Walkers provided stability to the elderly but cannot assist a person from sitting to standing. The objective of this project is to present the design and analysis of a lift assist walker. This report discusses the design and analysis of a collapsible lift assist walker capable of lifting a patient up to 250 lbs. from seated to standing in under 10 seconds. The designed walker utilized a two stage scissor mechanism with a gas spring assisted embedded linear actuator.

An experimental study of several variants of radius and strut angle of the body centered cubic unit cell was performed to determine the mechanical properties and failure mechanisms of the mesostructure. Quasi static compression tests were performed on an Instron® universal testing machine with a 50kN load cell at 0.2mm/min. The test samples were built using a SLM Solutions 125 selective laser melting machine with 316L stainless steel. Test specimens were based on 5mm cubic unit cells, with a strut diameter 10% of the unit cell size, with skins on top and bottom to provide a cantilever boundary constraint. Specimens were inspected for dimensional accuracy using precision calipers and inspected for morphology using a MicroVu® macroscope. The compressive properties of the mesostructure was compared to the compressive properties of macrostructure. The BCC unit cell behaves significantly different at the boundary layer of a constrained lattice. The failure mode at the boundary is characterized by plastic bending within the microstruts while the non boundary layer cells fail via plastic bending at the node. Manufacturing compensation parameters were determined for part shrinkage and droop. Two predictive numerical models were developed, based on the Gibson-Ashby model of cellular solids, as well as a finite element model. Numerical results did not agree well with the experimental results, indicating that the droop observed on the structures significantly affects the mechanical properties of the overall structure. The 25% radius cubic unit cell and 3^3 lattice withstood the greatest stress of all specimens tested and exhibited nearly ideal plastic deformation behavior.

Ceramics are very important materials with many unique properties used in numerous industrial applications. Ceramics could be very hard and very strong in comparison to metals; however, they are very brittle, thus they are prone to instantaneous and catastrophic failure. Therefore, their reliability is compromised and it is very important to have advanced techniques that allow evaluating their mechanical behavior in many unusual stress states. One of such testing methods is biaxial strength method, that allows to measure properties not only unidirectional, but also in a biaxial way. The research work for this thesis will be built on design and development of ring-on-ring test jigs that will measure a biaxial strength of thin ceramic disks.

During the conceptual design stage several concepts are generated, and a few are selected for detailed analyses. CAD models from conceptual design often follow the "over-the-wall" approach for downstream analyses such as FEA, CFD, heat transfer, and vibrations. A CAD-centric approach will be applied to the CAD-to-CFD process to help industry in an ongoing quest to shorten the design cycle time. The CAD-centric approach consists of using the CAD model as a source of data for downstream applications such as mesh generation, and CFD setup. The CAD model used in the CAD-centric approach contains the geometry to be analyzed and non-geometric data required to solve the CFD problem in the form of attributes. Attributes can be associated to entities of the geometry such as the faces, edges, and volumes. Any operations changing geometry require the CAD-centric model be reworked. One class of topology alterations is the discrete feature problem that is encountered when an array of features change in number. A method is proposed, developed and reported on that adapts the CAD-centric approach to account for discrete feature changes that occur during preliminary design.

Rapid battery exchange systems were built for an electric van and pedal assist electric bike as a method of eliminating the need to recharge the vehicles batteries in order to increase the feasibility of using electric propulsion as a method of efficient student transportation. After selecting proper materials it was found that the systems would need a protective coating to ensure consistent operation. 1020 cold rolled steel samples coated with multiple thicknesses of vinyl resin paint, epoxy resin paint, and powder coating were subjected to environmental wear tests in order to determine if the type and thickness of common protective coatings has an effect on the durability of the system over its lifetime. The tests consisted of a 2400 hour extended salt spray test, coating delamination testing, and modified impact testing. The extended salt spray test, delamination test, and deformation tests of the coatings all found that the type of coating and the thickness of the coating to have a significant effect on the measured outputs. The significant effect shown in the deformation test could not determine the proper material without the aid of microscopic studies of the surface geometry change due to the induced deformation. Powder coating the rapid battery exchange systems would result in proper performance if coupled with epoxy paint for repairs. Testing of the Rapid battery exchange system indicated that the use of mechanical aiming was not suitable for the application, a further adaptation of the system indicated that the system may be better suited toward personal bicycles as there was a large increase in transportation efficiency.

Osteoarthritis (OA) is a degenerative condition of articular cartilage that affects more than 25 million people in the US. Joint injuries, like anterior cruciate ligament (ACL) tears, can lead to OA due to a change in articular cartilage loading. Gait analysis combined with knee joint finite element modeling (FEM) has been used to predict the articular cartilage loading. To predict the change of articular cartilage loading during gait due to various ACL injuries, a tibiofemoral FEM was developed from magnetic resonance images (MRIs) of a 33 year male, with no prior history of knee injuries. The FEM was validated for maximum contact pressure and anterior tibial translation using cadaver knee studies. The FEM was used to model gait of knees with an intact ACL, anteromedial (AM) bundle injury, posterolateral (PL) bundle injury, complete ACL injury, AM deficiency, PL deficiency, complete ACL rupture, as well as a bone-patellar tendon-bone (BPTB) graft. Generally, the predicted maximum contact pressure and contact area increased for all the ACL injuries when compared to intact ACLs. While an increase in maximum contact pressure and contact area is an indication of an increased risk of the development of OA, the percent of increase was typically small suggesting that walking is a safe activity for individuals with ACL injuries.

Long-duration spaceflight has been shown to have significant, lasting effects on the bone strength of astronauts and to contribute to age-related complications later in life. The microgravity environment of space causes a decrease in daily mechanical loading, which signals a state of disuse to bone cells. This affects the bone remodeling process, which is responsible for maintaining bone mass, causing an increase in damage and a decrease in density. This leads to bone fragility and decreases overall strength, posing a risk for fracture. However, there is little information pertaining to the timeline of bone loss and subsequent fracture risk. This study used finite element analysis to model the human femur, the bone most adversely affected by spaceflight, and to simulate the environments of Earth preflight, a six-month mission on the International Space Station, and one year on Earth postflight. Changes in the properties of cortical and trabecular bone in the femoral neck were measured from the simulations, and used to provide evidence for high fracture risk and to predict when it is most prominent. It was found that a risk for fracture is extremely evident in the femoral neck in both cortical and trabecular bone. Cortical bone in the inferior neck exhibited high magnitudes of damage, while the superior neck suffered the greatest increases in damage that proceeded to increase upon return to Earth. The density of trabecular bone decreased the most significantly and was not fully recovered in the following year. While it is still unclear exactly when these changes cause the greatest risk for fracture, it is possible that they will add to and advance the onset of medical complications such as osteoporosis. Additionally, the results of this study support the claim that the current countermeasure of inflight exercise is insufficient in sustaining bone mass and preserving skeletal health. The effects of long-duration spaceflight on bone health should continue to be investigated especially if future missions are to last as long as one to three years.

This thesis focuses on different methods to analyze power transmission systems with computer software to aid in detection of faulty or damaged systems. It is split into three sections. The first section involves utilizing finite element software to analyze gear stiffness and stresses. A quasi-static and dynamic analysis are done on two sets of fixed axis spur gears and a planetary gear system using ABAQUS to analyze the stress, strain and gear mesh stiffness variation. In the second section, the vibrational patterns produced by a simple bevel gear system are investigated by an experiment and by dynamic modeling in ADAMS. Using a Fast Fourier Transform (FFT) on the dynamic contact forces, a comprehensive frequency-domain analysis will reveal unique vibration spectra at distinct frequencies around the gear mesh frequencies, their super- and sub- harmonics, and their side-band modulations. ADAMS simulation results are then compared with the experimental results. Constraints, bearing resistant torques, and other key parameters are applied as closely as possible to real operating conditions. The third section looks closely at the dynamic contact forces of a practical two-stage planetary gear. Using the same FFT approach in the second section, a frequency-domain analysis will reveal distinct frequencies around both the first-stage and the second-stage gear mesh frequencies, and their harmonics. In addition, joint time-frequency analysis (JTFA) will be applied to damaged and undamaged planetary gear systems with transient start-up conditions to observe how the frequency contents of the contact force evolve over time.

Cold spray has seen rapid advancement since its inception and has shown significant potential as a method of additive manufacturing. However, the large plastic deformation and repeated heating/cooling cycles that the material undergoes during the cold spray process can result in gradients in material structure and large residual stresses. The purpose of this study is to extend the existing EMMI material model to include anisotropic material response through the use of orientation distribution functions to predict residual stresses and anisotropy resulting from cold spray and similar additive manufacturing processes. Through the use of a finite element simulation, yield surfaces for a two-step tension problem were generated and analyzed to capture the effects of the four coaxiality parameters that govern the model.

<p>The graphite structure in compacted graphite iron (CGI) is more coral-like and interconnected only within each eutectic cell. The irregular surface of the graphite-matrix interface has blunt edges which results in the intimate adhesion of the graphite particles to the metal matrix producing more resistance to crack initiation and more vermicular paths arrest crack propagation. Furthermore, the coral-like graphite particles, which are characterized with round edges, also do not promote crack propagation and serve as crack arrestors once cracks are initiated. This unique morphology of graphite in CGI, thereafter, pays off in a higher tensile strength and modulus of elasticity while possessing reasonable thermal conductivity.</p> <p>This work is divided into two phases. The first phase establishes a foundation of a microstructure modeling technique which will be then applied to model CGI in machining. Modeling is being done to shift the approach away from trial and error as is currently being done to a more physics based approach. As machining is conceptually a controlled fracture process, this stage comprehensively studies and models the initiation and propagation of fracture in compacted graphite iron.</p> <p>The second phase serves as an application of the previously built model to capture the more complex scenario involving machining of CGI at different cutting speeds and feeds. The finite element modeling of CGI in machining provides an as of yet unavailable procedure on which future optimization techniques can be performed. The study of chip formation, cutting insert wear, and force measurements are performed in parallel with the modeling process and are employed as means to validate the FE model. Validation of both work phases has been completed to support the model developed in this thesis that captures the critical aspects of machining CGI under different operating scenarios.</p> / Doctor of Philosophy (PhD)