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Description
This dissertation presents methods for addressing research problems that currently can only adequately be solved using Quality Reliability Engineering (QRE) approaches especially accelerated life testing (ALT) of electronic printed wiring boards with applications to avionics circuit boards. The methods presented in this research are generally applicable to circuit boards, but the data generated and their analysis is for high performance avionics. Avionics equipment typically requires 20 years expected life by aircraft equipment manufacturers and therefore ALT is the only practical way of performing life test estimates. Both thermal and vibration ALT induced failure are performed and analyzed to resolve industry questions relating to the introduction of lead-free solder product and processes into high reliability avionics. In chapter 2, thermal ALT using an industry standard failure machine implementing Interconnect Stress Test (IST) that simulates circuit board life data is compared to real production failure data by likelihood ratio tests to arrive at a mechanical theory. This mechanical theory results in a statistically equivalent energy bound such that failure distributions below a specific energy level are considered to be from the same distribution thus allowing testers to quantify parameter setting in IST prior to life testing. In chapter 3, vibration ALT comparing tin-lead and lead-free circuit board solder designs involves the use of the likelihood ratio (LR) test to assess both complete failure data and S-N curves to present methods for analyzing data. Failure data is analyzed using Regression and two-way analysis of variance (ANOVA) and reconciled with the LR test results that indicating that a costly aging pre-process may be eliminated in certain cases. In chapter 4, vibration ALT for side-by-side tin-lead and lead-free solder black box designs are life tested. Commercial models from strain data do not exist at the low levels associated with life testing and need to be developed because testing performed and presented here indicate that both tin-lead and lead-free solders are similar. In addition, earlier failures due to vibration like connector failure modes will occur before solder interconnect failures.
ContributorsJuarez, Joseph Moses (Author) / Montgomery, Douglas C. (Thesis advisor) / Borror, Connie M. (Thesis advisor) / Gel, Esma (Committee member) / Mignolet, Marc (Committee member) / Pan, Rong (Committee member) / Arizona State University (Publisher)
Created2012
Description
Mostly, manufacturing tolerance charts are used these days for manufacturing tolerance transfer but these have the limitation of being one dimensional only. Some research has been undertaken for the three dimensional geometric tolerances but it is too theoretical and yet to be ready for operator level usage. In this research, a new three dimensional model for tolerance transfer in manufacturing process planning is presented that is user friendly in the sense that it is built upon the Coordinate Measuring Machine (CMM) readings that are readily available in any decent manufacturing facility. This model can take care of datum reference change between non orthogonal datums (squeezed datums), non-linearly oriented datums (twisted datums) etc. Graph theoretic approach based upon ACIS, C++ and MFC is laid out to facilitate its implementation for automation of the model. A totally new approach to determining dimensions and tolerances for the manufacturing process plan is also presented. Secondly, a new statistical model for the statistical tolerance analysis based upon joint probability distribution of the trivariate normal distributed variables is presented. 4-D probability Maps have been developed in which the probability value of a point in space is represented by the size of the marker and the associated color. Points inside the part map represent the pass percentage for parts manufactured. The effect of refinement with form and orientation tolerance is highlighted by calculating the change in pass percentage with the pass percentage for size tolerance only. Delaunay triangulation and ray tracing algorithms have been used to automate the process of identifying the points inside and outside the part map. Proof of concept software has been implemented to demonstrate this model and to determine pass percentages for various cases. The model is further extended to assemblies by employing convolution algorithms on two trivariate statistical distributions to arrive at the statistical distribution of the assembly. Map generated by using Minkowski Sum techniques on the individual part maps is superimposed on the probability point cloud resulting from convolution. Delaunay triangulation and ray tracing algorithms are employed to determine the assembleability percentages for the assembly.
ContributorsKhan, M Nadeem Shafi (Author) / Phelan, Patrick E (Thesis advisor) / Montgomery, Douglas C. (Committee member) / Farin, Gerald (Committee member) / Roberts, Chell (Committee member) / Henderson, Mark (Committee member) / Arizona State University (Publisher)
Created2011
Description
The large-scale anthropogenic emission of carbon dioxide into the atmosphere leads to many unintended consequences, from rising sea levels to ocean acidification. While a clean energy infrastructure is growing, mid-term strategies that are compatible with the current infrastructure should be developed. Carbon capture and storage in fossil-fuel power plants is one way to avoid our current gigaton-scale emission of carbon dioxide into the atmosphere. However, for this to be possible, separation techniques are necessary to remove the nitrogen from air before combustion or from the flue gas after combustion. Metal-organic frameworks (MOFs) are a relatively new class of porous material that show great promise for adsorptive separation processes. Here, potential mechanisms of O2/N2 separation and CO2/N2 separation are explored.
First, a logical categorization of potential adsorptive separation mechanisms in MOFs is outlined by comparing existing data with previously studied materials. Size-selective adsorptive separation is investigated for both gas systems using molecular simulations. A correlation between size-selective equilibrium adsorptive separation capabilities and pore diameter is established in materials with complex pore distributions. A method of generating mobile extra-framework cations which drastically increase adsorptive selectivity toward nitrogen over oxygen via electrostatic interactions is explored through experiments and simulations. Finally, deposition of redox-active ferrocene molecules into systematically generated defects is shown to be an effective method of increasing selectivity towards oxygen.
First, a logical categorization of potential adsorptive separation mechanisms in MOFs is outlined by comparing existing data with previously studied materials. Size-selective adsorptive separation is investigated for both gas systems using molecular simulations. A correlation between size-selective equilibrium adsorptive separation capabilities and pore diameter is established in materials with complex pore distributions. A method of generating mobile extra-framework cations which drastically increase adsorptive selectivity toward nitrogen over oxygen via electrostatic interactions is explored through experiments and simulations. Finally, deposition of redox-active ferrocene molecules into systematically generated defects is shown to be an effective method of increasing selectivity towards oxygen.
ContributorsMcIntyre, Sean (Author) / Mu, Bin (Thesis advisor) / Green, Matthew (Committee member) / Lind, Marylaura (Committee member) / Arizona State University (Publisher)
Created2019
Description
Optimal design theory provides a general framework for the construction of experimental designs for categorical responses. For a binary response, where the possible result is one of two outcomes, the logistic regression model is widely used to relate a set of experimental factors with the probability of a positive (or negative) outcome. This research investigates and proposes alternative designs to alleviate the problem of separation in small-sample D-optimal designs for the logistic regression model. Separation causes the non-existence of maximum likelihood parameter estimates and presents a serious problem for model fitting purposes.
First, it is shown that exact, multi-factor D-optimal designs for the logistic regression model can be susceptible to separation. Several logistic regression models are specified, and exact D-optimal designs of fixed sizes are constructed for each model. Sets of simulated response data are generated to estimate the probability of separation in each design. This study proves through simulation that small-sample D-optimal designs are prone to separation and that separation risk is dependent on the specified model. Additionally, it is demonstrated that exact designs of equal size constructed for the same models may have significantly different chances of encountering separation.
The second portion of this research establishes an effective strategy for augmentation, where additional design runs are judiciously added to eliminate separation that has occurred in an initial design. A simulation study is used to demonstrate that augmenting runs in regions of maximum prediction variance (MPV), where the predicted probability of either response category is 50%, most reliably eliminates separation. However, it is also shown that MPV augmentation tends to yield augmented designs with lower D-efficiencies.
The final portion of this research proposes a novel compound optimality criterion, DMP, that is used to construct locally optimal and robust compromise designs. A two-phase coordinate exchange algorithm is implemented to construct exact locally DMP-optimal designs. To address design dependence issues, a maximin strategy is proposed for designating a robust DMP-optimal design. A case study demonstrates that the maximin DMP-optimal design maintains comparable D-efficiencies to a corresponding Bayesian D-optimal design while offering significantly improved separation performance.
First, it is shown that exact, multi-factor D-optimal designs for the logistic regression model can be susceptible to separation. Several logistic regression models are specified, and exact D-optimal designs of fixed sizes are constructed for each model. Sets of simulated response data are generated to estimate the probability of separation in each design. This study proves through simulation that small-sample D-optimal designs are prone to separation and that separation risk is dependent on the specified model. Additionally, it is demonstrated that exact designs of equal size constructed for the same models may have significantly different chances of encountering separation.
The second portion of this research establishes an effective strategy for augmentation, where additional design runs are judiciously added to eliminate separation that has occurred in an initial design. A simulation study is used to demonstrate that augmenting runs in regions of maximum prediction variance (MPV), where the predicted probability of either response category is 50%, most reliably eliminates separation. However, it is also shown that MPV augmentation tends to yield augmented designs with lower D-efficiencies.
The final portion of this research proposes a novel compound optimality criterion, DMP, that is used to construct locally optimal and robust compromise designs. A two-phase coordinate exchange algorithm is implemented to construct exact locally DMP-optimal designs. To address design dependence issues, a maximin strategy is proposed for designating a robust DMP-optimal design. A case study demonstrates that the maximin DMP-optimal design maintains comparable D-efficiencies to a corresponding Bayesian D-optimal design while offering significantly improved separation performance.
ContributorsPark, Anson Robert (Author) / Montgomery, Douglas C. (Thesis advisor) / Mancenido, Michelle V (Thesis advisor) / Escobedo, Adolfo R. (Committee member) / Pan, Rong (Committee member) / Arizona State University (Publisher)
Created2019