Kettering University

THE PURPOSE OF THIS THESIS IS TO SOLVE THE ISSUE OF PRODUCTS BECOMING DISORIENTED DURING MANUFACTURING OF STANLEY FATMAX TAPE MEASURES. SEVERAL TESTS WERE RUN TO OBSERVE WHAT HAPPENED AND HOW THIS CAUSED THE MACHINE TO JAM. AN IDEA WAS DESIGNED USING AUTOCAD AND MANUFACTURED FOR THE MACHINE. SEVERAL MORE TESTS WERE UTILIZED TO SETUP THE DEVICE AND INSURE THE MACHINE WOULD WORK PROPERLY. THE RESULTS OF THIS THESIS ARE CONSISTENT WITH THE GOALS REQUIRED.

This project entails the improvement of readability on the Ford Motor Co. Roll Restrictor. The current method of marking, as well as alternate methods of marking were researched and analyzed by the author. These methods were then tested and documented to determine if the marking produced meets standards set by Ford Motor Co.

The Bone and Joint Center at Henry Ford Hospital has a long history of research in the area of biomechanics. One specific area of interest has been the development of and implications of osteoporosis in humans (Les, Spence et al. 2004; MacLeay, Olson et al. 2004; Macleay, Olson et al. 2004; Yeni, Christopherson et al. 2004; Les, Vance et al. 2005; Pechey, Les et al. 2007; Pechey, Les et al. 2007; Yeni, Shaffer et al. 2007; Michels 2009). A team led by Dr. Clifford M. Less has performed a significant amount of research concerning the onset of osteopenia and its relationship to the alteration of the mechanical properties of bone in mammals. Dr. Les and his team have been particularly interested in the onset of osteopenic symptoms in the ovine (sheep) radius as it is expedited by dietary induced metabolic acidosis (DIMA) and ovariectomy (OVX) (MacLeay, Olson et al. 2004; Macleay, Olson et al. 2004; Pechey, Les et al. 2007; Michels 2009). A great deal of previous research performed by Dr. Les and his team was characterized by mechanical testing of ovine bone at the materials level on a dynamic mechanical analysis machine; however, a recent study attempted to characterize bone properties on the structural level by utilizing a non-destructive dynamic four point sagittal bending loading modality to load the ovine radius and ulna ex vivo (Michels 2009). The results for this study proved promising, but some critics have pointed out that four point sagittal bending may not adequately reproduce the loading patterns incurred on the ovine radius and ulna in service. These critics suggest that a loading modality that places the ovine radius and ulna into axial compression might produce a superior testing environment. The primary purpose of this project was to design and build a fixture for use in compressive dynamic testing of the ovine radius and ulna ex vivo, as a possible alternative to four-point sagittal bending. The fixture was designed and manufactured successfully, and a validation study was performed. During the validation study, it was found that the new test fixture produced a strain distribution that was closer to the distribution previously observed in vivo by Lanyon and Magee et al. than that produced by four point sagittal bending(1979); specifically, the ratio of strain on the cranial face of the sheep radius to strain on the caudal face was closer to the in vivo value with the new axial compression loading fixture than with the four point sagittal bending fixture. Additionally, the validation study purposed to test the extent to which a stuctural "ring" property previously observed in four point sagittal bending would still exist under axial compression loading condititions. The data was inconclusive for this portion of the study.

This thesis covers the selection process and installation of the Kettering University wind turbine. An analysis of wind data was conducted to determine if there was any correlation between the different sites in Michigan. The data values from the data plots were entered into a spreadsheet. The centroid of each data plot was calculated and graphed to see a visual difference between the months of each site. These graphs were grouped together into various groups to see if there was a correlation there. Finally statistical analysis was performed on the original data. Box plots and test for variance were generated for the data sets. It was determined that there was no true correlation between the nine sites in Michigan that were analyzed.

This project describes a technique that is used to increase an areas organization, efficiency and maintainability. This technique is the methodology of 5S: Sort, Set in Order, Sweep, Standardize, and Sustain. At the accumulation of these five steps, everything will have a place and there will be a place for everything. Along with strict standards to maintain this, creating a work place that is not only clean, but designed to complete any task with ease. CAR Engineering implemented this technique and was able to achieve this goal in the Punch Press, Multi-Slide, Screw Machine, CNC, Tooling, Quality Control, and Shipping Departments. All departments now have standards for maintaining at the highest possible level of organization. Eradicating obstacles that would have slowed down the tasks performed by the employees, and created a clean, safe, and more easily accessible work area for all employees.

The Wabash Coating Cell at Innotec has been experiencing difficulties in applying the protective coating on the semi lights that are produced. Currently, spray guns are used to apply the coating. Since there is not an effect overspray collection system in place, all of the overspray is wasted. This is costing Innotec a lot of money. Also, the spray guns have difficulty covering the semi lights. This lack of quality causes a large amount of scrap, also costing a lot of money. A process redesign that increases quality as well as efficiency of the production line is required. This thesis describes the findings of the research of a dip and spin method of applying the coating to the semi lights.

The objective is to develop an improved, alternate, or more convenient method to measure axial force in propeller shafts which contain Cardan joints, namely determining another location on a component of the shaft at which to place strain gauges to be able to record and measure data more accurately and confidently.

In polymer research at Zimmer one responsibility is to develop ways to improve the polyethylene used in Zimmer products. This is largely done by implementing different crosslinking methods or different additives, to try to improve strength and or wear properties. One of the stages of testing a new material is tribological testing, where the wear properties of the material are analyzed. This process takes a substantial amount of time, anywhere from one to two months, which includes testing on the Ortho-POD machine. The swell ratio tester (SRT) equipment can test the wear properties of polymers in a much shorter time, but the accuracy of the test was unknown. A method validation will provide insight into the accuracy of the SRT test and a study of correlation between the SRT and the Ortho-POD test. The aim of the study is to provide an understanding if the SRT can be used as a quick preliminary test to screen potential material candidates can increase the productivity of implementing new polymers into production. The study provided knowledge into the accuracy of the SRT testing process and the correlation between the SRT test and the Ortho-POD test. The testing provided evidence that there was a correlation between the two machines and the result determined will aide Zimmer in further development.

Dimensional monitoring via vision is commonly used in high-volume manufacturing where component fitment is critical. For example, automotive manufacturers typically use vision to monitor the fabrication of the body in white structure. However, very few companies use vision in the assembly of large subassemblies. These subassemblies, such as the motor compartment, rear compartment and floor pan, could easily benefit from further analysis since they provide the foundation for the entire vehicle. While scrap could be reduced through the prevention of adding further value to an out-of-spec assembly, the primary benefit would be an improvement in quality. All automotive manufacturers dedicate a large effort toward ensuring the correct dimensional build. The consequences of not monitoring the dimensional build of the vehicle could result in mis-aligned panel gaps, improper part fitment and additional repair. Since all types of repair are non-value added work, manufacturers search for every opportunity to decrease repair costs. This paper presents a detailed vision station system for large subassemblies that seeks to decrease those repair costs and increase the build quality in the automotive industry.

The Waterhill faucet produced by Moen Inc. was the target of a product redesign in an effort to reduce production costs. This thesis focuses upon the process of designing a mounting system for the modified faucet. Previously, the faucet contained the diverter within the valve body. The new proposal utilized an under the deck diverter, allowing for a significant material reduction. The quotation and cost estimation process of newly created parts is also detailed.

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Spring fatigue testers are usually run at maximum speed to reduce the amount of time required to complete a test. However, at sufficiently high speeds, the dynamics of the tester and spring cause variations from calculated parameters. This paper will consider the impact of high speed testing on the Goodman stress a spring sees and how to predict it to make testing at high speeds more accurate. Springs were strain gauged and run at high speeds in the tester to determine the dynamic Goodman stress. The dynamic stress values were compared to static values to determine the percent increase. An equation was fit to experimental data that can be used to predict stress increases. Additionally, MATLAB was used to perform a finite element analysis of the dynamics of the spring.

This document pertains to the use of National Instruments (NI) software packages, LabVIEW and DIAdem, as alternatives to the EVALUATION software package used in the university crash test lab for crash analysis calculations and reports. It also includes an experiment procedure and prototype for the MECH-231L: Signals Analysis for Mechanical Systems Lab.

Fuel cells have inherent issues when utilized as the single power source for a given load. Coupling a fuel cell with traditional energy sources such as capacitors and batteries can address these issues. It is of interest to explore and quantify the performance gains when combining these sources to support a single load as fuel cells continue to gain popularity for use in high-volume instances. The objective of this research project is to develop a method of integrating and monitoring a system comprised of a fuel cell, capacitors, and batteries. This has been accomplished through the usage of a sophisticated data acquisition system, applicable sensors, a variety of hardware, and multiple software packages. Additionally, an operating procedure has been developed to allow user who are familiar with the hardware to reproduce the output of the system for demonstrational purposes. The evaluated outputs of the complete system are current and voltage graphs of multiple components sharing a common time scale.

The design of spare parts racks for use in the rotational dip corrosion pretreatment system allows the spare parts process to remain in-house, and take advantage of process improvements and quality improvements associated with the new system. The methods include fluid calculations and computer aided analysis of designs to confirm drainage, dimensional, and force related requirements. The results show that the racks will meet all process, cost, and strength requirements. The spare parts racks will be able to provide the equipment necessary to provide sufficient spare parts to the paint shop for two models, for the life of the models.

The thesis will be written about the development of a traceability system for the 6R80 PCB test station.

This thesis provides McLaren with a much needed design worksheet for bolted joints. In the past, incorrect fastener selection has proven to adversely affect project timing. McLaren will implement this thesis as a tool to improve the design process of future projects.

This thesis project is a study of crystalline urea deposits in Urea SCR aftertreatment exhaust systems. Flow lab testing is conducted to determine the causes of the deposis. The test results lead to some conclusions about the deposit's dependence on temperature, flow, and injection geometry.

Various sources of dirt contaminate the metal stamping process in many facilities. This thesis involves determining some of the factors that contribute to the dirt and offers ways to reduce their occurrence. Through some simple cleaning procedures, the first run quality can be increased.

Ankle issues at some point will affect nearly seventy-five percent of people during their lifetime; in 2003 alone, there were more than 11 million doctor visits in the United States for ankle problems (Brenner, 2004, Statistics, 2006). There is an annual expenditure of over $200 million on remedies trying to alleviate the pain in the ankle, which does not include the costs associated with these visits to the doctors (Brenner, 2004). A contributing factor to the number of ankle related visits is due in part to the limited knowledge of how the ankle functions during common, everyday activities. This study was conducted to improve the current knowledge base of tibio-talar joint motion. Six subjects walked on a treadmill, located inside a custom bi-plane x-ray system, while their motion was captured using high-speed cameras. 3D motion was analyzed for both the tibia and talus bones. These movements were output numerically and statistically analyzed. This analysis thereby, quantified healthy, uninjured, tibio-talar joint contact area and relative rotations between these two bones.

The thesis begins with the problem topic and why a condition assessment of HEP needs to be executed on Unit 4. The thesis discusses the process used by Unit 4 to create steam which is used to generate electricity. The thesis then goes into detail about the types of failure mechanisms and types of NDE methods. The majority of the thesis discusses the condition assessment completed in September of 2008. This chapter discusses the findings of the NDE. Also covered in the thesis is an estimated cost if a failure of a HEP system were to occur on Unit 4. Ending the thesis is the author¿s conclusions and recommendations based off the thesis project. Finally, the thesis contains the references, glossary terms, and Appendix A and Appendix B. Appendix A contains figures of the HEP systems inspected and pictures of the inspection. Appendix B contains the ABET program outcomes.

The purpose of the thesis is to evaluate the effect input parameters have on measurable outputs in order to eliminate flash and develop a stronger, safer weld. The weld under investigation is a friction weld between a pressurized vessel and stud. Through a series of DOE testing, the effects of the input parameters were studied to understand the relationships affecting the quality of the weld. The results of the tests were recorded and analyzed to find an ideal weld schedule. It was concluded that additional testing is required to find a schedule, however, the relationships discovered are key to developing an ideal weld.

This project was a success meeting all criteria: ? An acceptable window for range of operation was determined and the system currently functions in this state. ? All pertinent documentation was retrieved and utilized in the completion of this project. ? A routine was developed that shuts the system down, allowing it to run on one pump that turns on intermittently over long weekends and extended periods of shutdown. ? This project was completed with no cost to Spring Hill Manufacturing.

The end goal of the project is to design, manufacture, and install a drain fixture on every press that will successfully drain the material hopper without wasting or spilling material. Once these are installed, all of the material contained in the material hopper can be removed and re-used. This will eliminate any scrap losses, safety hazards from spills, and reduce mold change times. The project will be complete when every press is equipped with one of these devices. It is critical to design the drain fixtures to be more cost effective than a previous design.

The primary goal of this thesis was to determine the validity of the current wire rope specification. In order to determine the necessary component level strength, a correlation between the tensile strength of the wire rope component of the buckle pretensioner assembly, and the end item buckle pretensioner assembly must be made. This was accomplished by designing and utilizing new test fixtures to accurately represent environmental cycling and tensile strength of the wire rope component. Strength data was also collected at the assembly level. Data from both the component and assembly level test series was analyzed to determine the percent decrease in strength after assembly. Future programs can look to this data to determine what strength wire rope is necessary for their application.

The manual clamps produced at DE-STA-CO must pass a series of tests, one being a cycle test. At this time there are dozens of cycle test fixtures, each accommodating individual clamps. This fixture will successfully be able to cycle each DE-STA-CO manual clamp through its full range of motion and output the data for the developers. This information is relevant in designing future generations of products and will have a drastic impact on testing methods for the company.

This thesis focuses on the development and integration of a process to cut and handle the aluminum extrusions necessary to supply a pallet production line. Chapter will provide information about the currently running process, the determination of process guidelines, aluminum extrusion cutting methods, manufacturers of cutting equipment, integrating into the production line, and estimated cost of this project. By the conclusion of this thesis a method to cut and supply the aluminum pallet production line will be developed.

Through this thesis, a successful design of an automatic strand condition system was accomplished. The design eliminates the need for water used as a method of cooling the polymer strands. The temperature of the strands will be cooled sufficiently without moisture retention, while also transporting the strands to the pelletizer from the extruder at regular production rates. The system also reduces the length of the production line allowing for less floor space to be utilized.

This thesis focuses on the development of a process to remanufacture high pressure oil pumps. A brief overview of high pressure oil pumps and the system that they work in will be discussed. Reviva¿s current process for purchasing high pressure oil pumps will be reviewed. The methods developed for disassembly, cleaning, inspection of components, and proper assembly of the pumps will be discussed in detail. Theoretical calculations for the pump are discussed and how they relate to the station design and actual testing of the pumps. A portion of the thesis will be devoted to failure analysis of remanufactured pumps to develop the highest quality pumps. By the conclusion of this thesis a proper method to remanufacture high pressure oil pumps meeting all prior criteria will be developed.

An automobile with superb aerodynamic performance is necessary to meet consumer demand for fuel economy. The functional requirements for drag with Cadillac design cues dictates a need for state of the art design suitable for use in luxury automobiles. Utilizing a design of experiments orthogonal array, several of Cadillac's key design cues were tested to determine the optimal performance characteristics for each. Several design cues stood out as aerodynamic enablers and will be researched and tested for future refinement. A new method of testing was used that looked into yaw counts and zero degree attack, simulating more of a real world scenario which brought into view the advantages of other design cues primarily in the front of the automobile. By combining design's desires with the added knowledge of each area of the vehicle more freedom can be given to the design of the vehicle while still obtaining the optimum aerodynamic performance.

This thesis attacks the issue of heat treatment variation head-on by directly measuring the variation produced. Conclusions and recommendations are presented first, followed by the informational chapters which go into detail regarding the results. The gear production process is explained, to give the reader a basic understanding of the different operations. This is followed by subsequent chapters on the overview of the experiment, pinion results, ring gear results, and further investigations that can be conducted in the future.

The Automotive Foundation division of Bosch has recognized a lack of standardization of the data collected from vehicle benchmark studies when following the historical testing methods. There have also been recognized available cost savings based on a reduction in labor and components required to complete a full test schedule. A standardized format for data collection and analysis in addition to overall cost savings can be witnessed through the implementation of a new vehicle benchmarking procedure.

Increasing pressures from oil cost and environmental impact have had a negative effect on the all-wheel drive market, which is a main market segment for BorgWarner. New technologies to continue the improvement of all-wheel drive performance while reducing cost and fuel consumption were needed, and the redesign of existing transfer case components had the potential to provide a viable solution. The proposed design modifications were implemented in prototype components and tested against current production units to display improved performance. The prototypes showed a performance increase on the order of 70-80% over the production design, necessitating further testing for stability of the new design. After testing through a thermal range of -20 to 100 degrees Celsius, the new design maintained its increased performance over the production parts. This consistent improved performance from the new design allows not only the production of higher-performance units, but also the reduction in size and weight of current units while maintaining the same performance. This will drive down cost to BorgWarner, its customers and the end user and will also reduce the fuel consumption and environmental impact on vehicles in which the system is installed.

The following thesis will provide more information on the process used during consolidation, including before and after results. Cost analysis of spare part reduction will follow. Finally, the continuous improvement strategy for maintenance and upkeep of the revamped system will provide a guide to continue this process for the rest of the facility.

Through testing and examination of the laser attenuation tool to verify if the tool works correctly, so it can be used to test the attenuation of fiber.

At this time, glass-fiber-reinforced plastics have proven to meet the structural and durability demands of automobile interior and exterior parts. Good mechanical properties and a well-developed, install led manufacturing base has aided in the insertion of fiber-glass-reinforcement plastics within the automotive industry. However, natural-fiber- reinforced polymer composites are known to be a very cost effective solution to long-glass fiber reinforcement. With the economy in a recession and with the market trending towards ?greener ideas?, Intertec Systems has not yet made a footprint into the use of natural materials. Replacing the glass fiber with an alternative fiber would be cost effective and help Intertec overcome the shortcomings that all glass-reinforced plastics exhibit. These guidelines, in turn, would help determine the best alternative fiber.

Per customer requirements, Airbag Control Units (ACU)are now being produced with Engineered Plastic as its surrounding housing. This is different from past designs which incorporate a metallic housing. A large difference in these two material types is their resistance to material changes over time. While designing ACU's, it is pivotal to identify all system resonances and thus use software to filter out any inputs seen by the sensors as a result of these resonances. However, engineered plastics may change their resonance characteristics if the material properties change over time. Due to this it is important to understand if the algorithm and/or filtering may have to adapt to these changes over time.

The objective of this project is to design and manufacture a functional, safe, and effective cannulated bone screw used for fusions, fractures, or osteotomies. The study consists of designing and testing a screw for minimal insertion force and torque along with an adequate pull-out force. The testing and analysis is needed to ensure a safe and effective product.

The inertia of an automotive transmission is not well documented, and is generally based on geometric data. The other rotating parts have their inertia determined by the use of empirical data. The inertia of a Nissan 240SX transmission is determined by testing its resistance to acceleration with two different tests. The first uses a variable speed motor to rotate the transmission, measuring the speed and torque. The second test uses a constant force to rotate the transmission, again measuring speed and torque. The data gathered is used to determine the inertia, which is compared to an analytical determination of the inertia that was calculated using geometrical data. The result of the tests found that the use of an analytical method is justified . The analytical method gives an inertia of 1.98 x 10-3 kg*m2, while the constant force test gives 2.15 x 10-3 kg*m2, and the motor test gives 2.92 x 10-3 kg*m2. All of these are very small when compared to the inertia of the auto motor, being only 0.1 to 0.2% of the auto?s motor inertia. Thus on most cars the inertia of the transmission can be safely neglected.

The task was to valuate the current testing methods and the complete systems developed to measure time response in air and fluid and to provide a tested standard approach supported by studied data patterns and variables affecting testing procedures and testing units

This thesis focuses on the design and troubleshooting of a new semi-automated assembly machine.

Scaling factors and life models are regularly used by engineers within the Harley-Davidson Motor Company. The issue with using the scaling factors and life models is there is no standard method to obtain and apply them to known information. Also, the idea that scaling factors are a single value instead of a range of values leads many engineers to incorrectly estimate the component life data. The primary objective of the thesis is to determine scaling factors and life models for selected components. The secondary objective of the thesis is to document the procedure for future reference. Analyzed components were chosen after extensive data mining through warranty and test databases. Each component was analyzed using Weibull and fatigue modeling to eventually obtain the scaling factor range and life models. Through the step necessary to obtain the scaling factors and life models of the components it was determined that scaling factors are a range of values dependent on the failure relationship between the various data sources. The procedure developed will be used to train engineers to perform the necessary calculations to obtain the desired scaling factors and life models on future components.

This thesis was completed at Pratt & Whitney Auto Air Inc. in Lansing Michigan, for the Operation and Engineering Departments in an effort to improve the efficiency of the Phosphoric Acid Anodizing area.

Quality performance has become a growing area of concern for the Steelcase brand Details®. The Details brand focuses on work tools that assist with organization and productivity in the workplace. The objective of this thesis project was to improve the Details quality system and allow currently collected quality data to be measured and tracked in a more efficient and useful way. Through the use of the system developed by this thesis project it was hypothesized that quality metrics such as defective parts per million (ppm), customer complaints, and number of receiving issues (i.e. mislabeling, missing hardware packs, etc.) would decrease. A quality metrics dashboard-style user interface was created to track and display this data. Use of the dashboard allows Details management team to become aware of and respond to issues faster. The thesis document will discribe why and how the dashboard was created. It will also explain the conclusions derived from the use of the dashboard.

The thesis project is to create the design and methodology required to consolidate a large palletized assembly cell into a compact, more efficient U-shaped assembly cell. The line is designed to maximize efficiency in order to reduce labor and floor space requirements. The design achieves efficiency by eliminating potential causes of waste and fully utilizing labor and resources. Scrap and Downtime reports taken from the current palletized line are taken into account as well as varying customer demands.

This thesis project regards the design, build, and implementation of an assembly static build cell to assemble the 2010 Ford F150 Harley edition front bumper. It also includes modifications that needed to be made to the equipment after trial and PPAP runs, as well as learning experiences throughout the duration of the project. The thesis shows why it was important to move the Harley edition bumper assembly process off of the current assembly line and the steps taken to make this happen.

The Analysis of the Automated Forming Process of Thermo-Plastic Tubing is a thesis of better understanding of the relationship between the temperature of the automated formers heater block and it's surroundings.

This paper discusses the design and implementation of an assembly cell for the manufacturing of the Ram head emblem made for Dodge. A cost analysis and justification of the project are shown showing a significant savings over the old method currently being used. A working floor plan is shown along with all necessary steps required to implement this plan.

This thesis involves the re-design of the flux, pre-heat, and solder sections on Packard line 5103 at GE Sensing in St. Mary's PA. Data was collected to determine the source of high scrap rates on the line. Engineers then based their decision off this data to re-design the entire line. The flux, pre-heat, and solder sections are only a segment of the line, which is the basis for the thesis. CAD software was utilized to refine the design and bench testing was performed on the prototyped units to ensure proper production quality could be met.

The Thesis explains the process capability of fuel line insertions with respect to the key processing characteristics of most production based tube constructions and quick connectors at TG Fluid Systems. In the supporting chapters, the writer's methodology, design of experiment, key processing characteristics data, and raw tested data are provided. All of the measured and tested data are analyzed to form conclusions about the process capability of the insertion process. Based on the conclusions, recommendations are made.

Lowering the cost required to produce a product is critical to be competitive in manufacturing. In our metal fabrication facility an area recognized as in need of improved performance and reduced cost is the lubrication systems on mechanical presses. Key parts of the lubrication systems are the type of oil used, the maintenance program, and the programming of these systems. By considering factors that affect key parts of the system and overcoming bottle necks we can identify opportunities and make recommendations that will improve reliability and decrease cost.

The three main points I looked at to save money was expediting costs, reusable and disposable dunnage, and evaporating coolant instead of shipping it out. The biggest cost savings that was controllable was switching over to burn coolant using the evaporator available from another ZF Plant. Creating a process to track shipment dates and schedules would help to reduce expediting costs, but there is no available change for reusable and disposable dunnage.

The main purpose of this project was to assess the new Northwest Airlines exit door barrier. The current barrier used by Northwest Airlines is a single strap system, one inch in width and three feet from the fuselage floor. The single strap structure was not intended to prevent mechanics from falling out of the aircraft, but to warn the employees that the door was open. For this reason, the Aircraft Mechanics Fraternal Association requested that a new barrier be used to prevent mechanics from falling out of the aircraft. After a design was established assumptions were made so that a worst case scenario could be depicted and a four hundred pound mass was chosen as well as a five mile per hour velocity. Using Newton's Second Law of Motion I was the able to find the total stress experienced by the barrier structure. This force was then applied to the new barrier system by a point load. Free body diagrams were created and reaction forces were found by using Newton's Third Law of Motion. These reaction forces were then used to find the margin of safety for each component of the barrier. With this ratio it was determined that the aluminum support tubes would fail during service. Therefore, a material change was required. Other than Newton's Third Law of Motion, components were justified by using comparisons and strength properties. With the material change to steel the new barrier design proved to be structurally stable and was then subjected to testing to verify the hand calculations. After a series of pull-tests were done using an Instron Machine the new safety barrier was approved by Northwest Airlines and put into service for all narrow body aircraft.

As hybrid and electric vehicles become viable alternatives to standard modes of transportation, there is a demand to replicate the performance of internal combustion engine (ICE) vehicles. Means Industries is developing a prototype two speed transmission using controllable one-way clutches that will replace the common one speed gear box used in current electric vehicles. This technology is more cost effective than standard automatic or manual transmissions and will be smaller, thus, cutting down on weight and material. A program that can take possible transmission characteristics, vehicle dynamics, motor specifications, and drive cycles and output overall energy consumed and motor efficiency can help optimize an EVT. The program, called the EVT program, will allow Means Industries to select optimal gear ratios for a two speed transmission and calculate increased performance and efficiency. An electric vehicle with a single speed gearbox cannot achieve peak efficiency at high speeds because the motor requires more energy to propel the vehicle. A lower second gear ratio allows the motor to operate at lower revolutions per minute (RPM) which will propel the vehicle to higher speeds with decreased energy consumption, making the motor more efficient

There have been issues with the solenoid valves not functioning properly at high temperatures. As a result Eaton has had to pay money for these claims. This thesis is going to investigate some of these issues mainly having to do with the amount of voltage required to actuate the valve at higher temperatures as well as the size of the air gap in the valves and how that plays a role.

AAM does not currently have a simplified analysis tool to evaluate the critical speed of 2-pc propshafts at the very early stages of design/development. Although AAM has highly accurate FEA based analysis methods, these methods cannot be used until detailed propshaft designs are completed in 3D math. A simplified analysis tool (Visual Basic Based) is desired in order to make early design judgment upfront, such as Tube Sizing. The current tool that AAM has is based on the SAE AE07 Propshaft Manual which is intended for 1-piece propshaft designs. The AE07 manual analysis method uses a pin-pin constraint assumption, which is not valid for multi-piece propshafts designs with center slip spline and center bearing design features. Development of a new tool will enable AAM to make design decisions upfront in the design process, prior to completing detailed designs in 3D math, and conducting more detailed FEA based analysis.

Mechanical characteristics of plastic feature designs are compared using a statistical interpolation.

This thesis evaluates two proposed processes to replace current production processes for solder reflowing at Innotec. A wave solder process and a Hot air reflow process are both evaluated and adapted to meet the production needs of Innotec. Both processes are required to reflow solder paste used in BoardFree? applications. Of these two processes one must be chosen and show an improvement over current processes in quality control, part quality, cost of operation, and a decreased floor space requirement.

The first chapter of this thesis explains the problem topic and gives background information on the problem and on the company. The second chapter is what conclusions were gained after all testing was complete. The third chapter explains the basic functions of how a torque converter operates. The fourth chapter describes what equipment was used, and what torque converter configurations were tested. The fifth chapter discusses and analyzes the data gathered from all the tests along with a brief conclusion.

During the super plastic forming process TI 6Al-4V experiences a decrease in tensile properties. At 1400°F to 1450°F the yield strength starts to decrease considerably. The ultimate strength decreased slightly from 1400°F to 1450°F similar to but not as much as the yield strength. From 1350°F to 1550°F the elongation stayed consistent. The temperature to avoid is 1450°F when super plastic forming parts. At that temperature the yield drops below specification requirements to which some parts are made to.

This thesis presents the design and validation of a test fixture used to develop heavy duty truck suspensions. The design of the test fixture was approached from a stress, deflection, packaging, and budgetary perspective. CAD and FEA were used in the design process. The half suspension test fixture only tests either the driver or passenger side of a truck suspension at one time, it allows testing of vertical, lateral, and longitudinal loads. This test fixture can reproduce "scrub" loads experienced by tandem axle trucks, vertical loads induced by vehicle weight and road impacts, and longitudinal loads created by brake/drive accelerations.

To save money and improve quality, Vconverter Corporation would like to use formed 409 stainless steel (SS) tubing to eliminate the use of sheet stainless steel blanks to form H-Oval and Y-Oval shells as the new converter shells. 409SS is used as the fabrication material since it is the cheapest of the stainless steels and has the properties ideal for automotive exhaust. H-Oval and Y-Oval shells are specific oval shapes designated by the automotive industry to meet packaging requirements on vehicles

This thesis examines the possibility of a new mechanical assist device to the Spectranetics 0.9 Turbo Elite catheter. Testing was performed on multiple iterations of the wire mesh sheath to determine the best possible design regarding the different variables involved (wire size, tip diameter, core diameter, and picks per inch). The designed proved to clear an average lumen diameter of 4.68mm (n=15). The largest lumen created by this design was 7.25mm. This average diameter created was 61.5% larger than the average of a similar device currently in the field.

The goal of this thesis is to design a shutdown valve for 10-12 Ton air conditioning compressors and propose a test plan using benchmarks from other products at Emerson Climate Technologies. The thesis offers a force balance derivation to aid in further design work, three valve designs, and a proposed test plan to assess functionality of the valve. Additionally, there is an opportunity/risk analysis between the three valve designs based on suggested performance, complexity of design, and estimated manufacturing costs.

In an attempt to expose themselves to new business opportunities, ATEK Medical acquired an additional facility in Heredia, Costa Rica. While transferring existing production lines to the new facility, ATEK Medical must be able to provide no interruption in delivery to the customer. In order to accomplish this, a duplicate line was established in the Grand Rapids, MI facility. This line, the ¿Universal¿ Line, required qualification and led to line improvements. Ultimately, Phase I of the project, the transfer of the Silicone Manual and Silicone Auto Inflate Lines, was successfully supported by the ¿Universal¿ Line.

This Thesis contains an investigative study into Hurricane planning and an updateable detailed hurricane contingency plan specifically made for the Central Florida District Plant Engineering Department. This contingency plan will guide Plant Engineers in the Central Florida District with preparation and recovery efforts during the hurricane season and an actual hurricane threat. The hurricane plan itself will be organized into four different sections chronologically ordered. The first section will give information and instructions to prepare for the hurricane season starting annually in June. The next two sections will outline instruction and information for preparing for a hurricane that is moving in the potential path of facilities in the Central Florida District. The last section gives detailed information and instruction to post-hurricane recovery efforts.

This thesis serves as a reccomendation for Dura Automotive - Fremont. The company was not able to fund the capital necessary for machine implementation. It will be kept for future reference when capital is available.

Innotec is using a laser to cut circuits for an automated manufacturing line instead of a progressive die. Not knowing the optimal settings for the laser, cut quality was often poor and corrected by unsystematic iterations. A code was written to cut a matrix of profiles and analyze the relationship between power, speed, and assist gas. Running the laser at 200 inches per second, full power is required. Innotec may reduce the oxygen gas pressure below current settings to extend the life of a tank as a cost savings to the company.

The main objective of this thesis project was to compile the information needed to put together ACE certified standard work for the mixed model cell at Pratt & Whitney AutoAir, Inc. and the primary purpose of the thesis was to present the results of creating this standard work for the mixed model cell. ACE certified standard work consists of tools such as takt time, product-quantity analysis, process matrices, spaghetti diagrams, capacity analysis, operations bar charts, and manpower and machine percent loading. Accomplishment of this main objective will help advance the mixed model cell to higher ACE status with an ultimate goal of achieving ACE Gold level. The tools of ACE standard work can be used to improve the cell¿s overall efficiency and identify areas of waste.

The purpose of this thesis is to improve the correlation behind and overall repeatability of the FEV Launch Feel Tool by analyzing and incorporating new processed parameters that were not previously considered. It was found that considering pedal position rate as well as alternate definitions of peak and start acceleration positively influences correlation for vehicle launch performance feel. Further studies can be done to continuously improve the understanding of correlation between subjective ratings and objective data.

The GLock 19 pistol has under gone failures of casing ejection during critical situations for police and military alike. The cause of this failure is determined, using signal analysis and high-speed video data acquisition. In addition, a proposal of how to help prevent the problem is discussed.

This thesis involves the analysis of the impact the manufacturing plants have on battery drain and battery replacements under warranty. Other areas, such as product engineering, shipping lots, the shipping process and dealerships were also studied. General Motors has focused its efforts on the manufacturing plants for the past few years, thinking that the majority of battery drain, and therefore battery replacements, are caused by the assembly process. The assembly plants have taken many steps to improve the assembly process, yet battery replacements under warranty still remain high. This thesis studies the steps taken by the manufacturing plants to reduce battery drain. It also studies new methods currently being developed for testing electrical modules within the assembly plants. It recommends further study into the product engineering process, shipping lots and shipping process, and dealership process.

A capability study on the critical dimensions of the front panels for both washers and dryers. A study of 30 parts each with five and six critical dimensions, respectively. For incapable processes, recommendation is made to improve or change the process to improve capability (to a standard Cpk of 1.67).

Shop employees are not using work instructions on the Parker Cylinder website and make mistakes during cylinder assembly. At times, different plant managers elect different manufacturing methods for their employees and the product is not processed or manufactured in a consistent manner. The desirable goal is to have every commercialization plant produce cylinders consistently, and with high quality standards.

Delphi Steering is a primary manufacturer of vehicle halfshafts in the automotive industry. Cages, which retain ball bearings within the inner race and the ball grooves of the outer race in outboard joint assemblies, are essential components in the production of halfshafts. In the cage manufacturing process, scrap has historically been an ongoing issue which contributes to high production costs. This thesis project aims to significantly reduce scrap in the cage machining process and seeks to identify and remove the causes of defects and errors in cage manufacturing using a set of quality management methods.

Benteler Automotive's Engine & Exhaust Systems (EES) group has several customers for which warranty return parts are continuously returned, analyzed, and collected on a monthly basis. Currently, only a select few customers have a warranty system in place, typically defined by the customer, by which Benteler adheres in order to track and maintain history on parts returned with manufacturing defects or warranty issues otherwise. However, none of these systems share standardized characteristics or parameters, and no single process or tracking system encompasses all of EES customer programs which have warranty returns delivered to Benteler. Therefore, there is no uniform warranty history or review process to be used as reference material for Benteler's internal engineering and future product concepts. A 'standard' review process and tracking system would be beneficial in order for Benteler Automotive to align themselves with customers' product interests, strive for continued conformance, and to streamline the implementation of corrective actions in the manufacturing process.

When calibrating spark timing and cam phaser schedules on an internal combustion engine, one important factor is the mass fraction of already burned exhaust gas, residual gas, within the combustion mixture. Utilizing residual gas in the combustion process can improve engine efficiency if the amount of residual gas is optimized. Using current, production engine control systems and sensors, directly measuring this quantity is not feasible; therefore a model is used for estimating the residual gas mass fraction. This thesis focuses on directly measuring the residual gas mass fraction, verifying the accuracy of our engine models, and proposing improvements to our engine controller models in order to improve efficiency by maximizing dilution with residuals and optimizing ignition timing.

This thesis details the investigation into the feasibility of installing a semi-automated small parts assembly line. The investigation included time studies of current process, studies of previously purchased automation, the designs of tested improvements to the line, and a study of a sample automated assembly line. The thesis recommends the installation of a semi-automated small parts assembly line.

This paper discusses the trends of alternative fuels in the automotive industry and the reasons behind this market shift. Following this is a closer look at the electric drivetrain with focus on the types of batteries available for use in electric and hybrid vehicles. The advantages and disadvantages of each type are weighed for this application. A way to approximate the mass and volume of batteries needed based on vehicle weight is presented. Finally, the effects of an electric drivetrain on the vehicle structure are evaluated including the changes in vehicle mass, center of gravity, and body-in-white dimensions and performance.

The primary purpose of this thesis is to implement a full locking differential, including a front drive disconnect mechanism and operator controls, in a MTD Products Inc. four wheel drive utility vehicle.

This paper discusses issues related to current tool handling and proposes procedures that ensure the proper placement and management of tooling. Following this, methods for the determination of tool life and the benefit associated with experimental derivation of various cutting parameters are discussed. Finally, tool management and tool monitoring solutions are explored and evaluated in their ability to maintain tool handling procedures.

This thesis evaluates different areas of fuel economy improving strategies. Recent changes in CAFÉ law create the need to improve economy from where it is today. Data used for comparison in this thesis had been collected from vehicles previously tested by FEV. The data was used to show trends and comparisons in order to determine key fuel economy savings areas. FEV predicts there will be a high demand for this type of data and analysis and in order to capitalize on this demand this information is needed for continued profitability and success.

In order to reduce heat rate losses, valves that are normally closed during unit operation will be tested for leak by. Using computer modeling, a leakage rate for the tested valves can be determined and leaky valves identified. Valves that cause high heat rate losses will be replaced.

Calcium chloride is a additive that when mixed with road salt, can be used to efficiently combat winter snowfall and icy road conditions. Calcium chloride distribution systems are being integrated into new snowplowing trucks. Kits are available to retrofit older trucks that were not originally equipped with a calcium chloride system. However, these kits and expensive, they range from around $3000 all the way to $30,000+. As a small town with a limited budget, the City of Zion needed an affordable and reliable plan to implement a calcium chloride system onto it?s aging trucks until newer trucks were purchased. This cost study goes on to show that a sufficient system can be assembled from off the shelf parts, all of which are available within an extremely close proximity to the City?s location. For just under $600 per truck a generic system has been devised to retrofit all the different makes and models of trucks in the fleet. This low cost will allow to the City of Zion to better afford a system to implement this calcium chloride technology without paying the premium demanded by aftermarket installers.

This thesis project was implemented to use a computer simulation to model enhancements on an existing machining line. The computer simulation will be used to calculate the increase in production correlating to the modification implemented. After all simulation data is obtained the models will be compared and contrasted to one and other. This ananlysis will determine which line will save the most money. The project must also take into account the current ecomonic situation of the company. This means initial investment will have to be kept to a minimum.

An outline for the mechanical design of a machine to convey and rotate flat material in short stacks or bundles. While designed specifically for the corrugated paperboard industry, it is applicable to any industry where the material being conveyed has relatively flat surfaces on the top and bottom.

The process of sheet metal hemming is generally a three-step process that is utilized during the assembly of production automotive closure panels. The hem has a significant impact on a vehicle?s overall perceived quality. A vehicle with perceived high quality has a hem with small bend radii and tight panel gaps. The desired tight gaps and small radii have been difficult to achieve with aluminum closure panels due to aluminum?s lack of formability in comparison to steel. Recently, new aluminum alloys have been developed and the need arose for a simple, controlled, reproducible fixture to evaluate the bendability and hemmability of aluminum alloys. The test chosen for this task was the three-point bend test. The maximum fiber strain at the outer bend radius and the hem line surface quality was observed to determine the correlation between aluminum three-point bend testing and production-type hemming. Additionally, a comparison of the material pre-strains and strain paths was also investigated. When the proper punch geometry and gap setup was chosen the three-point bend test was capable of producing similar maximum outer fiber strains produced in production-type hemming processes. It was discovered that the current method of pre-straining may not fully represent the pre-strains of a production closure panel. The current method of pre-straining bend test samples produces positive major and very small minor strains, while the production hem samples produce positive major and minor strains. The three-point bend is also capable of evaluating and distinguishing different aluminum alloys similar to production-type hemming based on surface quality ratings. During bend testing and examination of the production hem samples material B was bent around a smaller radius than material A without showing signs of cracking. Overall, the three-point bend test was determined to be an effective tool in determining the bendability/hemmability of aluminum alloys and is capable of producing similar outer fiber strains to production-type hemming processes.

The thesis project began with the analysis of the scrap management program at Skilled Manufacturing's automotive plant. From there, various scrap buying companies were researched in order to find the best one to account for SMI's new aerospace division, which manufactures different materials than the automotive division. A document, which had questions about various materials, was made to help with this process. A similar local company was visited in order to see an example scrap management program. The most efficient scrap company was contacted and a meeting was set up to organize the scrap management program for SMI. The necessary parts were ordered, and a document was created that contains information about each part and material currently manufactured at SMI aerospace. This Excel spreadsheet will continue to be updated as new jobs are awarded to SMI.

The goal of this thesis was to investigate the cause for ongoing periodic machine failures on the line 5 bottom press assembly and propose an adequate recommendation for action. For this to be successful the current process must be validated for process control and desired machine parameters. Newtonian, stress, and fatigue calculations where the tools used to evaluate the effects of production settings on the components. Through a focused scope and mathematical results the components would be tested for adequate operational application. A clear decisive analysis would single out the weakest link in the mechanism in order to orient resources toward valuable improvements. This exploration has shown the peak loads and stresses on the bottom press assembly and their effect on the weakest linkages in the mechanisms. The Rotex GS aluminum coupling, located between the servo motor assembly and the Raco ball screw actuator, proved to fail due to fatigue failure. By using the MRC-196 motion program loads, torques, and stresses where use to graphically show fatigue and calculate a safety factor. The modified Goodman diagram showed the fatigue stresses barely inside the tolerance limits. The safety factor calculated was 1.15. This value does not give enough confidence to pass the fatigue failure test. The aluminum coupling is the weakest component of the line 5 bottom press assembly and should be improved first to improve longevity of the mechanism.

The prices of oil in industry are on the rise. Price fluctuation may occur as often as a day to day basis. To combat these ever changing oil prices a study of oil usage and consumption at Fenton Operations of Acument Global Technologies was held. An Oil Spend Reduction Team was formed to conduct this study. The main goal of this study is to reduce the amount of money being spent on oil. This was examined from three aspects. These aspects are to utilize the supplier with the lowest price, to minimize the amount of oil used, and to maximize the amount of oil that can be reused within the manufacturing facility. The main focus of the project is to reuse oil within the manufacturing faciliy which results in the highest percentage of spend reduction.

The vertical mixer is a very technical piece of machinery, which specializes in the mixing of propellants, explosives, and pyrotechnics. Through several years at B&P Process two designs have developed. One containing two hydraulic motors, which are used to power the system. The original design contains an electric motor, gear reducer and drive train to power the device. The thesis analyzes the machines to find which is most reliable, most efficient, and lease expensive. Analysis of friction and drive loses will be the main concern, as well as cost of individual parts and their lead times. The conclusion will be used by B&P to determine which design will be used in future production.

Muscle pain affects millions of people, yet treatment outcomes are very poor. This thesis first sought to study surface electromyography (sEMG) to determine whether or not fatigued muscles exhibit different sEMG signal characteristics than those of healthy normal muscles. The second objective of this thesis was to determine if a prototype sEMG instrument was capable of measuring signal characteristics that would allow it to differentiate between fatigued and healthy normal muscles. If so, then a third objective of this thesis was to conduct clinical testing to evaluate whether or not mild, non-invasive electrical stimulation had an effect on muscle fatigue as evidenced by changes in sEMG signal. Such finding could provide insight into the therapeutic effect of electrical stimulation devices, which might lead to novel treatment strategies for muscle pain. As a result of this work, it was determined that the prototype sEMG instrument was not capable of measuring signal characteristics that would permit differentiation between healthy normal and fatigued muscles, thus obviating the ability to test the effect of mild electrical stimulation on fatigued muscles.

Applied Mechanics was approached with a request to perform infant mortality testing on the main bearings for the CR line of compressors. To do this, a machine would first have to be designed and built to perform this testing. Many things needed to be taken into account when designing the machine, including cost, ease of use, and accurately reproducing conditions seen in a compressor. The end result of this work is a complete set of drawings for a test machine which has since been manufactured, assembled, and used for this testing.

The objective of this thesis was to determine the feasibility of damping systems to reduce steering wheel vibration, or nibble and developing in house testing capabilities. Damping systems tested were fluidic tuned, active, and stationary mass systems. Vibration testing and polar moment of inertia measurements were used to evaluate dampers, test hardware, and test methods. Math models of damping systems and damping versus PMI were developed for evaluation. Using these metrics the effective frequency and damping was determined. Systems were subsequently compared to each other and math models.

This thesis will provide ArvinMeritor's Off-Highway group with a compilation of fundamental wet disc brake theory, sources for further research, an analysis tool for generic design calculations, and test procedures for determining the accuracy of the analysis tool, and performance of the braking system.

DENSO lacks a control of the inspection process of Condenser Assembly in the Core Assembly area. An associate completes the inspection process, and can look at many parts a day, causing a known variable to the defect through repetitive action. Once the core passes through the braze process, the part is not repairable and goes to scrap.

Downtime caused by numerous preventable factors were decreasing machine availability on the 4T65 channel plate Lucas Cell operations. The low availability was resulting in a loss of parts produced during planned production time, which resulted in cost losses due to the overtime needed to make up the production losses. Detailed analysis was conducted to determine the factors causing the downtime. Once the factors were determined, investigation into how to fix the issues was completed and implementations towards problem elimination were made. Continued data analysis through the Andon system will be made, which alerts when abnormalities happen and will continue to be used to determine downtime problems to fix in the future.

The Titanium Double Harpoon Soft Tissue Anchoring system is a device that can be used to repair full or partial tears of the rotator cuff. It utilizes ZipLoop Technology which allows the surgeon to complete a repair without having to tie arthroscopic knots.

The purpose of the thesis was to find a filtration system that will cause less die wear in the stamping process. The thesis provides a cost savings analysis of the new filtration system. The die lube and filtration system supplies two presses in tandem, or supplies a single press with lubrication. The problem with the old system was that it had just one filtration method to remove fragments from the lubrication. This problem could turn out to be a costly one. If the fragments are not kept under control then bacteria growth begins in the tank due to poor oxygen circulation from the accumulation of metal fragments. This means the company has to shut down the presses to drain and refill the tank, which will cost time and money for the company. By accomplishing this thesis a significant savings was realized for the company

ABSTRACT The focus of this thesis is on the integration of a plasma welding machine into the manufacturing line of Falls Filtration Technologies, Inc.; the need originated from a failing contract agreement caused by an inability to weld a new product design. This document encompasses the investment analysis, rudiments of the plasma welding process, laboratory testing reports, weld tool designs, and all applicable production documentation that led to the successful implementation of a Thermal Arc Ultima 150 Plasma Welder and the preservation of the contract aforementioned.

This project will attempt to identify and refine the understanding of correlation between drop tower testing and HYGE sled testing. Through the study of previous test conducted, the analysis of data, and current trends, the ability for drop tower to predict sled testing in certain areas will be enhanced. This will result, among other benefits, in a cost and time savings for Key Safety Systems, Inc.

This thesis studies how a disc brake caliper deflects when the brake is applied. The purpose is to explore the effect of friction material compressibility on various types of calipers as it relates to caliper deflection simulations.

New EPA emissions standards require hydrocarbon emissions testing to be performed at sub-zero temperatures. BorgWarner electric air pumps are a secondary air system used to reduce hydrocarbon emissions on cold starts. The new sub-zero testing procedures make it possible for any water inside of the BorgWarner air pump to freeze, seizing the impeller of the air pump and causing the vehicle to fail emissions testing. A frozen air pump triggers a service code in the vehicle's On-Board Diagnostic (OBD) system, even if the pump is operational. To prevent a faulty error code from occurring due to ice formation in the pump, a method needed to be devised for the OBD sytem to differentiate between a temporarily frozen air pump and a faulty air pump. The customer needed a method that would free a frozen air pump within 1000 seconds. BorgWarner chose to attach an electric, PTC-element heater to the air pump in order melt the ice within 1000 seconds. This thesis presents the results of an electric heater study for the next-generation 1000-T3 BorgWarner air pump.

This thesis discusses alternatives to improve the current small sort operation in the Omaha, NE UPS facility. The main topic is to explore whether or not SPA'ing before inducting into the Bullfrog will provide a cost savings. Work measurement and cost analysis are investigated to determine the best alternative.

Pratt & Whitney is an original equipment manufacturer and over-hauler of jet engines for commercial and military applications. This thesis was completed at the Pratt & Whitney AutoAir facility in Lansing, Michigan for the Thrust Reverser Overhaul & Repair Division (TRV) in efforts of repair development and process improvements. The scrap rate for the PTFE (polytetraflouroethylene) tape repair on the main slider for the PW 4168 Thrust Reverser currently stands at 2.5 million parts/million repaired. This examination details the research completed to investigate the causes, the procedure, the materials used and the technical documentation of the repair. It discusses the current process limitations, the standard work & tooling, process certification and the proposed augmentations to improve and enhance the repair for process standardization, repeatability, reliability and product quality to reduce the scrap rate to 6 parts/million repaired.

The impact of the body shop car wash on the body shop inverted power and free carriers produces excessive repair costs and restriction of throughput. An above average rate of failure exists due to the contamination of the carrier components with cleaning solution from the body shop car wash. A savings of $188,000 per year and reduction in production downtime is achievable if the contamination of the carrier components is prevented. Additional savings can also be achieved by savings in operating costs. Capital budgeting indicates that the option that yields the highest internal rate of return is installing shrouding in the body shop car wash and refurbishing it. But due to a future conversion to a different pre-treatment system, and increased quality, a solution that utilizes a stage zero is most beneficial to the company. The suggested action is to propose a stage zero that replicates the body shop car wash for 1.05 million dollars. If not approved, then implementation of the car wash refurbishment and a shrouding trial is the next best option. Implementation of either solution will produce a savings in carrier maintenance, a savings in energy costs, and a reduction in downtime.

Due to the oil temperature exceeding the Eaton specification for maximum gear case temperature, a need exists to develop a design that will reduce the unusually high oil temperature. Elevated gear case temperatures above Eaton specification will lead to supercharger component durability issues. Thus, the solution to reducing the gear case oil temperature is critical to a successful launch of the product. This thesis will investigate possible conceptual solutions to reduce the problem mentioned above. The current TVS R900 was used for proof of concept. The conceptual solutions outlined in this thesis are the use of a shield around the timing gears and water cooled front cover. The objective of the shield is to reduce the heat energy by only allowing a thin film of oil into gear mesh. By inserting a shield around the gears a smaller amount of oil is able to get into the mesh. Slots may be added in various locations to allow for oil to be removed from the timing gears prior to mesh. As a result, only a light film of oil will go through the gear mesh. The objective of the water cooled front cover is to remove the heat energy via a water cooling channel, thus reducing the gear case oil temperature. Comparisons between actual measured data and heat transfer calculations will be compared. The two conceptual solutions will be analyzed as directionally correct or not directionally correct.

The thesis showed a progression of a successful Installation Qualification and Operators Qualification. The purpose for the Installation Qualification (IQ) was to ensure the equipment and its ancillary support systems are installed correctly and are operating safely. The purpose for the Operational Qualification (OQ) is to summarize and document the acceptable operation window for key process parameters for the LLD Braid replication.

The use of advanced high strength steel (AHSS) provides benefits for weight reduction and safety in the automotive industry. With the use of thinner AHSS material saving and superior crash energy management can be achieved. The Automotive industry has been searching for materials that help reduce the weight of the vehicles with the objective of increasing fuel economy as well as meeting governments new vehicle safety regulations in crash test. With this, there is a need to use more corrosion resistant material with less thickness than the traditionally uses, such as carbon steel or high strength low alloy (HSLA) steels. The development of AHSS has achieved this result. An example of an AHSS is TRIP 780 steel. New material and complex structures present a great challenge for current welding technology. Therefore, a greater knowledge and understanding is needed of how these materials can be welded, manufactured, formed and assembled.

This thesis presents the results of a study intended to determine the extent to which the Verity method may be used to predict the fatigue life of a number of components specific to applications at Tenneco Automotive. Extensive investigation was performed to determine how the fatigue life predictions may be used to 1) guide a preliminary design 2) reduce the number of samples which must be tested to achieve high confidence in a life estimate 3) increase the accuracy of a prediction obtained for a full system Exhaustive correlation proves that the Verity method provides an accurate estimate of the mean fatigue life for all continuously welded structures, and provides a conservative life estimate for hanger rod-to-pipe joints. Furthermore, the life prediction obtained by the Verity method may be used to calculate the estimated B10 life of a continuously welded part, and may be used to find a range of life values which can substitute for real test specimens. The study has laid the groundwork for future work, which will allow a reduction in the number of required testing samples, and possibly more accurate predictions for full system fatigue.

This thesis analyzes the axial deflection of a duplex angular contact ball bearing under centric thrust loading. Both theoretical and experimental analyses were performed to examine this behavior. The purpose of this infromation is to put Emerson Power Transmission in a better position to both design and manufacture duplex angular contact ball bearings.

General Motors-Flint North factory 5 is currently running at a volume of 1,800 units per shift, down from 4,000 per shift previously. In the near future the production levels will drop even more to about 1000 units per shift. Running a facility at a fraction of the volume it was designed for can create a financial and ergonomic disadvantage. General Motors is in need of a volume reduction strategy that will address the "GMS" principles, which are safety, people, quality, responsiveness, and cost (SPQRC). The strategy that was created thoroughly address all of the aforementioned problems. The new strategy allows for more concentrated work areas and less floor traffic, while maintaining current HPU levels. Also in an effort to reduce the costs of the strategy, the current infrastructure of the facility was utilized as much as possible. The new strategy is suitable for the proposed levels of production and should be as efficient as the previous while meeting the parameters given.

This thesis is used to prove a new production method for an eductor housing panel that is made by Jedco Inc. It entails a detailed descriptions of the new production method, its improvements over the old process method, and a cost analysis proving the cost savings of the project.

The lack of plentiful data regarding the proposed mobility advantages of the Mechanical Counter Pressure (MCP) suit concept facilitated the preliminary testing of the joint torques produced by the concept. The current space suit, the Extravehicular Mobility Unit (EMU), is a gas pressurized suit, sometimes referred to as a "gas bag" approach to providing the pressurized environment for the crewmember. The MCP concept applies pressure to the body surface through elastic materials stretched around crewmember's body. A test apparatus was created using an anthropomorphic mannequin arm modified to eliminate rotational flexures and a simple test stand to which it is mounted. A MCP sleeve, based off of the longitudinal and hoop stresses of a pressure vessel, was fabricated using Neoprene rubber. The first layer applied longitudinal stresses along the arm and second layer, the hoop layer, applied stress around the circumference of the arm. As verified by testing, the layers applied approximately 4.3 psid of pressure against the arm. This is equivalent to the pressures provided by the EMU. The joint torques were tested using a force gauge and calculated using the length of the arm. The resulting torques were similar to those of the EMU. Using the theoretical calculations, it would be possible to improve the design by selecting different material based on their properties.

This thesis investigates the issue of DC to AC inverter cooling in electric hybrid vehicles. Current inverters are cooled via single sided heat exchangers. In this thesis, I will attempt to cool the same inverter on both sides, theoretically, to improve overall performance.

To find a substitute BMI Graphite Prepreg that mets current mechanical requirements, but lowers cost and is more readily available.

In this thesis present and future diesel emission technology is presented with the intent to educate internal users on the importance and complexity of the subject. The emission regulations for both North America and Europe are presented and compared to illustrate the complexities present in transplanting European diesel technology into the North American market. Furthermore diesel aftertreatment technology such as the DOC, DPF, SCR, and LNT are reviewed in detail to help the user to understand which emission technology will be used in dynamic aftertreatment applications. The impact that diesel power trains will have on the North American automotive market is reviewed for several of the major OEMs within the passenger car and light duty truck market. Subsequent conclusions are drawn and presented from the research conducted on emission standards, emission technology, and power train forecasts.

This thesis was done to better improve quality, reduce time in change over, and to increase the reliability of the automation in the Euro Cover production cell at Innotec. Three project areas where looked at and a cost analysis was done to prove them viable to the company.

The Control Arm Bushing Assembly Machine is a machine designed to press three bushings into four different control arms. The thesis completed by the student consisted of the design of the press station, machine guarding, and cell layout. This machine is a job for a customer of ESE, L.L.C., therefore there will be no savings to ESE, L.L.C..

To concept, design, and manage the procurement, build, and checkout of a test system to pressure check and determine leakage in NASA development heat exchangers and various other equipment. A test panel was constructed and used to perform leakage testing on a development heat exchanger, proving it's design to be effective.

The Thesis purpose is to have produced uniform ejector bars and center knockouts for each injection molding machine. The previous system, which left decisions up to a mold setter, was flawed, allowing for mistakes that could caused damage to the molds and to the injection mold machines. The new system placed specific ejector bars and center knockouts at each molding machine in a holder designed to hold them. This new process results in a large cost savings to Nifco America.

Substitution for the current plunger leakdown fluid in Delphi hydraulic valve lifters is examined primarily due to offensive odor and potential health/safety risks. New fluids have been previously pursued through the chemical department. However, lack of both comprehensive data and effective overall system integration suspended the project. Data are presented herein to prove the engineering viability and environmentally benign nature of the new fluid. Data was correlated from various test stands and production lines to a universal leakdown stand in order to prevent central contamination by any new fluids. Evaporation rates, temperature shift relations and chemical properties were tested and compared clearly demonstrating the applicability of the new fluid. The engineering results showed that the new fluid was superior to the current fluid despite a price increase resulting from a refining process. The engineering benefits and decreased required quantity for the new fluid relative led directly to approval for final system integration.

Current tracking methods for radiator products produced at DENSO Manufacturing Michigan Inc. are insufficient. Defective parts can get mixed into approved production parts resulting in customer claims. The purpose of this project is to design and justify the implementation of a laser engraving system that would allow part tracking through the process and confirm part quality before shipping.

This thesis describes the forming of a connector that utilizes a space saving design. The connection also improves reliability and cycle time in a mass manufacturing setting.

Generating different types of hyperelastic material models and comparing them to tested data. The goal is to find out more information about hyperelastic material models and if there is one model that will work for all applications or not.

This thesis proves the strength and finacial efficience of a new product to potentially replace a sales declining ACL relplacement implant product of Biomet Sports Medicine. The anatomy of the knee and the ACL replacement process is explored, using this information the testing procedure, and results were put into a report to submit to the FDA for marketing clearence.

The automotive industry of the 21st century has incredible expectations placed on its products, especially in crash safety. When a new bumper program begins at Cosma Engineering, only a rough design is known and initial iterations require costly CAE analysis to create a baseline design. This thesis used a design of experiments method to create sixty-three bumper models by varying generic parameters. IIHS/RCAR crash tests were performed using LS-DYNA, and an approximation model was constructed to predict the force and displacement values at buckling. Now engineers can use custom approximation software to estimate bumper crash performance early in design.

In the fast paced world of NASCAR racing it is necessary to have the ability to accurately measure key parameters of the vehicle while testing under racing conditions. This thesis outlines the design, production, and testing of a laser sensor system capable of measuring dynamic camber, toe, Ackermann steering, and bump steer of a NASCAR race vehicle on track. The design and development process for this system required significant problem solving using the most advanced engineering practices available. The system produced as a result of this project satisfied all of the requirements of Toyota and the NASCAR? teams they support. The end result of this thesis is a system capable of producing accurate and reliable data about suspension kinematics and compliance on the race track. This system helped TRD engineers obtain useful data to improve the performance of Toyota race vehicles.

This thesis explains researched analysis studies used to discover difficult to solve root cause issues associated with mechanism production. Two programs, root cause analysis, and multiple regression analysis were developed based on this research for future use with the company. The research of these two programs was started partly due to the reoccurrence of quality issues when the original analysis of the problem failed to properly diagnose the problem. With the use of these programs, the chances and risks of repeat issues could potentially be eliminated, which would save company money that would otherwise be lost to part sorting and containment, along with other costs. These analysis studies are a useful tool for solving company production issues when more common problem solving methods fail to identify the issue.

The study of a brake noise countermeasure will provide insight into why brake noises occur. Dynamic brake system modeling is very complex and still not well understood in today's world. The thesis is a model of the major components of a braking system that influence brake noise. A model of the major parts of the brake system for one wheel are modeled and changes are made to show effectiveness of a common countermeasure for brake noise. Complex eigenvalue analysis is used to isolate unstable modes of interest in the system and correlate to an observed brake squeal mode. The study provides further insight into modeling a braking system as well as the results of a countermeasure. Improvements are made throughout to achieve a more realistic model.

This thesis consisted of a series of experiments performed on vehicle LCD navigation screens using high intensity lights to simulate the sun. Variables taken into account included the angle that the occupant was viewing the screen, and differences of touch screens and non-touch screens. Research was conducted to better understand the physics behind how light reflections behave. The results and conclusions helped write new requirements for GM LCD navigation screens.

In the NASCAR racing environment, teams are limited to a few track tests a year by the governing body. Since the test time is limited teams put as many sensors and measuring tools as possible on the vehicle including Toyota systems such as wheel force transducers, tire pressure measurement and tire temperature measurement. These systems produce copious amounts of data which requires quick analysis at the track. To improve the speed of the data analysis procedure a new computer program was developed. Initially methods for reading and displaying data into LabVIEW, the programming language used, were created separately. Next adding these methods together and increasing the refinement of the program yielded the first version of the Intuitive Data Display. This first version was presented to selected TRD employees and Toyota team members. Their feedback led to changes and improvements in the program which became the second version of the program. This second version achieved the criteria originally set forth at the projects conception. It was able to display data from many measurement systems including the wheel force transducers. The program could be distributed easily to TRD personnel and Toyota team members, required little or no training to run and could be reconfigured quickly for use by each Toyota team. It succeeds in simplifying the data analysis procedure but with more development time additional features would improve its abilities and performance.

Explore the effect various architectural changes have on the exhaust flow generated noise. In order to accomplish this, a prototype silencer was created that could be modified for such changes. Also, a new test method was developed and utilized to provide sufficient data in order to form conclusions. Testing was conducted by holding all but one of the variables constant and recording the sound. An analysis was then performed to determine this one variables contribution to the overall flow noise. Finally, statistical software was used to determine the validity and accuracy of the regression equations.

This thesis investigated and validated the theoretical accuracy of the equations used to calculate leakage. The derivations of the leakage equations for calculating lap leakage, orifice leakage, transitional lap lengths, eccentricity factors, and window leakage have been presented. A comparative study was conducted for valves with windowed and fully annular configurations using data generated from a computational fluid dynamics analysis and data generated from the available methods. The most critical valve geometries, overlap lengths, and environmental conditions were identified and incorporated into the study. The results of the study revealed that the equations and methods used to calculate fully annular leakage corresponded quite well with the data yielded from the computational fluid dynamics analysis. However, the methods developed to account for complex flow phenomena from windowed valves were shown to be somewhat inaccurate, but were found to be mostly conservative in their leakage estimates. The results of the study have been tabulated and presented in a manner that recommends the most accurate method for specific valve geometries and environmental conditions. It was concluded that the currently available methods are sufficiently conservative in their leakage estimates. However, testing should be conducted once funding becomes available. This will allow real world test data to be compared to data generated from each method as well as data generated from the computational fluid dynamics analysis. Ultimately, testing will reveal the accuracy of the methods, and allow changes or corrections to be made based on real world data.

With the increasing pressure of reducing costs while improving quality, MTU Detroit Diesel has begun sourcing alternative suppliers for many components, including, in this case, new pistons and rins, and a new oil to coolant water heat exchanger. This thesis will be the documentation of an endurance run, testing these components on a S2000G65 Generator engine through rigorous fatigue tests aimed to simulate more abuse than the engine hours suggest. Through this testing, and appropriate data collection and component analysis, the goal of validating the components should be attainable.

The conventional method of checking the tooth contact pattern of an automotive rear axle assembly is performed by a human operator, which suggests purely subjective results. With the use of an automated vision system, the error in these results can be accounted for. Prior to the check, a gear marking compound is applied to the rear axle by a dispense system, which has flaws of its own due to uncontrolled parameters. The author of this thesis set out to find a solution to this problem, and made some interesting discoveries while going through the procedure.

Altron Automation, Inc. wanted to reduce excess material and labor hours in machine frame construction incorporated in its custom designed machines. This thesis investigates the background of the situation and establishes multiple FEA scenarios. It then uses these results to develop an improved method of preliminary machine frame design, explains the process of this method, and establishes estimated cost savings from implementing this method.

When a turbocharged vehicle is traveling in extreme humid, rainstorm weather conditions at constant highway speeds for an extended period of time, condensation is known to form in the bottom of the charged air cooler. If the charged air cooler accumulates too much condensate and the customer attempts a wide open throttle maneuver, all of the condensate from the charged air cooler is pushed threw the throttle body and will cause the engine to bog down and lose significant performance disabling the customer to use the performance they desire. The major steps taken in coming up with a solution to the condensation problem started with conducting research in not only what General Motors is doing to fix the problem but also what other competitors are doing as well. The project had to be feasible in terms of what can be done within the criteria and parameters. Concluding what process the thesis is going to take on solving the condensate issue, initial testing was to begin. The initial idea for an assembly was to work on a concept of find a great change in pressure to be the driving force for the condensate. The initial testing began using a condensate extraction tube assembly. Large amount of the initial testing was done simulating the problem as best as possible without the use of the very expensive climatic wind tunnel. Water was poured in manually into the charged air cooler and tests such as wide open throttles, flow rate analysis, and electrical engine software tests were conducted. After the initial testing passed, the extraction tube assembly must also prove that it will stay within all of the criteria and parameters provided. The engine must be able to attain for the amount of extra water we are burning off directly into the intake manifold. After all simulation tests have been passed, the vehicle installed with the extraction tube assembly was taken into the climatic wind tunnel for final testing. After the results of the first climatic wind tunnel test came in, the vehicle was taken back to conduct more tests. The first climatic wind tunnel test came back positive, but it is believed that the suction rate could be amplified to make the assembly more efficient. The system is proven to work. The tooling for the charged air cooler end caps could not be significantly changed so I looked into using a new design that incorporates the current charged air cooler end caps. I came up with the low port extraction assembly which uses the exact same concepts as the extraction tube assembly but with no cost changes to the already tooled end caps. More simulation testing of the assembly was used to make extraction rates better and quicker. More orifice fine testing was complete. After obtaining a more efficient flow rate, the vehicle was taken back to the climatic wind tunnel for a final test, and proved that this thesis project using the low port extraction assembly solved the charged air cooler condensate issue.

B800 series separator plates are stamped in a progressive die. Each part has N teeth protruding from the outer [minor] diameter (12312, N=12; 12313, N=13; 12314, N=16). The inner diameter is stamped out with a separate punch than the outer diameter and teeth. Since the teeth and the minor diameter are stamped with the same punch, a relationship between the location of the inner diameter and the minor diameter will also represent a relationship between the teeth and the inner diameter and therefore the true position of the teeth is relative to the inner diameter and can be predicted based on the location of the minor diameter. Examining this relationship will give insight in to nominal minor diameter locations to be stamped in the press. Also, the use of a press gage to determine minor diameter location will be support or denied.

This thesis deals with the optimization of the cylinder head joint on a directly injected two cylinder two stroke. The main goal was to eliminate the necessity of a secondary, post engine hot test, torquing operation. In combination with this, difficulties associated with development of parts using low cost Asian suppliers is addressed. The result is a solution consisting of a newly developed fastener specification and head gasket which meet all given criteria for cost, durability, and leakage.

This thesis investigated the chain strand vibration (moan noise) variability between BorgWarner (BW) 44-93 transfer cases. After follwoing BW test procedures and creating new ones, it was determined that variability between the chain and sprockets was the cause for the variation in noise levels. Part inspection data revealed that chain length and measurement over pins on the sprockets is driving the variation. It was reccomended to conduct a similar study between more parts, including the same 44-93 transfer case and other vehicle lines.

This thesis was written to provide BSH Home Appliances with a documented proposal providing recommendations of equipment suitable for replacement of two existing chillers, one 533 ton chiller and one 125 ton chiller.

This thesis introduces the background of the wheel alignment equipment; how it works and what it affects. Each of the three main components of the equipment are divided into their own chapters, which includes the measuring heads, floating plate assemblies, and the front toe set automation. The problems are investigated and solutions are proposed for each of these components. The protoype for the solution of the measuring heads was tested sucessful. The investigation and recommended solutions are based on the author's direct observations.

This thesis discusses the research, development, and actions required to install a method of gaining modal data at Pratt & Whitney Auto Air. Strengths and weaknesses of three testing methods are analyzed and justification is given for the method chosen. Explanations are also given on the nature of modal analysis and why is is important. For the purpose of FEA analysis, a overview of composite materials and how they are produced is included to show how material properties can be affected. For the experimental modal analysis portion, there is a detailed testing procedure for use of the modal hammer. The procedure contains all information relating to the test equipment. Data gathered is summarized within the text and the raw data is located in the appendices. Based on the research and data gathered, conclusions and recomendations were made toward the continuing the project at Auto Air.

An in depth study on the effects of torsion bar rate, yoke setting, and valve balance on vehicle crown sensitivity. Vehicle crown sensitivity is objectively measured in terms of hand wheel torque and hand wheel angle. Use of design of experiment and statistical methods to determine hardware setups that reduce the vehicle's overall sensitivity to road crown.

The evaporation rates of chemical stimulants whose physical properties that are similar to those used in chemical warfare were studied. The chemical stimulants selected had a range of vapor pressure between 0.2-20 mmHg. Studies included both observing the selected chemical stimulants in laboratory conditions and simulation of the evaporation rates using mathematical models (Drop Program & COMCAD). Evaporation rates of chemicals that have vapor pressures of lower then 1 mmHg are greatly affected by its solubility in water. It was determined that the more soluble in water the chemical is, the slower it evaporates. Due to the fact an older version of COMCAD which did not take solubility into consideration was used to simulate the evaporation rates, the simulation results showed the evaporation rates of those chemicals to evaporate faster then what was observed experimentally. Also, universal modeling constants for the COMCAD could not be accurately found as a result.

Project that identifies a problem with current operations, researches the best possible solution, and implements that solution. The project is intended to decrease Falls Filtration Technologies (FFT) dependence on outside vendors and give FFT more control over the manufacturing process. An overall cost savings is also expected.

In a growing global economy, any cost reduction that a company can achieve puts them in a position of gaining a competitive edge. Innotec identified a cost reduction in the Latchkeeper cell through the elimination of sorting. The integrated sprue and slug sifter was the solution to eliminating sorting cost. This machine is capable of sorting out finished goods from scrap by actuating a meshed plate in a linear back and forth motion that is controlled by a computer program. Through the development and build of an automated sprue and slug sifter, Innotec has eliminated manual sorting cost for the Latchkeeper cell, resulting in a cost savings of $300 per month.

Romulus Engine Operations assembles the Generation IV V8 engine utilized in all GM trucks. To be able to guarantee the assembly quality and operation, every engine must be thoroughly tested. The testing utilized to guarantee this quality is called cold testing. This involves test cells on the assembly line in which the engines are attached to electric drive motors as well as various sensors. Each engine is electrically driven and tested to ensure proper function of all systems. When major internal engine components, such as the oil pump, are changed, they must be rigorously tested in the cold test cells (prior to full production) to document the new test data that will be seen. Cold testing is a vital link in maintaining Romulus' quality and any change to the engines being tested must be aggressively researched and prepared for.

Driving a design with CAE is a relatively new process. Using CAE tools such as HyperWorks allows the engineer to take a component design and optimize it for the loads the component will be subjected to. Using CAE the engineer can apply only the needed loads and constraints so as not to over engineer the component. This thesis uses CAE tools to take a current Load Floor design and optimize the design based on industry standards. The objective was to meet the performance standards while reducing overall cost and part weight. This thesis proved that CAE tools can be a valuable tool to help engineers take the design process from start to finish efficiently and quickly while reducing cost and part weight.

The BorgWarner shift motor control system is responsible for shifting the transfer case range gear for traction versatility. Designing this system graphically reduces development time without sacrificing testing and validation while allowing for parameters of the plant model to change giving the flexibility to account for design variation between part-time and full-time two speed torque transfer systems. This system is simply one part of a much larger control module referred to as the Core Controls Algorithm. This controls algorithm contains all the necessary items to control the shift system and also allow for integration with other vehicle systems. Further testing and modeling is suggested.

This thesis details the work needed to meet gap and flushness requirements of the customer to achieve a better overall fit and finish. Also it includes the details on how the repeatability of the magnesium beam was achieved and the processes involved. The methods used to verify the repeatability of the magnesium beam includes tests such as a Dimensional Specification Test using a CMM table to verify locations around the magnesium beam. A Fit and Finish test was used to evaluate the gap and flushness of the instrument panel using the corrected magnesium beam. In conclusion, the gap and flushness of the cockpit was improved and now falls within and exceeds customer expectations. The correction to the magnesium beam needed does not affect the other programs currently in production using the same beam. Also repeatability of the magnesium beam cavities was verified.

Veyance Technologies Inc., formerly known as Goodyear Tire & Rubber Company, currently does not have a timely, reliable ability to predict the performance of the construction and compound composition of their rubber tracks. The drive lugs of their rubber tracks for the Case New Holland STX Quadtrac are "jumping" in the drive pockets. It is thought that they are jumping because the drive lugs are too soft and are deflecting too much and "jumping" to the next drive pocket. For that reason a new drive lug deflection tester is desired. This thesis describes the needed criteria and design parameters needed for a tester to help the engineers improve the quality of their rubber tracks. Three different tester concepts are mentioned and described. The tester concept that best satisfied the needed criteria and design parameters was chosen to continue with. A design was created with many reviews and revisions on the design were performed until a final tester design was agreed upon. At this time the tester has not been purchased. The group wants to compare the static tester to a dynamic tester that has multiple capabilities. The dynamic tester is currently being investigated to determine if it also satisfies the needed criteria. A decision on purchasing the dynamic tester or static tester has not been decided at this point in time.

Creation of a benchmarking facility for General Motors Powertrain in Pontiac, MI. This also included making a process for benchmarking products and dealing with the General Motors Powertrain consolidation to Pontiac,MI where all sectors of powertrain are now located.

The US Army's up-armored tacticles vehicles are under continous improvements and experimentation. Modification of the Rhino Linings REXMAR MT polyurethane is being tested and compared to various adhesive resins. A desire to compare how the adhesive resins effects the ballistic performance of composite armor exists.

To define how the manual transaxle is effected by other components in the automobile. To develop a document/chart which is easy to understand and use; a document/chart which can be sent to other component engineers so that they may easily understand how their component can effect the manual transaxle.

Due to the increasing shortage of fossil fuels and rising gas prices alternative forms of energy are becoming a growing concern. This led to the idea of developing a linear electromagnetic engine that would no longer require the use of gasoline to run. A theoretical math model was developed as a prototype of the engine based off of an already existing 8 HP internal combustion engine produced by Honda. Electromagnetic, magnetic, and engine dynamics calculations were performed in order to determine the power output of the engine. The engine was then compared to the already existing Honda engine, as well as an already existing Briggs and Stratton Etek electric motor. The power curves of the three motors were then analyzed in order to determine which engine would be the best choice for an application in small commercial equipment. Also, future design concepts for the prototype engine were created and analyzed.

Each seat built on the assembly line requires a "kit" consisting of side shields, switches, and other small parts. In filling the kit, operators have a pick sheet from which they have to decide which parts to pick and in what order to match the sequence of the assembly line. Human error plays its part, as well as damage from mishandling due to the pace that operators percieve that they should be working. These problems were solved by installing a pick to light system, which operates with information sent from the same system that runs the sequencing of the assembly line. This ensures that all parts picked are in order and correct. Processes were also developed to further define the functions of the operator in this area, allowing them to work at a more manageable pace without impacting the quality of the parts they come in contact with.

Processes of concern are Receiving Inspection, Finished Material Verification and Database Integration. Through a rapid period, BAE Industries Inc. has out-grown their current processes to accommodate the growth it experienced. It is the request of BAE Industries Inc. that this thesis investigate solutions to these problems. The objective of this thesis is to offer a practical analysis of situations (both current and proposed), a proper use of developing new processes and procedures and supply evidence demonstrating the new processes and procedures will provide an efficiency increase and ultimately a cost savings for BAE Industries, Inc. The current situation will be evaluated largely through direct observations, department records, and department documentation. New processes and procedures will be evaluated with the intention of increasing efficiency and after several options are found viable will be taken into consideration when executing a cost savings analysis of said new process or procedure against the current situation. All considerations must adhere to the rules and regulations of the ISO/TS 16949:2002 Quality Management System (QMS).

This thesis was written in an effort to collect vibration data from a gear manufacturing machine and make correlations relating that data to the manufactured gears performance once installed into a transmission and in effort to predict the manufacturing machine's tool life. A vibration data acquisition system was interfaced with a coroning machine and vibration signatures for each gear manufactured were collected and analyzed using computer analysis software. Testing was performed using a suspect machine tool that was associated with previously manufacturing gears with unfavorable performance conditions, as well as testing on incoming gear conditions and testing to predict machine tool life. The testing using the suspect coroning tool yielded results that allowed the author to differentiate between machine tools that would exhibited similar characteristics, thus possibly similarly unfavorable performance conditions in the gears they would manufacture. The testing dealing with incoming gear conditions and machine tool life yielded no initial correlation results. Although trends in tool life were realized more testing will be needed to be performed to make a correlation sufficient enough to use in predicting tool life.

To determine if the dual faced strut is a viable technology that can be applied in the development of future products. This will be done through analytical models and testing of prototypes. The 4R70W intermediate one way clutch will be used to test this idea. The part will be modified to accompany the dual faced strut, and tested to verify if it can meet current production part performance specifications.

The redesigned heavy-duty shelves were determined to be acceptable based on the pass/fail criteria of ELP-001A and ELP-002A. All of the NSF guidelines for designing shelves in a refrigerator or freezer were also adhered to. Follow up testing on the smaller versions of the shelves will be conducted to prove their strength. By outsourcing the building of the welded assembly, a cost savings of $144,000 will be seen annually. For each assembly, there is a savings of $3-$4 due to labor reduction and material costs reduction. The largest volume shelf is the 22-in assembly, and has a conservative projection of 15,535 pieces for the coming year. After the redesign, this shelf alone saves the company over $52,000. In the first year, a tooling cost of $125,000 will make a net savings of $19,000. With further considerations made, if the cost of production could be $80 per shelf, the company would save $626,000. If brought down to $25 per shelf, the company would save $1,456,000. By passing all criteria set by Hussmann and design criteria set forth by the NSF, the shelves can be produced. Because the new shelf assemblies show a savings in future forecasts, the company would benefit from implementing the new design of shelves. The redesigned shelves will be a feasible alternative to the current design of heavy-duty shelves.

Fastener and bolt self-loosening has been studied many times in the past, but never with respect to the internal combustion engine connecting rod bolted joint. MAHLE and its customer experienced significant problems with bolt self-loosening in a V8 engine that was studied in this thesis. This particular engine sustained several documented failures during durability testing that all involved failures with causes that either could not be determined due to catastrophic cylinder failures or that were related to bolt loosening/low joint clamp load. Upon further investigation of this phenomenon, it was found that a majority of the failures occurred in the #7 and #8 cylinders, which are in the rear of the engine adjacent to the flywheel. This indicated that the occurrence was not random. MAHLE Industries Inc. immediately began an investigation to determine the root cause of these failures and possible solutions. This thesis is the culmination of that work. The thesis includes all preliminary background imformation, complete theoretical analysis, all pertinent connecting rod, engine and bolted joint calculations, and documents all testing required to come to the final conclusions as to how to prevent bolt self-loosening in the connecting rod.

This thesis is a study of an assembly line, with each station being improved upon in order to improve quality, reduce production time, and reduce the variability in the drive shaft production process.

This thesis will cover the cost of a Grohmann Machine to apply door seals. Europe has the machine and the US has been working on the manual process. This thesis will go over the validation process, show the savings with the automated machine vs. the manual and will determine if this machine should be implemented into the plants.

Throughout the Hydraulics and Cylinder Division of Parker Hannifin Corporation, a number of reoccurring mistakes and errors such as bad packaging methods, wrong parts and accessories, cross shipment, bad paint job, and wrong paint color have been identified in the Painting and Shipping Department. In order to eliminate some of the mistakes, standardized work procedures and new employee trainings have been created based on the Lean Management and ISO 9000. The work was accomplished by reviewing the current work instructions and finding alternatives that will improve the processes while maintaining continuous workflow and current work productions rates such as the number of parts shipped per day as well as the amount of dollars required to attain daily goals. Each process underwent multiple time studies for verification purpose. The use of set guidelines improves employee performance and the ability to minimize errors, while maintaining desirable production rates. In addition, new employees trainings reduce the number of questions and decrease the amount of time spent figuring out the correct way to accomplish the desired work. Furthermore, set guidelines and training are accessible at any time to all employees, increasing the quality of the products, customer satisfaction, and decreasing the number of errors. It also makes traceability easier, errors easier to identify, errors easier to correct, and errors easier to favor constant processes improvement. Finally, companies that follow Lean Management, ISO 9000, and continuous workflow through all stages of productions are able to better market their products and provide and exceed the customer satisfaction through guaranteed quality control and continuous innovations. They are able to identify the mistakes and errors before the products reach the customers.

This project is the development of a three pinion differential assembly designed to replace a current production four pinion in some applications. A three pinion design is a logical choice to fill the gap between light vehicle low-torque applications and heavier higher torque applications, but problems such as arriving at a proper gear geometry using three pinions are faced. Problems such as this are addressed while maintaining a low cost, light weight, efficient design that can match at least 75% of the current differentials performance.

The primary purpose of this thesis is to modify and test the ElectroJet EFI on an HFE engine with the intent to meet the performance criteria set forth in the System Requirement Document.

This thesis deals with the integrity of a staked shaft inside of a lifter body. The investigation is conducted to find the best way to gage the integrity without using destructive means. Discussions on inflection testing, yield strength testing, and toughness testing are all presented within the text, and conclusions drawn on each.

This thesis documents the process by which a small cold-forging manfacturer was converted from using 2D AutoCAD to using a 3D CAE tool to improve its design and revision process for engineering drawings. Metal Forming and Coining has recognized the need to constantly evolve with the changes in the automotive industry and as more of the major manufacturers switch to using 3D analysis tools for validation and design, so should MFC consider these tools a necessity to working alongside the customer in an effort to continue to bring quality products to the automotive and commercial truck markets.

A Cadillac being assembled in the United States ships to many regions. Regions may include the Middle East, Asia, and throughout Europe. Operators are require to choose from up to 30 different parts to put on a specific car, depending on make, model, color, and region its being shipped to. If a line worker on the right side puts an Arabic mirror on, while the left side line worker puts on a Korean mirror, then the error may not be caught and could potentially reach the customer. This thesis will look into taking this error away from the operator. The strategy will include kitting the parts off the line, loading the parts onto a vehicle so that they will be delivered at the right time. This will eliminate operators putting the wrong part on the a vehicle. This thesis will also look into how we will kit the parts. It will investigate what kind of conveyance menthod we want to use, whether it will be high tech and expensive or some simple solution. Cost and economics will be a large part of all decision making processes. The end result is a less complex operation where operator error is reduced. Having the right part delivered to the line when needed, instead of the operator choosing from many different parts will reduce the error.

Hardware-In-the-Loop (HIL) simulation uses real-time feedback from physical hardware in dynamic system simulation. HIL simulation of chassis control systems uses physical brake hardware feedback to control a virtual vehicle simulation. Packaging differences between the HIL and vehicle hardware generate differences in hardware response time detrimental to performance. This paper covers the development of a HIL simulator, its correlation to a physical vehicle, and benchmarking of system hardware. A Design Of Experiment (DOE) was then conducted to optimize HIL hardware response. The DOE results drove the development of a basic virtual hardware model used to 1) confirm test validity, and 2) tune future HIL simulator hardware response to match the physical vehicle.

The vision systems on Assembly Line 1 - Station 40 and Assembly Line 2 - Station 20 were experiencing too many vision errors. Errors were tracked to see which types and bodies were the worst. Several different changes were made to each station to improve the first pass yield of both stations. The end result was far fewer vision errors and a much-improved first pass yield.

Flint Assembly has corporate goals of continuously reducing by-products sent to the landfill. While a lot of corporations and manufacturing facilities are going green, it is not easy for Assembly plants to commit to being landfill free. The purpose of the thesis was to supply plausible solutions to divert their currently land filled waste to alternative means: reducing, reusing, recycling, and energy recovering. The initial step to complete this goal was to define the multiple waste streams that Flint Assembly produces, does not recycle, and then to understand how and why they are created. After this, it was important to research more into depth how they were created to see if they could then be eliminated, and if not reduced, reused, recycled, and energy recovered. Several cost analysis were done to see the feasibility of the solutions to minimize and eliminate Flint Assemblies waste. Waste streams that were already being recycled were also evaluated and supplied avenues of improvement to increase revenue that could be generated by these by-products. In doing all of this, Flint Assemblies environmental work force and their top management teams have an idea of the steps that can be taken to become landfill free and weigh the alternatives to determine the most practical for their facility.

The goal of this thesis is to evaluate the most efficient and cost effective heating and ventilation system for General Motors Flint Metal Center that is monitored/controlled by the current Energy Management System. This thesis evaluates the current heating system and investigates options for improvement. It recommends converting the Administration Building's heating system from steam to forced hot water and the Plant to a natural gas heating system in an attempt to generate energy savings. This thesis also evaluates the current Energy Management System; how it works, what are its faults, and how can it be improved. The end result is achieving the plant floor and office temperatures mandated by the WFG Energy & Utility Services Group. This will lead to measurable energy cost savings.

This thesis serves the purpose of improving the recycling efforts at the UPS CACH facility. Office paper and plastic bottles will be the first additional items collected, with suggestions on how to feasibly implement the program. Suggestions for future efforts are made, primarily including reducing and reusing materials. Waste management costs will be reduced and monetary credits will be received for recycled material.

This research thesis examines the current systems used by Robert Bosch LLC for common rail injector testing. It includes research on other alternatives for injector testing. It also analyzes and proposes another testing method for Robert Bosch LLC. The analysis for the proposal includes physical system modelling.

Filler blocks offer a potential cost savings in steering wheels composed of large amounts of polyurethane. Attached to the armature, they can reduce polyurethane raw material usage as well as reduce the cycle time of manufacturing the steering wheel. Different processing options for making filler blocks for the DS steering wheel program were examined, specifically EPP foam molding, blow molding, and injection molding. In addition, different designs and materials were investigated. It was concluded that injection molding filler blocks with polypropylene regrind would be the most cost effective option of those looked at, resulting in an overall reduced manufacturing cost over the lifetime of the program.

This thesis documents the discovery of the potential of sustainable delivery of high-energy Excimer UV laser light through a flexible tube with a flowing liquid solution. Two prototypes based on some preliminary research were constructed to prove the concept of guiding light with a flowing liquid in a given tube. Results from the two prototypes show great potential as a way to deliver Excimer laser energy and ought to be further researched.

The presence of special-cause variation in multi-swedge assembly machines at TG Fluid Systems USA has made it impossible to achieve the required process capability to produce a consistent fuel line assembly. To achieve the desired process capability on multi-swedge assembly machines a feedback loop poka-yoke was implemented. With the presence of a feedback loop poka-yoke, process capability would be improved and product would become more consistent saving the company approximately $2571.05 per year.

This thesis discusses a reliability problem associated with the current oil pump in a refrigeration compressor at Emerson Climate Technologies. It also goes over the ideas to fix the problem by redesigning the oil pump. The restrictions and criteria on the new design are reviewed along followed by the conclusions to the project. Next, the author decided on which new design to go with for the compressor. The author really focuses on how the design is supposed to work and how all of the parameters for the parts were determined, such as reed thicknesses. The concept of the design was tested and discussed along with the results of that testing. After that, the thesis talks about installing the oil pump into a compressor for testing. All of the compressor testing and results are included in the report. Finally, the production feasibility of the new design is discussed. Areas of importance such as reliability, manufacturability, and cost are all mentioned.

This work examines the necessity of analysis on vibration fixtures. Problems such as over-testing, and under-testing often create a range of frequencies that the fixture should stray from. This creates a problem for fixtures that resonate at too low of a frequency not allowing the engineer to get an accurate test. Hand calculations using simple cantilever beams were completed to provide a general direction for the design. Four different designs are analyzed. The first being a baseline standard fixture, and three others being modifications of the latter. Research and analysis shows that S1R1, a triangularly supported structure, produces the highest natural frequency of the 4 designs. The three modified designs utilized simple modifications of a structure and nearly doubled the natural frequency in each case. This project creates a benchmark for future structures created by the company.

The thesis was to design an active head restraint that would reduce the effects of whiplash in a rear impact. This was done by creating a pro-active head restraint that would compress during loading and account for various sized heads in terms of weight. The head restraint deploys by sensor at time of rear impact.

LuK with an abundance of automotive costumers, has found a need for varied products, for although the essential components of a torque converter remain the same, their structure must be tailored to produce the optimum geometry for the desired application. Therefore, a new model and drawing must be created every time a variant part is made. Producing a model from scratch takes time, and this time increases dramatically with increasingly complex geometries. This thesis evaluates the possiblility of modernizing the design process so that the components can be designed and drafted using ProProgram. This option would use the design guidelines as a base, thereby helping to improve quality and could yield a component design relatively fast, improving efficiency and design time.

This thesis, as mentioned before, is a series of tests to determine the best adhesive for a combination of different materials. This is an important project because the Agency often uses different materials in its projects, and are forced to test for the best adhesive at the time of the build. This steals valuable time from the project, and can often be devastating to the success of the project.

As a company ATEK Medical is always looking for ways to apply lean manufacturing principles to the current and future production lines. Evaluations are performed on the product flow, material handling, packaging, and organization of the workspace in multiple areas of the whole facility by multiple levels of employees. The idea of moving all of the production lines between Cleanrooms 5 and 6, just into cleanroom 5 developed. This thesis explains all of the steps taken in ensuring that this layout change was a success. These steps include researching the requirements, developing multiple layouts to order to find the best, and creating a detailed outline for the moving of the equipment.

This thesis covers the process by which experiments were designed to test a laser alignment system, by which customized fixtures were designed to allow its implementation on horizontal casting machines, and by which procedures were developed to ensure its proper use.

To facilitate the design and validation of exhaust systems, quantification of tail pipe noise contribution to vehicle cabin is usually necessary. In this paper, transfer path analysis (TPA)concept has been applied to investigate the contributions from tail pipe and other noise sources. The interaction between tail pipe noise and its transmission path to vehicle cabin is also observed. An artificial sound source has been designed for transfer function measurement and an all-wheel drive dynamometer situated in an anechoic chamber is used as a testing platform to collect operational data. A validation methodology has also been implemented by comparing the measured and predicted interior noise response with a big auxilary muffler (BAM).
Test results have shown a reasonable agreement between the measured and predicted cabin noise response with a BAM, thus validating the effectiveness of applying TPA concept to the tail pipe contribution analysis. The technique applied will provide insightful details regarding the need in solving exhaust related NVH issues. It will also speed up the exhaust system development process with a known transfer function. Changing the tail pipe input sound and using the transfer function can predict a change in vehicle interior sound without conducting physical testing.

This thesis gathers data via a DOE (Design of Experiment). Each of the control factors of the experiment will be anylized for desired comparative outputs and averages. The parameters varied in the transmission include existing and experimental materials along with pneumatic actuation techniques. The DOE's results will improve interaction understandings about the existing and experimental materials in the transmission.

Beamforming using a microphone array is becoming an increasingly popular technique for cancelling out unwanted noise from audio recordings. One of the main difficulties encountered with the practical application of beamforming is that the exact positions of the microphones used need to be known. This system solves that problem by using speakers attached to the microphones in order to find the distance between each unit. Once these distances are known, an algorithm calculates the position of every microphone on an arbitrary coordinate system using a mathematical technique called trilateration.

Federal Mogul currently uses engine dynamometer testing for the bulk of piston fatigue benchmarking and development. Dynamometer testing can be very costly and time consuming so there is a need for an alternative methods of pressure cycle testing. A new hydraulic fatigue system has many advantages when compared with traditional engine endurance testing, but there are also several potential short comings that need to be addressed. The main focus of this research is to validate the use of hydraulic fatigue testing in piston research and benchmarking. This thesis focuses on the prominent short comings of the pulsator system and explores compensatory methods for correcting such issues. This document covers thermal mechanical and hydraulic methods of replicating running engine cycles. The hydraulic fatigue results are analyzed along side dynamometer and FEA results. The final results of this research will ultimately prove or disprove hydraulic fatigue testing as feasible method for replacing preliminary engine tests.

Steel Industries needs to increase production capabilities to meet customer demand and continue achieving targeted growth rates. To accomplish this, it is planned to install a 2000-ton press for open-die forging. Two feasible choices exist for providing the hydraulic power to this press. The first is a traditional hydraulic system made by The Oilgear Company, and the second is a recently developed system made by UNiGY. By comparing the long-term cost of each system, as well as maintenance requirements, unique capabilities, and other differences, it was decided that the UNiGY system would provide the greatest benefit for Steel Industries at the lowest cost.

The purpose of this report is to demonstrate the effectiveness of the Chrysler Greenbelt practical problem solving techniques. This report demonstrates how to eliminate customer satisfaction audits scores (CSA) using the Shanin principles approved by Chrysler. CSA issues are issues identified by Chrysler to better satisfy the consumer. Scores are rated on severity and the A Post has been written as an L-1 or even a L-5 in some severe conditions which are for visual customer complaints. Currently there write ups of the "A Post", molding not being flushed properly against the instrument panel, and it is causing re-work to be done on and off line. The result is a loss in daily production, and downtime. The problem exists on more than one model, so it is of utmost importance to identify and understand the issues behind it.

To create a method for Machine Tool & Gear to inspect the toughness of the AAM differential pinion shafts as specified by the prints.

This thesis involves the design and development of the new power data option, Power Cove, for Nucraft Furniture. The thesis starts at the beginning stages working with the designers to come up with an initial design. From there development on parts and the function of the product is worked on. Once a design is decided on, the Power Cove is tested to for functionality. Finally the thesis goes through the training to actually get the Power Cove into production.

This thesis project focuses on Pratt & Whitney's insourcing of a vendor operation for the F-100 Rear Duct. The main purpose for insourcing this operation was cost savings, but reducing the lead-time of the part was also important. There were many challenges that were overcome during the course of this project. The single operation being insourced had to be broken into three separate operations to enable manufacturing to produce an acceptable part. The correct machinery and tooling had to be identified and implemented, as well as the necessary inspection methods. Upon completion of the project, the savings to the company were calculated to be approximately $585,000 over the life of the contract and an effective lead time reduction of roughly four days.

Compare the functionality, corporate benefits, planning, implementation and estimated cost of Product Lifecycle Management (PLM), Laboratory Information Management Systems (LIMS), and a custom designed Microsoft (MS) Access relational database. Choose a solution that best fits Thetford Corporation's situation.

This thesis focuses on the design of the structure of a 300 ton hydraulic press with an 80 ton cushion. It follows a logical order to get the final design stepping from: conception of the design, determining the critical parts within it, calculating the required dimensions of these parts, developing a 3 dimensional cad model and creating dimensioned blueprints. The result of the thesis is a successful 300 ton hydraulic press with an 80 ton cushion.

This thesis project serves to create a standardized test method for finding the variation in rear facing child restraints in their response during a Rear facing infant seat (RFIS) passenger airbag deployment. This method of testing shows the variation in terms of how it affects HIC. It includes the use of a linear impacting device, an ECE standard Steel seat, and a 12-month-old Child Restraint Air Bag Instrumentation (CRABI) anthropomorphic testing device. The test method was developed using and best applies to The Graco Comfort Sport child restraint.

A vehicle must go through rigorous validation testing internal to General Motors before being released into production. One of these tests is the max pothole test. As customer desires lead to larger wheels and tires, there is an increased difficulty level in passing this test. Larger wheels and tires tend to drive a greater force into the suspension system due to a higher spring rate. This in turn will cause damage to the vehicle and failure in a pothole test, ceasing vehicle production. The goal of this project is to lead the development of a bi-state hydraulic jounce bumper to the testing stage that will better manage the high loads of suspension end of travel.

Complete web-based maintenance monitoring of manufacturing applications can improve reaction time to potential problems, reduce down time, wasted cost, and increase production output. These benefits summarize GM Parma?s need of a web-based condition monitoring system for the Muller Weingarten progressive presses. This thesis outlines the steps to developing a complete web-based maintenance monitoring system using CIMPLICITY software, reviews vibration analysis relative to press applications, and compares the setup and use of two vibration data collection systems, MachineXL and Emonitor. Created using CIMPLICITY HMI Plant Edition, the system is user-friendly and displays at a glance all necessary press health information and system statuses such as press speeds, counterbalance and hydraulic overload settings, bearing and oil temperatures, tonnage monitor data, lube monitor data, and Andon system calls. A link also allows the user to view all vibration analysis information and alarms using MachineXL Condition Overview viewer, the stronger vibration software for Parma?s press application. If utilized effectively, this system can improve GM Parma?s predictive and preventative maintenance programs and save the plant from wasted costs.

This thesis proves that it is possible to power a hydraulic pump directly off of the engine of a utility vehicle in order to power accessories. This makes the product more appealing to customers in the market as well as opens up opportunities for other accessories to be added.

The thesis outlines the DOE process to optimize foam use when developing seat back and cushion pads. Seat pads need to optimize the amount of foam used because cost and weight are becoming increasingly important in the completive automotive market. The amount of foam used has a large impact on comfort, so change the amount of foam used in a seat is a complex process when comfort is considered. The steps outlined in the thesis provide a useful method to optimize comfort and foam use.

The primary purpose of this thesis is to create an efficient production system for the Reliance Electric area by implementing a new design for production, new packaging system, and reduction to the inventory kept in the facility.

The purpose of this thesis is to document the current problems with the inventory system at TSM Corporation and implement a new inventory control system. The author researched the tool crib and familiarized himself with the issues that were occurring on a day-to-day basis. The author worked as the crib attendant for a two week time period to gain a better understanding of how the current system was being operated. Once the author had a good understanding of what needed to be done in order to manage the tool crib, alternate methods of inventory control were looked at to determine which would utilize the tool crib the best. At this time, more research was done to figure out which kind of equipment was available and the advantages and disadvantages of each piece of equipment. Once a sufficient amount of research has been done and the data collected, the author made a decision on what will meet the objectives of the project and develop the company. At this time the author found the most efficient software to use for this application would be the AutoCrib software. The author chose this software because of it versatility and reliability. No equipment was added to the project for the tool crib due to the fact that is has a high initial cost and upkeep cost. The author knows that additional equipment is not needed if the software is used correctly and the access to the tool crib is managed in a reasonable manner.

The low cost revision of the automated loading board loader needed to increase reliability and reduce maintenance. This was achieved with the use of PC based G-code CNC software, servo motors with encoders, a single frame design, and 80/20 guarding system.

This thesis is a feasibility study on the possibility of replacing a hydraulic transmission and motor on a ZTR (Zero-Turn-Radius) lawn mower with an electric drive system. A mathematical method is developed to determine the needs for this application to assist the development of the actual product and in this thesis the MTD The Tank is used to illustrate the use of the equations. Many different possible types of motors are explored and based on the needs of the application and the outcome of the sample calculations a general direction is developed. With this research, information that was needed was identified which would need further assistance from the customers. The information attained from this study will help the business development team and the product engineers to approach the customers and give insightful details of this new development.

This thesis included the optimization and implementation of a counter-based preventative maintenance scheme which includes software to control and monitor all incoming data from the PLC units.

This thesis outlines the development of a multichannel, wireless, piston temperature telemetry system. The system is inductively powered. This project resulted in a system that transmits power to the connecting rod of a running engine-and piston temperature data off of the connecting rod, without wires. This project acheived a cost savings of 50 percent of previous telemetry methods, and should minimize the time-to-test for each engine platform. The long term, high speed durability issues that exist in current telemetry methods should be eliminated as well.

This thesis focuses on optimizing mass and material for the cross section of propeller shaft (drive shaft) tubes. In addition, the product, process and manufacturing as well as business case are analyzed. Finally, proof of these finding are covered in final chapters.

As part of the Product Development Team for the second generation Alpha 2 Traction Power Inverter Module, this thesis is a thermal study to improve operating conditions. The thesis has found that there can be an increase in current use in steady state conditions. This translates to a increase in the power rating of the system, increasing the use of the AC traction motors used to propel the vehicle. With an increase in motor use, the systems efficiency increases.

This thesis is the compiled work for the completion of Jerry Birchmeier's Senior Thesis Project for Kettering University, completed at BAE Industries. The document includes a description of the company, a description of the project, the scope and paramenters of the project, structural analysis for the project, the outcome of the project, three dimensional models of the project, and drawing for individual components of the project. The thesis also includes a quote from the outside source use in fabricating the weldment, as well as the ABET Program Outcomes for the thesis project.

This paper discusses the importance of Noise Vibration and Harshness (NVH) testing. This paper also explores improvements for the FEV Vehicle Interior Noise Simulation (VINS) calculation. VINS is a FEV developed tool for Noise, Vibration, and Harshness (NVH) diagnostics. NVH is an engineering field that is growing because of new government regulations. NVH is used in many fields other than automotive. Examples of other uses for NVH are civil engineering, aerospace, off road vehicles, and industrial equipment. NVH is very involved in making our environment more pleasant to live in, by helping to reduce noise from various sources that have not been previously regulated such as snowmobiles and lawnmowers. This paper demonstrates a different approach for the calculation of the engine mount vibration contribution to sound in the cabin of the vehicle; by taking into account the cross talk between mount vibrations in the transfer path in the cabin. It also explores the basic theory and math behind the VINS calculations and Transfer Path Analysis (TPA).

Ticona produces a metallic molded-in color material that could potentially benefit the automotive market, by providing a large cost savings in addition to an increase in part performance. To assist in the understanding of the current automotive market a cost analysis and value proposition were created to guide the sales and marketing team in its efforts. This included research and market characterization in the automotive interior market and the processes coating or finishing plastic parts as well as their applications.

The Winchester Federal Mogul facility makes friction lining. Some mixes for the lining involve resins and therefore make the mix a "wet" mix. When the mix nears the end of the mixing cycle, the bulk density of the mix is measured to determine how the material will act in later processes. As of now the operator takes a cup and scoops out a scoop-full of mix and weighs it. Variations occur from operator to operator from how firmly the scoop is packed full of material and how full the scoop is.

The surface treatment machine currently cannot keep a steady baseline with respect to its chemical conversion bath. A viable data collection tool is required to quickly check conditions on-line and prevent further problems. The volume that each pump doses within the bath was examined by measuring the amount of solution each core takes out as well as the pump's output over a given interval of time. These two variables appeared to primarily determine the machine's running condition. The data herein proved the machine was not always running properly as the original conditions had changed significantly. In order to maintain chemical bath concentration, a spreadsheet was designed to check the machine's running condition. Within the spreadsheet design, the production department adds a key variables and the spreadsheet ultimately informs production with respect to data acceptability. If the information is unacceptable, the spreadsheet notifies production that the machine's running condition has indeed changed.

The purpose of this document is to provide a method to improve airbag seam integrity while maintaining cost effectiveness. This thesis was produced with the sponsorship of TRW Automotive of Washington, Michigan. Airbags must maintain seam integrity during deployment in the event of an automobile accident. The airbag seams are subject to heat from the inflator, as well as stress due to the internal pressure. Because of the destructive nature of deployments, and the importance of airbag reliability, methods to improve seam integrity were researched. Once a method to improve seam integrity is found, testing will be conducted to determine which design to implement or research further. Given the relatively thin profit margins on top of a highly competitive auto safety market, determining a cost effective solution is also essential.

The purpose of this thesis is to increase the utilization percentage of a common-rail pump flange machining cell (Cell #3), in which excessive changeover time is believed to be causing a low utilization percentage. Decreasing the duration of a changeover will increase this cell?s utilization and bring its production levels up to those of the other cells. The project must: > Decrease average changeover duration in order to increase utilization of Cell #3, with a goal of reaching that of Cells #1 and 2 > Avoid purchases of new machining equipment, as these costs would exceed the opportunity cost of the current scope of this project > Ensure necessary gauging and specification measurement checks required for production flanges are not skipped, thus ensuring flange quality This thesis will identify parts of the changeover procedure in Cell #3 of common-rail pump flange machining which can be conducted in a more efficient manner. Key successful changes in Cell #3 either helped to slightly decrease the duration of some sections of the changeover or helped increase changeover repeatability and relative ease: > A second CMM was dedicated to flange measurement in the measurement lab > Some measurements were moved from less-capable ScanMax to CMM with a PAS (Process Audit Summary) dictating hourly checks > A functional gauge was developed for in-cell use to help alert operators if one of several major features was out of tolerance coming off an OP 35 machine > A changeover matrix in a PQI (Product and Quality Instructions) was corrected and expanded, adding both flange and machine part numbers > The machine parts cabinet was organized with labels for flange part type, operation number, and machine part number > A changeover checklist was recreated to show the most efficient way to complete a changeover in a step-by-step arrangement Although this thesis project dealing with common-rail diesel pump flange machining did achieve a reduction in changeover time, this reduction was not significant enough for Cell #3 to match the utilization percentage of the two other cells. The first criterion was not fully met: > Decrease average changeover duration in order to increase utilization of Cell #3, with a goal of reaching that of Cells #1 and 2 Through careful consideration paid to the second and third criteria, these were successfully attained: > Avoid purchases of new machining equipment, as these costs would exceed the opportunity cost of the current scope of this project > Ensure necessary gauging and specification measurement checks required for production flanges are not skipped, thus ensuring flange quality

The perpetual quality of fastened joints determines not only the functionality of the vehicle, but also has a large impact on customer satisfaction in the near and long term. The ability of the assembly plant to accurately meet the torque specifications for these fastened joints is a result of both the assembly process and more importantly the design of the joint. Identifying and eliminating poorly designed fastening operations during the launch phase will save the company time and resources.

The implementation of ACE tools at PWAA highlighted the inefficiency of the engineering department. Through careful observation it was found that a major source of engineering lost time was due to the computer programs they use. To combat this problem, this thesis centered on creating standard work instructions for various processes that would be completed by an engineer using SAP or Solumina on a daily basis. This engineering business documentation proved to be a success, limiting errors made, giving step by step instruction, and decreasing training time. Since the induction of SWI?s there has been a reduction of lost time by the engineering department and an increase of productivity.

This thesis designs, prototypes, and tests a remote catheter advancement device. The device has two purposes, to be remotely operated so the physician is removed from harmful radiation doses as well as to achieve the slow ablation speed that Spectranetics recommends so larger lumens are produced by the laser catheter.

The thesis project was the design, sourcing and integration of a step-pad installation machine for the 2009 Ford F150 rear end module program. The author assisted in the design and revisions of the machine, election of the vendor, and the integration of the machine with the production assembly process.

This thesis is about an analysis of a pulsation damper which goes on a pump to alleviate pressure pulsations. It covers some basic acoustics and noise control as well as dynamic systems. Next it covers the development of the charateristic equation which is then used to optimize the design.

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.

The thesis project uses statistical control and six sigma tools to identify issues affecting quality. These issues are then investigated and corrrected in order to improve the process. This is done in a pilot cell as a new way to more effectivly utilize the information gained at quality check points.

This thesis explores the potential for the implementation a non-contact measurement system in Alex Products for both pre-production as well as production applications. Several different non-contact metrology technologies were researched and the most applicable technology was selected, stripe sensing active triangulation. Three different products that utilize that technology were considered and tested. The best product for Alex Products? application improvements was selected, resulting from the product?s capabilities and usability. The current metrology processes were understood and an in-depth cost analysis was performed to demonstrate the savings that could be captured with the implementation of the non-contact system. The cost analysis resulted in an annual savings of $120,361 and a return on investment of 11 months. Additional opportunities were explored such as preventing quality issues and providing contract metrology services; this would further increase the annual savings, reduce the return on investment time, and potentially provide a means of additional revenue generation.

This thesis illustrates the process used to analyses the grinding process at Romulus Engine Operations to machine the cylinder block deck face and also includes a statistical process control and capability study of the process. The thesis contains recommendations by the author to improve the process in order for the engine block to meet the part print specification for deck face flatness.

This thesis covers the design process of a new product line called the Floating Dock Lift. The new product was designed to be aesthetically pleasing as with typical floating docks. Structural calculations were done to show the safety and quality of the system. A prototype was manufactered and went through field testing. The thesis covers any issues and recommendations for the Floating Dock Lift product line.

The ASA-5 Automatic Slack Adjuster has been upgraded to include new features that improve the overall performance of the product and its marketability. New documentation (i.e. DFMEA, DVP&R, CAD models and drawings) has been created with the purpose of facilitating future development in the product, such as the R-ASA concept, which is in its intial stages.

These thesis serves as an analysis for the proposal to eliminate rework parts while also reducing loss due to scrap. The nature of this project was empirically based but also involved an extensive amount of research.

Intake manifolds on gasoline engines incorporate electronic actuators to operate air control valves for tuning and emission purposes. The Bosch GPA-S actuators, developed in Germany for this purpose, are selling competitively in Europe but have not acquired market share in North America since their introduction in 2005. This thesis assesses the competitive abilities of the two Bosch GPA-S actuators in this potential market. The investigation begins with an evaluation of the actuator market. A SWOT analysis indicates both the internal and external factors relevant to the success of the GPA-S. Competing companies are also introduced. The product features important to the customer are identified using DFSS tools, and specific functional requirements are presented. A benchmark study that incorporates a practical, low-cost test setup compares the performance and robustness of both GPA-S models to six competitive actuators. The robust assessment follows the Taguchi Optimization Methods to identify the base functional characteristics important to the customer. All eight actuators are included in a teardown analysis to determine design efficiency, and to identify advantageous component features and production methods. The competitive assessment concludes with a cost study comparing the two GPA-S models to two benchmark actuators.

The goal of this project is to decrease the number of failures seen with Campbell Hausfelds current oil free air compressor. The specific approach being taken is in the area of the piston bearing failures. The project tests the idea of decreasing the cylinder bore and increasing it's stroke in order to decrease the bearing loads and in turn increase it's usable life. The project should produce a more reliable product at minimal expense resulting in a more satisfied customer as well as saving Campbell Hausfeld money.

The thesis shows the steps taken in analyzing the current training matrix available to employees and the evidence that was gathered to show support for both increasing the amount of training or keeping the current training matrix as is. Surveys and research were conducted to find how much of an improvement increase training would create as well as how well employees would respond to different forms of training. The final recommendation of the thesis was to increase computer training of employees to help employees work more efficiently and increase productivity.

The primary goal of this thesis is to make improvement to the World Engine design allowing for increased engine variants, thereby allowing GEMA to sell more engines. Design changes will be made to many of the World Engine components to increase the reliability and strength of them. The increased strength of the components will allow increased performance targets from the engines.

This thesis compares the two machines that perform the same test but on different products and uses different methods. The reason for this study to be done was to try to standardize testing methods across all products. GRR test were performed to be able to compare the machines based on performance. Also the costs of the machines were accounted for in the judging process. With the information gathered the best machines for each product was recommended.

A methodology for setting wheel first resonance targets was created to improve vehicle structure born road noise. This target was then related to simulation practices for wheel development implementation. The target created lead to improved mid-frequency road noise performance.

Solid oxide electrolytic cells (SOECs) are key components in demonstrating the feasibility of high temperature steam electrolysis (HTSE). The extreme operating conditions, however, limit performance by degrading the materials, particularly the oxygen electrodes. Pr2NiO4 has shown to be an excellent oxygen electrode, but a possible degradation mechanism occurs with a structural phase shift near 800°C that changes the thermal expansion and increases resistance. This project investigated Pr2NiO4 and the impact of neodymium substitutions on polarization resistance at various temperatures. Five compositions based on Pr2-xNdxNiO4 (x = 0, 0.5, 1, 1.5, and 2) were produced by the glycine nitrate process and fabricated into symmetric half-cell samples by screen printing. The cells were tested with impedance spectroscopy at temperatures from 550°C to 800°C in 50°C increments. The polarization resistances of all samples except for pure Nd2NiO4 were on the order of 0.1 Ù?cm2 at 800°C. The results also suggest that Pr2NiO4 and Pr1.5Nd0.5NiO4 have nearly similar characteristics, implying that small substitutions of neodymium may avoid the phase shift and prevent increasing resistance.

The goal of this thesis is to provide much needed information regarding the vibration behavior of the front of dash area on an automotive car body. The front of dash area is the sheet metal that separates the engine compartment from the passenger compartment. The information presented in this thesis was collected using two different tools. The first, a laser vibrometer, is a mature technology that was used as a gold standard for comparison. The laser measures surface velocities of the target surface. Then it produces velocity maps of those individual particle velocities. The second, SenSound technology, is a new type of measurement tool. SenSound uses nearfield acoustic holography, NAH, to generate maps of pressure, velocity, and intensity.

The thesis assesses a cost analysis for the cost savings that are present with the use of nominal gages for engineering assessment. Also, the thesis outlines the process, software, and design of a nominal adjustable gage that brings the nominal adjustable gage to perfect body position.

This thesis studied the impact that All-Wheel Drive has on the fuel economy of passenger vehicles. To be able to test this problem a 2008 Cadillac CTS4 was equipped with GPS equipment to measure the deceleration and a scan gauge to measure constant speed fuel economy. The testing was accomplished during different configurations. These tests were done at different configurations to look at the contribution of All-Wheel Drive components to fuel economy. All of the testing was accomplished on a straightaway at Ford Proving Grounds. After testing was completed calculations were done to determine fuel economy.

This thesis is discusses the development of a steering knuckle transducer that is used to measure on vehicle brake torque. The scope of this thesis involves the design, testing, and calibration of the transducer. The thesis also includes a conclusions and recommendations chapter that will be useful if the project is pursued further.

This thesis covers the consolidation and automation of filtration galleries through 5 major chapters: Development phase, which covers the initial thought process and brain storming of the project; Selection phase, which covers the process through which the third party contractor was chosen; the Implementation phase which involves how the changes were made; the Testing phase which outlines the strategies to test whether the systems are robust or not; and the Conclusion and Recomendations. The Filters that were modified were Henry Filters and the devices that were implanted were hardwire connections to other machines, infrared sensors to track scrap level, and a fiber optic connection to a station in the central office.

With an increase in volume requirements, a production line was unable to keep up with the demand. A new single operation machining process reduced the amount of time it took to machine the part. The new process also proved to be very stable for quality parameters. A new line layout increased the part flow and cycle time of the rest of the line. This resulted in exceeding the customer requirements and eliminating the need to run costly overtime.

The automotive industry is becoming increasingly competitive, forcing suppliers to seek out a competitive advantage. Negative vacuum forming is a new manufacturing process for automotive instrument panels and provides high quality components at a lower cost. This thesis describes the process in depth, comparing and contrasting its advantages and disadvantages with other instrument panel manufacturing methods. Through various trials and through research of industry experts, a set of design and process guidelines is developed to help Intertec Systems successfully implement negative vacuum forming on future programs, and to do so with less time and money spent on trials and tuning, thereby further increasing Intertec Systems' competitive advantage and helping them to become a world class supplier of instrument panels.

Scientific methods for refinement of computerized loose abrasive figuring and polishing processes for silicon carbide optical surfaces Abstract: Optical surfaces on flat, spherical, and aspheric mirrors, lenses, and replication molds are required to be exceptionally accurate in terms of both ?figure? and ?finish?. Optical figure describes how closely the real surface conforms to the idealized surface and thus influences how accurately light is re-directed upon reflection or refraction. Optical finish describes the specular or ?mirror? quality of a surface and its effect on the absorption and scattering of light encountering the surface. Typical tolerances for optical figure for the surfaces under examination for this thesis are 0.01-0.20 micron RMS. Typical tolerances for optical finish are 0.50-20.0 nanometer RMS. These tolerances tend to be approximately 100x more stringent than conventional machining processes such as grinding, milling, turning, etc. Silicon Carbide is desirable as a mirror material for many scientific and aerospace applications since it may be optically polished, has a low density, high thermal conductivity, high modulus of elasticity, low and highly isotropic thermal expansion and other properties. Silicon Carbide is also considered lower in cost compared to other ?exotic? mirror materials, such as beryllium, that are used for particularly demanding applications. Discussion: This thesis is focused on development and documentation of processes to apply free form, CNC (computerized numerical control) loose abrasive figuring and finishing of chemical vapor deposited (CVD) Silicon Carbide (SiC) mirror surface. Loose abrasive figuring and finishing technologies employ pads or jets to apply abrasive slurries onto a surface in a controlled manner to remove material while refining the figure and finish. ATIS will benefit from the results of this thesis by improving processing time, process yield, and process predictability for this unique and promising but very difficult material. Technical Approach: A CVD SiC flat will be used for purposes of this study. In addition, the flat will be prepared by a variety of precursor operations prior to applying CNC controlled loose abrasive processes. Precursor operations include CNC loose abrasive grinding and optical precision hard wheel grinding. ATIS has developed a CNC machine for purposes of automated figuring and finishing of optical surfaces known as a computer polishing machine (CPM). The CPM will be used to finish the test specimen. The CPM can apply a wide variety of loose abrasive slurry processes using pads or jets. Generally the finer the abrasive the more refined the optical finish at the expense of material removal rate. The coarser the abrasive the greater the material removal rate at the expense of optical finish. An ideal optical finishing process utilizes an efficient progression of coarse to finer abrasives to first arrive at a satisfactory surface figure and then to refine the surface finish. The CPM is designed to systematically remove material on ?high? zones relative to ?low? zones by proportionately varying the dwell of the loose abrasive tool across the surface. Primary focus of the thesis will be material removal rates as a function of resultant surface finish. The CPM will be operated in a constant velocity mode and will not be driven in a variable velocity mode that would be necessary to improve the optical figure of the specimen. Figuring run experiments will also be run if time and budget permits.

This thesis explores the validity of Tunerz vibration dampers when used on a compound archery bow. Through testing with strain gauges as well as an accelerometer, the damping was analyzed and a conclusion drawn was that as the weight of the arrow fired increases, the effectiveness of the dampers decrease. When testing the frequencies it was found that the dampers are effective in reducing vibrations in the bow.

Background: After conducting MoldFlow simulations on a few different door modules it was found that when MoldFlow is presented with a part that has a large surface area to thickness ratio, that the deformation results tend to be off. Results: The results shown from this thesis show that MoldFlow results alone do not adequetely predict the trend or the magnitude of deflection for a specific door module. They also show that by using the anchor plane tool within MoldFlow that the results are greatly improved, and by using a MoldFlow to ANSYS conversion that the results are improved slightly more. Conclusions: The analyses indicate that using MoldFlow and the anchor plane tool results in more accurate results, while benefits of translating it into ANSYS and reanalyzng it do not outweight the effort to do so, in this case. Further study is recommended using other door modules, large parts, etc.

Superior Controls is a system integrator with one area of specialty in traceability. Superior currently utilizes various technologies to mark parts with two-dimensional data matrices. The two-dimensional matrices are then used to track the part throughout its lifetime. Superior incorporates such part markers into its gage systems and integrates them into various other applications. The requirements of the marker are based on the material and matrix size. The two-dimensional data matrix best practices database allows for the user to check the applicability of a given marker to the part desired for marking or if marking it is even feasible, thus reducing research and testing time each time a new part needs to be marked. The database includes laser and indent part markers and was created using Microsoft Access.

The implementation of new government safety regulations merits the investigation of occupant comfort as affected by new safety requirements. A newly instated federal regulation, known as FMVSS 202a, governs the distance that may exist between an occupant's head and head restraint. As manufacturers create head restraints compliant to this requirement, consumers increasingly complain of the discomfort associated with the close proximity of the head restraint to the occupant's head. A new design concept, developed on a front row seat, is presented to meet these new safety regulations without sacrificing occupant comfort. The design's ability to maintain a constant backset throughout a target recline range is evaluated by means of an occupant comfort clinic, J826 Oscar Manikin measurements, and CMM measurements. Details of the design's functionality and kinematics are given. The prototype property was sucessful in decreasing the rate of backset change as seat back angle increased, but failed to maintain constant backset values.

Honeywell?s High Speed Blister packer lacks efficiency during production. Honeywell is a well-known manufacturing leader, serving customers worldwide with aerospace products, automotive products, turbochargers, and specialty materials and services. They also manufacture control technologies for buildings, homes and industry. Honeywell continually looks to improve designs and become more cost effective. The objective of this thesis is to examine an inefficient machine and make it more efficient through utilizing lean manufacturing skills, engineering, and six sigma tools.

The development of viscous damping and applying it towards the use in an automotive jounce bumper.

A new design of a split arm paper roll clamp has been developed at Allied Systems Company. The design was verified through finite element analysis and through engineering spreadsheet calculations. The majority of the design was found through many design iterations in a 3D parametric CAD solid modeling program. The paper roll clamp has a 6,000 pound capacity and can handle a roll range of 60"-10". It also has the ability to rotate 360 degrees continuously. The paper roll clamp was designed with high visibility for the operator. The pads are spaced 9.5? apart and the arms are spaced 14.25? apart for maximum operator visibility. This attachment will pave the way for a new generation of split arm paper roll clamps for Allied Systems Company.

The Lessons Learned of the Spring Hill Body Shop is a matrix of information regarding several aspects of the tooling and processes utilized in the Body Shop before the 2007 re-tooling. This matrix provides a reflective analysis in order to guide engineers and leadership into making informed decisions regarding the acquisition and implementation of new tooling and processes.

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.

A press inspection plan is necessary for progressive press asset sustainment at General Motors Parma. The eight presses at Parma have a combined total of 225,650,502 cycles. General Motors Parma has encountered a number of mechanical failures with the eight progressive presses. By using a program of modular inspections performed by GM personnel the failures can be identified earlier, addressed promptly, and repaired once they are found. The various components of the press system had to be identified. A press inspection document with a common format had to be developed to for each press system or component. In conjunction with the format, several supporting diagrams were selected to go along with these pieces to go into the inspection form. The common format was applied to all of the press components. A list of the tools necessary to complete the press inspection was made. The press system inspection form was then ready to include in planned maintenance schedule.

The Primary objective of this study is to create a process to calculate heat loads for multiple oven styles and scenarios in the area of automotive finishing. As energy costs continue to rise, it is imperative for automotive manufacturers to reduce the amount of energy used in the production of automobiles. One area energy expenses can be significantly reduced is in automotive finishing. This thesis will focus on the design aspect; however the final goal of the study is to develop a method of trialing operating conditions. This will assist in the optimization of a given system with regards to safety, quality, and reduced energy consumption. This thesis will focus on the calculation of heater loads based upon a given oven system and paint curing criteria.

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.

Fractional horsepower refrigeration condensing units are tested and analyzed for energy usage. High efficiency components are substituted and tested to see each component's contribution to energy efficiency improvement. Component cost is analyzed and compared to efficiency contribution, and a final high efficiency unit design is decided on.

This thesis explores current threaded adapter technology and its disadvantages including it's time consuming set-up and tear-down time and its strenuous adapter insertion and removal methods. Through finite element analysis and material research, a new quick-disconnect manifold was created which reduces set-up and tear-down times as well as the force required for assembly and disassembly.

This thesis documents the preliminary design completed for an aftermarket see through tachometer, more specifically the Clear View Tachometer.

This thesis entails the research and design criteria of a product called Sandwiform. Sandwiform is a patented technology used by Cadence Innovation in many automotive platforms. Currently, there are very few design guidelines documented and readily available to Cadence Engineers. This thesis contains information pertinent to Sandwiform design, such as the cause of certain appearance defects as well as strength characteristics.

Noise and vibration is an important element in automotive development. This paper describes an investigation done to correlate powertrain- and vehicle-level timing drive NVH performance. A series of powertrains and vehicles are evaluated, and statistical analysis is used to compare different timing drive designs and develop a correlation. This paper has the potential to aid FEV in future development projects in the area of timing chain whine. With the information presented, engineers can establish a starting point for future development projects where a timing drive NVH problem is discovered.

The thesis includes laboratory and field testing that was completed on all areas of the Q vehicle. The problematic components or systems found became a focus and extensive testing was conducted. The resulting data and conclusions were recorded in the form of graphs, charts, and written documents. The testing was performed and recorded using the most accurate equipment available. A list of solutions and recommendations were created. All recorded data was gathered and shared through the corporate network to create future testing guidelines.

This thesis report is focused on the optimization of the cylinder head cubing transportation system. The inability to efficiently supply and remove castings to and from machines restricts the throughput of the system. Through Witness simulation models, optimization has been recommended to increase daily production of the cylinder head cubing process. Many of the variables throughout the process were controlled to get a better understanding of the impact on the rest of the system.

Customer satisfaction and the production of the best powertrains in the world are of the utmost concern to General Motors. The 4T45 Final Drive Unit was experiencing quality issues resulting in catastrophic failure and the dissatisfaction of General Motors¿ customers. The Final Drive Internal Gear was determined to be the part of the Final Drive causing the failure. Root cause analysis was required in order to determine the root cause of the failure. Concentricity, also known as runout, was discovered to be the most likely cause of failure. In order to confirm runout as the root cause, durability testing has been scheduled for the Final Drive Internal Gear. The production process of the 4T45 Final Drive Internal Gear was not using the best gaging techniques to identify and prevent problems with part concentricity. So, in order to manufacture the best quality production parts, the latest advances in gaging techniques will now be used in the production process. General Motors has not experienced any catastrophic failures relating to the Final Drive Internal Gear, since the start of this thesis project.

This thesis attempts to attain more accurate notch factors for the use of finite element analysis and system integration. It does so by coming up with a design of experiments involving the building of 16 different designs, controlling 5 different variable inputs. Fatigue testing is done and the actual fatigue data is compared to expected fatigue life, which is obtained through part strain data, and the notch factor is created. Statistical data is necessary to validate the notch factors.

This thesis is intended to take an in depth look into a current dated design of G-Force Race Cars Pro-Modified rear-end housings. It touches on the current design, how it performs, what options can be taken to update the design as well as performance, and finally testing the model using finite element analysis. The updated design has a tradeoff between weight and performance along with other design factors. In the end a even balance of both is sought after for a newly unvailed housing.

The process used to track tooling inventory at many programs managed by PSMi takes a very manual labor approach. Counting of these tools for restock as well as keeping an active float inventory currently is carried out by a hand count. Because several system on the market exist to improve the productivity of the inventory tracking system, an investigation was performed to determine the viabiltiy of these options. Several time studies, quotations, and a cost benefit analysis were used to analyze the data and arrive at a solution. Numerous people were consulted, 3 programs analyzed, and 6 cases were examined. The systems of chioce used in the study were a scan card (bar code) system, the current manual labor system, and 3 different styled vending machine systems. As a result, the system of choie was determined to be the scan card system. It was found to have the least initial investment, the shortest payback period, and the lowest cost per part sold for moderate production levels (under approximately 100,000-150,000 parts sold per year).

Elesys North America produces a Passenger Presence System that is used to control airbag deployment. Careful and thorough data analysis is used to determine the parameter specifications used in the controlling software in order to accurately and reliably predict whether or not to activate the airbag. There were two areas in the data collection process that showed room for improvement. The first was the collection of OCATD data in which human-like test dummies are used to collect data. The previous method of storage of the OCATDs allowed the shape of the dummies to be deformed by surface contact. To solve this issue, harnesses were designed that attached to the OCATDs and allowed them to be hung suspended in the air, thereby eliminating any contact with other objects. The second area for improvement was with the weight placement machine (WPM) that is used to raise and lower heavy weights on and off of test seats. The machine was operated by a winch and was conrolled by a hand-operated switch. Since the timing of the raising and lowering of the loads is critical, human error was a possible influence on the collected data. To solve this issue, the WPM was modified to be fully automated. The drive system was converted to an electro-mechanical linear actuator. All necessary stress analysis was performed. Also, a future design concept for the WPM was created and analyzed. Major bolt calculations were done, and an FEA analysis verified the design.

This thesis presents the development of a model to predict vehicle ride height and a vehicle preparation process for ride height measurement.

To identify the principal root causes of transmission synchronizer sliding-sleeve spline wear (snubbing), focus on the analysis on the one or two main causes, and develop a test that can consistently reproduce the failure in the laboratory. Through testing identify the most robust design option.

This thesis proposes to calculate statistical correlations that exist between spark plug tip temperatures and the corresponding IMEP rating value (heat range). This relationship can then be used to predict the IMEP value of new spark plug designs through thermal FEA analysis.

The desired results of this project would be to publish a company wide design guideline(s) with all the different combinations that Takata can use to show to the customer. This will make the Takata design engineering team and possibly the customer better understand, quickly, what possible design alternatives are available. After researching existing armatures and working through many different calculations, identifying what the customer?s needs are, Takata can save a lot of time and money knowing exactly what the end goal of the program is along with improved Customer satisfaction

This thesis outlines the problem behind the demand for the system such as those with quality and customer service concerns. Further the document details the design and implementation demands for such a system.

Altair Engineering is a company that has built a reputation on providing advanced weight saving solutions to manufacturers through the use of computation based optimization and application of FEA. Over the past few years composites have begun to filter down through the aerospace industry to more terrestrial applications from small volume automobiles to mountain bikes to the packaging industry. The anisotropic nature of these materials requires significant modifications to the design and FEA processes. Additionally, much of this work is not correlated to field data or available as general engineering literature. This thesis researches design, analytical, and build techniques of lightweight materials and to then execute each one of those tasks with measurement and performance criteria.

Designing and developing an air inlet panel using the best design practices described in this thesis will ensure the bulk of manufacturing and functionality concerns that arise during initial production runs are addressed. Furthermore, utilizing this approach to cowl panels will create significantly less opportunity for quality issues.

Many parameters on a customer bore affect the seal retention. Press fit and surface finsh must be controlled in order to insure proper seal ability. They determine the force at which the seal can be installed and removed. If an ideal dimension can be found for these two variables, then design work can be made more efficient.

The general problem of the thesis is that a specific surface profile or shape is not known how it affects the change in surface parameters throughout a part's life. The outcome of this thesis will determine a machined surface profile that causes the least amount of surface parameter change after testing. Parts must be gathered first. The steel covers will be separated into 3 specific surface profiles, Triangle, Plateau, and Peak. The friction material surfaces will be measured before and after for reference. Once all parts are measured, pairs of TCC's and covers are matched for testing. Each friction material will be tested with each surface profile. Once testing is complete, the parts will be measured again and all data collected and compiled. After the data is reviewed, conclusions can be formed to hopefully answer the orginal problem of the thesis. Next steps can be formed as well to continue research if the orignal question is not answered or more questions/problems arise.

The idea of the thesis is to provide an energy and cost analysis of the current lighting system used in the C.S. Mott Center. The current energy consumption and cost are determined. It also explores new alternatives to lighting; thus, creating new energy consumption and costs. The thesis then compares the new values to the current values and shows there is a tangible difference between the two systems. The alternative lighting systems resulted in reduction of the energy consumption by as high as 61% and a cost saving up to 35% over a 20 year span.

Automobiles parked in direct sunlight become dangerously hot inside in a very short period of time. Several recorded instances of children either being left behind in or entering a vehicle have resulted in injury or death from the extreme environment that develops. GHSP of Grand Haven, MI is developing a safety system to prevent injury to occupants trapped in hot vehicles, the progress of which is recorded to form this thesis. The proposed safety system consists of temperature detection, occupant detection, and a logic controller. The temperature detection utilizes SMA wire to provide a thermal switch that is passive in nature, not requiring battery power to function. Existing occupant detection systems are evaluated to best suit the vehicle interior application. A logic system will be designed to interpret inputs from the previously mentioned sensors and other vehicle signals to generate an output or series of outputs to ensure rescue of the endangered occupants.

In the past few months, the amount of scrap in the L18 camshaft department at General Motors Powertrain - Bay City has been unacceptably high. The largest scrap item in the department is base circle runout. In order to get this manufacturing process under control, studies and tests were performed to assess what factors affect base circle runout, and how it can be reduced or eliminated. It is critical to controlling base circle that the induction hardening process is functioning within its developed parameters.

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.

Shaft swaging is a method of material forming, used to create ridges on which a gear is pressed. These is a common method for securing gears to shafts in the electric gearmotor industry. This paper attempts quantify the strength of swages used, as well as to design an improved feature (a knurl) for securing the two parts together. This paper describes the processes that are performed to create the parts used in this study, as well as standard production parts, the tests used to capture their performance, and the process of designing an improved feature to join gears and shafts used in electric gearmotors.

The thesis documents the design and validation testing of a CNC lathe condensing tower. The thesis also covers the different design iterations and results of final testing of the design.

Various heat treatments of 6061 aluminum were tested for rotating beam fatigue to determine the affect that the heat affected zone (HAZ) has on the fatigue characteristics of 6061-T6 aluminum. It was determined that a typical HAZ of 6061-T6 aluminum has fatigue characteristics similar to 6061-T6 and 6061-T4, with a similar s-N curve. The s-N curve of the typical HAZ samples fell between the curves for 6061-T6 and 6061-T4 at higher stresses and slightly below the 6061-T6 and 6061-T4 curves at low stresses. It was also determined that overheated 6061-T6 aluminum has different fatigue characteristics from 6061-T6, 6061-T4 and typical HAZ of 6061-T6, with fewer cycles to that the other tested materials.

Seal testing is one of the main functions of Federal Mogul?s Sealing System Technical Center, in Ann Arbor. Currently, the seals that are being tested are visually checked for leakage one or two times per day by technicians. Automating this process would increase accuracy of the test data and free up the time of the technicians.

On the 2008 Chevrolet Z71 Tahoes are stainless steel side step assist tubes to assist passengers in entering and exiting the vehicle. The tubes are an oval shape and have a 1-D bend at the ends of the tube, to accommodate the placement of the crushed step pad. With this type of bend, the assist step wrinkles or tears the stainless steel of the tubes where the bend is located. These wrinkles do not meet G.M. standards and can not be implemented for production. General Motors needs to be able to produce step assist tubes for the 2008 Z71 Tahoe that meet visual and quality requirements, and be on budget at a production rate of one assist bar every 45 seconds.

The Development of the Chroming Process for the 2009 Honda Acura TL Key Fob contains the research, testing and optimization details for the creation of a chrome feature on the 2009 TL key fob produced by Continental Automotive Systems. The scope and background as well as testing and optimization efforts are detailed.

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

Steady package flow control from the primary sort aisle to secondary sort aisle is an important part of operations at the United Parcel Service Dallas facility. Packages are sorted from the primary down transverse slides to a common collection belt that feeds the secondary sort. If the secondary sort falls behind then the main collection belt must be shut down to allow sorters to catch up. This causes jams at the intersection of each slide that feeds the collection belt and causes further operational delays. A system that could control the flow of packages down theses slides to the collection belt would help reduce the number of jams, damaged packages, and operational delays.

The primary purpose of this project is to identify the key components necessary for a robust tool and die management system that will maintain consistent part quality, thus reducing scrap and repair costs making the corporation more profitable.

This Thesis followed the design process for developing a building and machinery layout capable of processing and fabricating heavy timber for use in unique construction projects. The design went through several changes and eventually met all the criteria that Timber Systems requested.

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.

Hendrickson Truck Suspension Systems? vocational severe durability track development program required that specialized transducers for collecting road load and displacement data be designed. This thesis will document the development, calculated sensitivity, calibration, and functionality of the transducers.

To design a prototype research gauge that will collect and record data. The thesis also includes an experiment which was performed to get the ideal installation settings for Superior Controls Threadcheck Gauges.

This thesis covers the design and implementation of the newly revised Saleen S281 Horn Emblem. The new emblem decreases warranty costs while improving customer satisfaction. The original horn emblem designed back in 2004 for the new 2005 Mustang, was engineered as a domed urethane part. This would have worked, except the new Mustang had a horse which protruded from the standard Ford horn emblem. Since the surface was not completely planed the urethane Saleen emblem did not adhere as well as originally planned. When the flat Saleen part was coupled with the domed Ford part an adhesion issue presented itself as the outer edges of the emblem would not stay attached because of the curvature. This became Saleen's largest warranty issue since the company was founded in 1984.

This thesis was conducted to bring the new side stand retraction course into required specification. Once within spec tests were run on the new course and the course at the Florida Engineering Center. These results along with results from past tests on the old TTF retraction course were compared to validate the results on the new course and to verify the need for the new course.

This thesis improves the process of acquiring vehicle stiffness information. It reduces the amount of time required for testing. This process also gathers more information than the current test procedure used today.

Determining the most efficient components of a compressed air system by determining compressor size, receiver size, location, piping and handling leaks.

A device that overlays the thumb in order to assist it mimic natural motion for rehabilitation purposes was designed and is currently being evaluated. It has not been manufactured as of yet, but an initial prototype was developed to assist in designing. The current design is fully adjustable in order fit a variety of different patients. It has four independent degrees of freedom and one dependent. This allows for a large range of complex motion while the one dependent joint helps to decrease the burden of the control interface.

In order to reduce emissions of vehicles equipped with diesel engines a study was performed to understand the various approaches to improve catalyst operation following an engine start. The investigation included engine calibration parameters which may be utilized for increased exhaust temperatures following engine start, the design and evaluation of components intended to retain heat in the exhaust system, and the location of catalysts. The study found all approaches to hold potential for catalyst warm-up with particular promise being shown in the area of heat retention, particularly by utilizing air gap components.

This thesis provides a possible solution to issues relating to HVAC cooling systems used on mine protected vehicles. This is an important consideration due to the physical harm that is associated with heat stress. The system uses a liquid cooled vest to help regulate the body temperature. The subjective level of testing indicates that the vests are an effective method of keeping cool in a hot environment, however, the test data collected is inconclusive.

The Littoral Combat Ship (LCS 1) is a first of a class combat ship being built by Marinette Marine Corporation for the United States Navy. This thesis goes step by step through the installation process of the ship's waterjet propulsion units.

The thesis document describes a chemical method of extracting water out of fuel sludge. The main purpose is to improve management of the fuel sludge in order to reuse it at the current facility. Fuel sludge is customary disposed of, which becomes costly for the company over an extended period of time. In the thesis, the topics of discussion include: components that contribute to formation of the fuel sludge; the steps taken to find the best possible treatment process, and instructions on how to implement the proposed idea in the current system.

An analytical method for determining bearing life in a high-speed centrifugal compressor. Also including methods for testing the analytical life.

A continuing engineering task is how to maintain the competitiveness of the Saleen S7R in the face of growing and advancing competition. This work presents a proposal for a significant design change that would aid in maintaining and improving the competitive advantage of the S7R through a redesign of through-body aerodynamic components in the front of the automobile chassis. The proposal was devised through analytical means, including an analysis of competing designs, computer-model packaging analysis, and rudimentary wind tunnel testing.

General Motors currently has no experience integrating, maintaining, or mastering a Geo-Pallet type of conveyance system. The dimensional capabilities of the new Geo-Pallet systems are unknown, and must be evaluated and controlled. General Motors Skilled Trades have no experience with Friction Drive pallet conveyance, and therefore a maintenance procedure must be developed; complete with calculated frequencies of preventative maintenance work.

Experiment and computer simulations using a continuum approach for modelling the spread of a sessile droplet within a porous media is created, validated, and verified. A non-dimensional, universal master curve for the primary and secondary spread is developed that applies for various substance-substrate combinations based on the using a very simple optical measurement technique. In conjunction, a method of measuring the atmospheric turbulence intensity is being developed for near realtime applications.

During this project, a test fixture that will house the pressure transducers and temperature thermo-couple will be brainstormed, developed and manufactured. This fixture will be the interface between the oil filter mounting surface on the vehicle and an actual oil filter or a universal filter. A data-logging computer program must also be selected and mastered in order to test and calibrate the overall system. Once the system is complete, it will be connected to an oil flow test stand and pressure data will be recorded. The system will record the pressure differential across an oil filter at a given flow rate and temperature generating a set of data points. Armed with this data, the fixture can then be mounted to a vehicle to gather temperature and pressure data. The flow rate will then be back-calculated based on the temperature and pressure data collected on the test stand. Once an engine rpm versus oil flow plot can be generated (connecting data points to form a curve), the appropriate personnel have been trained to operate the system, and all the above deliverables have been completed, the project will be complete.

The Inspection Area at Cooper Tire - Texarkana should be redesigned and refurbished to improve the inspection process and reduce maintenance costs.

The subject of this thesis is the result of an investigation into the accuracy of internal finite element analysis predictions for pierce points and into the number of active turns in the end turns of automotive helical coil springs as it pertains to vehicle suspension systems.

This thesis is a portion of a larger GM Design For Six Sigma project that examines the test and product variation of six Pontiac G6's. Using a precise a/f test method, vibration data was acquired from 42 tests and used to determine both the variance between the vehicles and the tests.

This thesis focuses on an induction heat treat process for gears. It will use a Design of Experiment methodology to deal with multiple factors required to control the current process. This process includes heating, quenching and tempering. From the experiments run, we have determined three main factors that affect the heat and quench process. Using the tempering experiment data we have generated an equation that will provide an optimization phase. GLI will continue to screen factors for the heat and quench process until an optimization process is achieved. The optimization equation for tempering will be tested and validated.

This thesis is a comparison of in-house vs. outsourced prototype solutions. It involves a cost comparison with current outsourced prototype expenditures compared to implementation of a prototype machine in-house. This would result in a cost savings for prototypes and would encourage better build quality due to cheaper design iterations.

The Tire Line is one of Fort Wayne Assembly's primary leaders in non-scheduled overtime due to its throughput performance and lack of accurate bottleneck identification based on data-driven techniques. This thesis will discuss important corrective action countermeasures implemented by the plant, as well as recommend modifications to workstation layout and design in order to move towards a leaner manufacturing environment and higher productivity potential. In addition, systematic tracking programs for plant monitoring and control have been put in place to identify future bottlenecks and processing issues.

This thesis deals with designing a gravimetric feeder, while keeping as many components of the existing volumetric feeder as possible. Keeping the same components would reduce cost by elminating the need for manufacturing parts specific to a single product. Feeder rate tests were conducted to calculate the efficiency of the gravimetric feeder and how it compares to the current volumetric feeder.

The objective of this thesis project was to design a pot chuck fixture which will replace an old clamp-shell fixture that are used in the industrial ball nut grind cell. The end result that is sought out is to compare the time studies of each fixture and see if the new fixture actually reduce changeover set-up time between different fixture installations.

This thesis covers the investigation of the run out problem in the following chapters. The introduction chapter covers the problem topic, the background of the topic, criteria detailing the problem, the methodology of the investigation, and the purpose and overview of the problem. The second chapter covers the conclusions and recommendations of the project. The investigation chapter thoroughly walks through the investigation process from start to finish. The last chapter covers the improvements seen after a fix was implemented.

This Thesis follows the design of an Engine Block Fixture and a Pick and Place machine. Solidworks 2006 was used to model the design, and spreadsheets were used to calculate certain features of the design. The end result met the critera and was a successful project.

This thesis serves as a guide for implementing an Automated Guided Cart system in a General Motors bodyshop. Included within are the various options available for guided cart systems and the preferred method of their use. This guide can be used for both new and existing facilities.

During the design process of transfer case housings at ArvinMeritor Inc., there are very few guidelines for structural integrity design focus. The current design methods hinge upon personal experience in the design field and the experiences of co-workers one may turn to as resources. ArvinMeritor Inc. would like some form of suggestive material for designers that would portray tried and true methods for improving structural integrity in their parts. This will allow ArvinMeritor to decrease the weight of its products during the design optimization process. This thesis investigates the legitimacy of using various techniques to enhance the TG-2213 transfer case?s structural rigidity. The techniques include: wall thickness variation, bearing cup depth variation, and internal rib use. These techniques are evaluated for the TG-2213 transfer case and a recommendation is made for the TG-2213 and for generalized use.

The thesis will solve steady state power requirement equations to find out how the power will be distributed through each driveline element. These calculations will be used to develop a tool for the selection of an axle set and transfer case based on availability. The tool will provide the customer with the best available product based on the application requirements.

The current fixture used to weld wastegate valves is far too cumbersome to use. It requires far too much manipulation by a worker to be effective. This welding fixture can be automated by using off the shelf components and utilizing a programmable logic controller. This welding fixture should not cost more then $2500 and the PLC will allow a high level of safety to be easily attainable.

LEAN Business practices can be applied to almost any type of industry to remove costly wastes in the production process and allow for greater profitability and flexibility. NSL Analytical Laboratories implemented a LEAN Business approach to the layout of the Metallurgical Lab in its new facilities in an effort to reduce waste and improve sample turn around time. The study used a 5S approach and value stream mapping to determine the optimum placement of equipment and supply storage. Equipment needs such as isolation and contamination avoidance were also determined. The study determined that the best layout for the Metallurgical Lab would be three distinct work areas that are isolated from each other: a central room for preparation of scanning electron microscope (SEM) and metalography samples and dedicated rooms for both the SEM and metallography instruments and microscopes. The proposed layout provides for optimum flow of samples through the preparation and test areas to minimize sample preparation and test time and as well as central storage of tools and supplies. The layout has been approved by management for implementation in the new facility.

The three sizes of Tolomatic B3B belt drive actuators using fiberglass/neoprene belts did not provide the thrust capacity of competitor actuators using alternative belting. Redesign of the B3B platform using wider, higher strength belting would result in higher actuator thrust capacity with little cost impact. A higher strength belt using polyurethane/steel was identified with higher tensile strength and lower cost that fit within the size constraints of the existing platform. New drive components were designed to handle the increased loads permitted by the new belt material and which allowed the new B3W actuators to be 100% retrofittable with B3Bs. The new B3W10 design increased thrust from the B3B10 at 100 lbf to 150 lbf; a 50% increase with a base cost increase of 6.1%. The B3W15 thrust increased from 140 lbf to 250 lbf; a 79% increase over the B3B15 it replaced at a 14% increase in cost. And the B3W20 thrust increased 97% to 325 lbf from the B3B20 rating of 165 lbf at no cost increase.

This thesis compares the mechanical properties of thermoplastic and thermoset composites for use in high performance applications. The project is validated by outsourced test data, in house testing and a final product. The thesis concludes with general comparison data and next steps to creating the next generation of high performance thermoplastic composites.

This thesis develops methods for using offline simulation and hardware-in-the-loop simulation techniques for the simulation of diesel vehicles. These vehicle simulations will be used to characterize the severity of fuel system pressures, in order to rank from most to least severe. Then based on these simulations the application can be determined if it is necessary to perform physical testing or not.

A prototype design for the upper roll pin in a 40 ton rotary press is presented and analyzed. The design incorportates the usage of epoxy-bonded strain gauges to detect load, which will replace the current load cell configuration. It also incorporates a larger bolt, one of the key components in the assembly. An engineering analysis presents findings on past failure, and also the viability of the proposed design.

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.

With the current global concern shifting to energy conservation, this thesis discusses three alternatives which can be used to increase energy conservation in an office environment. These alternatives consist of replacing existing CRT monitors with LCD monitors, replacing existing toggle light switches with motion sensing switches and replacing standard efficiency HVAC units with high efficiency HVAC units. However, the more energy efficient options may not be a sound financial option, so a financial analysis is used to determine if the alternative will produce a return on investment within the first five years of the initial purchase. While none of the alternatives cost justified, a cost savings per dollar value is given to determine which option will give the highest energy savings per dollar spent.

This project was to design an office chair seat back adjuster that is distinctive amongst the market and is cost effective. The design was incorporate into the angled J-bar of Gill Industries?, Inc., hereafter Gill, Genero tilt. Benchmarking will be utilized to create a best in class adjuster. The design development utilized Computer Aided Design (CAD), mockups, and Finite Element Analysis (FEA). The designs were evaluated on cost efficiency, customer's voice, and robustness of design.

This thesis explains the improvements implemented to the facility that reduce machine downtime, improve quality, and increase overall productivity. Areas explored are in process operations, lean manufacturing, and engineering changes.

This thesis concerns the testing of several common and proprietary materials for use in a pump. The pump will be exposed to severe de-ionized water and a test needs to be created for the candidate materials and then carried out. Also, the document gives a brief introduction to corrosion, discussing points that are applicable to the future corrosion work on pumps exposed to DI water.

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.

To improve the shop floor production by networking drafting dept. and manufacturing equipment computers together.

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.

The primary objective of my thesis is to be an engineer on a design of a new distribution center for one of our customers. The process of designing a distribution center requires a team of engineers to overcome several obstacles. The main objective of Siemens L&A is to design, install, and integrate a conveyor system for the customer that will handle packages within specified dimensions at a specific rate. My objectives as a mechanical engineer on this project will be to perform belt length calculations, horsepower calculations, speed calculations, ordering and designing mechanical hardware, and installation drawings of the conveyor.

To develop a factor of safety for Dura Automotive's P221 torsion lock sector

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

Cruise and redundant control (ex: radio and climate control) switches are a mid-to-upper level option on most currently produced vehicles. These switches are commonly mounted on the steering wheel for easy access by the driver. The switches consist of electrical and mechanical mechanisms, and a class "A" surface. Extensive tests pertaining to their frequent use, exposure to wearing material and chemicals, and close proximity to the driver air bag are required. All of these requirements add cost, resulting in the switches as the single most expensive component in the overall steering wheel. The TRW Occupant Safety Systems Value Management Steering Wheel team recently concentrated their efforts on analyzing steering wheel switches in order to understand the current design variations. Once this was completed, new and alternative designs for the electrical and mechanical mechanisms in the steering wheel switches were investigated and analyzed. Finally, a cost analysis was performed to determine which switch make-up led to the lowest cost switch in today's market, as well as the future's market for developing technologies.

This project consist of developing a MS Excel based reference tool used for chassis design.

This thesis created a set of guidelines that will enable the author's employer to implement a construction waste diversion program. There was not an practical way for this to be accomplished before, but the guidelines developed will ensure that the progress of implementing a construction waste management program will be pushed ahead.

This thesis is a proposal for the improvement of the shipping department at ZF Lemforder. The research is broken up into three categories: Product flow equipment, loading and unloading equipment, and Organization of shipping. The research that was conducted was a search of products or processes that could improve the shipping department. Once several products were found that could be beneficial pricing was found for these processes. The current pricing and the pricing of these new systems were analyzed and compared. The conclusions and recommendations are the proposal to ZF Lemforder for the improvement of the shipping department

This thesis is a study of the affects of end joints and angle on the critical speed of driveshafts. It discusses how joints could possibly affect critical speed. Also, how angle could affect the critical speed of the driveshaft. The tests conducted in this study were designed to observe their affects on critical speed.

Background LuK USA LLC lacked the fundamental knowledge of the torque loads on a one way clutch in a heavy duty diesel application. This lack of knowledge made it difficult to properly design a OWC to be durable and inexpensive. To understand the torque loads on the OWC, measurements had to be made in a vehicle. Results The torque loads were found to be lower than expected. The correlation between the loads in the vehicle and the loads the OWC is tested at showed that the parts were beings over tested and over designed. The testing requirements for the OWC need to be revised.

OPW Fueling Components has struggled developing a sufficient carwash style vacuum. The ECO product line was purchased and resources were not allocated to make the product marketable. Upon redesign using CAE such as CAD, CFD, and FEA, OPW plans to have competitive vacuum systems that are marketable to the petroleum industry.

Non-functional torque ranges and tolerance limits can cause joint failures which result in non-functional assemblies that are not easily detected or prevented by human intervention. These non-functional assemblies can delay manufacturing and create scrap parts. In an effort to remove human intervention and prevent joint failures due to non-functional torque ranges and tolerance limits, this thesis provides a procedure to determine functional torque ranges and tolerance limits and states recommendations for further actions to be taken.

This thesis addresses arcing that occurs amongst grounding components for the ELPO bath at GM's Lansing Grand River paint facility. Research was conducted to determine if vehicle bodies float in the ELPO bath since this was thought to cause arcing. Experimental prototypes, analysis of buoyancy equation, and ELPO operation manual were used to prove the vehicle body does not float. Once vehicle body floating was proven not to occur then an analysis of other problems that contributed to arcing took place. Factors that contributed to arcing were part geometry, maintenance, and part replacement. A solution for each one of these contributing factors are given.

There was no comparison of three Child Safety Restraint standards, Federal Motor Vehicle Safety Standards, Canadian Motor Vehicle Safety Standards, and ECE R-44. This document focuses on child seat integrity, injury criteria, occupant excursion, head impact protection, sled and dummy instrumentation, test conditions and procedures, test dummies, and positioning and dummy installation. A comparision is made between all three standards. This document is then concluded by making a suggestion for an alterative test that would satisfy all of three standards requirements for the focii.

During the spring of 2006, the 4L80 case center support rough cut turning machine operator noticed that case center supports which were shot blast after heat treat and before being shipped to GM resulted in a longer tool life on a problematic insert than was previously achieved. This thesis investigates whether the increase in tool life is repeatable and if so, what physical properties correspond with the increase in tool life. Three tool life tests comparing production to shot blast case center supports were performed, two on the plant floor, one at an outside job shop, as well as material tests for residual stress, surface hardness, and surface roughness. The third tool life test proved that the addition of a post-heat treat shot blast cycle to the case center support manufacturing process resulted in an increased tool life of 249 versus 138 case center supports per insert, comparable to the results from the first test, as well as increased dimensional accuracy measured at gage points during testing. Material testing displayed greatly increased compressive residual stress and hardness in the surface of the shot blast case center supports. As a result of these tests, the addition of a post-heat treat shot blast procedure to production manufacturing processes of grey cast iron transmission components may be considered as a way to extend the tool life of silicon nitride inserts used to perform rough cut turning operations.

The thesis provides a solution to increase throughput of the Kettering University Advanced Engine Research Laboratory through use of an engine test cart. This cart allows for the engine to be mounted to a cart outside of the test cell and simply rolled into place. The previous method required mounting the engine directly to the test cell floor preventing preparation of additional engines until the tested engine had been completely removed.

The thesis is a gap analysis between the Integrated Corrective Action Process (ICAP) and Windchill, which is an off-the-shelf database development software. The ICAP requires a secure online database to streamline the process and allow the information produced during the process to be viewable by others who have granted access. The thesis defined a gap analysis, outlined the ICAP, explored the capabilities of Windchill, and identified the deficiencies between the two systems by utilizing the Lean Six Sigma methodology.

In an effort to reduce costs associated with the splined tube driveshafts Dana will be supplying to Jeep, the hybrid driveshaft has been investigated. The new design has been tested according to Dana specifications and passed. A weight analysis indicates that the design change would increase the weight by 5.49 lb. The cost estimate indicates an annual saving of 2.75% based on given volume. The new design should be presented to DaimlerChrysler with these findings.

Thesis was performed to determine if it is cost effective to implement Automatic Guided Carts (AGCs) into the body shop for door subassembly delivery. Also, research to determine if the AGCs will be able to reduce hours per vehicle, be delivered within sequence to the B-line, and reduce inventory on the plant floor by integrating just in time delivery into the system. The plant is interested in this research due to a new model being added to the plant and issues with the current method of delivery door subassemblies to B-line. The information gathered through this thesis project will further expand General Motors knowledge base about AGC application and issues and the benefits associated. A business case was written to evaluate the cost of remaining with the team member driven tuggers or to implement the AGCs into the system. The business case proved there was a cost savings, plus a cost avoidance which would save the plant $480,000 annually.

This thesis covers the exciting topic of vehicle performance testing for automotive journalism. It covers the creation of the testing procedure set up to evaluate the acceleration characteristics of the vehicles reviewed using a 3-axis accelerometer. Three acceleration tests are covered: 0-60 miles per hour, the quarter mile and a 60-0 mile per hour braking test.

Engineering has facilitated the concise, informational synopsis of what electro-magnetic interference entails, its sources and attributors, and why electronic devices fail during EMC test in validation. This thesis serves as a background for mechanical design engineers and provides engineering with a quick reference on particular definitions of importance concerning EMI. New technologies for mechanical design options and verification are provided in this study along with experimental data confirming their contribution to mitigating EMI in device design.

This thesis is an account of a manufacturing process improvement project completed at Fisher Dynamics in Saint Clair Shores, MI. The U-251 2nd Row SIR 60% Inboard Recliner Assembly Line and the U-222/28 3rd Row Power Recliner Assembly Line which were significant offenders of process inefficiency were optimized by applying Lean Manufacturing principles and eliminating waste. This project benefited Fisher with an annual cost savings of approximately $120,000. The scope of the project was to define where waste is present and to design a solution for improvement. The solution was to be designed for easy implementation while keeping the cost for the solution to a minimum. Value stream mapping and work measurement were the lean manufacturing tools used to define the elements of waste for both lines. Elements of waste were then analyzed using the Pareto Principle to determine where the most significant amounts of improvement are possible. After defining and measuring the specific elements of waste, the Pareto Principle was applied to determine where the best opportunity for improvement can be made. The Pareto Principle, in reference to this project, simply states that eighty percent of the problems at each line are caused by the greater twenty percent of the waste present. After waste was defined and analyzed, a solution was designed to eliminate it. Each line was modified to eliminate waste while maintaining a continuous flow of material from the start of the process to the finish with no inventory building up between stations. A proposal was created and then reviewed by the plant engineer to decide if any adjustments were needed to make the solution feasible.

The possibility exists in the motor home coach industry for issues of weight distribution; such as a side to side weight difference up to 15%. The source is obtained through testing and determining the effects of height control valves on weight distribution, ride quality and roll stability. An optimum design improving the weight distribution, ride quality and roll stability not only develops the overall quality of the vehicle but save costs by incorporating an equivalent, inexpensive height control valve.

The primary purpose of the thesis is to determine where Ford vehciles stand as far as paint appearance is concerned. In order to determine this, specialized equipment was used in order to measure the different characteristics of paint appearance on a large sample of Ford and competitor vehicles. The results proved that Ford's overall paint appearance was aproximatley mid-pack for most vehicle segments. From this data, and information supplied by various knowledgable sources, conclusions were made as to what actions Ford could take to improve their competitiveness in paint appearance.

This thesis begin with chapter one. Chapter one begins by explaining the problem at hand, which is that the majority of the employees are not currently capable of creating groundlines. Next, some backgorund information is provided to narrow in on what is actually needed from the thesis, in this case a tool specifically for the CVI group. Criteria and methodology are given which together provide a foundation of what rules and step will used to create the thesis. The end of chapter one explains the purpose to the thesis, which is to elaborate on the steps taken to create the thesis. Chapter two provides conclusions and recommendations for the problem at hand. Chapter three discusses the current state of groudline creation, addressing how there is only one groundline expert in the group and breifly examines the tools that are used. Chapter four tells how the tools were changed and how the author went about creating the manual. Chapter five presents what the user manual contains and how it is laid out. This concludes the thesis portion and the appendix begins which contains the user manual.

The purpose of this analysis was to determine whether patterns exists among the Z-scored absolute power, relative power, relative power ratio, or coherence values of eyes closed EEG of Fibromyalgia patients with respect to a normative database. Z-scored absolute power, relative power, relative power ratios, and coherence in the EEG of 20 Fibromyalgia patients was analyzed for similar patterns within the delta, alpha, theta, and beta frequency ranges and their functional locations in the brain. Quantative analysis included the mean and standard deviation values from FFT spectral analysis for the Fibromyalgia group in relation to a normal control group. It was found that distinct patterns exist within the Z-scored power and coherence values of eyes closed EEG of Fibromyalgia patients. Z-scored delta and theta coherence < -2 was observed in 100% of the patients in the frontal-frontal correlations, and 75% or more showed significantly low coherence scores between more than 25 electrode pairs. Significant deviation was observed in over 90% patients in the frontal lobes, and absolute power Z-scores are suggestive of significant, low amplitude delta, theta, and alpha frequencies in the frontal lobes.

As costs in raw material increase, it is evident that there is a greater demand for powertrain remanufacturing facilities. To date, our companies experience has been limited when designing such facilities. With the use of guidelines and benchmarks, the design of a remanufacturing facility can be simplified and expedited. If these guidelines are used in the future, there would be a potential cost and time savings for our company and customer.

Waukesha south operations (WSO) currently stages 2 to 3 days worth oflarge, high value parts. The parts are stored off-site and are shuttled to WSO in daily milkruns. An in house visual inventory system and storage location improves part availibility for the production lines, free up off-site storage space and cut down on transportation costs is presented in this thesis

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 manufacturing field has used robots in many different and complicated applications for years. Robotics is working its way into the medical field assisting doctors and surgeons in procedures performed on people. A need for a movable piece of equipment able to locate and close wounds without the assistance of a doctor or surgeon would be important when medical personal are not available on the scene of accidents, on the battle field, or in the operating room when surgeons are moving from one patient to another the robot could be used to close the surgical incisions. The Robotic Surgical Closure System in this thesis improved previous equipment including the stapling system, irrigation system, robotic closure system, mobility of robot, and feasibility of vision system use on subjects skin. The subjects for this thesis consisted of pig skin. Equipment improvements allowed the current system to increase efficiency, become more user friendly, more sanitary, and determine the feasiblity of use of a 3-d vision system.

The objectivew of this project is the build and test a birth simulator that will help clinicians practice maneuvers used in alleviating shoulder dystocia. Using a hinge and spring system the maternal mannequin will be able to perform primary maneuvers such as McRobert's Maneuver as well as secondary maneuvers such as Wood's Screw, Rubin's Maneuver, and the delivery of the posterior arm.

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.

A universal production cell, a collection of three machines, was designed and built to allow for the production of nylon tubing for fuel and fuel vapor systems. The machines were designed to conform to any size or construction of tubing with little or no additional tooling needed. The universal machines shaped, assembled, and tested any type of nylon tubing. The universal cell was designed, tested and proven successful within TG Fluid Systems's manufacturing environment.

In past years, General Motors Powertrain Bay City has caused several disruptions due to out of tolerance 4T65 channel plate flatness. To correct this from happening, studies have been conducted as to what affects flatness, how to control it, and how to properly measure it. It is vital that the channel plate mill be properly setup as it is the only machine creating and affecting flatness. The only way to properly check channel plate flatness is in the mock assembled or clamped state. This can be done using a CMM and does not require an expensive laser gage.

The piston assembly design of reciprocating compressor used in air conditioning is altered to reduce cost while not jeopardizing the reliability or manufacturability of the piston assembly. The initial concepts were altered to meet the parameters of cost and manufacturability. Finite Element Analysis of the piston assembly assisted in proving the design change would not affect the reliability. Although, further testing beyond the scope of this thesis is required to properly prove reliability standards of the new piston assembly design.

The laboratory technology at our facility did not allow remote monitoring capabilities for lab equipment, which can result in out-of-tolerance test issues for lengthy periods of time. A communication system was developed, taking advantage of wireless technology, to allow remote monitoring capabilities for the lab environmental chambers. It was setup as a preliminary system, and can be improved by replacing the current computer used with a dedicated computer, which can be accessed through VPN.

The Thesis will cover the pass through brackets for the new Cami and Ford buisness. It will take into consideration the amount of Work In Progress that produced, the inventory and the approximate financial and spacial burden of these parts. The thesis will also the roll restrictor buisness for Ford. This will cover the layout of the machinery, the production rates and the amount of inventory produced. The last topic covered will be the hydro-mount buisness this will cover the layout of the machinery, the material handling, the production rates and approximate cost to the company. It will track the man hours for production and weight the cost with the profit margin. The thesis will then sum up the conclusions reached by the student. It will suggest reccomendations that the student feels are practical solutions.

This thesis outlines the development of a plastic component which is used to replace a metal component. Steel stampings are inserted into the plastic to make for a fire fail-safe feature. This thesis results in a cost reduction for the employer and the employer's customer.

The purpose of this thesis project is to determine the best solution for the HVAC issues within the general offices at the UPS Beaver Avenue facility in Pittsburgh, PA. A detailed analysis of the current HVAC system was performed and deficiencies were noted. New system alternatives were investigated and new designs were considered. All alternate solutions were compared based on cost analysis and the alternative that best suited the application was recommended.

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.

Dampener track placement is vital to vibration dampening and mirror glass image stability. This thesis covers the affects of changing the number and location of dampeners radially around the glass center of pivot and the affect of altering the distance from the glass center of pivot.

A study into the contributing factors which effect the noise an automatic transmission shifter produces when cycling its shift interlock.

As Dott Industries has grown from its start-up as custom plater of plastic automotive components in 1988 to its present size, minimal emphasis has been placed on their racking tools. The effects of this lack of importance has been seen over the past few years in many areas, including wasted production time, poor part quality, high scrap amounts, high tooling repair costs, and other essential fields. With the implementation of a system to control and follow these racking tools, Dott Industries will be able to save money, production time, and reduce scrap.

This study will examine the relationships between mesh sizes, geometry and the accuracy of the result produced by finite element analysis software in common geometries. The results of this study will be used to improve and clarify engineering standards.

This thesis documents the steps followed while creating an online web portal for Outside Service mechanics to enter repair and maintenance information regarding the UPS fleet of vehicles. The new process will reduce the number of clerical hours for automotive management to approve invoices and for UPS Financial Service Center personnel to process the invoices. The web site will have the ability to communicate with the UPS AIS which will yield a higher level of data integrity within the system.

Standardizing a method in which to audit bolted joints after assembly. The outlined method considers clamp load as a function of fastener geometry, as opposed to the current method of measuring static torque during fastener audits. Static torque does not correlate to clamp load as well as dynamic torque because of the variablity of friction. Clamp load is the parameter that determines the integrity of a bolted joint. Dynamic torque is analyzed as a function of angular displacement of the fastener to calculate clamp load.

The thesis shows the three options my company had to solve a problem due to a change in our customers paint requirement for a new part. It explains the benefit and downsides of each option and the final solution that was chosen in detail.

This thesis is a feasibility study of processing a polycarbonate hatch glass through the Bowling Green Assembly Plant. This thesis discusses the various issues created by processing the polycarbonate hatch glass through the current system and details out solutions for each problem with respect to cost and cycle time.

Accelerator pedal design requirements and throttle mapping are not currently developed simultaneously at Nissan Technical Center N.A. A new process was developed to promote a more robust product as seen by the customer. The new process of development describes the methodology including testing with both subjective and objective data to determine the throttle mapping, accelerator pedal stroke and accelerator pedal force requirements. The results of the process were validated by expert evaluators and a customer clinic held in Torrance, California. It was confirmed that a more appealing product with concern to acceleration control can be achieved through the new development method.

The feasibility of integrating an automated vision inspection system into the manufacturing stamping process.

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.

To reduce the accelerated wear on the cutters several changes were made to help increase the life and cost of the cutter. These changes ranged from a peeling process, cutter coating material and machinery characteristics.

The U.S. Navy's bias toward electric, rather than pneumatic or hydraulic powered systems, may soon adversely affect the ability of the Oldenburg Group to win marine defense contracts. To avoid this, a process was created by which a system of hydraulic cylinders could be evaluated for possible conversion to electro-mechanical linear actuators. The results and methodology of the investigation into the replacement of hydraulic actuators with their electric equivalents is presented in this thesis. Through consultation with vendors, referencing of all available actuator application guides and the use of the authors engineering knowledge, the information needed to properly specify an electro-mechanical actuator and a process to derive that information from the present hydraulic system were determined. Using these tools, a test of the procedure was performed on a piece of existing equipment, which was then evaluated for its feasibility. Through the performed test it was determined that the process effectively streamlined the conversion from hydraulic cylinders to electro-mechanical actuators.

The purpose of this investigation was to define, through the use of cadaveric testing, the relative contributions of forearm muscle activity to dynamic elbow stability in resisting valgus force. Eight fresh frozen elbow joints were tested. Using a custom designed device, the strain in the medial ulnar collateral ligament was measured during individual muscle loading of the flexor pronator mass and extensor supinator mass at 45? and 90? elbow flexion angles. Kinematics was measured at these two elbow flexion angles when the MUCL was intact and later when it was fully torn. Findings suggest that the anatomical orientation of the flexor carpi ulnaris, flexor digitorum superficialis and flexor carpi radialis allow them to function as dynamic stabilizers, with the flexor carpi ulnaris being the primary stabilizer, in conjunction with the MUCL to maintaining elbow valgus stability. The significance of the extensor supinator mass (ESM) in elbow valgus stability remains unclear.

During a sample vehicle's operation, an interior acoustic boom and increased vibration levels are experienced during part load acceleration when the torque converter is locked at approximately 2500 engine rpm. During this specific driving condition, the acoustic boom, as well as increased passenger compartment floor vibrations, was suspected to be caused by a resonance in the rear leaf spring suspension system. A modal and operating deflection shape analysis was performed on the leaf spring system to characterize the shapes. After numerous rounds of analysis, it was determined that the leaf spring system is linear during static conditions and becomes nonlinear during operation, complicating countermeasure applications. Therefore, the modal analysis and ODS comparison cannot be used to fully analyze this system.

This thesis accounts for the construction and analysis of a computer program which enables digital intake system analysis. It functions by applying or removing transmission loss curves from bench-tests of intake systems to baseline intake sound files of vehicles. This enables a preview of the effectiveness of a particular system without actual installation. The program outputs include audible and visual analysis tools. This thesis also enables expected Transmission Loss curves to be applied and removed digitally, eliminating actual construction of intake systems. Piecewise analysis is then also possible, determining which intake silencing equipment has the greatest and least effect in a given situation, and enabling customers to view results with minimal effort and expense.

The purpose of this thesis was to increase quality and through-put by a proactive and planned approach for tool repairs rather than a reactive approach. This was done by the determination of the best tooling preventative maintenance system for SMCO?s lost foam tools and fixtures. Benchmarking and research were crucial to the process. The advantages of the proposed solution included a projected yearly savings of over half a million dollars. The new system is now being implemented and spread to other areas.

This thesis covers the effect that consistent cooling water pressure and flow has on the Lost Foam Molding Process. The current delivery method has fluctuating pressures and flows that lead to inconsistent final cooling temperature, leading to an inconsistent process, resulting in quality defects and downtime. The thesis shows the observations of the fluctuating pressures and flows and the effect it has on the mold machine and the molding process. The author then develops a method of delivering cooling water with consistent pressure and flow. The testing shows that the consistent cooling water reduces the fluctuations of the final cooling temperature. This results in a more consistent process.

Automotive body hemming is a complex process in which there are numerous points at which problems may arise. As quality standards rise throughout the automotive industry, it is becoming increasingly important to control variation and identify defects occurring throughout all processes. Hemming processes have traditionally been difficult to control due to the numerous factors affecting quality as well as limited understanding of the process for many people. Because the automotive engineer has several methods to inspect hemmed panels, it is important for them to manage these tools effectively to maximize their quality. This thesis illustrates that though there are numerous quality defects specifically found in hemmed panels it is possible to control the areas which produce them to create a higher quality product. It is important to first provide general knowledge related to how the mechanics of the hemming operation functions. By providing this information, affected persons will have a clearer understanding of how to approach quality defects. Numerous inspection techniques are also available to the engineer, however, without proper understanding of how these tools work together in the process, the highest possible quality cannot be achieved.

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.

This thesis is a general summary of the availible methods of protecting steel structure from hyfrofluoric acid damage. The acid is produced as a byproduct of the casting process, and rapidly corrodes any unprotected steel it comes in contact with. The thesis explores methods ranging from stainless steel construction to a simple coating of bearing grease, and examines all of the solutions from the standpoint of cost, downtime, safety, environmental impact and effectiveness.

DaimlerChrysler is unsatisfied with results of current tooling for the 3.5 liter camshaft bore operation. TruLine offers a solution in the form of composite tooling. Due to advantageous properties of composite, cutting edge preparation, and polycrystalline diamond selection, TruLine produces a superior part. A full test is in process, and its completion is recommended. Mahar should claim cost savings from this project and look for additional applications for TruLine's composite tooling.

This thesis project is to provide Kettering University and General Motors, Mansfield Metal Stamping Center, with a report of the investigation and findings for reducing the costs associated with lubrication oils. The information reports on the cost, feasibility, installation and implementation of the reclamation, recycling, management, and leak processes associated with lubrication oils.

The purpose of this thesis is to evaluate the current designs of door panels. On the mounting side of the door panel there are features that hold trim fasteners in place, which hold the door panel to the sheet metal. A new design is suggested within this thesis. This is needed to reduce investment and piece cost as well as reduce ergonomic forces. Investment will be reduced due to the fact that the mold is not as complex, minimizing tooling cost. With the reduction of plastic in each door, the piece cost is significantly less. Ergonomics are improved since less effort is required to assemble the door panel. This is due to the new design of the mounting feature. With these changes, a door panel is manufactured ergonomically efficient and more cost effective.

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.

An increase in orders of tooling for Gudel, Inc. press automation modules made a study necessary to determine if the components in the current tooling line were cost effective enough. A study of several clamps and loader tooling components was requested. To evaluate the cost effectiveness of the components, a cost comparison study was performed.

A procedure to establish whether good or bad EMI-2?s are being sent back to Germany for recalibration does not exist at this time. Robert Bosch Corporation requested a procedure be created that would allow technicians to run the EMI-2 on a standard test bench with a calibration pump in order to determine the condition of this machine.

This thesis determines the best method of resistance spot welding quality verification to be the Bosch PSQ Current Voltage Feedback system for quality and reliability.

My company currently has a limited catalogue of materials. Through extensive research and experimentation, I have expanded the company's capabilities. Several alloy and carbon steels exotic to the company were successfully cold forged. In light of these results, the company can formally expand its catalogue of materials and use that to gain new business.

The prototype sheet-metal assembly process is suceptible to many different failure modes. Defective parts and necessary reworking that result from assembly process failures increase cost and decrease process efficiency. Failure mode occurrence distributions are established through a Failure Mode Analysis. Analysis results are used to effectively address specific failure modes and direct quality improvement.

Unhardened camshaft lobes are the source of a significant number of warranty claims on vehicles that use GM Bay City?s truck camshafts. The error proofing systems currently in use are not capable of ensuring only properly hardened cams are shipped out of the plant. An Andec eddy current system is capable of checking all lobes and camshafts reliably and without causing any delays in the process.

This thesis explains the processes and requirements for completing an HVAC Door Design Guide System. It thoroughly explains each process, modeling, drafting, and FEA, in great detail and describes the aspects of each tool in the Unigraphics software. An overview and description of the EASA software and the process used to complete the programming is also discussed in great detail to give the reader an understanding of how powerful and unique the software is. A business case description is also included describing the costs and relative savings associated with the system.

Quality, safety, and profitability are among the top priorities for the General Motors Detroit-Hamtramck Assembly Center. In order to maintain the standards of the facility during the launch of two new vehicle models, an existing process needed to be redesigned. Two operations (right and left sides) in the plant assembly process include aligning the knuckle on the hub assembly to the strut of the front suspension and securing its position with two nuts and two bolts. The force measured to accomplish this task using the existing method, and with the new vehicle models, is 45 pounds, while the ergonomic guideline is 32 pounds. This thesis presents the results of the investigation and implementation of a cost efficient assembly process that provides for proper alignment of the knuckle to the strut, while eliminating ergonomic concerns.

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.

ESE's new building needed to be better organized and fitted to handle more complex jobs. Specialized assembly cells were developed, hydraulic and electrical test stands were built, and mobile job shelves were also built and tested.

The purpose of this thesis was to create a device which is used to control the gravity of a counterweight. The device met several criteria and federal guidelines. The device was designed to control 2000lbs of load, be easily confirmed as engaged, have a machine disabling sensor and, be engaged by one individual. The author conducted interviews with safety associates and conducted research into applicable guidelines. The design of the new lockout took into account these guidelines and criteria. The device was designed to have multiply factors of safety for each component in order to instill confidence in it's function. The resulting device meet all requirements and provided a safe and efficient method for lockout.

The thesis investigates cost saving opportunities in shipping Ranger Utility Vehicles. The thesis develops a shipping system designed around improved trailer density and regional distribution centers. Crate research and design is presented as well as the logistical research.

Total hip arthroplasty requires many artifical components. This thesis focuses on one component of the acetabular prosthesis: the cement mantle between the liner and the shell. Cement is most often used between these two components during revision hip arthroplasty. Reviewing studies archived on PubMed, a well-known medical publication database, led to the conclusion that the best cement thickness is 2 - 4mm. Only two studies were found that directly tested the strength of the cement bond between the liner and the shell of acetabular prostheses. More testing is needed to determine the overall significance of cement mantle thickness between the acetabular liner and shell.

With an increased emphasis on cost savings, the need for an efficient mig welding system had become sought after. The use of a Lincoln Powerwave provided less spatter, better assembly quality and a faster cycle time as compared to a Hobart CV Welder. The implementation of Lincoln Powerwave welders would significantly benefit our company?s efficiency in the mig weld assembly process.

Currently a dynamometer is used to generate the rear park brake lever load and travel values that brake suppliers use to calculate how much load and travel it will take a certain vehicle to hold on a specific grade hill. These requirements are then given to Dura Automotive Systems Inc. to calculate the park brake system requirements. Typically, numbers produced by the dynamometer (static movement) do not correlate with the vehicle numbers (dynamic movement). The primary purpose of this Thesis is to develop a test procedure that will produce test stand data (static data) that correlates to vehicle data (dynamic data).

While many in the engineering community know the term Six Sigma, there is still a general lack of understanding in regards to its origins and methods. Lear Corporation wishes to explore the implementation and impact of the Six Sigma procedures by investigating the Validation Process. The goal of implementing the Validation Process was to improve the throughput of the Test Lab by 50%.

The goal of this thesis is to propose a solution to the problematic configuration of the cooling system for the resistance welders. The open loop system currently uses city water to cool the machines. Not only is the cost of water a burden, but the low temperatures of the incoming water can do damage to the internal components of the resistance welders. In a step by step fashion, this thesis analyzes the systems's requirements and walks through the design process to present a closed loop cooling system ideal for the resistance weld department.

Bearing assembly is a complex procedure that requires an in-depth understanding of component orientation and reaction. The current computer application that defines assembly is lacking in detail. Assembly can be analyzed using equations for stress and deflection of circular rings, but requires further analysis to understand high stresses encountered during the assembly process. With further analysis and more testing, a new application can be created to design single row radial contact ball bearings.

The objective of this thesis project is to build and test a prototype hydromount based on the Goodyear patent No. 5,205,546 then determine the effect this has on the dynamic properties of the engine mount, and the production feasibility of such a mount. The molded products division of Goodyear in St. Marys, Ohio produces hydromounts for several large automotive manufacturers. Goodyear has a patent for a switching mount from 1992 that covers several different designs of a mount where one is able to turn the fluid damping on and off electronically. One of these mounts was built and tested several years ago. This mount had an air bladder on the perimeter of the mount with a valve to control airflow to and from this bladder. The focus of this project is to build a mount based off an alternative design shown in the patent with an air bladder inside the channel assembly at the center of the mount. This mount will be designed around a current production GM mount to maximize the use of current production parts. Once a prototype mount is completed, it will be tested to see the effects of the switching on dynamic properties. It may also be tested on a vehicle, depending on the availability of a car from GM. Upon successful completion of the project, there will be a working prototype, along with data showing the different dynamic properties of the mount.

This thesis evaluates and develops an alternative heating technology to better improve upon current heating applications at Magna - Intier Automotive Seating. Two prototype heat elements are proposed in this thesis. Conclusions and recommendations are proposed based on preliminary testing data and observations.

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.

Design engineers continually spend time creating their own individual design tools to aid them in various designs they encounter. Designing an oil pressure actuated variable camshaft timing component often requires many of these tools to be created, wasting company labor through having to create these tools repeatedly. A design tool was created to negate this need, save company time, as well as standardize the design process.

Background: Federal-Mogul Corporation currently supplies customers with low cost, small rubber cross section bolt isolators. They are used in current NVH cover application. The isolators are assembled with a bolt and a sleeve, and provide the load necessary for the NVH cover gasket to seal. Some customers are concerned with the performance of the rubber isolators in high temperature applications. These isolators lose a significant portion of their load due to the compression set of the rubber grommet due to high under hood temperature, which may cause the gasket to leak. Federal-Mogul was asked by one of its customers to investigate an alternative design that would address the above mentioned isolator issues. Isolator made of spring wire was chosen to be investigated. Federal-Mogul has never attempted to apply such a component in the automotive application, although commonly applies it the heavy-duty industry. The heavy-duty applications differ extremely from the automotive ones. They do not require same design parameters and they do not have to pass the same tests as automotive. Therefore, it was important to carefully analyze the spring bolt isolator design for automotive applications. Results: The outlined spring bolt isolator design performs identical functions ,as far as sealing, as the current rubber isolator. Further development is needed for NVH, packaging, and assembly.

The objective of this thesis project is to put in place a system that will allow parts produced to be tracked, from the time they arrive in the shop in raw material form, to the time they are shipped to the customer. This has been a problem at Rima due to the outsourcing of particular operations such as heat treatment and plating. Currently when these parts come back from being outsourced we have very little knowledge of which lot of raw material they are from or when they were machined. With a lot number traceability system in place it would allow Rima to quickly resolve any issues if a situation were to occur in which out of specification parts were produced, and need to be segregated before they were shipped to the customer.

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.

U-Compressor Mounting Bracket is a senior thesis project designed in Louisville, KY for General Electric Consumer and Industrial. The U-Compressor Mounting Bracket?s goal is to reduce the cost of materials used in producing refrigerators. Specifically by reducing material used in the compressor mounting bracket. The new part also has to perform as well as the current part or better. The compressor mounting plate has to be capable of holding the compressor and condenser throughout shipping and at the customer?s home for the life of the fridge without breaking. In material costs, an estimated savings of three hundred thousand dollars a year has been calculated. That makes the part financially viable. Several steps were taken in order to prove that the new compressor mounting bracket met performance requirements. The first major step was to talk with a tooling engineer to make sure that the part was feasible from a manufacturing standpoint. The engineer made several suggestions to improve the part and make it easier for production. The next part of the process was to do a finite element analysis (FEA). This would point out design weakness as well as give a good comparison between the new design and the current production part.