Other Mechanical Engineering Commons^™

Virtual Process Modeling Of Metal Additive Manufacturing Basedon Direct Energy Deposition In-Situ Failure, Jachin J. Ramirez

2025 Fall Honors Capstones Projects - Archive

This study builds a mesoscale finite element simulation to examine how internal stresses form during additive metal manufacturing using directed energy deposition. The goal is to track how heat and stress develop layer by layer and determine where a failure criterion could appear during the print. The model uses temperature-dependent material properties for Inconel 718 and a moving heat source defined with custom G-code.

Thermal results are mapped into a mechanical simulation to watch stress accumulate as new layers are added. Different scan paths were tested to determine whether varying heat exposure could reduce the extent of a region exceeding …

Thermal Modeling Techniques For Additively Manufactured Porous Metals, Lucas D. Rambo

Master's Theses

Advances in additive manufacturing have enabled the creation of metallic components with tailored porosity, offering design flexibility for thermal, structural, and fluid transport applications. This thesis investigates the effective thermal conductivity (ETC) of porous Inconel 625 (IN625) and Inconel-ceramic composites (IN625-RAM2) fabricated by Laser Powder Bed Fusion (LPBF) using Elementum 3D’s PermiAM technology. Experimental measurements of thermal conductivity using the laser flash method are compared to numerical models built from micro-computed tomography data. Simulations were performed using both finite element (FE) and finite volume (FV) methods to evaluate thermal transport in real microstructures. The study investigates the effects of micro- …

Computational Modeling Of Torque Arm And Load Cell Interactions In Uta Racing Brake Dynamometer, Anthony A. Aiyedun

2025 Spring Honors Capstone Projects - Archive

The UTA Racing Team is developing a brake dynamometer to measure the coefficients of friction of various brake pads and calipers under controlled conditions. The dynamometer simulates on-track braking scenarios, testing brake pads at temperatures up to 1300ºF and pressures similar to racing environments. Its primary goal is to generate accurate friction vs. temperature graphs for various brake pad and rotor combinations, addressing the need for dedicated testing equipment. This project creates an ANSYS simulation of the torque arm and load cell interaction. The computational model accurately represents the relationship between applied torque and measured load cell force, incorporating precise …

Computational Study On Suppression Of Airfoil Flow Separation Using High-Frequency Translational Surface Actuation, Bibek Gupta

Honors Theses

Flow separation is a phenomenon that occurs when pressure increases in the streamwise direction of a flow, making a distinctive boundary layer or separation bubble. It causes aircraft to experience an increase in drag and noise and a decrease in a lift, hence degrading their aviation performance. This study uses numerical simulations to understand better the effects of high-frequency translational surface actuation (HFTSA) on flow separation control. The numerical simulations mimic the experimental parameters of an experiment performed by Okoye et al. on using the HFTSA system to control flow separation. A symmetrical airfoil structure of chord length of 0.3 …

Design For Additive Manufacturing, Michael Charonnat, Leonardo Franco-Muñoz, Sam Noble, J.P. Purdom

Mechanical Engineering

This document outlines the critical design details and timeline for the Design for Additive Manufacturing Senior Project sponsored by Solar Turbines, Inc. The scope of this project encompasses the redesign of two of Solar Turbine’s cast parts for metal additive manufacturing in order to minimize lead time, cost, and weight. With the overall objective of performing in-depth analysis exploring affordability & feasibility, this redesign process will aid Solar Turbines in expanding their knowledge of Design for Additive Manufacturing principles and enable them to further incorporate the use of additive manufacturing into their production processes. The first part that the team …

Impact Of Magnetocaloric Material Properties On Performance Of A Magnetocaloric Heat Pump., Michael G. Schroeder

Electronic Theses and Dissertations

In the field of magnetocaloric heat pumps much research has been performed around machine design and theoretical machines, but little has been researched around practical problems such as variability in material properties. The present work defines a simulation tool that has been proven with experimental data. Magnetocaloric material cascades were statistically analyzed and parameterized, such that they could be recreated parametrically using a split Lorentz function with normally distributed parameters. Correlated curve-defining values with standard deviations were used as input into the simulation tool to determine the effect of variation on cooling heat pump performance for a household refrigerator application. …

Kinesthetic Learning Experience Simulation Using An Online Intervention To Improve Hands-On Ability, David Leach

Dissertations, Master's Theses and Master's Reports

Students enrolled in mechanical and manufacturing engineering programs employ differing levels of mechanical aptitude and practical hands-on ability. Many students lack practical experience tinkering with mechanical devices and mechanisms prior to entering their post-secondary years. Student attention spans in traditional classroom environments appear to be decreasing with the ever-increasing addiction to immediate gratification provided by electronic devices, gaming software, and social media platforms. The question is then raised whether or not modern engineering students have the ability to improve mechanical aptitude by simulating a kinesthetic or tactile learning experience through an online tutorial. This project describes the development and testing …

Simulating Dynamic Failure Of Polymer-Bonded Explosives Under Periodic Excitation, Rachel Kohler, Camilo Duarte Cordon, Marisol Koslowski

The Summer Undergraduate Research Fellowship (SURF) Symposium

Accidental mishandling of explosive materials leads to thousands of injuries in the US every year. Understanding the mechanisms behind the detonation process is crucial to prevent such accidents. In polymer-bonded explosives (PBX), high-frequency mechanical excitation generates thermal energy and can lead to an increase in temperature and vapor pressure, and potentially the initiation of the detonation process. However, the mechanisms behind this energy release, such as the effects of dynamic fracture and friction, are not well understood. Experimental data is difficult to collect due to the different time scales of reactions and vibrations, so research is aided by running simulations …

Simulation And Analysis Of A Drilling Fluid Using A Herschel-Bulkley Model, Daniel Powell

Mechanical Engineering ETDs

In the study, a drilling fluid with known properties is analyzed and simulated in the laminar regime through a pipe with dimensions of 1.5m in length and 0.02m in diameter. The purpose of the conducted analysis is to demonstrate the advantages of the Herschel-Bulkley model currently used in the oil and gas industry for analyzing non-Newtonian drilling fluids.

For comparison, the analysis is also performed using more simple models for non-Newtonian fluids such as the Bingham Plastic model and the Power Law model and for a Newtonian fluid (water). In addition to analytical models, computations are conducted using …

Advancement And Validation Of A Plug-In Hybrid Electric Vehicle Model Utilizing Experimental Data From Vehicle Testing, Kevin Lloyd Snyder

Wayne State University Theses

The objective of the research into modeling and simulation was to provide an iterative improvement to the Wayne State EcoCAR 2 team's math-based design tools for use in evaluating different outcomes based on hybrid powertrain architecture tweaks, controls code development and testing. This thesis includes the results of the team's work in the EcoCAR 2 competition for university student teams to create and test a plug-in hybrid electric vehicle for reducing petroleum oil consumption, pollutant emissions, and Green House Gas (GHG) emissions.

Plant model validations and advancements brought the vehicle plant model directionally closer to the actual vehicle's experimental data …

Development Of A Pyrotechnic Shock Simulation Apparatus For Spacecraft Applications, Joseph Binder, Matthew Mccarty, Chris Rasmussen

Aerospace Engineering

This report details the research, design, construction, and testing of a pyrotechnic shock simulation apparatus for spacecraft applications. The apparatus was developed to be used in the Space Environments Lab at California Polytechnic State University. It will be used for testing spacecraft components with dimensions up to 24”x12”x12” as well as CubeSats. Additionally, it may be used as an instructional or demonstrational tool in the Aerospace Department’s space environments course. The apparatus functions by way of mechanical impact of an approximately 20 lb stainless steel swinging hammer. Tests were performed to verify the simulator’s functionality. Suggestions for improvement and further …