Manufacturing Commons^™

A Modification To The Skiving Process For The Manufacture Of Offset Geometry Strip-Fin Heat Sinks, Daniel Luberda

McKelvey School of Engineering Graduate Student Theses & Dissertations

High-powered electronics are extremely prevalent, and a vast majority of these devices use some form of heat sinks as either an active or passive cooling device. Although two-phase cooling technology has rapidly advanced to accommodate increasing heat loads on modern electronics, the added costs and complication inherent in two-phase cooling solutions makes effective air-cooled heat sinks potentially valuable.

A more effective heat sink can occupy a smaller footprint to dissipate the same heat flux, meaning material and packaging costs can be reduced. Aluminum heat sinks are produced through a variety of manufacturing processes, including machining, bonding, extrusion, casting, forging, 3D …

Bbt Acoustic Alternative Top Bracing Cadd Data Set-Norev-2022jun28, Bill Hemphill

STEM Guitar Project’s BBT Acoustic Kit

This electronic document file set consists of an overview presentation (PDF-formatted) file and companion video (MP4) and CADD files (DWG & DXF) for laser cutting the ETSU-developed alternate top bracing designs and marking templates for the STEM Guitar Project’s BBT (OM-sized) standard acoustic guitar kit. The three (3) alternative BBT top bracing designs in this release are
(a) a one-piece base for the standard kit's (Martin-style) bracing,
(b) 277 Ladder-style bracing, and
(c) an X-braced fan-style bracing similar to traditional European or so-called 'classical' acoustic guitars.

The CADD data set for each of the three (3) top bracing designs includes …

Open Innovation Trends, Issues And Policy Suggestions In Manufacturing Industry, Rongping Mu, Jingjing Guo, Jin Kang, Shuang Ma, Kangwei Chi

Bulletin of Chinese Academy of Sciences (Chinese Version)

At present, the new technology revolution and industrial transformation are accelerately reshaping the international industrial division of labor. It is urgent to adhere to the basic principles of "open cooperation, green and low carbon, value co-creation, and codevelopment", promote open innovation and cooperation in key areas of the manufacturing industry, and improve the open innovation and development capability in the manufacturing industry. This study first summarizes the open innovation trends of global manufacturing industries. Second, it analyzes major countries' policies in promoting open innovation in the manufacturing industry. Third, the current situation and problems of China's manufacturing open innovation is …

Dice Testing With The Running Chi-Square Distribution, Warren Campbell, Hunter Wimsatt

SEAS Faculty Publications

Dice are not fair. Producing a geometrically precise, uniform die is not possible. Casino dice come as close as possible to perfectly random dice because they are machined to an accuracy of a few ten-thousandths of an inch and the putty used for the pips (dots) is the same density as the plastic die body. Polyhedral dice used in games like Dungeons and Dragons are far more difficult to manufacture to high tolerances. Some dice are fairer than others. Since 20-sided dice (D20s) are very difficult to manufacture precisely, they were the focus of this study. The running chi-square distribution …

Integration Of Solar + Storage Installation Upstream In Modular Construction, Ondrej Labik

LSU Master's Theses

High initial costs, mainly due to inefficient construction processes, remains the greatest barrier for residential adoption of solar+storage (SPS) system. Modular construction, having a factory-controlled environment and control over the home design, is well suited to address these issues (e.g., efficiencies, waste, inventory control, quality). Furthermore, these areas have great potential in modular construction to address the high initial cost issue. This study focuses on the integration of SPS installation upstream in modular housing. Although moving the SPS installation process into the factory has many barriers (e.g., including change of scope of work at some workstations without affecting the whole …

Bbt Side Mold Assy, Bill Hemphill

STEM Guitar Project’s BBT Acoustic Kit

This electronic document file set covers the design and fabrication information of the ETSU Guitar Building Project’s BBT (OM-sized) Side Mold Assy for use with the STEM Guitar Project’s standard acoustic guitar kit. The extended 'as built' data set contains an overview file and companion video, the 'parent' CADD drawing, CADD data for laser etching and cutting a drill &/or layout template, CADD drawings in AutoCAD .DWG and .DXF R12 formats of the centerline tool paths for creating the mold assembly pieces on an AXYZ CNC router, and support documentation for CAM applications including router bit specifications, feeds, speed, multi-pass …

8 Dof Quadrupedal Hopping Robot, Clayton T. Elwell, John Bennett, Tyler Mccue, Daniel Munic

Mechanical Engineering

The goal of our senior project was to fabricate an eight degree of freedom (DOF) prototypical quadrupedal robot, develop a controller than commands the quadruped to repeatedly jump 10 cm in the air, and fabricate a modular test stand to safely deploy our controller on the quadruped. The creation of a functional quadruped will bring attention to Dr. Siyuan Xing and Charlie Refvem’s research group, Cal Poly Legged Robots, and will give future Cal Poly undergraduate and graduate students a learning tool to explore dynamic control of biomimetic robotic systems.

Over the course of our senior project, we successfully manufactured …

Coil Quick (Rv Sewer Hose Compressor) Device, Arturo Guijosa-Ruiz, David M. Bourgoin

Mechanical Engineering

The purpose of this design project is to design, build, and test an RV sewer hose compactor device that can be used by the project sponsor and marketed to other RV owners. The goal of the RV sewer hose compactor device is to mechanically compress an RV sewer hose from its fully extended length to its fully compressed and storable state. Since a prototype device has already been developed, this project will aim to improve the prototype design to make it smaller, quicker, quieter, and more durable. Additionally, we improved the device to make it more user friendly and have …

Design Of A Proprioceptive Actuator Utilizing A Cycloidal Gearbox, Craig John Kimball

Master's Theses

Legged robotics creates the demand for high torque compact actuators able to develop high instantaneous torque. Proprioceptive actuator design theory is a design theory that removes the need for a torque feedback device and relies on the stiffness in the leg for absorbing the high Ground Impact Forces created by walking locomotion. It utilizes a high torque density motor paired with a gearbox with a high gear ratio for torque multiplication. Previously work has been done to design a proprioceptive actuator design that utilizes a planetary gearbox to create a modular low-cost actuator for legged robotics. The purpose of this …

Interactive Lego Girl Scout Arm, Chris Suzuki, Emi Okuyama, Bryson Shores, Karina Sandoval

Mechanical Engineering

This Senior Project Report document outlines the senior design project for Girl Scouts of California’s Central Coast (GSCCC) led by a team of four Mechanical Engineering students at California Polytechnic State University, San Luis Obispo. The project encompasses the researching, designing, prototyping, and testing of a LEGO robotic arm for the Girl Scouts to learn more about STEM (Science, Technology, Engineering, and Mathematics) and provide support to each Girl Scouts cookie sales in their stores. Their goal was to build a LEGO robotic arm that will interact with customers at the Girl Scout stores and promote the girl scouts' interest …

Baja Bug Suspension, James Ankers, Rebecca Hansen, Dakota Robert Hollingsworth, Thomas Alfred Spycher

Mechanical Engineering

The goal of this senior project was to design and build a long travel front suspension system for a VW Bug. This started by defining the scope of the project and performing preliminary research. In this step, similar products were investigated, and research was done on stakeholders and customers. Next, concept development, design, and evaluation were performed. With this, the first iteration of our CAD model was designed, and physical prototypes were made. Using all this information, and feedback from advisors and sponsors, multiple iterations of our CAD were performed until the design was ready to manufacture. Drawings were taken …

Multifamily Complex Smart Locks For Property Management And Tenant Security, April Mills, Allen Chen, Dana Kumamoto, Michael Cook

Mechanical Engineering

Maintaining and managing hundreds of locks and physical keys for an apartment complex can be time consuming and costly, especially when the apartments turn over to new tenants. Our goal was to develop a smart door lock that is compatible with Obodo’s management app for apartment complexes to make accessing apartments secure and simpler for tenants and easier to manage for owners.

We designed and manufactured one smart door lock that is powered with four AA batteries and utilizes a dynamic NFC device and Bluetooth technology. The board can enter a sleep mode which reduces power consumption. The dynamic NFC …

Radiology Associates Medical Scan Forecasting, Everett M. Notaro, Mitchell Carpenter, Tyler Deis, Kimberly Williams

Industrial and Manufacturing Engineering

After discontinuing their subscription with Shinyapps and relying on a manual forecasting process, Radiology Associates needs a new method to forecast the number and types of scans that will be executed at each site location. Radiology Associates utilizes Quinsite, which incorporates a live link to their database, as a host for all their Tableau dashboards. This project will create an accurate forecasting model utilizing complex forecasting methods to be hosted by Quinsite which is accessible by all management within Radiology Associates. To begin this process, an exponential smoothing model was created in Tableau to solidify dashboard and storyboard design. Additionally, …

Increasing Legends Salon Revenue Per Square Foot, Jacob William Andreatta, Margaret Faison Gustafson, Julia Galina Odisho, Joshua Spry Morrison

Industrial and Manufacturing Engineering

Katie MacNamara acquired Legends Hair Salon in Atascadero, California in January of 2021. After a few months of learning to run her own business she discovered that her retail revenue per square foot was not high enough. Her goal, and the project objective, was to raise her revenue while also increasing space for her stylists. The metrics used for these objectives were revenue per square foot and the square footage of the retail areas. The beginning state metrics were 48.75 square feet of retail and a retail revenue per square foot of $2.15 with a total of six stylist stations. …

Eagle Medical Tray Denesting & Debris Removal Process, Nicholas Allen Ungefug, Noah Chavez, Susana Shu-Lin Okhuysen, Michael Augustine Pennington

Industrial and Manufacturing Engineering

Eagle Medical Incorporated is a contract medical device packaging and sterilization company. The company purchases thermoformed medical packaging trays, which maintain the sterility of medical devices, from various manufacturers. To ensure packaging quality and to prevent cleanroom contamination, Eagle Medical inspects and sterilizes each blister tray that they order. This process is an essential non-value-added activity that creates a bottleneck. Cleanroom employees must stop packaging medical devices and attend to the processing of blister trays and packaging solutions. The blister trays arrive at Eagle’s facility in nested stacks. Vibration and movement during shipping further compresses the stacks, which makes separation …

Grey-Taguchi Approach To Optimize Fused Deposition Modeling Process In Terms Of Mechanical Properties And Dimensional Accuracy, Md Asif Bin Syed, Qausar Rhaman, Hasan Md Shahriar, Mohammad Muhshin Aziz Khan

Graduate Student Scholarship

Fused Deposition Modeling (FDM) is a process that allows for the rapid production of functional parts through the deposition of fused material layers in a sequential manner. FDM has flexibility and the potential to create complicated parts. This study aims to optimize the FDM process parameters in terms of tensile strength, flexural strength, and longitudinal shrinkage using the Grey-Taguchi approach. The input parameters chosen to study the effects on dimension and mechanical properties are layer thickness, the raster angle, fill density, the number of contours, printing temperature, and printing speed. The Taguchi L27 orthogonal array is used as the statistical …

The Effect Of Surface Gas/Liquid Entrapment On Drag Reduction, Haosen Tan

Mechanical Engineering Research Theses and Dissertations

Economic globalization has made today’s world more closely linked, where transportation (e.g. shipping, pipeline) has played an important role. Approximately over 60% (in air), 80% (underwater), and 100% (in pipeline) propulsive power is used to overcome surface drag, so reducing surface drag will have a substantial impact economically and environmentally.

To develop a surface that has lower drag, the intuitive idea is to convert no-slip boundary conditions to slip or partial slip ones. To achieve that, the most promising approach is to replace the solid-liquid boundaries completely or partially with gas-liquid or liquid-liquid boundaries, because the shear stress is much …

Center For Manufacturing Excellence Capstone Project: Sec Rivals Checkers, Ward Winstead

Honors Theses

Each year, the seniors in the Haley Barbour Center for Manufacturing Excellence complete a capstone project. A team comprised of seniors in varying disciplines work to develop a business model focused on producing a specific product. This team, SEC Rivals Checkers, chose to produce wooden checker boards where each half of a board is custom to a specific SEC school. These halves were designed to be interchangeable, so a variety of different combination could be created when utilizing the product. Through initial marketing analysis, cost estimation, prototyping, and process development, the original SEC Rivals Checkers idea was developed into a …

Customized Sidearm Case: Leading A Cme Capstone Team From Concept To Production, Robert B. Sharp

Honors Theses

The goal behind this thesis is to document and analyze my performance as the project manager for the Customized Sidearm Case capstone team during the Center for Manufacturing Excellence’s senior capstone experience. The capstone experience begins the fall of students senior year where a select number of product ideas submitted by the students are chosen, and teams are built around these projects. The objective of the project is to walk a product from the concept phase through the entire design process resulting in a full-scale production run during the spring semester. My product pitch of a wooden sidearm case, customized …

Examining The Different Snap-Through Characteristics Of Bistable Cfrp Composite Laminates, Vishrut Deshpande

All Theses

Bistable carbon fiber composites, whose bistability arises from having asymmetric fiber layouts in different layers, have shown immense potential for use in shape morphing and adaptive structure applications. While many studies in this field focus on these composite laminates’ external shapes at the two stable states, their snap-through behavior of shifting from one stable shape to the other remains a critical aspect to be investigated in complete detail. Moreover, symmetric loading conditions have been extensively studied based on the classical lamination theory, but the asymmetric loading conditions received far less attention. Therefore, this study examines an asymmetric, localized point load …

Ambient Temperature Phase Change Launcher, Johnny Molloy

Senior Honors Projects

JOHNNY MOLLOY (Mechanical Engineering) Ambient Temperature Phase Change Launcher Sponsor: Bahram Nassersharif (Mechanical Engineering)

Deployment of payloads stored in watertight cylindrical bodies in underwater environmental conditions are of interest to the marine and naval community. The proposed work will investigate the possibility of using inert carbon dioxide gas compressed into its liquid state and stored under pressure to launch payloads by means of expansion from a cylindrical tube. To suit the needs of the Naval Undersea Warfare Center (NUWC), this launching system must fire from up to 14 ft underwater, have two degrees of freedom, and the payload must not …

An Experimental Analysis Of Thin Sheet Metal Bending By Ultrafast Laser Peen Forming, Bryce J. Tessmann

All Theses

This study demonstrates the viability of femtosecond laser peen forming for bidirectional sheet metal bending. Ultrafast laser forming is a valuable method thanks to its flexibility, negation of springback, no need for a confining or protective layer, and minimalization of thermal degradation in comparison to other forming processes. However, femtosecond lasers have traditionally been believed to be unsuitable for laser forming in comparison to nanosecond lasers, particularly bidirectional bending, because the induced shock waves were expected to be weak. Conversely, in this study it is elucidated that the femtosecond laser-induced shock waves are extremely strong (several hundred GPa) but the …

Additive Manufacturing Of Variable Contrast Computed Tomography Anatomical Phantoms Using A Single Feedstock In Fused Filament Fabrication, Cory J. Darling

LSU New Orleans Theses and Dissertations

Anatomical phantoms used in biomedical education and training benefit greatly from Fused filament fabrication’s (FFF) ability to rapidly produce complex and unique models. Current materials and methods used in FFF have limited ability to accurately produce phantoms that can mimic the radiological properties of multiple biological tissues. This research demonstrates that the CT contrast of FFF produced models can be modified by varying the concentration of bismuth oxide in acrylonitrile butadiene styrene (ABS) filaments and a tunable CT contrast that mimics the CT contrast ranging from fatty tissue to cortical bone using a single composite filament without introducing artificial image …

Properties Of 25cr7ni Stainless Steel Fabricated Through Laser-Powder Bed Fusion., Arulselvan Arumugham Akilan

Electronic Theses and Dissertations

Stainless steel is a low carbon high alloyed system with higher concentrations of Cr& Ni, which impart high corrosion resistance to them. Alloys with approximately 25% Cr & 7% Ni in their chemical composition are commercially referred to as ‘Super Duplex Stainless Steel’. They have a unique phase composition of approximately 50% ferrite & 50% austenite, yielding a robust combination of high mechanical strength & corrosion resistance. They find extensive interest & application in the fields which demand a longer service life under intense mechanical / corrosive environment such as offshore oil rigs & pipelines in nuclear power plants. Traditional …

Autonomous Material Refill For Swarm 3d Printing, William C. Jones

Mechanical Engineering Undergraduate Honors Theses

3D printing currently offers robust and cheap rapid prototyping solutions. While standard 3D printing remains at the periphery of mass production, the technology serves as a starting point for the development of swarm manufacturing. Since swarm manufacturing is predicated upon autonomy, swarm technology companies such as AMBOTS are seeking to minimize human involvement in the swarm’s functions. At present, the 3D printing swarm consists of the printers, a transporter which can take them between job sites, and the floor tiles which provide power and support the build surfaces. To add to this ecosystem, this project is focused on the design …

Multistage Modeling Of Fatigue Of Ti-6al-4v Fabricated By Different Additive Manufacturing Techniques, Lionardo Lado, Saeed Ataollahi, Mohammad J. Mahtabi

Honors Theses

Thanks to its high strength-to-weight ratio and corrosion resistance, Ti-6Al-4V has gained a lot of attention in additive manufacturing (AM) of complex parts with aerospace and medical applications. The realistic loading condition in these applications is mostly cyclic. However, the main challenge with AM of this alloy - and in general AM of metallic parts - is fatigue resistance and durability of the part, which has been reported to be much lower than the conventional materials. In this study, fatigue life performance of three additive manufacturing methods was compared using the Multistage Fatigue model (MSF). MSF model predicts the fatigue …

Effects Of Sizing Agents On Mechanical Properties Of Carbon Fiber–Polymer Composites Via Fused Filament Fabrication Additive Manufacturing., Benjamin D. Mitchell

Electronic Theses and Dissertations

This study demonstrated the effects of changing the sizing agent parameter during the preparation of carbon fibers on the mechanical properties of composite made with acrylonitrile butadiene styrene (ABS) as the matrix material and carbon fibers as the fiber material. Three types of sizing agents produced by Allnex were used to coat three different batches of carbon fibers that were mixed with a torque rheometer and extruded with a barrel-style melt extruder into continuous spools of 1.75 mm filament for use with commercial 3D printers. Tensile tests were conducted on the filaments and tensile bars printed from the materials. Results …

Triggering Thermal Runaway In Lithium-Ion Batteries, Chris John

Honors Scholar Theses

The proliferation of lithium-ion batteries enables electric devices such as cell phones to electric vehicles to become a reality. A latent danger, however, exists in these batteries. Mechanical, thermal, or electrical damage can initiate a phenomenon known as thermal runaway (TR). This damage causes internal short circuits within the battery, releasing heat and triggering exothermic decomposition reactions. The battery will catch fire if rapid cooling is not present. While experimental designs exist for evaluating TR, significant safety hazards and impracticality may impede testing efforts. Finite element analysis, therefore, becomes a vital tool in modeling TR and mitigation techniques. However, there …

Machine Learning Tools In The Predictive Analysis Of Ercot Load Demand Data, Md Riyad Hossain

Theses and Dissertations

The electric load industry has seen a significant transformation over the last few decades, culminating in the establishment and implementation of electricity markets. This transition separates electric generation services into a distinct, more competitive sector of the industry, allowing for the introduction of greater unpredictability into the system. Forecasting power system load has developed into a core research area in power and energy demand engineering in order to maintain a constant balance between electricity supply and demand. The purpose of this thesis dissertation is to reduce power system uncertainty by improving forecasting accuracy through the use of sophisticated machine …

Monitoring Of Tool Wear And Surface Roughness Using Anfis Method During Cnc Turning Of Cfrp Composite, Md Mofakkirul Islam

Theses and Dissertations

Carbon fiber-reinforced plastic (CFRP) is gaining wide acceptance in areas including sports, aerospace and automobile industry . Because of its superior mechanical qualities and lower weight than metals, it needs effective and efficient machining methods. In this study, the relationship between the cutting parameters (Speed, Feed, Depth of Cut) and response parameters (Vibration, Surface Finish, Cutting Force and Tool Wear) are investigated for CFRP composite. For machining of CFRP, CNC turning operation with coated carbide tool is used. An ANFIS model with two MISO system has been developed to predict the tool wear and surface finish. Speed, feed, depth of …