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The Use Of Sacrificial Support Structures In A Rapid Machining Process, Wutthigrai Boonsuk, Matthew C. Frank 2019 Iowa State University

The Use Of Sacrificial Support Structures In A Rapid Machining Process, Wutthigrai Boonsuk, Matthew C. Frank

Wutthigrai Boonsuk

Rapid prototyping techniques for CNC machining have been developed in an effort to produce functional prototypes in appropriate materials. One of the major challenges is to develop an automatic fixturing system for the part during the milling process. The current proposed method, sacrificial support fixturing, is similar to the support structures used in existing rapid processes, such as Stereolithography. During the machining process, the sacrificial supports emerge incrementally and, at the end of the process, are the only entities connecting the part to the stock material. In this paper, we propose methodologies for the design of sacrificial support structures for ...


Applications Of Laser Machining For Fiber Optic Sensor Development, Lauren Sailor 2019 Purdue University

Applications Of Laser Machining For Fiber Optic Sensor Development, Lauren Sailor

The Journal of Purdue Undergraduate Research

No abstract provided.


Baja Sae Ecvt Mechanical Design, Tyler Lee Connel, Will Daniel Antes, Matt Stephen Balboni, Benjamin James Colard, Julian Edward Finburgh 2019 California Polytechnic State University, San Luis Obispo

Baja Sae Ecvt Mechanical Design, Tyler Lee Connel, Will Daniel Antes, Matt Stephen Balboni, Benjamin James Colard, Julian Edward Finburgh

Mechanical Engineering

This objective of this project was to design, manufacture, and test the mechanical systems of an electronically-controlled continuously variable transmission (eCVT) for the Cal Poly Baja SAE vehicle.


System Integration Of C-Arm Robotic Prototype Using Motion Capture Guidance For Accurate Repositioning, Alireza Yazdanshenas 2019 University of Texas at Tyler

System Integration Of C-Arm Robotic Prototype Using Motion Capture Guidance For Accurate Repositioning, Alireza Yazdanshenas

Mechanical Engineering Theses

One of the important surgical tools in spinal surgery is the C-Arm X-ray System. The C-Arm is a large “C” shaped and manually maneuvered arm that provides surgeons and X-ray technicians the ability to take quick quality X-rays during surgery. Because of its five degrees of freedom, the C-Arm can be manually maneuvered around the patient to provide many angles and perspectives, ensuring surgical success.

This system works fine for most surgical procedures but falls short when the C-Arm must be moved out of the way for complicated surgical procedures.

The aim of this thesis is to develop an accurate ...


Bulk-Explosion-Induced Metal Spattering During Laser Processing, Cang Zhao, Qilin Guo, Xuxiao Li, Niranjan Parab, Kamel Fezzaa, Wenda Tan, Lianyi Chen, Tao Sun 2019 Missouri University of Science and Technology

Bulk-Explosion-Induced Metal Spattering During Laser Processing, Cang Zhao, Qilin Guo, Xuxiao Li, Niranjan Parab, Kamel Fezzaa, Wenda Tan, Lianyi Chen, Tao Sun

Lianyi Chen

Spattering has been a problem in metal processing involving high-power lasers, like laser welding, machining, and recently, additive manufacturing. Limited by the capabilities of in situ diagnostic techniques, typically imaging with visible light or laboratory x-ray sources, a comprehensive understanding of the laser-spattering phenomenon, particularly the extremely fast spatters, has not been achieved yet. Here, using MHz single-pulse synchrotron-x-ray imaging, we probe the spattering behavior of Ti-6Al-4V with micrometer spatial resolution and subnanosecond temporal resolution. Combining direct experimental observations, quantitative image analysis, as well as numerical simulations, our study unravels a novel mechanism of laser spattering: The bulk explosion of ...


Maquiladoras In Central America: An Analysis Of Workforce Schedule, Productivity And Fatigue., Jose L. Barahona 2019 Western Kentucky University

Maquiladoras In Central America: An Analysis Of Workforce Schedule, Productivity And Fatigue., Jose L. Barahona

Masters Theses & Specialist Projects

Textile factories or Maquiladoras are very abundant and predominant in Central American economies. However, they all do not have the same standardized work schedule or routines. Most of the Maquiladoras only follow schedules and regulations established by the current labor laws without taking into consideration many variables within their organization that could affect their overall performance. As a result, the purpose of the study is to analyze the current working structure of a textile Maquiladora and determine the most suitable schedule that will abide with the current working structure but also increase production levels, employee morale and decrease employee fatigue ...


C6 Wheels, Samuel L. Pizot, Luke Martin, Josh Warner, Jonah Levis 2019 California Polytechnic State University, San Luis Obispo

C6 Wheels, Samuel L. Pizot, Luke Martin, Josh Warner, Jonah Levis

Mechanical Engineering

This document details the C6 Wheels project being undertaken for senior design. The objective is to design and manufacture carbon fiber reinforced polymer wheels for the Cal Poly Formula Society of Automotive Engineers (FSAE) team. The wheel shells will be used on FSAE’s competition vehicles. FSAE requested the wheels to improve the handling characteristics of their vehicles by reducing the unsprung and rotational mass. They have attempted carbon fiber wheels previously but have not yet run any on their vehicles. FSAE specifically proposed the design of carbon fiber shells with an aluminum center as opposed to full carbon fiber ...


Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator 2019 California Polytechnic State University, San Luis Obispo

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the ...


Sand Foot: A Prosthesis For Walking On Sand, Samantha A. Galicinao, John Dewing, Daniel Dugan Dotson, Christopher Urasaki 2019 California Polytechnic State University, San Luis Obispo

Sand Foot: A Prosthesis For Walking On Sand, Samantha A. Galicinao, John Dewing, Daniel Dugan Dotson, Christopher Urasaki

Biomedical Engineering

This critical design report describes the product development of a prosthesis for use on sand. Quality of Life Plus (QL+), a national non-profit organization aimed to develop prostheses for veterans and people with disabilities, introduced this project and its accompanying challenger, Sgt. Brady, to Cal Poly’s Interdisciplinary Senior Project class in September 2018. After consulting with Sgt. Brady and QL+ and performing extensive research, the Sand Foot team defined customer requirements and engineering specifications to meet these requirements. Comfortability, durability, and sandproof were key customer requirements. Several conceptual models were brainstormed and a final design was selected based on ...


Human Powered Vehicle Trainer, Nicholas Hung Nguyen, Gregory Reece Bridges, Jacinta Garcia, Mitchell Sidney Smith 2019 California Polytechnic State University, San Luis Obispo

Human Powered Vehicle Trainer, Nicholas Hung Nguyen, Gregory Reece Bridges, Jacinta Garcia, Mitchell Sidney Smith

Mechanical Engineering

This Final Design Review (FDR) document describes the final design and completed prototype of a Mechanical Engineering senior project team at California Polytechnic State University, San Luis Obispo. The project goal is to create an adjustable human powered vehicle training bike for George Leone that allows a rider to gain confidence with the unique reclined bike geometry ahead of the World Human Powered Speed Challenge at Battle Mountain, Nevada. This document outlines the customer’s needs and technical research performed which together determine the project’s scope and engineering specifications. Next, we present the initial idea generation process and its ...


Design Of Natural Composite I-Beam For Sampe 2019, Brian Harkness 2019 Union College - Schenectady, NY

Design Of Natural Composite I-Beam For Sampe 2019, Brian Harkness

Honors Theses

In recent years, the demand for high performance, lightweight, fiber-reinforced composites have grown substantially. Fiberglass and carbon fiber have exemplary material properties that meet the demand and have set the industry standard for performance materials. Although these materials meet their design function, they suffer from high environmental impacts throughout their life cycle and are not cost effective to produce. Flax fiber composites have comparable properties to fiberglass but can be produced more efficiently and production requires much less energy consumption. Flax is a readily available, renewable material that will easily biodegrade once it is the end of its useful life ...


Thermoplastic Composite Heat Recovery Ventilator, Keegan Guinn 2019 Union College

Thermoplastic Composite Heat Recovery Ventilator, Keegan Guinn

Honors Theses

Heat recovery ventilation continues to increase in importance as building codes mandate reduced air infiltration and increased energy efficiency. Heat recovery ventilators are able to reduce building heating and cooling loads by transferring heat between the exiting air and incoming ventilation air. In the role of heat recovery ventilation, additively manufactured polymer composite heat recovery ventilators offer significant advantages over traditionally manufactured metallic alloy heat recovery ventilators. Through the implementation of additive manufacturing, the internal geometry of the heat recovery ventilator can be optimized to decrease the head loss across the system and features to improve heat transfer such as ...


Bulk-Explosion-Induced Metal Spattering During Laser Processing, Cang Zhao, Qilin Guo, Xuxiao Li, Niranjan Parab, Kamel Fezzaa, Wenda Tan, Lianyi Chen, Tao Sun 2019 Missouri University of Science and Technology

Bulk-Explosion-Induced Metal Spattering During Laser Processing, Cang Zhao, Qilin Guo, Xuxiao Li, Niranjan Parab, Kamel Fezzaa, Wenda Tan, Lianyi Chen, Tao Sun

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Spattering has been a problem in metal processing involving high-power lasers, like laser welding, machining, and recently, additive manufacturing. Limited by the capabilities of in situ diagnostic techniques, typically imaging with visible light or laboratory x-ray sources, a comprehensive understanding of the laser-spattering phenomenon, particularly the extremely fast spatters, has not been achieved yet. Here, using MHz single-pulse synchrotron-x-ray imaging, we probe the spattering behavior of Ti-6Al-4V with micrometer spatial resolution and subnanosecond temporal resolution. Combining direct experimental observations, quantitative image analysis, as well as numerical simulations, our study unravels a novel mechanism of laser spattering: The bulk explosion of ...


Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz 2019 California Polytechnic State University, San Luis Obispo

Fluid Power Vehicle Challenge - The Incompressibles - Final Design Report, Nicholas Gholdoian, Russell Posin, David Vitt, Alex Knickerbocker, Kyle Franck, Julian Rodkiewicz

Mechanical Engineering

This report provides a comprehensive description of the research, analysis and design work that The Incompressibles have completed thus far in the senior project process. This document includes all the work that The Incompressibles have completed for the team’s Preliminary Design Review (PDR), Critical Design Review (CDR), the work leading up to the 2019 FPVC competiton and the competition results. This report includes the initial research that the team completed for the fluid power competition, first iterations of designs, final iterations of designs, manufacturing results and processes, and finally testing and results from competition. With a new design for ...


Insulated Solar Electric Cooker Immersion Heater, Emily Burnside, Kaeley Dicks, Joshua R. Stevens, Brady Banks 2019 California Polytechnic State University, San Luis Obispo

Insulated Solar Electric Cooker Immersion Heater, Emily Burnside, Kaeley Dicks, Joshua R. Stevens, Brady Banks

Mechanical Engineering

This report is the final design review (FDR) report for our team completing the Insulated Solar Electric Cooker (ISEC) Immersion Heater mechanical engineering senior project. The goal of this project is to standardize and perform analysis on a preexisting, inexpensive solar-powered immersion heater for cooking use in developing countries, reducing the adverse effects presented by traditional biomass cooking fires. We also designed a manufacturing process to improve repeatability and to reduce labor investment of heater production. The ISEC research team from the California Polytechnic State University Physics Department have been working on the development of this immersion heater and have ...


Adapted Trailer Hitching System, Joseph Neil Hearn, Maxwell M. Selna, Maximilian D. Cossalter, Eric B. Ringsrud 2019 California Polytechnic State University, San Luis Obispo

Adapted Trailer Hitching System, Joseph Neil Hearn, Maxwell M. Selna, Maximilian D. Cossalter, Eric B. Ringsrud

Mechanical Engineering

This report highlights the entire design process of an adapted trailer hitching system for Taylor Morris: a navy veteran and quadruple amputee. This begins with problem definition through customer and product research. Objectives are generated after the problem is defined and the boundary of the project is set. This outcome of the project focuses on modifications/improvements to the vehicle side of the problem and leaves the trailers untouched. Engineering specifications are developed to constrain the concept design direction, which ultimately dictates the outcome of the final design. The final design is used as a basis to manufacture a structural ...


Evaluation Of Tensile Properties For Selective Laser Melted 316l Stainless Steel And The Influence Of Inherent Process Features, Paul Swartz 2019 California Polytechnic State University, San Luis Obispo

Evaluation Of Tensile Properties For Selective Laser Melted 316l Stainless Steel And The Influence Of Inherent Process Features, Paul Swartz

Master's Theses and Project Reports

Optimal print parameters for additively manufacturing 316L stainless steel using selective laser melting (SLM) at Cal Poly had previously been identified. In order to further support the viability of the current settings, tensile material characteristics were needed. Furthermore, reliable performance of the as-printed material had to be demonstrated. Any influence on the static performance of parts in the as-printed condition inherent to the SLM manufacturing process itself needed to be identified. Tensile testing was conducted to determine the properties of material in the as-printed condition. So as to have confidence in the experimental results, other investigations were also conducted to ...


Investigation Of Nondestructive Testing Methods For Friction Stir Welding, Hossein Taheri, Margaret Kilpatrick, Matthew Norvalls, Warren Harper, Lucas Koester, Timothy Bigelow, Leonard J. Bond 2019 Georgia Southern University

Investigation Of Nondestructive Testing Methods For Friction Stir Welding, Hossein Taheri, Margaret Kilpatrick, Matthew Norvalls, Warren Harper, Lucas Koester, Timothy Bigelow, Leonard J. Bond

Electrical and Computer Engineering Publications

Friction stir welding is a method of materials processing that enables the joining of similar and dissimilar materials. The process, as originally designed by The Welding Institute (TWI), provides a unique approach to manufacturing—where materials can be joined in many designs and still retain mechanical properties that are similar to, or greater than, other forms of welding. This process is not free of defects that can alter, limit, and occasionally render the resulting weld unusable. Most common amongst these defects are kissing bonds, wormholes and cracks that are often hidden from visual inspection. To identify these defects, various nondestructive ...


Design And Control Of Fiber Encapsulation Additive Manufacturing, Matt Saari 2019 Southern Methodist University

Design And Control Of Fiber Encapsulation Additive Manufacturing, Matt Saari

Mechanical Engineering Research Theses and Dissertations

This work presents the design, development, and analysis of the Fiber Encapsulation Additive Manufacturing (FEAM) system developed at the Laboratory for Additive Manufacturing Robotics \& Automation at the Lyle School of Engineering at Southern Methodist University. The innovation introduced by FEAM is the ability to insert a continuous fiber of different material into the flowing extrudate. Correctly positioning the fiber feed inside the extrudate while turning the fiber in arbitrary directions is a critical aspect of the technology. This will allow for the full exploitation of the capabilities of the FEAM technology to produce robotic components that actuate and sense. Several ...


Repurposing Plastic Waste In El Cercado, Joseph Dooling, Kirby Townsend, Brendan Smith 2019 Loyola Marymount University

Repurposing Plastic Waste In El Cercado, Joseph Dooling, Kirby Townsend, Brendan Smith

Honors Thesis

This project aims to assist the community of El Cercado in the Dominican Republic in turning their plastic waste into useful products. The design team developed a first iteration shredder, injector, and aluminum mold which future design teams could further iterate in order to make products out of waste plastic. Different products were researched to ensure that they can be sold or used in the community. The goal of producing these items is to stimulate economic activity in the community by creating economic opportunity. The design shall also be sustainable in three ways. It shall reuse plastic waste while also ...


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