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<p>  </p> <p>In this thesis, cellulose nanofiber (CNF) reinforced polylactic acid (PLA) filaments were produced for 3D printing applications using melt extrusion. The use of CNF reinforcement has the potential to improve the mechanical properties of PLA, making it a more suitable material for various 3D printing applications. To produce the nanocomposites, a master batch with a high concentration of CNFs was premixed with PLA, and then diluted to final concentrations of 1, 3, and 5 wt% during the extrusion process. The dilution was carried out to assess the effects of varying CNF concentrations on the morphology and mechanical properties of the composites. The results showed that the addition of 3 wt.% CNF significantly enhanced the mechanical properties of the PLA composites. Specifically, the tensile strength increased by 77.7%, the compressive strength increased by 62.7%, and the flexural strength increased by 60.2%. These findings demonstrate that the melt extrusion of CNF reinforced PLA filaments is a viable approach for producing nanocomposites with improved mechanical properties for 3D printing applications. In conclusion, the study highlights the potential of CNF reinforcement in improving the mechanical properties of PLA for 3D printing applications. The results can provide valuable information for researchers and industries in the field of 3D printing and materials science, as well as support the development of more advanced and sustainable 3D printing materials.</p>

This thesis contains the design and simulation test results for the implementation of a new all-wheel drive (AWD) torque vectoring (TV) control system. A separate algorithm using standard control methods is included in this study for a comparison. The proposed controller was designed to be applied to an AWD independent drive electric vehicle, however the main concepts can be re-purposed for other vehicle drive train configurations. The purpose of the control system is to assist the driver in achieving a desired vehicle trajectory whilst also maintaining stability and control of the vehicle. This is accomplished by measuring various real time parameters of the vehicle and using this information as feedback for the control system to act on. The focus of this thesis resides on the controller. Hence, this study assumes perfect observation of feedback parameters, therefore some uncertainties are not accounted for. Using feedback parameters, the control system will manage wheel slip whilst simultaneously generating a torque around the center of gravity of the vehicle by applying a torque differential between the left and right wheels. The proposed TV algorithm is simulated in MATLAB/Simulink along with another separate TV algorithm for comparison. Both algorithms are comprised of two main parts: a slip ratio controller applied to each wheel individually and stability controller that manages yaw rate and side slip of the vehicle. The new algorithm leverages the super twisting algorithm for the slip ratio controller and uses a fusion of a linear quadratic regulator with the integral term of a super twisting algorithm to implement the yaw rate and side slip controller. The other algorithm used for comparison derives its implementation for the slip ratio controller and yaw rate and side slip controllers from simple and standard first order sliding mode control methods. Both control algorithms were tested in three different main tests: anti-lock braking, sine dwell (SD) steering, and constant steering angle (CSA) tests. To increase the comprehensive nature of the study, the SD and CSA tests were simulated at 3 speeds (30,50, and 80 mph) and the steering angle parameter was varied from 2 to 24 degrees in increments of 2. The result of this study proves that the proposed controller is a feasible option for use in theory. Simulated results show advantages and disadvantages of the new controller with respect to the standard comparison controller. Both controllers are also shown to provide positive impacts on the vehicle response under most test conditions.

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<p>Demand for lightweight, cost-effective, structural components is driving the development of continuous fiber thermoplastic tow preforms, also known as 3D-tow or tow reinforcements, to add material performance to hybrid-molded structures as an alternative to metal components. Tow reinforcements offer the performance advantages of continuous fiber composites within molded structures. The tow reinforcements also feature more tailorability of performance compared to fabric or organo-sheet reinforced hybrid-molded structures, improving their potential for design optimization. However, the added complexity of 3D-tow reinforcement structure requires the development of unique design principles and computer aided engineering (CAE) methodologies to effectively design components which meet manufacturing and performance requirements. </p> <p><br></p> <p>A systematic evaluation of design considerations was performed comparing parts manufactured with various design features, configurations, and materials. Choosing the structural profile and balance of material properties was shown to be an important component of achieving the desired performance especially where the tow reinforcement must work in conjunction with the overmolding material to provide structural performance. </p> <p><br></p> <p>By experimentally testing representative structures with features found on automobile components and molded sports equipment, performance was evaluated for a range of material combinations and reinforcement content. Tow reinforcements were made from continuous glass or carbon fiber reinforced PA6 prepreg tape and injection overmolded with unfilled or glass fiber filled PA6 adding a shear web and rib structures. Tow reinforcement significantly reduced warpage, and in tensile loading, demonstrated potential for 340\% strength increase over parts without tow. However, three-point bend performance was dominated by the overmolding material. High strain to break overmolding materials are recommended to avoid premature overmolding material cracking. </p> <p><br></p> <p>Tensile performance of tow reinforced structures is not accurately captured by conventional modeling processes. When wrapped around load introduction points, the fibers of a thick tow traverse a shorter distance at the inner radius than the outer radius leading to waviness on the inner region of each wrap. The Hsaio and Daniel model was used to predict local elastic properties of the wavy fiber composite and spatially varying material properties were applied to 3D finite element models of a suspension link. Neglecting fiber waviness overpredicted experimental tensile stiffness and strength by 36\% and 33\% respectively while modeling waviness overpredicted stiffness and strength by only 9\% and 14\% respectively. Tow wrap configuration, waviness propagation, and material parameters have significant effect on tensile performance while the tow has little effect on compressive performance.</p> <p><br></p> <p>In addition to fiber waviness, tow bundles also spread to reconcile path length differences. A method for accounting for tow spread orientations was developed and combined with fiber waviness modeling techniques. The effects of simulating the resulting fiber orientations and effective elastic properties was used to model representative beams in tension and bending load cases and compared to previous experimental results. Accounting for fiber waviness in tension demonstrated greatly improved part stiffness predictions. Spread tow bundles improved predicted strength and stiffness over simulations where tow was constrained to a uniform cross section. Increased tow reinforcement increased bending stiffness, but failure behavior was significantly influenced by the overmolding material.  </p> <p><br></p> <p>The studies in this work identified key performance attributes of 3D-tow reinforced hybrid composite structures. Design principles and modeling techniques were developed in this work, providing improved performance predictions which brings the technology closer to widespread adoption. </p>

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