Kettering University

This thesis uses Ansys, a finite element modeling software, to perform a non-linear structural analysis of a modified flange/seal system. The flanges in this project were used as interconnects between superconducting RF cavities in a 1.3 GHz cryomodule. Fermi National Accelerator Lab is developing these cryomodules for the International Linear Collider (ILC). The proposed flange modification investigated in this thesis is the addition of slots. These slots will allow radial insertion of the bolts in the flanges and reduce the overall length of the 1.3 GHz cryomodule, and thus reduce the length of the ILC.

A large amount of downtime on a single piece of equipment is cause for a close examination of the reasons for that downtime and a significant effort to minimize the downtime. If the cam machine's 9% downtime were improved, either by modifying its problem areas, or by replacing the machine, there is potential for $71,088 in savings every year.

An alternative chrome plating method that will produce a chrome-like finish for plastic parts that can be used on any type of material, is environmentally friendly, faster than current methods, and is more comparible to a painting process than a plating process.

As you are well aware, in 2003 Ford required that all of its suppliers no longer supply parts containing or plated with hexavalent chromium and many other prohibitive substances as of January 2004. That deadline has since been pushed back to June 2005. They made this requirement, because of the End of Life (ELV) Directive. This was put into European law in October of 2000. Its purpose is to de-pollute all ELV prior to them being dismantled so that they can be properly recycled. This includes metal components such as clips and fasteners as well as non metal components like foams and rubber. Hex chrome seems to be the biggest problem of all prohibitive substances. Most metal components are plated with hex chrome, because of its ability to prevent corrosion and it is cheaper than many of the alternatives. It has also been discovered that hex chrome is hazardous to humans.

Blank scrap rejection rates are high at GM Mansfield on TP-11 and TP-12 and in need of reduction. In particular purchased laser-welded blanks result in large inventory costs when they are scrapped due to their purchase price of approximately $19.00 per blank. This thesis investigates and proposes an improved blank reject scrap accounting system, as well as investigates reasons for high blank rejection rates on the two focus presses.

Calibration methods for the polyurethane foam used in crash testing for FMVSS 213.

Design of an independent rear suspension system for 1967-1970 Mustangs. The system must require no welding by the installer. The system must also allow for removal of the differential without removing the cradle.

Hamilton Sundstrand designs and manufactures components and systems for commercial and military jet engines. Weight is a significant design consideration in the aerospace field. Without compromising safety, lighter designs are continuously strived for to stay competitive. HS is also responsible for designing mounts for components. An accurate process for analyzing brackets is crucial in preventing failure while maintaining a light weight design. Predicting the stresses in bolted connections is difficult due to the nonlinear behavior of friction and contact. Shell models are easier to use and can be solved using a linear static method, minimizing build and solve time. However, shell models predict erroneously high stresses around the bolt hole due to artificial stiffening which triggers redesigns and heavier brackets. Eliminating this artificial stress from the analysis will ensure light weight bracket designs.

High NVH leves on the Nissan X61B HVAC have led to customer complaints. The levels increase over time as the unit is used. These levels can be reduced to an acceptable point through three design changes to the system. If these changes are implemented the NVH issues currently being experienced will be eliminated resulting in increased customer satisfaction.

High cost of production, poor quality performance, and manufacturing difficulty of the Renovator-20 has heightened product concern. The hydraulic drive system is the main source of the problems experienced by the Renovator-20. Utilizing an integrated hydrostatic transmission in place of the hydraulic system, the author derived a functional design. If the concept unit were used as a guide for Renovator-20 production the company could expect to see increased quality performance and simpler assembly.

The Product Engineering division has been developing smaller scale engineering tools in MathCAD and Microsoft Excel to calculate needed information. The dynamic interaction of the components and their affect on lock and unlock performance is difficult to predict and understand without a dynamic model. A dynamic model built correctly will incorporate and improve upon most of these engineering resources. The simulation will save time for both the engineering and design groups. Eaton is currently using less efficient, more expensive, and time consuming methods of design, troubleshooting, and validation testing of current production than necessary. The current engineering tools are for the majority only static and do not take into account many of the dynamic mechanical principles/transitions and their effect on overall performance. A simulation of this dynamic performance was needed. The simulation was created successfully. The validation and correlation testing was completed on time. The output of the simulation has a 12% error to the test data. These results are extremely positive giving the variance that exists in the tester data and lack of resolution on the machine. The tool is now in the process of being implemented into the design process.

The escalading cost of aluminum necessitates Quality Boat Lifts, Inc. to find a more material efficient design for their boatlifts. A design utilizing a smaller beam size in a truss shape would decrease aluminum usage by more than 50% while not compromising load strength.

The following thesis covers the beginning stages of the development of the off vehicle standardized brake caliper disk thickness variation generation fixture. The scope of this thesis involves the elimination of any design flaws that exist in the original design as well as proof of concept, the ability to create disk thickness variation.

The objective of this project is to design build and test an articulating finger for a multifunctional prosthetic hand using a differential drive system to drive the proximal and distal phalanges The creation of an anthropomorphic articulating prosthetic finger will help improve the quality of life among amputees Current robotic prosthetic finger designs have limitations like design space that limit the amount of motors that can be used to achieve the desired motion Using a differential gear drive eliminates this problem by allowing only one motor to drive all three joints of the finger This thesis uses CAD design programs prototype fabrication and machining techniques to create an articulating prosthetic finger with a differential gear drive

The purpose of this project has been to determine the best technical approach to integrate flexible on-board Material Handling Equipment into the Army?s future 34 ton semi-trailer concept, the Multi-Functional Trailer (MFT). Current technologies and combinations of them are examined in the effort to choose the best possible solution. CAD designs and scenarios are set up to aid in the final recommendation for the project.

The purpose of this thesis project is to reduce the number of rejects from the GMT191 and GMT345/GMX020 FHVAC assembly lines. In successfully doing so, First Time Quality should increase along with an increase in throughput. Several tasks were performed to achieve this goal. An investigation into the cause of false rejections looks at issues with the testers, the parts themselves, or any issues caused during assembly. Rework procedures have been provided to aid operators in quickly and correctly troubleshooting tester and component issues. The design and utilization of tools or devices to aid in troubleshooting rejects is included. An improvement to the manner in which reject data is stored and reviewed has been investigated with solutions provided to simplify the process and make it more efficient.

The thesis contains the information on the steps taken to make a machine for a manufacturing process. It also contains detail drawings of the machine.

The use of ACE in our workplace requires that processes be reviewed frequently so they can be improved to reduce ergonomic risks and increase repeatability. In the three processes reviewed, one tool for each process was introduced and evaluated, and found satisfactory in both criteria above. More tests should be run once the physical tools are received. The satisfaction of the above criteria means the tools will remove ergonomic risks to the cell operators, increasing production. They will also increase repeatability, which improves process reliability and also increases production.

Thesis includes research, design and testing of timing chain lubrication orifice to reduce warranty failures of DaimlerChrysler 2.7L engine.

This thesis discusses the theory and principles that apply to the new manufacturing methods of the GM Powertrain Warren Transmission plant. With the theory and principles in place the installation of a new procedure to track first time quality across the assembly room was initiated. The new tracking method includes verification stations which document the number of nonconformities per operation. The data is then presented in various metrics for performance evaluations. The quality team and assembly team can then tackle the nonconforming issues presented to improve the quality of the final product.

This thesis documents the changes of a horn assembly and further proves how the new horn assembly changes impacted the performance. It includes the modification of an existing design that will prevent the system from degrading from environmental effects. In addition to design, horn background and market trends are examined.

This thesis included the selection of six materials that cover the range of materials that Webasto has to choose from for use as rollerblind fabric. A failure mode effects analysis was created, identifying potential problems with rollerblind fabric. Using this FMEA, each material was evaluated via testing or surrogate data for its worthiness in each area identified. At the end of this exercise, an optimal material was identified based on the testing performed and cost.

This thesis is a comprehensive benchmarking study on high performance seating and what attributes should be included when designing a high performance seat.

This thesis project was conducted with the intent of understanding the mindset of Nissan customers. Nissan does not score well in J.D. Powers and Associates surveys so by understanding the expectations and needs the customer has of their vehicle, they can better cater to their demands. In order to compete in the customer market, it was important to understand all customers, which was done by comparing the mindsets of competitor customers in similar segments. Nissan's understanding of the customers in the market will improve their ability to better satisfy the customers needs, which will eventually raise scores on the surveys as Nissan works to accomodate the customer mindset.

Total joint replacement for painful arthritis of the hip is one of the most flourishing surgeries of the last century. Pain relief is achieved in ninety-five percent or more of patients, and the majority of patients who undergo surgery have greater mobility and increased function. Over the last two decades, however, physicians? and patients? understanding of the risks, benefits, and goals of total joint arthroplasty has evolved and the limitations of artificial joints are becoming clearer. Hip replacement prosthetic joints using a polymer / metal bearing have been only guaranteed for a 10 year lifetime due to mechanism failure. This failure resulting in the unexpectedly short lifetime is caused by implant loosening as a result of osteolysis. Analysis of the periprosthetic tissue indicates evidence of debris concentration due to material wear of the prosthetic joint. With debris from the material being a main contributor to why these replacements fail, femoral head surface characterization research is imperative to understand the effects of femoral head and acetabular cup wear on the failure of hip replacement prosthetic joints.