Engineering topics
Schmitz, Tony
Publications and source records attributed to Schmitz, Tony.
Optimization of an aerostructural machining process using physics-guided Bayesian stability modelling
Existing algorithms for predicting milling chatter have not been widely adopted in industry since they require specialized instruments to measure the stability inputs. This study describes how the machining process for a meter-scale aluminum aerostructure was optimized using a physics-guided Bayesian stability model. The study was performed in collaboration with an industrial partner on production machines to evaluate the practicality of the proposed method under real-world conditions. For each cutting tool, the Bayesian approach automatically selected a small number of cutting tests, which were monitored using a microphone to observe the chatter frequency. The algorithm learned the system dynamics, cutting forces, and stability map from these test results. A novel algorithm for predicting tool bending stress was incorporated into the test selection algorithm to avoid tool breakage. On average, each set of optimized cutting parameters required less than six tests to identify and were 97% more productive than baseline parameters from the cutting tool manufacturer. The machining program was then further optimized using commercial feedrate scheduling software to remove cutting force spikes and reduce air cutting time. Five components were machined using the optimized process. These results demonstrate the potential for physics-guided Bayesian models to improve productivity in industrial settings.
Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing
The Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing project objective is to automatically tune machining parameter predictions from physics-based models using process data and Bayesian machine learning. The intent is to enable a step change in aerospace manufacturing by combining machine learning, physics-based process models, and sensors/data in a comprehensive digital environment that simultaneously considers the computer numerically controlled (CNC) machining center capabilities, the workpiece material and geometry, and the workpiece support (fixturing). The project hypothesis is that this combination will enable improved performance in machining operations.
Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing
This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.
Hybrid metal additive/subtractive machine tools and applications
Additive manufacturing creates parts by depositing a preform, typically layer by layer. Subtractive manufacturing involves removing material from a preform to create parts. Hybrid machine tools combine both additive and subtractive processes in the same workspace. They can be used to create parts that meet functional tolerance and surface finish requirements, or to create features that are difficult to produce using additive or subtractive processes alone. Here, this paper describes hybrid metal additive/subtractive machine tools. It covers design considerations, sensors and controls, process management, programming and software, and the impact on the design space. It also identifies future research challenges.
Physics-informed KNN milling stability model with process damping effects
This paper describes a k-nearest neighbors, or KNN, model for milling stability including process damping effects. A physics-based, frequency domain milling stability solution is used to generate the training data, but does not incorporate process damping effects. The data set is then updated using limited tests to capture the process damping behavior. A “stair step” approach is used to select the test points, where a first spindle speed-axial depth combination is selected based on the physics-based stability map, subsequent tests are defined using the previous test result, and data points are updated by knowledge of process damping behavior and the test results. Furthermore, the KNN modeling approach demonstrates the ability to predict both stable and unstable results, including process damping behavior.
Chatter detection in simulated machining data: a simple refined approach to vibration data
Vibration monitoring is a critical aspect of assessing the health and performance of machinery and industrial processes. This study explores the application of machine learning techniques, specifically the Random Forest (RF) classification model, to predict and classify chatter—a detrimental self-excited vibration phenomenon—during machining operations. While sophisticated methods have been employed to address chatter, this research investigates the efficacy of a novel approach to an RF model. The study leverages simulated vibration data, bypassing resource-intensive real-world data collection, to develop a versatile chatter detection model applicable across diverse machining configurations. The feature extraction process combines time-series features and Fast Fourier Transform (FFT) data features, streamlining the model while addressing challenges posed by feature selection. By focusing on the RF model’s simplicity and efficiency, this research advances chatter detection techniques, offering a practical tool with improved generalizability, computational efficiency, and ease of interpretation. The study demonstrates that innovation can reside in simplicity, opening avenues for wider applicability and accelerated progress in the machining industry.
Process damping identification using Bayesian learning and time domain simulation
Process damping can provide improved machining productivity by increasing the stability limit at low spindle speeds. However, existing methods for identifying process damping models experimentally require specialized setups and/or multiple cutting tests. While the phenomenon is well known, the modeling challenges limit pre-process parameter selection that leverages the potential increases in material removal rates. This paper proposes a physics-informed Bayesian method that can identify the cutting force and process damping models from a limited set of test cuts without requiring direct measurements of cutting force or vibration. The method uses time domain simulation to incorporate process damping and provide a basis for test selection. Here, new strategies for efficient sampling and dimensionality reduction are applied to lower computation time and minimize the effect of model error. The proposed method is demonstrated and the identified cutting and damping force coefficients are compared to values obtained using machining tests and least-squares fitting.
Using GANs to predict milling stability from limited data
Milling is a key manufacturing process that requires the selection of operating parameters that provide efficient performance. However, the presence of chatter, a self-excited vibration causing poor surface finish and potential damage to the machine and cutting tool, makes it challenging to select the appropriate parameters. To predict chatter, stability maps are commonly used, but their generation requires expensive data, making it difficult to employ these maps in industry. Therefore, there is a pressing need for an approach that can accurately predict stability maps using limited experimental data. This study introduces the new Encoder GAN (EGAN) approach based on Generative Adversarial Networks (GANs) that predicts stability maps using limited experimental data. The approach consists of the encoder, generator, and discriminator subnetworks and uses the trained encoder and generator to predict the target stability map. This versatile method can be applied to various tool setups and can accurately predict stability maps with limited experimental data (five to 10 cutting tests) even when there is little information available for unknown parameters. In conclusion, the study evaluates the proposed approach using both numerical data and experiments and demonstrates its superior performance compared to state-of-the-art benchmarks.
Minimum cost, stability constrained preform optimization for hybrid manufacturing
Not Available
Structured light scanning artifact-based performance study
Structured light scanning is used to create a digital twin of a manufactured part, where features are extracted to determine if the part meets the designer’s intent and required tolerances. This paper describes repeatability and reproducibility analyses for a commercially-available structured light scanning system and measurement artifact. The repeatability study used five repeated scans at 15 measurement positions. Repeatability was assessed by randomly selecting one of the five scans at each of the 15 positions and creating a part mesh. This process was performed 50 times and the statistics for the dimension variations were calculated to isolate the scanning effects only. The same sequence was then performed for 10 of the 15 positions and five of the 15 positions to evaluate the repeatability sensitivity to the number of measurement positions. Reproducibility was assessed by selecting 15 positions to create a mesh and repeating the 15-position measurement sequence 10 times using different positions for each mesh construction. The statistics for the dimension variations were then calculated. This incorporated the effects of both scanning and the position and orientation of the part relative to the scanner. This sequence was repeated for 10-position and five-position scans to evaluate the corresponding sensitivity. Finally, the artifact dimensions from structured light scanning were compared to coordinate measuring machine measurements of the same features.
Limited-constraint WAAM fixture for hybrid manufacturing
This paper describes a limited-constraint alternative to the traditional over-constrained build plate clamping in metal additive manufacturing. A fixture design is presented that enables build plate thermal growth within its plane while restricting deformation perpendicular to that plane. A prototype fixture is designed, fabricated, and tested for wire arc additive manufacturing (WAAM). Experimental results are presented for depositing 1.2 mm diameter 5356 aluminum wire on a 5052 aluminum build plate. The build plate deformation is measured for various clamping torques and a 77.3% reduction in distortion is achieved using the limited-constraint approach with identical WAAM parameters.
Hybrid manufacturing by additive friction stir deposition, metrology, CNC machining, and microstructure analysis
Aerospace flight panels must provide high strength with low mass. For aluminum panels, it is common practice to begin with a wrought plate and remove the majority of the material to attain the desired structure, comprising a thinner plate with the desired pattern of reinforcement ribs. As an alternative, this study implements hybrid manufacturing, where aluminum is first deposited on a baseplate only at the rib locations using additive friction stir deposition (AFSD). Structured light scanning is then used to measure the printed geometry. This geometry is finally used as the stock model for computer numerical control (CNC) machining. This paper details the hybrid manufacturing process that consists of: AFSD to print the preform, structured light scanning to generate the stock model and tool path, three-axis CNC machining, and post-process measurements for part geometry and microstructure.
Integration of discrete-event dynamics and machining dynamics for machine tool: Modeling, analysis and algorithms
Machining dynamics research lays a solid foundation for machining operations by providing stable combinations of spindle speed and depth of cut. Furthermore, machine learning has been applied to predict tool life as a function of cutting speed. However, the existing research does not consider the discrete-event dynamics in machine shop, i.e., the machine tool needs to process a series of parts in queue under various practical production requirements. This paper addresses the integration of discrete-event dynamics and machining dynamics to achieve cost savings in machining. A learning-based cost function is first proposed for the studied integrated optimization problem of machine tool. The proposed cost function utilizes the predicted tool life under different stable cutting speeds for further optimizing speed selection of machine tool to deal with the discrete-event dynamics in machine shop. Then, according to the practical production requirements, effective mathematical optimization models are developed for the related integrated optimization problems with the consideration of cost, makespan and due date, respectively. Numerical results show the effectiveness of our proposed methods and also the potential to be used in practice.
Process planning for hybrid manufacturing using additive friction stir deposition
Additive friction stir deposition (AFSD) provides a solid-state approach to metal deposition that does not rely on local melting and solidification, but rather on kinetic energy and plastic flow. Here, in this study, AFSD is combined with structured light scanning, turning, and milling to produce metal components while considering the unique requirements imposed by the hybrid manufacturing process sequences. Two demonstrations are presented which include: 1) a cylindrical build plate selection to enable coordinate system transfer between deposition and turning of a hollow cone; and 2) intermittent deposition-machining operations with structured light scanning to fabricate a two-sided hexagon-cylinder geometry.
Cutting force estimation from machine learning and physics-inspired data-driven models utilizing accelerometer measurements
Monitoring cutting forces for process control may be challenging because force measurements typically require invasive instrumentation. To remedy this situation, two new methods were recently developed to estimate cutting forces in real time based on the use of on-machine accelerometer measurements. One method uses machine learning, while another uses a physics-inspired data-driven approach, to generate a model that estimates cutting forces from on-machine accelerations. The estimated forces from both approaches were compared against cutting force data collected during various milling operations on several machine tools. The results reveal the advantages and disadvantages of each model to estimate real-time cutting forces.