This thesis presents a new mechanical design for an exoskeleton actuator to power the sagittal plane motion in the human hip. The device uses a DC motor to drive a Scotch yoke mechanism and series elasticity to take advantage of the cyclic nature of human gait and to reduce the maximum power and control requirements of the exoskeleton. The Scotch yoke actuator creates a position-dependent transmission that varies between 4:1 and infinity, with the peak transmission ratio aligned to the peak torque periods of the human gait cycle. Simulation results show that both the peak and average motor torque can be reduced using this mechanism, potentially allowing a less powerful motor to be used. Furthermore, the motor never needs to reverse direction even when the hip joint does. Preliminary testing shows the exoskeleton can provide an assistive torque and is capable of accurate position tracking at speeds covering the range of human walking. This thesis provides a detailed analysis of how the dynamic nature of human walking can be leveraged, how the hip actuator was designed, and shows how the exoskeleton performed during preliminary human trials.

This thesis focuses on the development of a health monitoring system for gearbox transmissions. This was accomplished by developing and understanding a two-stage gearbox computer model that emulates an actual gearbox test rig. The computer model contains actual gearbox geometry, flexible shafts, bearings, gear contact forces, input motor torque, output brake torque, and realistic gearbox imbalance. The gear contact force of each gear stage and the input bearing translational acceleration were the main outputs compared between a healthy gearbox and damaged gearbox computer model. The damage of focus was a fatigue crack on the input pinion gear. A sideband energy ratio comparison yielded the computer simulation accurately modeled the difference between a healthy and damaged gearbox. The next step in this study involved the development of a repeatable procedure to initiate and propagate a fatigue crack at the tooth root in an actual spur gear. A damaged spur gear allows for a future comparison of an actual healthy and damaged gearbox system in the lab. A custom fatigue fixture was designed and manufactured for a Martin S1224BS 1 spur gear. The fatigue crack was initiated by position control fatigue testing which deflects the gear tooth a set amplitude for a number of cycles. Over the length of the test, the load that the tooth can withstand in bending decreases as damage begins to occur. Once the max load on the gear has dropped by a significant percentage (5-15%) a crack has initiated and begun to propagate across the tooth face. The use of a scanning electron microscope confirmed the presence a fatigue crack.

The objective of this thesis is to develop vibration-based fault detection strategies for on-line condition monitoring of gear transmission systems. The study divides the thesis into three sections. First of all, the local stresses created by a root fatigue crack on a pinion spur gear are analyzed using a quasi-static finite element model and non-linear contact mechanics simulation. Backlash between gear teeth which is essential to provide better lubrication on tooth surfaces and to eliminate interference is included as a defect and a necessary part of transmission design. The second section is dedicated to fixed axis power trains. Torsional vibration is shown to cause teeth separation and double-sided impacts in unloaded and lightly loaded gearing drives. The transient and steady-state dynamic loading on teeth within a two stage crank-slider mechanism arising from backlash and geometric manufacturing errors is investigated by utilizing a non-linear multi-body dynamics software model. The multi-body model drastically reduces the computation time required by finite element methods to simulate realistic operation. The gears are considered rigid with elastic contact surfaces defined by a penalty based non-linear contact formulation. The third section examines a practical differential planetary transmission which combines two inputs and one output. Planetary gears with only backlash errors are compared to those containing both backlash and tooth defects under different kinematic and loading conditions. Fast Fourier Transform (FFT) analysis shows the appearance of side band modulations and harmonics of the gear mesh frequency. A joint time-frequency analysis (JTFA) during start-up reveals the unique vibration patterns for fixed axis gear train and differential planetary gear, respectively, when the contact forces increase during acceleration.

While composite structures exhibit exceptional strength and weight saving possibilities for engineering applications, sometimes their overall cost and/or material performance can limit their usage when compared to conventional structural materials. Meanwhile ‘biocomposites’, composite structures consisting of natural fibers (i.e. bamboo fibers), display higher cost efficiency and unique structural benefits such as ‘sustainability’. This analysis will determine if the integration of these two different types of composites are beneficial to the overall structure. Specifically, the structure will consist of a one internal bamboo veneer biocomposite ply; and two external carbon fiber weave composite plies surrounding the bamboo biocomposite. To acquire results of this study, the hypothesized composite structure will consist of varied trapezoidal corrugated specimens and tested in uniaxial compression loading. Thereafter, this test data will be used to ultimately design, manufacture, and test a structural biocomposite/composite box, intended to carry extremely high compressive loads; relative to its own weight. A finite element analysis of this test will be used to validate experimental data. After running the experiment, the carbon fiber with bamboo test sample results were compared to that of only carbon fiber test sample. The carbon fiber samples resulted in a maximum compressive load difference of only 23% higher loads when compared to the carbon fiber with bamboo, on average. These findings are discussed throughout.

Traditional methods for increasing the energy absorption of a structure involve using a stronger material or increasing the volume of the structure, resulting in a higher cost or additional weight. Additive manufacturing (AM) can be used to maximize the energy absorption of materials with the ability to create complex geometries such as cellular structures. Previous work has shown that the energy absorption of additively manufactured parts can be improved through functionally graded cellular structures; however, this strategy has not been applied to ultra-high strength steel materials. This work characterizes the effect of multiple functional-grading strategies (e.g. uniform, rod-graded, size-graded) on the energy absorption to weight ratio of laser powder bed fusion (L-PBF) produced M300 maraging steel lattice structures. Each structure is designed with the same average relative density to analyze the structures on an equal mass basis, to evaluate manufacturability, mechanical response, and compare experimental results with numerical simulation.

The primary objective of this research is to formulate a methodology of assessing the maximum impact loading condition that will incur onto an aircraft’s landing gear system via Finite Element Analysis (FEA) and appropriately determining its corresponding structural and impact responses to minimize potential design failures during hard landing (abnormal impact) and shock absorption testing. Both static and dynamic loading condition were closely analyzed, compared, and derived through the Federal Aviation Administration’s (FAA) airworthiness regulations and empirical testing data. In this research, a nonlinear transient dynamic analysis is developed and established via NASTRAN advanced nonlinear finite element model (FEM) to simulate the worst-case loading condition. Under the appropriate loading analysis, the eye-bar and contact patch region theory were then utilized to simulate the tire and nose wheel interface more accurately. The open geometry of the nose landing gear was also optimized to minimize the effect of stress concentration. The result of this research is conformed to the FAA’s regulations and bound to have an impact on the design and development of small and large aircraft’s landing gear for both near and distant future.

This dissertation focused on development and utilization of numerical and experimental approaches to improve the CFD modeling of fluidization flow of cohesive micron size particles. The specific objectives of this research were: (1) Developing a cluster prediction mechanism applicable to Two-Fluid Modeling (TFM) of gas-solid systems (2) Developing more accurate drag models for Two-Fluid Modeling (TFM) of gas-solid fluidization flow with the presence of cohesive interparticle forces (3) using the developed model to explore the improvement of accuracy of TFM in simulation of fluidization flow of cohesive powders (4) Understanding the causes and influential factor which led to improvements and quantification of improvements (5) Gathering data from a fast fluidization flow and use these data for benchmark validations. Simulation results with two developed cluster-aware drag models showed that cluster prediction could effectively influence the results in both the first and second cluster-aware models. It was proven that improvement of accuracy of TFM modeling using three versions of the first hybrid model was significant and the best improvements were obtained by using the smallest values of the switch parameter which led to capturing the smallest chances of cluster prediction. In the case of the second hybrid model, dependence of critical model parameter on only Reynolds number led to the fact that improvement of accuracy was significant only in dense section of the fluidized bed. This finding may suggest that a more sophisticated particle resolved DNS model, which can span wide range of solid volume fraction, can be used in the formulation of the cluster-aware drag model. The results of experiment suing high speed imaging indicated the presence of particle clusters in the fluidization flow of FCC inside the riser of FIU-CFB facility. In addition, pressure data was successfully captured along the fluidization column of the facility and used as benchmark validation data for the second hybrid model developed in the present dissertation. It was shown the second hybrid model could predict the pressure data in the dense section of the fluidization column with better accuracy.

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