improve measurements, detect anomalies, classify …

Classifying Multi-Generational Products For The Circular Economy, Buddhika M. Hapuwatte, Fazleena Badurdeen, I. S. Jawahir

Institute for Sustainable Manufacturing Faculty Publications

Manufacturers are increasingly interested in the circular economy (CE) and potential of circular productions. To fully utilize CE, better guidance at the design stage is needed to establish closed-loop flows and prioritize higher value retaining end-of-use (EoU) practices such as reuse and remanufacture (i.e., parts harvesting). Intergenerational commonality (IC) is a method to increase EoU parts harvesting. However, closed-loop parts harvesting potential depends on the compatible timing between design generations’ production and EoU returns curves. Therefore, in this paper, we explore an approach to make an initial assessment on where IC as a closed-loop CE strategy can produce most benefit, …

Material Extrusion-Based Additive Manufacturing: G-Code And Firmware Attacks And Defense Frameworks, Haris Rais

Theses and Dissertations

Additive Manufacturing (AM) refers to a group of manufacturing processes that create physical objects by sequentially depositing thin layers. AM enables highly customized production with minimal material wastage, rapid and inexpensive prototyping, and the production of complex assemblies as single parts in smaller production facilities. These features make AM an essential component of Industry 4.0 or Smart Manufacturing. It is now used to print functional components for aircraft, rocket engines, automobiles, medical implants, and more. However, the increased popularity of AM also raises concerns about cybersecurity. Researchers have demonstrated strength degradation attacks on printed objects by injecting cavities in the …

A New Course In Defense Manufacturing – An Introduction To Shipbuilding, Alley C. Butler

Manufacturing & Industrial Engineering Faculty Publications

This paper discusses the development and deployment of a new course in DMEI (Defense Manufacturing Engineering Innovation) titled, “Introduction to Shipbuilding.” This course has been taught using Zoom since 2021 at both the University of Texas Rio Grande Valley, a Hispanic Serving Institution, and Virginia State University, a Historically Black University. After a brief literature review, an outline of the course is presented with topics including the maritime market for shipbuilding, economics of shipbuilding, the classification agencies, metallurgy and welding processes, ship structure and assembly, shipyard layout, accuracy control, and shipbuilding planning and scheduling. Difficulties in obtaining an appropriate textbook …

Full Body Harness Design Modifications And Evaluation: A Senior Design Project, Martin Mead, Jordan Von Seggern

The Journal of Undergraduate Research

Full-body harness (FBH) is critical for the safe operation of industrial and recreational activities, from installing and maintaining infrastructure such as wind turbines to ziplining and mountaintop adventures. However, harness design remains in the proprietary information of companies with limited technical information available for improvements or readjustments to specialized applications. As the outcome of the Capstone project, the paper focuses on multiple technical aspects and the engineering processes for designing FBH for ziplining recreational users, from selecting and testing materials for operation in cold weather to improvements in design and manufacturing for user comfort. The project is guided by technical …

Mechanical Properties Evaluation Of 3d Printed Petg And Pctg Polymers, Kalpesh Krishnarao Bhosale

Electronic Theses and Dissertations

3D printing is also known as additive manufacturing (AM) which has become a popular manufacturing trend over the years. Due to its unique advantages of fast production rate, ability to create complex geometrical features, toolless manufacturing and many more attracts various industries from Aerospace to general cosmetics. Along with the advancement in material science, various polymers including Polylactic Acid (PLA), Polyethylene terephthalate glycol (PETG) and many more are available for 3D printing. Due to the wide range of applications in PLA, it is necessary to improve its toughness to make it more suitable by adding Poly Cyclohexylenedimethylene Terephthalate glycol (PCTG) …

Distillery, Clare Nicholas, Patrick Hanlon

Williams Honors College, Honors Research Projects

The goal for this project is to make a cost effective still. We will be implementing cost saving parts to create a cheap but effective still. From initial research conducted, we will try to combine a stainless steel still and copper still together so that the cheaper material (stainless steel) and the component that removes sulfur compounds (copper) are both implemented. The ME side of the project will focus on the actual design and construction of the parts that will be implemented into the still. Included in the design process will be calculations of heat transfer for the current and …

Design And Development Of Smart Wardrobe Technology, Mikhail Filatov

All Graduate Theses, Dissertations, and Other Capstone Projects

The increasing demand for online shopping in the 21st century is causing rapid growth in technology and methods in marketing and sales fields. Present thesis work scrutinizes the process of design and development of the device that simplifies the process of trying on and buying clothes in online retail stores, the development of which is based on the known basics of operational, mechanical, and electrical designs for computational systems, with account for ergonomics and manufacturing sustainability. The following research represents the market analysis for competition identification, description of all operational modes of the system, list of mechanical and electrical components …

Exploring Additive Manufacturing In A Space Environment - A Capstone Design Project Experience, Zain Zafar Khan, Zachary Alan Sobelman, Sharanabasaweshwara Asundi

Mechanical & Aerospace Engineering Faculty Publications

The employment of additive manufacturing in the non-standard environments like space, ships, or submarines has the potential to be an advanced utility not only in the pre-flight production of aerospace components and structures, but also for the onboard manufacturing of components and tools necessary for future space missions. For example, the ability to produce tools and structural components on the International Space Station can provide the space community the opportunity to make repairs and upgrades to the space station without wasting time and resources transporting such materials through additional missions. Additive manufacturing would allow for space missions to use on …

Anisotropic Material Behavior Of 3d Printed Fiber Composites, Jordan Garcia

Theses and Dissertations--Mechanical and Aerospace Engineering

Literature has shown that 3D printed composites may have highly anisotropic mechanical properties due to variation in microstructure as a result of filament deposition process. Laminate composite theory, which is already used for composite products, has been proposed as an effective method for quantifying these mechanical characteristics. Starting with the analysis of comparing the printing orientation of premanufactured carbon fiber reinforced filament, the mechanical properties of 3D printed objects were examined. The mechanical properties changed not only as a result of machine choice, but how the sample is oriented along the printing bed. The analysis continued with looking at the …

Machine Learning For Advancing Automation And Quality Control In Robotic Welding, Joseph Kershaw

Theses and Dissertations--Mechanical and Aerospace Engineering

Welding is a vital manufacturing process across a diverse range of industries to permanently join metallic components into needed assemblies. Though widely used and studied, the process is not fully understood due to the myriad of interconnected physics that present themselves during the welding process. Electrical, thermal, structural, and fluidic mechanics are simultaneously at work influencing one another to achieve the bonding that manufacturers desire. In addition to general manufacturing issues, such as tool wear or misalignment, micro-level changes to the material structure and composition can have cascading impacts on the final weld. This complexity makes it difficult, if not …

Generalizable And Adaptable Data-Driven Methods For Overcoming Barriers To Practical Industrial Condition Monitoring, Matthew B. Russell

Theses and Dissertations--Electrical and Computer Engineering

The future of smart manufacturing relies on predictive maintenance systems that intelligently minimize expensive downtime through timely assessment of machine condition. Deep Learning (DL) has achieved excellent performance in industrial condition monitoring experiments, but the constraints of the manufacturing environment prevent many algorithms from being practically deployed on the factory floor. Ubiquitous sensing from online machines generates high velocity data streams that require new techniques for efficient transmission and storage. Despite these ever-increasing data lakes, many applications still lack the data needed for training DL fault diagnosis and wear tracking models since most data is unlabeled and only from nominal …

Recycling Metal Chips Into Usable Materials, Alex Mortensen, Ben Mortensen

Williams Honors College, Honors Research Projects

This report entails the scope, design considerations, and plans for creating a metal chip converter into metal briquettes. The construction is a set of machines with multiple processes to make the conversion happen. The process includes washing fine metal chips, drying them off, compressing them, and melting them down into usable briquettes. This project is intended to make a simple process to recycle metal chips into usable material for reuse. The project's objective is to reduce the costs of storage and recycling waste by offering a solution to recycle it into materials the shop can reuse.

The Passing Board, John Fitzgerald

Williams Honors College, Honors Research Projects

For my Honors Research Project I am taking a more personal route and looking to solve a childhood question/issue by designing a board that is small and easy to transport while also giving the best bounce pass possible. My proposed project would be a board that a soccer player can play a bounce pass onto and receive the ball from. The base of this design sounds simple enough, however, I would like to implement a way that the board can be adjusted to alter the angle of return of the soccer ball after the bounce. I also want to design …