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Description
Small metallic parts of size less than 1mm, with features measured in tens of microns, with tolerances as small as 0.1 micron are in demand for the research in many fields such as electronics, optics, and biomedical engineering. Because of various drawbacks with non-mechanical micromanufacturing processes, micromilling has shown itself

Small metallic parts of size less than 1mm, with features measured in tens of microns, with tolerances as small as 0.1 micron are in demand for the research in many fields such as electronics, optics, and biomedical engineering. Because of various drawbacks with non-mechanical micromanufacturing processes, micromilling has shown itself to be an attractive alternative manufacturing method. Micromilling is a microscale manufacturing process that can be used to produce a wide range of small parts, including those that have complex 3-dimensional contours. Although the micromilling process is superficially similar to conventional-scale milling, the physical processes of micromilling are unique due to the scale effects. These scale effects occur due to unequal scaling of the parameters from the macroscale to the microscale milling. One key example of scale effects in micromilling process is a geometrical source of error known as chord error. The chord error limits the feedrate to a reduced value to produce the features within machining tolerances. In this research, it is hypothesized that the increase of chord error in micromilling can be alleviated by intelligent modification of the kinematic arrangement of the micromilling machine. Currently, all 3-axis micromilling machines are constructed with a Cartesian kinematic arrangement with three perpendicular linear axes. In this research, the cylindrical kinematic arrangement is introduced, and an analytical expression for the chord error for this arrangement is derived. The numerical simulations are performed to evaluate the chord errors for the cylindrical kinematic arrangement. It is found that cylindrical kinematic arrangement gives reduced chord error for some types of the desired toolpaths. Then, the kinematic redundancy is introduced to design a novel kinematic arrangement. Several desired toolpaths have been numerically simulated to evaluate the chord error for kinematically redundant arrangement. It is concluded that this arrangement gives up to 5 times reduced error for all the desired toolpaths considered, and allows significant gains in allowable feedrates.
ContributorsChukewad, Yogesh Madhavrao (Author) / SODEMANN, ANGELA A (Thesis advisor) / Davidson, Joseph K. (Thesis advisor) / Santos, Veronica J (Committee member) / Arizona State University (Publisher)
Created2014
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Description
The ocean is vital to the health of our planet but remains virtually unexplored. Many researchers seek to understand a wide range of geological and biological phenomena by developing technologies which enable exploration of the deep-sea. The task of developing a technology which can withstand extreme pressure and

The ocean is vital to the health of our planet but remains virtually unexplored. Many researchers seek to understand a wide range of geological and biological phenomena by developing technologies which enable exploration of the deep-sea. The task of developing a technology which can withstand extreme pressure and temperature gradients in the deep ocean is not trivial. Of these technologies, underwater vehicles were developed to study the deep ocean, but remain large and expensive to manufacture. I am proposing the development of cost efficient miniaturized underwater vehicle (mUV) with propulsion systems to carry small measurement devices and enable deep-sea exploration. These mUV's overall size is optimized based on the vehicle parameters such as energy density, desired velocity, swimming time and propulsion performance. However, there are limitations associated with the size of the mUV which leads to certain challenges. For example, 2000 m below the sea level, the pressure is as high as 3000 psi. Therefore, certain underwater vehicle modules, such as the propulsion system, will require pressure housing to ensure the functionality of the thrust generation. In the case of a mUV swimming against the deep-sea current, a thrust magnitude is required to enable the vehicle to overcome the ocean current speed and move forward. Therefore, the size of the mUV is limited by the energy density and the propeller size. An equation is derived to miniaturize underwater vehicle while performing with a certain specifications. An inrunner three-phase permanent magnet brushless DC motor is designed and fabricated with a specific size to fit inside the mUV's core. The motor is composed of stator winding in a pressure housing and an open to water ring-propeller rotor magnet. Several ring-propellers are 3D printed and tested experimentally to determine their performances and efficiencies. A planer motion optimal trajectory for the mUV is determined to minimize the energy usage. Those studies enable the design of size optimized underwater vehicle with propulsion to carry small measurement sensors and enable underwater exploration. Developing mUV's will enable ocean exploration that can lead to significant scientific discoveries and breakthroughs that will solve current world health and environmental problems.
ContributorsMerza, Saeed A (Author) / Meldrum, Deirdre R (Thesis advisor) / Chao, Shih-hui (Committee member) / Shankar, Praveen (Committee member) / Saripalli, Srikanth (Committee member) / Berman, Spring Melody (Committee member) / Arizona State University (Publisher)
Created2014
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Description
Origami is an art transforming a flat sheet of paper into a sculpture. Among various types of origami, the focus is on a particular class called the `Rigid Origami' ("RO"). A Rigid Origami, unlike other forms, is not intended to be folded into fancy shapes. On the contrary, an RO

Origami is an art transforming a flat sheet of paper into a sculpture. Among various types of origami, the focus is on a particular class called the `Rigid Origami' ("RO"). A Rigid Origami, unlike other forms, is not intended to be folded into fancy shapes. On the contrary, an RO has a simple and a geometrically well-defined crease pattern and does not have curved/smudged faces. The folds can be carried out by a continuous motion in which, at each step, each face of the origami is completely flat. As a result, these planar faces experience very minimal strain due to loading. This property allows it to be used to fold surfaces made of rigid materials. Tapping into the geometrical properties of RO will open a new field of research with great practical utility. Analyzing each new RO pattern will require generating numerous prototypes; this is practically impossible to do, as it consumes a lot of time and material. The advantages of Finite Element Analysis
umerical modeling become very clear in this scenario. A new design concept may be modeled to determine its real world behavior under various load environments and may, therefore, be refined prior to the creation of drawings, when changes are inexpensive. Since an RO undergoes a non-local deformation when subjected to a disturbance, the usage of conventional FEA will not produce accurate results. A non-local element model was developed which can be used in conjunction with the finite element package ABAQUS, via its user-defined element (UEL). This model was tested on two RO patterns, namely Miura-Ori and Ron Resch, by carrying out basic simulations. There are many other interesting origami patterns, exhibiting different meta-material properties, yet to be explored. This Finite Element Approach equips researchers with necessary tools to study those options in great detail.
ContributorsKrishnaraju, Deepakshyam (Author) / Jiang, Dr. Hanqing (Thesis advisor) / Yu, Dr. Honyu (Committee member) / Mignolet, Dr. Marc (Committee member) / Arizona State University (Publisher)
Created2014
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Description
Damage detection in heterogeneous material systems is a complex problem and requires an in-depth understanding of the material characteristics and response under varying load and environmental conditions. A significant amount of research has been conducted in this field to enhance the fidelity of damage assessment methodologies, using a wide range

Damage detection in heterogeneous material systems is a complex problem and requires an in-depth understanding of the material characteristics and response under varying load and environmental conditions. A significant amount of research has been conducted in this field to enhance the fidelity of damage assessment methodologies, using a wide range of sensors and detection techniques, for both metallic materials and composites. However, detecting damage at the microscale is not possible with commercially available sensors. A probable way to approach this problem is through accurate and efficient multiscale modeling techniques, which are capable of tracking damage initiation at the microscale and propagation across the length scales. The output from these models will provide an improved understanding of damage initiation; the knowledge can be used in conjunction with information from physical sensors to improve the size of detectable damage. In this research, effort has been dedicated to develop multiscale modeling approaches and associated damage criteria for the estimation of damage evolution across the relevant length scales. Important issues such as length and time scales, anisotropy and variability in material properties at the microscale, and response under mechanical and thermal loading are addressed. Two different material systems have been studied: metallic material and a novel stress-sensitive epoxy polymer.

For metallic material (Al 2024-T351), the methodology initiates at the microscale where extensive material characterization is conducted to capture the microstructural variability. A statistical volume element (SVE) model is constructed to represent the material properties. Geometric and crystallographic features including grain orientation, misorientation, size, shape, principal axis direction and aspect ratio are captured. This SVE model provides a computationally efficient alternative to traditional techniques using representative volume element (RVE) models while maintaining statistical accuracy. A physics based multiscale damage criterion is developed to simulate the fatigue crack initiation. The crack growth rate and probable directions are estimated simultaneously.

Mechanically sensitive materials that exhibit specific chemical reactions upon external loading are currently being investigated for self-sensing applications. The "smart" polymer modeled in this research consists of epoxy resin, hardener, and a stress-sensitive material called mechanophore The mechanophore activation is based on covalent bond-breaking induced by external stimuli; this feature can be used for material-level damage detections. In this work Tris-(Cinnamoyl oxymethyl)-Ethane (TCE) is used as the cyclobutane-based mechanophore (stress-sensitive) material in the polymer matrix. The TCE embedded polymers have shown promising results in early damage detection through mechanically induced fluorescence. A spring-bead based network model, which bridges nanoscale information to higher length scales, has been developed to model this material system. The material is partitioned into discrete mass beads which are linked using linear springs at the microscale. A series of MD simulations were performed to define the spring stiffness in the statistical network model. By integrating multiple spring-bead models a network model has been developed to represent the material properties at the mesoscale. The model captures the statistical distribution of crosslinking degree of the polymer to represent the heterogeneous material properties at the microscale. The developed multiscale methodology is computationally efficient and provides a possible means to bridge multiple length scales (from 10 nm in MD simulation to 10 mm in FE model) without significant loss of accuracy. Parametric studies have been conducted to investigate the influence of the crosslinking degree on the material behavior. The developed methodology has been used to evaluate damage evolution in the self-sensing polymer.
ContributorsZhang, Jinjun (Author) / Chattopadhyay, Aditi (Thesis advisor) / Dai, Lenore (Committee member) / Jiang, Hanqing (Committee member) / Papandreou-Suppappola, Antonia (Committee member) / Rajadas, John (Committee member) / Arizona State University (Publisher)
Created2014
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Description
Multi-touch tablets and smart phones are now widely used in both workplace and consumer settings. Interacting with these devices requires hand and arm movements that are potentially complex and poorly understood. Experimental studies have revealed differences in performance that could potentially be associated with injury risk. However, underlying causes for

Multi-touch tablets and smart phones are now widely used in both workplace and consumer settings. Interacting with these devices requires hand and arm movements that are potentially complex and poorly understood. Experimental studies have revealed differences in performance that could potentially be associated with injury risk. However, underlying causes for performance differences are often difficult to identify. For example, many patterns of muscle activity can potentially result in similar behavioral output. Muscle activity is one factor contributing to forces in tissues that could contribute to injury. However, experimental measurements of muscle activity and force for humans are extremely challenging. Models of the musculoskeletal system can be used to make specific estimates of neuromuscular coordination and musculoskeletal forces. However, existing models cannot easily be used to describe complex, multi-finger gestures such as those used for multi-touch human computer interaction (HCI) tasks. We therefore seek to develop a dynamic musculoskeletal simulation capable of estimating internal musculoskeletal loading during multi-touch tasks involving multi digits of the hand, and use the simulation to better understand complex multi-touch and gestural movements, and potentially guide the design of technologies the reduce injury risk. To accomplish these, we focused on three specific tasks. First, we aimed at determining the optimal index finger muscle attachment points within the context of the established, validated OpenSim arm model using measured moment arm data taken from the literature. Second, we aimed at deriving moment arm values from experimentally-measured muscle attachments and using these values to determine muscle-tendon paths for both extrinsic and intrinsic muscles of middle, ring and little fingers. Finally, we aimed at exploring differences in hand muscle activation patterns during zooming and rotating tasks on the tablet computer in twelve subjects. Towards this end, our musculoskeletal hand model will help better address the neuromuscular coordination, safe gesture performance and internal loadings for multi-touch applications.
ContributorsYi, Chong-hwan (Author) / Jindrich, Devin L. (Thesis advisor) / Artemiadis, Panagiotis K. (Thesis advisor) / Phelan, Patrick (Committee member) / Santos, Veronica J. (Committee member) / Huang, Huei-Ping (Committee member) / Arizona State University (Publisher)
Created2014
Description
This thesis seeks to further explore off-design point operation of gas turbines and to examine the capabilities of GasTurb 12 as a tool for off-design analysis. It is a continuation of previous thesis work which initially explored the capabilities of GasTurb 12. The research is conducted in order to: 1)

This thesis seeks to further explore off-design point operation of gas turbines and to examine the capabilities of GasTurb 12 as a tool for off-design analysis. It is a continuation of previous thesis work which initially explored the capabilities of GasTurb 12. The research is conducted in order to: 1) validate GasTurb 12 and, 2) predict off-design performance of the Garrett GTCP85-98D located at the Arizona State University Tempe campus. GasTurb 12 is validated as an off-design point tool by using the program to predict performance of an LM2500+ marine gas turbine. Haglind and Elmegaard (2009) published a paper detailing a second off-design point method and it includes the manufacturer's off-design point data for the LM2500+. GasTurb 12 is used to predict off-design point performance of the LM2500+ and compared to the manufacturer's data. The GasTurb 12 predictions show good correlation. Garrett has published specification data for the GTCP85-98D. This specification data is analyzed to determine the design point and to comment on off-design trends. Arizona State University GTCP85-98D off-design experimental data is evaluated. Trends presented in the data are commented on and explained. The trends match the expected behavior demonstrated in the specification data for the same gas turbine system. It was originally intended that a model of the GTCP85-98D be constructed in GasTurb 12 and used to predict off-design performance. The prediction would be compared to collected experimental data. This is not possible because the free version of GasTurb 12 used in this research does not have a module to model a single spool turboshaft. This module needs to be purchased for this analysis.
ContributorsMartinjako, Jeremy (Author) / Trimble, Steve (Thesis advisor) / Dahm, Werner (Committee member) / Middleton, James (Committee member) / Arizona State University (Publisher)
Created2014
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Description
Cavitation erosion is a significant cause of wear in marine components, such as impellers, propellers or rudders. While the erosion process has been widely studied on metals, the effect of cavitation on polymers is not well-understood. The stress response in metals differs greatly from that of polymers, e.g. rate and

Cavitation erosion is a significant cause of wear in marine components, such as impellers, propellers or rudders. While the erosion process has been widely studied on metals, the effect of cavitation on polymers is not well-understood. The stress response in metals differs greatly from that of polymers, e.g. rate and temperature effects are far more important, thus damage and wear mechanisms of polymers under cavitating flows are significantly different. In this work, heat-driven failure caused by viscous dissipation and void nucleation resulting from tensile stresses arising from stress wave reflections are investigated as two possible material failure mechanisms.

As a first step in developing a fundamental understanding of the cavitation erosion process on polymer surfaces, simulations are performed of the collapse of individual bubbles against a compliant surface e.g. metallic substrates with polyurea coatings. The surface response of collapse-driven impact loads is represented by a idealized, time-dependent, Gaussian pressure distribution on the surface. A two-dimensional distribution of load radii and durations is considered corresponding to characteristic of cavitating flows accelerated erosion experiments. Finite element simulations are performed to fit a response curve that relates the loading parameters to the energy dissipated in the coating and integrated with collapse statistics to generate an expected heat input into the coating.

The impulsive pressure, which is generated due to bubble collapse, impacts the material and generates intense shock waves. The stress waves within the material reflects by interaction with the substrate. A transient region of high tensile stress is produced by the interaction of these waves. Simulations suggests that maximum hydrostatic tension which cause failure of polyurea layer is observed in thick coating. Also, the dissipated viscous energy and corresponding temperature rise in a polyurea is calculated, and it is concluded that temperature has influence on deformation.
ContributorsPanwar, Ajay (Author) / Oswald, Jay (Thesis advisor) / Dooley, Kevin (Committee member) / Chen, Kangping (Committee member) / Arizona State University (Publisher)
Created2015
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Description
In this research work, a novel control system strategy for the robust control of an unmanned ground vehicle is proposed. This strategy is motivated by efforts to mitigate the problem for scenarios in which the human operator is unable to properly communicate with the vehicle. This novel control system strategy

In this research work, a novel control system strategy for the robust control of an unmanned ground vehicle is proposed. This strategy is motivated by efforts to mitigate the problem for scenarios in which the human operator is unable to properly communicate with the vehicle. This novel control system strategy consisted of three major components: I.) Two independent intelligent controllers, II.) An intelligent navigation system, and III.) An intelligent controller tuning unit. The inner workings of the first two components are based off the Brain Emotional Learning (BEL), which is a mathematical model of the Amygdala-Orbitofrontal, a region in mammalians brain known to be responsible for emotional learning. Simulation results demonstrated the implementation of the BEL model to be very robust, efficient, and adaptable to dynamical changes in its application as controller and as a sensor fusion filter for an unmanned ground vehicle. These results were obtained with significantly less computational cost when compared to traditional methods for control and sensor fusion. For the intelligent controller tuning unit, the implementation of a human emotion recognition system was investigated. This system was utilized for the classification of driving behavior. Results from experiments showed that the affective states of the driver are accurately captured. However, the driver's affective state is not a good indicator of the driver's driving behavior. As a result, an alternative method for classifying driving behavior from the driver's brain activity was explored. This method proved to be successful at classifying the driver's behavior. It obtained results comparable to the common approach through vehicle parameters. This alternative approach has the advantage of directly classifying driving behavior from the driver, which is of particular use in UGV domain because the operator's information is readily available. The classified driving mode was used tune the controllers' performance to a desired mode of operation. Such qualities are required for a contingency control system that would allow the vehicle to operate with no operator inputs.
ContributorsVargas-Clara, Alvaro (Author) / Redkar, Sangram (Thesis advisor) / McKenna, Anna (Committee member) / Cooke, Nancy J. (Committee member) / Arizona State University (Publisher)
Created2015
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Description
Recent studies of the occurrence of post-flutter limit cycle oscillations (LCO) of the F-16 have provided good support to the long-standing hypothesis that this phenomenon involves a nonlinear structural damping. A potential mechanism for the appearance of nonlinearity in the damping are the nonlinear geometric effects that arise when the

Recent studies of the occurrence of post-flutter limit cycle oscillations (LCO) of the F-16 have provided good support to the long-standing hypothesis that this phenomenon involves a nonlinear structural damping. A potential mechanism for the appearance of nonlinearity in the damping are the nonlinear geometric effects that arise when the deformations become large enough to exceed the linear regime. In this light, the focus of this investigation is first on extending nonlinear reduced order modeling (ROM) methods to include viscoelasticity which is introduced here through a linear Kelvin-Voigt model in the undeformed configuration. Proceeding with a Galerkin approach, the ROM governing equations of motion are obtained and are found to be of a generalized van der Pol-Duffing form with parameters depending on the structure and the chosen basis functions. An identification approach of the nonlinear damping parameters is next proposed which is applicable to structures modeled within commercial finite element software.

The effects of this nonlinear damping mechanism on the post-flutter response is next analyzed on the Goland wing through time-marching of the aeroelastic equations comprising a rational fraction approximation of the linear aerodynamic forces. It is indeed found that the nonlinearity in the damping can stabilize the unstable aerodynamics and lead to finite amplitude limit cycle oscillations even when the stiffness related nonlinear geometric effects are neglected. The incorporation of these latter effects in the model is found to further decrease the amplitude of LCO even though the dominant bending motions do not seem to stiffen as the level of displacements is increased in static analyses.
ContributorsSong, Pengchao (Author) / Mignolet, Marc P (Thesis advisor) / Chattopadhyay, Aditi (Committee member) / Oswald, Jay (Committee member) / Arizona State University (Publisher)
Created2015
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Description
As the robotic industry becomes increasingly present in some of the more extreme environments such as the battle field, disaster sites or extraplanetary exploration, it will be necessary to provide locomotive niche strategies that are optimal to each terrain. The hopping gait has been well studied in robotics and

As the robotic industry becomes increasingly present in some of the more extreme environments such as the battle field, disaster sites or extraplanetary exploration, it will be necessary to provide locomotive niche strategies that are optimal to each terrain. The hopping gait has been well studied in robotics and proven to be a potential method to fit some of these niche areas. There have been some difficulties in producing terrain following controllers that maintain robust, steady state, which are disturbance resistant.

The following thesis will discuss a controller which has shown the ability to produce these desired properties. A phase angle oscillator controller is shown to work remarkably well, both in simulation and with a one degree of freedom robotic test stand.

Work was also done with an experimental quadruped with less successful results, but which did show potential for stability. Additional work is suggested for the quadruped.
ContributorsNew, Philip Wesley (Author) / Sugar, Thomas G. (Thesis advisor) / Artemiadis, Panagiotis (Committee member) / Redkar, Sangram (Committee member) / Arizona State University (Publisher)
Created2015