DFM/DFMA(A) – analysis and aspects of applying systematic engineering for a microwave testfixture design

In this paper, manufacturability analysis and collection of design aspects is made for a microwave test-fixture. Aspects of applying systematic design for a microwave test-fixture design and manufacturing are also analysed. Special questionnaires for the component and machining are made in order to enable necessary information to ensure DFM(A) – aspects of the component. The aspects of easy manufacturing for machining the microwave test-fixture are collected. Material selection is discussed and manufacturing stages of prototype manufacturing are presented.

Tuning the design procedures for laser processed microwave mechanics

This research has been focused at the development of a tuned systematic design methodology, which gives the best performance in a computer aided environment and utilises a cross-technological approach, specially tested with and for laser processed microwave mechanics. A tuned design process scheme is also presented. Because of the currently large production volumes of microwave and radio frequency mechanics even slight improvements of design methodologies or manufacturing technologies would give reasonable possibilities for cost reduction. The typical number of required iteration cycles could be reduced to one fifth of normal. The research area dealing with the methodologies is divided firstly into a function-oriented, a performance-oriented or a manufacturability-oriented product design. Alternatively various approaches can be developed for a customer-oriented, a quality-oriented, a cost-oriented or an organisation-oriented design. However, the real need for improvements is between these two extremes. This means that the effective methodology for the designers should not be too limited (like in the performance-oriented design) or too general (like in the organisation-oriented design), but it should, include the context of the design environment. This is the area where the current research is focused. To test the developed tuned design methodology for laser processing (TDMLP) and the tuned optimising algorithm for laser processing (TOLP), seven different industrial product applications for microwave mechanics have been designed, CAD-modelled and manufactured by using laser in small production series. To verify that the performance of these products meets the required level and to ensure the objectiveness ofthe results extensive laboratory tests were used for all designed prototypes. As an example a Ku-band horn antenna can be laser processed from steel in 2 minutes at the same time obtaining a comparable electrical performance of classical aluminium units or the residual resistance of a laser joint in steel could be limited to 72 milliohmia.

DFM(A)- aspects for a fixed electrical attenuator design

The goal of this paper is to describe a complete and extensive prototype design of a fixed electrical attenuator. The paper starts by describing the function and by giving some basic information about the attenuators. After a comprehensive description of the component, the facts of reverse engineering are discussed. The method itself is applied to ease manufacturing and design stages of this component. Information about materials and applied manufacturing technologies are also included in this report. By applying some specified DFMA-aspects the final design turned out to be a potential prototype device to be manufactured and for further analyse.

DFM(A)- aspects for a microwave waveguide ring resonator design

In this research manufacturability analysis is made for an E-plane waveguide ring resonator. About the electrical characteristics of the waveguide ring resonator is discussed. Possibilities to utilize concurrent engineering method both for designing and making manufacturability analysis for MW- and RF-components are discussed. For helping to establish the necessary guidelines for easy manufacturing and assembly of the waveguide ring resonator a specialised DFM(A)-questionnaire is generated. The questionnaire gives also new information for collaborative designing approach in MW-/RF- engineering. The advantages and disadvantages of the concurrent engineering design method are evaluated in the research.

DFM(A)- aspects for a horn antenna design

In this paper aspects of design for manufacturability and assembly (DFMA) are applied to the design of coaxially fed standard gain horn antenna for 1.70 - 2.60 GHz. Possibilities to utilize cross-technological approach method is examined. Methods of DFMA for laser processing are covered and practical design guides and methods are developed. Antenna construction for easy manufacturing and specialized performance is shown. Required dimensions and tolerances are discussed and suitable materials for laser processing are selected.

DFM(A)- aspects for an sma connector design

In this research, manufacturability analysis is made for an SMA connector. Analysis and aspects of applying virtual prototyping for an SMA connector design and manufacturing are also investigated. Special questionnaires for the component and machining are made in order to enable necessary information to ensure DFM(A) –aspects of products. The aspects of easy manufacturing for machining the SMA connector are collected. Material selection is discussed, and manufacturing stages of prototype manufacturing are presented. The main focus of this research is on prototype manufacturing, but also aspects considering volume production are discussed. A special purpose SMA connector is designed for printed circuit board edge mounting.

Sähkögeneraattorin runkokappaleen valmistustekninen tarkastelu

Työssä tarkastellaan sähkögeneraattorin runkokappaleen valmistettavuutta. Työ on tehty eräälle yritykselle, joka jätetään mainitsematta. Työhön liittyvät valmistuskuvat ovat salaisia ja niiden yleinen esittely ei ole mahdollista. Yritys kehittää uutta sähkögeneraattorituoteperhettä ja generaattorin runkokappale halutaan mahdollisimman helpoksi ja kustannustehokkaaksi valmistaa. Sähkögeneraattoreita on tarkoitus valmistaa vuositasolla kymmeniä tai jopa pari sataa kappaletta. Mahdolliset valmistusmenetelmät on rajattu ennen työn aloittamista MAG-hitsaukseen ja valamiseen, niiden ollessa todennäköisimmät valmistusmenetelmät. MAG-hitsauksessa huomioidaan prosessin tehostamiskeinot ja robotisoidun hitsauksen mahdollisuus. Valaminen rajattiin hiekkavaluun, joka on kertamuottimenetelmä ja soveltuu yksittäiskappaletuotannosta aina sarjatuotantoon. Materiaaliksi hitsaukseen valittiin rakenneteräs S355 ja valettaviksi materiaalivaihtoehdoiksi pallografiittivaluraudat EN-GJS-400-15U ja EN-GJS-500. Teoriaosuudessa on esitelty teettäjän pyytämä valmistusmenetelmien perusteoria ja sen jälkeen on tarkemmin tarkasteltu hitsattavan ja valettavan runkokappaleen muotoiluun liittyvää teoriaa. Hitsattavan kappaleen robotisoituun hitsaukseen liittyy myös vahvasti kappaleenkäsittely ja hitsauskiinnittimet, jotka välillisesti vaikuttavat myös kappaleen muotoiluun. Tätä työtä kirjoitettaessa generaattori on suunnitteluvaiheessa. Runkokappale on suunniteltu valmistettavaksi levyosista hitsaamalla. Tämä kehitysversio analysoidaan Design for manufacturing and assembly -menetelmän keinoin, ja runkokappaleelle esitetään rakennemuutosehdotuksia, jotka parantavat kappaleen valmistettavuutta. Runkokappaleen valmistaminen valamalla vaatii tuotteen muodon valuteknisen tarkastelun. Lopuksi hitsausta ja valamista verrataan toisiinsa ja arvioidaan niiden ominaisuuksia keskenään. Työssä ei päädytä lopulliseen valmistusmenetelmän valintaan, koska ei ole tiedossa käytössä olevia laitteistoja. Laitteistot määräävät käytetyt rakenneratkaisut ja valmistusmenetelmät.

Suunnittelun mahdollisuudet alumiiniveneen rungon valmistuskustannusten optimointiin mitoitusdirektiivi huomioiden

Tässä diplomityössä tutkittiin valmistuksellisia ja rakenteellisia mahdollisuuksia alumiiniveneen rungon valmistuskustannusten optimointiin vallitseva runkomitoitusdirektiivi huomioiden. Varsinaista kustannussäästötavoitetta työlle ei määritetty, mutta tavoitteena oli selvittää runkokonstruktion kustannusten painopisteiden mukaisesti kehityskohteet ja uusi kehitetty runkokonstruktio, joka täyttää mitoitusdirektiivin vaatimukset. Nykyistä ja kehitettyä runkokonstruktiota verrataan kustannusten sekä valmistettavuuden kannalta ja tehdään johtopäätökset. Kehityskohteiden löytämisessä sovellettiin valmistus- ja kokoonpanoystävällisen suunnittelun DFM(A)-periaatteita ja teoriaa, jotka esiteltiin työn teoriaosuudessa. Valmistuskustannusten määrittämisen tueksi teoriaosuudessa esiteltiin hitsauksen ja osavalmistuksen (laserleikkaus, särmäys) kustannusmallit, joita hyödynnettiin soveltuvin osin kustannuslaskennassa. Merkittävänä osana selvitystyötä oli myös SFS-EN ISO 12215-5-(6) runkomitoitusstandardin tulkitseminen ja referointi työn kannalta merkittäviin osa - alueisiin. Nykyisen runkokonstruktion kustannusanalyysin ja valmistettavuusarvion pohjalta päädyttiin rakenteellisiin ja valmistuksellisiin kehitystoimenpiteisiin, jotka täyttävät runkomitoitusdirektiivin rakenteelliset vaatimukset. Rakenteelliset toimenpiteet käsittivät mm. materiaalivahvuuksien, jäykisterakenteen ja osamäärän optimointia. Valmistukselliset toimenpiteet liittyivät mm. hitsauksen tuottavuuden tehostamiseen ja sen kustannusvaikutuksiin. Rakenteellisilla kehitystoimenpiteillä olisi mahdollista saavuttaa noin 6 % säästö ja valmistusmenetelmien kehittämisellä noin 17 % säästö valmistuskustannuksista.

Analysis of a Non-Traditional Micro Tube Hydroforming Process

As the demand for miniature products and components continues to increase, the need for manufacturing processes to provide these products and components has also increased. To meet this need, successful macroscale processes are being scaled down and applied at the microscale. Unfortunately, many challenges have been experienced when directly scaling down macro processes. Initially, frictional effects were believed to be the largest challenge encountered. However, in recent studies it has been found that the greatest challenge encountered has been with size effects. Size effect is a broad term that largely refers to the thickness of the material being formed and how this thickness directly affects the product dimensions and manufacturability. At the microscale, the thickness becomes critical due to the reduced number of grains. When surface contact between the forming tools and the material blanks occur at the macroscale, there is enough material (hundreds of layers of material grains) across the blank thickness to compensate for material flow and the effect of grain orientation. At the microscale, there may be under 10 grains across the blank thickness. With a decreased amount of grains across the thickness, the influence of the grain size, shape and orientation is significant. Any material defects (either natural occurring or ones that occur as a result of the material preparation) have a significant role in altering the forming potential. To date, various micro metal forming and micro materials testing equipment setups have been constructed at the Michigan Tech lab. Initially, the research focus was to create a micro deep drawing setup to potentially build micro sensor encapsulation housings. The research focus shifted to micro metal materials testing equipment setups. These include the construction and testing of the following setups: a micro mechanical bulge test, a micro sheet tension test (testing micro tensile bars), a micro strain analysis (with the use of optical lithography and chemical etching) and a micro sheet hydroforming bulge test. Recently, the focus has shifted to study a micro tube hydroforming process. The intent is to target fuel cells, medical, and sensor encapsulation applications. While the tube hydroforming process is widely understood at the macroscale, the microscale process also offers some significant challenges in terms of size effects. Current work is being conducted in applying direct current to enhance micro tube hydroforming formability. Initially, adding direct current to various metal forming operations has shown some phenomenal results. The focus of current research is to determine the validity of this process.

Improving the Manufacturability of Active Microfluidic Devices using Stereolithography (SL)

Thesis (Master's)--University of Washington, 2016-06

Analysis Of The Dna Fourier Transform-infrared Microspectroscopic Signature Using An All-reflecting Objective.

The Fourier transform-infrared (FT-IR) signature of dry samples of DNA and DNA-polypeptide complexes, as studied by IR microspectroscopy using a diamond attenuated total reflection (ATR) objective, has revealed important discriminatory characteristics relative to the PO2(-) vibrational stretchings. However, DNA IR marks that provide information on the sample's richness in hydrogen bonds have not been resolved in the spectral profiles obtained with this objective. Here we investigated the performance of an all reflecting objective (ARO) for analysis of the FT-IR signal of hydrogen bonds in DNA samples differing in base richness types (salmon testis vs calf thymus). The results obtained using the ARO indicate prominent band peaks at the spectral region representative of the vibration of nitrogenous base hydrogen bonds and of NH and NH2 groups. The band areas at this spectral region differ in agreement with the DNA base richness type when using the ARO. A peak assigned to adenine was more evident in the AT-rich salmon DNA using either the ARO or the ATR objective. It is concluded that, for the discrimination of DNA IR hydrogen bond vibrations associated with varying base type proportions, the use of an ARO is recommended.

Effect Of Platform Connection And Abutment Material On Stress Distribution In Single Anterior Implant-supported Restorations: A Nonlinear 3-dimensional Finite Element Analysis.

Although various abutment connections and materials have recently been introduced, insufficient data exist regarding the effect of stress distribution on their mechanical performance. The purpose of this study was to investigate the effect of different abutment materials and platform connections on stress distribution in single anterior implant-supported restorations with the finite element method. Nine experimental groups were modeled from the combination of 3 platform connections (external hexagon, internal hexagon, and Morse tapered) and 3 abutment materials (titanium, zirconia, and hybrid) as follows: external hexagon-titanium, external hexagon-zirconia, external hexagon-hybrid, internal hexagon-titanium, internal hexagon-zirconia, internal hexagon-hybrid, Morse tapered-titanium, Morse tapered-zirconia, and Morse tapered-hybrid. Finite element models consisted of a 4×13-mm implant, anatomic abutment, and lithium disilicate central incisor crown cemented over the abutment. The 49 N occlusal loading was applied in 6 steps to simulate the incisal guidance. Equivalent von Mises stress (σvM) was used for both the qualitative and quantitative evaluation of the implant and abutment in all the groups and the maximum (σmax) and minimum (σmin) principal stresses for the numerical comparison of the zirconia parts. The highest abutment σvM occurred in the Morse-tapered groups and the lowest in the external hexagon-hybrid, internal hexagon-titanium, and internal hexagon-hybrid groups. The σmax and σmin values were lower in the hybrid groups than in the zirconia groups. The stress distribution concentrated in the abutment-implant interface in all the groups, regardless of the platform connection or abutment material. The platform connection influenced the stress on abutments more than the abutment material. The stress values for implants were similar among different platform connections, but greater stress concentrations were observed in internal connections.

Is Thyroid Stunning Clinically Relevant? A Retrospective Analysis Of 208 Patients.

Current guidelines have advised against the performance of (131)I-iodide diagnostic whole body scintigraphy (dxWBS) to minimize the occurrence of stunning, and to guarantee the efficiency of radioiodine therapy (RIT). The aim of the study was to evaluate the impact of stunning on the efficacy of RIT and disease outcome. This retrospective analysis included 208 patients with differentiated thyroid cancer managed according to a same protocol and followed up for 12-159 months (mean 30 ± 69 months). Patients received RIT in doses ranging from 3,700 to 11,100 MBq (100 mCi to 300 mCi). Post-RIT-whole body scintigraphy images were performed 10 days after RIT in all patients. In addition, images were also performed 24-48 hours after therapy in 22 patients. Outcome was classified as no evidence of disease (NED), stable disease (SD) and progressive disease (PD). Thyroid stunning occurred in 40 patients (19.2%), including 26 patients with NED and 14 patients with SD. A multivariate analysis showed no association between disease outcome and the occurrence of stunning (p = 0.3476). The efficacy of RIT and disease outcome do not seem to be related to thyroid stunning.

Combined Analysis Of νμ Disappearance And νμ→νe Appearance In Minos Using Accelerator And Atmospheric Neutrinos.

We report on a new analysis of neutrino oscillations in MINOS using the complete set of accelerator and atmospheric data. The analysis combines the ν(μ) disappearance and ν(e) appearance data using the three-flavor formalism. We measure |Δm(32)(2)| = [2.28-2.46] × 10(-3) eV(2) (68% C.L.) and sin(2)θ(23) = 0.35-0.65 (90% C.L.) in the normal hierarchy, and |Δm(32)(2)| = [2.32-2.53] × 10(-3) eV(2) (68% C.L.) and sin(2)θ(23) = 0.34-0.67 (90% C.L.) in the inverted hierarchy. The data also constrain δ(CP), the θ(23} octant degeneracy and the mass hierarchy; we disfavor 36% (11%) of this three-parameter space at 68% (90%) C.L.

Phylogenetic Analysis Of The Microbial Community In Hypersaline Petroleum Produced Water From The Campos Basin.

In this work the archaea and eubacteria community of a hypersaline produced water from the Campos Basin that had been transported and discharged to an onshore storage facility was evaluated by 16S recombinant RNA (rRNA) gene sequence analysis. The produced water had a hypersaline salt content of 10 (w/v), had a carbon oxygen demand (COD) of 4,300 mg/l and contains phenol and other aromatic compounds. The high salt and COD content and the presence of toxic phenolic compounds present a problem for conventional discharge to open seawater. In previous studies, we demonstrated that the COD and phenolic content could be largely removed under aerobic conditions, without dilution, by either addition of phenol degrading Haloarchaea or the addition of nutrients alone. In this study our goal was to characterize the microbial community to gain further insight into the persistence of reservoir community members in the produced water and the potential for bioremediation of COD and toxic contaminants. Members of the archaea community were consistent with previously identified communities from mesothermic reservoirs. All identified archaea were located within the phylum Euryarchaeota, with 98 % being identified as methanogens while 2 % could not be affiliated with any known genus. Of the identified archaea, 37 % were identified as members of the strictly carbon-dioxide-reducing genus Methanoplanus and 59 % as members of the acetoclastic genus Methanosaeta. No Haloarchaea were detected, consistent with the need to add these organisms for COD and aromatic removal. Marinobacter and Halomonas dominated the eubacterial community. The presence of these genera is consistent with the ability to stimulate COD and aromatic removal with nutrient addition. In addition, anaerobic members of the phyla Thermotogae, Firmicutes, and unclassified eubacteria were identified and may represent reservoir organisms associated with the conversion hydrocarbons to methane.