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At least 271 records · Page 15

All sources NASA NTRS DOE OSTI

DOE OSTI2017

A dynamic control approach for energy-efficient production scheduling on a single machine under time-varying electricity pricing

This paper proposes a dynamic control algorithm to enable an energy-aware single machine scheduling under the time-varying electricity pricing policy, in which price rates remain fixed day-to-day over the season. The key issue is to assign a set of jobs to available time periods where different electricity prices are assigned, while considering requested due dates of jobs so as to minimize total penalty costs for earliness and tardiness of jobs and total energy consumption costs, simultaneously. As the first contribution of this study, we develop a new mixed integer nonlinear programming (MINLP) model that aims at determining job arrival times and resulting earliness and tardiness of jobs and energy consumption costs for machine idle and normal processing. Second, an efficient heuristic approach based on continuous-time variable control models and algorithm is developed. The proposed heuristic adaptively changes job arrival times and due dates, which finally determine production sequence over the time periods of different electricity prices, machine turn-off, and machine idle with minimum energy consumption costs and just-in-time (JIT) penalty. Energy and JIT performance of the proposed approach is examined using real energy and machining parameters of a HAAS machine and compared to those of the metaheuristic approach. For relatively large size data groups, the proposed approach incurs about higher energy consumption costs on average, which are offset by up to lower JIT costs, resulting in lower total costs on average compared to the metaheuristic approach. Further, the proposed time-scaled heuristic algorithm yields extremely short computational time, which enables production managers to flexibly select proper production strategies and to implement them for different production environments.

42 ENGINEERING↗

DOE OSTI2024

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.

42 ENGINEERING↗

DOE OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗

DOE OSTI2025

Security Assessment of an LBP16-Protocol-Based Computer Numerical Control Machine

Subtractive manufacturing systems, specifically, computer numerical control machines, have revolutionized the manufacturing industry. Computer numerical control machining is the preferred method for producing finished parts due to its efficiency, speed and suitability for high-volume production. Securing computer numerical control machines is a priority. Compromises or disruptions of these machines can result in significant downtime, loss of productivity and financial loss. This study examines the vulnerabilities and risks associated with computer numerical control machines, in particular, systems utilizing the LBP16 protocol for controller-machine communications. The study reveals that an adversary can execute cyber-physical attacks such as sabotage and denial of service. The potential security threats emphasize the importance of implementing robust security measures to mitigate the cyber risks to computer numerical control machines.

Forihat, Yahya [Virginia Commonwealth University, ↗

DOE OSTI2018

Effect of Width of Kerf on Machining Accuracy and Subsurface Layer After WEDM

Wire electrical discharge machining is an unconventional machining technology that applies physical principles to material removal. The material is removed by a series of recurring current discharges between the workpiece and the tool electrode, and a ‘kerf’ is created between the wire and the material being machined. The width of the kerf is directly dependent not only on the diameter of the wire used, but also on the machine parameter settings and, in particular, on the set of mechanical and physical properties of the material being machined. To ensure precise machining, it is important to have the width of the kerf as small as possible. The present study deals with the evaluation of the width of the kerf for four different metallic materials (some of which were subsequently heat treated using several methods) with different machine parameter settings. The kerf is investigated on metallographic cross sections using light and electron microscopy.

36 MATERIALS SCIENCE↗

DOE OSTI2021

QUBO formulations for training machine learning models

Abstract Training machine learning models on classical computers is usually a time and compute intensive process. With Moore’s law nearing its inevitable end and an ever-increasing demand for large-scale data analysis using machine learning, we must leverage non-conventional computing paradigms like quantum computing to train machine learning models efficiently. Adiabatic quantum computers can approximately solve NP-hard problems, such as the quadratic unconstrained binary optimization (QUBO), faster than classical computers. Since many machine learning problems are also NP-hard, we believe adiabatic quantum computers might be instrumental in training machine learning models efficiently in the post Moore’s law era. In order to solve problems on adiabatic quantum computers, they must be formulated as QUBO problems, which is very challenging. In this paper, we formulate the training problems of three machine learning models—linear regression, support vector machine (SVM) and balanced k-means clustering—as QUBO problems, making them conducive to be trained on adiabatic quantum computers. We also analyze the computational complexities of our formulations and compare them to corresponding state-of-the-art classical approaches. We show that the time and space complexities of our formulations are better (in case of SVM and balanced k-means clustering) or equivalent (in case of linear regression) to their classical counterparts.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Use of machine learning to analyze chemistry card sort tasks

Education researchers are deeply interested in understanding the way students organize their knowledge. Card sort tasks, which require students to group concepts, are one mechanism to infer a student’s organizational strategy. However, the limited resolution of card sort tasks means they necessarily miss some of the nuance in a student’s strategy. Here in this work, we propose new machine learning strategies that leverage a potentially richer source of student thinking: free-form written language justifications associated with student sorts. Using data from a university chemistry card sort task, we use vectorized representations of language and unsupervised learning techniques to generate qualitatively interpretable clusters, which can provide unique insight in how students organize their knowledge. We compared these to machine learning analysis of the students’ sorts themselves. Machine learning-generated clusters revealed different organizational strategies than those built into the task; for example, sorts by difficulty or even discipline. There were also many more categories generated by machine learning for what we would identify as more novice-like sorts and justifications than originally built into the task, suggesting students’ organizational strategies converge when they become more expert-like. Finally, we learned that categories generated by machine learning for students’ justifications did not always match the categories for their sorts, and these cases highlight the need for future research on students’ organizational strategies, both manually and aided by machine learning. In sum, the use of machine learning to analyze results from a card sort task has helped us gain a more nuanced understanding of students’ expertise, and demonstrates a promising tool to add to existing analytic methods for card sorts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Single-Atom Heat Machines Enabled by Energy Quantization

Quantization of energy is a quintessential characteristic of quantum systems. Here we analyze its effects on the operation of Otto cycle heat machines and show that energy quantization alone may alter and increase machine performance in terms of output work, efficiency, and even operation mode. We show that this difference in performance occurs in machines with inhomogeneous energy level scaling, while quantum machines with homogeneous level scaling behave like classical machines. Our results demonstrate that quantum thermodynamics enables the realization of classically inconceivable Otto machines, such as those with an incompressible working substance. Finally, we propose to measure these effects experimentally using a laser-cooled trapped ion as a microscopic heat machine.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

SU-F-T-521: Flattening-Filter-Free Beam Parameters Comparison From Different Linac Machine Types

Purpose: Novel linac machines, TrueBeam (TB) and Elekta Versa have updated head designing and software control system, include flattening-filter-free (FFF) photon and electron beams. Later on FFF beams were also introduced on C-Series machines. In this work FFF beams for same energy 6MV but from different machine versions were studied with reference to beam data parameters. Methods: The 6MV-FFF percent depth doses, profile symmetry and flatness, dose rate tables, and multi-leaf collimator (MLC) transmission factors were measured during commissioning process of both C-series and Truebeam machines. The scanning and dosimetric data for 6MV-FFF beam from Truebeam and C-Series linacs was compared. A correlation of 6MV-FFF beam from Elekta Versa with that of Varian linacs was also found. Results: The scanning files were plotted for both qualitative and quantitative analysis. The dosimetric leaf gap (DLG) for C-Series 6MV-FFF beam is 1.1 mm. Published values for Truebeam dosimetric leaf gap is 1.16 mm. 6MV MLC transmission factor varies between 1.3 % and 1.4 % in two separate measurements and measured DLG values vary between 1.32 mm and 1.33 mm on C-Series machine. MLC transmission factor from C-Series machine varies between 1.5 % and 1.6 %. Some of the measured data values from C-Series FFF beam are compared with Truebeam representative data. 6MV-FFF beam parameter values like dmax, OP factors, beam symmetry and flatness and additional parameters for C-Series and Truebeam liancs will be presented and compared in graphical form and tabular data form if selected. Conclusion: The 6MV flattening filter (FF) beam data from C-Series & Truebeam and 6MV-FFF beam data from Truebeam has already presented. This particular analysis to compare 6MV-FFF beam from C-Series and Truebeam provides opportunity to better elaborate FFF mode on novel machines. It was found that C-Series and Truebeam 6MV-FFF dosimetric and beam data was quite similar.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

High Metal Removal Rate Process for Machining Difficult Materials

Machining methods across many industries generally require multiple operations to machine and process advanced materials, features with micron precision, and complex shapes. The resulting multiple machining platforms can significantly affect manufacturing cycle time and the precision of the final parts, with a resultant increase in cost and energy consumption. Ultrafast lasers represent a transformative and disruptive technology that removes material with micron precision and in a single step manufacturing process. Such precision results from athermal ablation without modification or damage to the remaining material which is the key differentiator between ultrafast laser technologies and traditional laser technologies or mechanical processes. Athermal ablation without modification or damage to the material eliminates post-processing or multiple manufacturing steps. Combined with the appropriate technology to control the motion of the work piece, ultrafast lasers are excellent candidates to provide breakthrough machining capability for difficult-to-machine materials. At the project onset in early 2012, the project team recognized that substantial effort was necessary to improve the application of ultrafast laser and precise motion control technologies (for micromachining difficult-to-machine materials) to further the aggregate throughput and yield improvements over conventional machining methods. The project described in this report advanced these leading-edge technologies thru the development and verification of two platforms: a hybrid enhanced laser chassis and a multi-application testbed.

42 ENGINEERING↗

DOE OSTI2019

Influence of Electrospark Machining on Surface Performance

The influence of the conditions of electrospark machining on the structural changes and roughness of the machined surfaces and hence on their wear resistance is studied experimentally. After electrospark machining of 38Х2Н2МА steel with the minimum parameters, the roughness of the machined surface is found to be minimal. However, the depth of the modified layer (the zone of diminished microhardness) is a maximum. When using the maximum electrospark parameters, the roughness of the machined surface is a maximum, whereas the depth of the modified layer is a minimum. The zone of diminished microhardness affects the wear resistance of the working surfaces and the working life of the part as a whole. In specifying the conditions of electrospark machining, large currents I (А) must be used, or else subsequent operations will be required to remove the modified layer from the machined surface.

42 ENGINEERING↗

NASA NTRS1992

Mars vertical axis wind machines. The design of a Darreus and a Giromill for use on Mars

This report contains the design of both a Darrieus and a Giromill for use on Mars. The report has been organized so that the interested reader may read only about one machine without having to read the entire report. Where components for the two machines differ greatly, separate sections have been allotted for each machine. Each section is complete; therefore, no relevant information is missed by reading only the section for the machine of interest. Also, when components for both machines are similar, both machines have been combined into one section. This is done so that the reader interested in both machines need not read the same information twice.

Brach, David↗

NASA NTRS2002

Investigation of Dynamic Force/Vibration Transmission Characteristics of Four-Square Type Gear Durability Test Machines

In this study, design requirements for a dynamically viable, four-square type gear test machine are investigated. Variations of four-square type gear test machines have been in use for durability and dynamics testing of both parallel- and cross-axis gear set. The basic layout of these machines is illustrated. The test rig is formed by two gear pairs, of the same reduction ratio, a test gear pair and a reaction gear pair, connected to each other through shafts of certain torsional flexibility to form an efficient, closed-loop system. A desired level of constant torque is input to the circuit through mechanical (a split coupling with a torque arm) or hydraulic (a hydraulic actuator) means. The system is then driven at any desired speed by a small DC motor. The main task in hand is the isolation of the test gear pair from the reaction gear pair under dynamic conditions. Any disturbances originated at the reaction gear mesh might potentially travel to the test gearbox, altering the dynamic loading conditions of the test gear mesh, and hence, influencing the outcome of the durability or dynamics test. Therefore, a proper design of connecting structures becomes a major priority. Also, equally important is the issue of how close the operating speed of the machine is to the resonant frequencies of the gear meshes. This study focuses on a detailed analysis of the current NASA Glenn Research Center gear pitting test machine for evaluation of its resonance and vibration isolation characteristics. A number of these machines as the one illustrated has been used over last 30 years to establish an extensive database regarding the influence of the gear materials, processes surface treatments and lubricants on gear durability. This study is intended to guide an optimum design of next generation test machines for the most desirable dynamic characteristics.

Kahraman, Ahmet↗

NASA NTRS2010

Effect of the Machining Processes on Low Cycle Fatigue Behavior of a Powder Metallurgy Disk

A study has been performed to investigate the effect of various machining processes on fatigue life of configured low cycle fatigue specimens machined out of a NASA developed LSHR P/M nickel based disk alloy. Two types of configured specimen geometries were employed in the study. To evaluate a broach machining processes a double notch geometry was used with both notches machined using broach tooling. EDM machined notched specimens of the same configuration were tested for comparison purposes. Honing finishing process was evaluated by using a center hole specimen geometry. Comparison testing was again done using EDM machined specimens of the same geometry. The effect of these machining processes on the resulting surface roughness, residual stress distribution and microstructural damage were characterized and used in attempt to explain the low cycle fatigue results.

Telesman, J.↗

NASA NTRS2012

Virtual Machine Language 2.1

VML (Virtual Machine Language) is an advanced computing environment that allows spacecraft to operate using mechanisms ranging from simple, time-oriented sequencing to advanced, multicomponent reactive systems. VML has developed in four evolutionary stages. VML 0 is a core execution capability providing multi-threaded command execution, integer data types, and rudimentary branching. VML 1 added named parameterized procedures, extensive polymorphism, data typing, branching, looping issuance of commands using run-time parameters, and named global variables. VML 2 added for loops, data verification, telemetry reaction, and an open flight adaptation architecture. VML 2.1 contains major advances in control flow capabilities for executable state machines. On the resource requirements front, VML 2.1 features a reduced memory footprint in order to fit more capability into modestly sized flight processors, and endian-neutral data access for compatibility with Intel little-endian processors. Sequence packaging has been improved with object-oriented programming constructs and the use of implicit (rather than explicit) time tags on statements. Sequence event detection has been significantly enhanced with multi-variable waiting, which allows a sequence to detect and react to conditions defined by complex expressions with multiple global variables. This multi-variable waiting serves as the basis for implementing parallel rule checking, which in turn, makes possible executable state machines. The new state machine feature in VML 2.1 allows the creation of sophisticated autonomous reactive systems without the need to develop expensive flight software. Users specify named states and transitions, along with the truth conditions required, before taking transitions. Transitions with the same signal name allow separate state machines to coordinate actions: the conditions distributed across all state machines necessary to arm a particular signal are evaluated, and once found true, that signal is raised. The selected signal then causes all identically named transitions in all present state machines to be taken simultaneously. VML 2.1 has relevance to all potential space missions, both manned and unmanned. It was under consideration for use on Orion.

Riedel, Joseph E.↗

NASA NTRS2019

Using Machine Learning to Predict Core Sizes of High-Efficiency Turbofan Engines

With the rise in big data and analytics, machine learning is transforming many industries. It is being increasingly employed to solve a wide range of complex problems, producing autonomous systems that support human decision-making. For the aircraft engine industry, machine learning of historical and existing engine data could provide insights that help drive for better engine design. This work explored the application of machine learning to engine preliminary design. Engine core-size prediction was chosen for the first study because of its relative simplicity in terms of number of input variables required (only three). Specifically, machine-learning predictive tools were developed for turbofan engine core-size prediction, using publicly available data of two hundred manufactured engines and engines that were studied previously in NASA aeronautics projects. The prediction results of these models show that, by bringing together big data, robust machine-learning algorithms and automation, a machine learning-based predictive model can be an effective tool for turbofan engine core-size prediction. The promising results of this first study paves the way for further exploration of the use of machine learning for aircraft engine preliminary design.

Tong, Michael T.↗

NASA NTRS2021

Large-Scale High-Resolution Coastal Mangrove Forests Mapping Across West Africa With Machine Learning Ensemble and Satellite Big Data

Coastal mangrove forests provide important ecosystem goods and services, including carbon sequestration, biodiversity conservation, and hazard mitigation. However, they are being destroyed at an alarming rate by human activities. To characterize mangrove forest changes, evaluate their impacts, and support relevant protection and restoration decision making, accurate and up-to-date mangrove extent mapping at large spatial scales is essential. Available large-scale mangrove extent data products use a single machine learning method commonly with 30 m Landsat imagery, and significant inconsistencies remain among these data products. With huge amounts of satellite data involved and the heterogeneity of land surface characteristics across large geographic areas, finding the most suitable method for large-scale high-resolution mangrove mapping is a challenge. The objective of this study is to evaluate the performance of a machine learning ensemble for mangrove forest mapping at 20 m spatial resolution across West Africa using Sentinel-2 (optical) and Sentinel-1 (radar) imagery. The machine learning ensemble integrates three commonly used machine learning methods in land cover and land use mapping, including Random Forest (RF), Gradient Boosting Machine (GBM), and Neural Network (NN). The cloud-based big geospatial data processing platform Google Earth Engine (GEE) was used for pre-processing Sentinel-2 and Sentinel-1 data. Extensive validation has demonstrated that the machine learning ensemble can generate mangrove extent maps at high accuracies for all study regions in West Africa (92%–99% Producer’s Accuracy, 98%–100% User’s Accuracy, 95%–99% Overall Accuracy). This is the first-time that mangrove extent has been mapped at a 20 m spatial resolution across West Africa. The machine learning ensemble has the potential to be applied to other regions of the world and is therefore capable of producing high-resolution mangrove extent maps at global scales periodically.

coastal environment↗

NASA NTRSDate not supplied

Design Optimization Studies of Partially Superconducting Machines based on NASA’s High Efficiency Megawatt Motor

Single aisle class electric aircraft require high power density and efficiency megawatt electric machines to be competitive with their tradition turbofan counterparts. Superconducting machines are seen as a key enabling technology for achieving the electric motor power density and efficiency needed by single aisle class electric aircraft. NASA’s High Efficiency Megawatt Motor (HEMM) is a partially superconducting machine being developed at NASA Glenn Research Center as a technology demonstration of a practical near-term superconducting machine. HEMM is being developed to meet the requirements of the generators on NASA’s STARC-ABL reference aircraft. HEMM is expected to achieve greater than 16 kW/kg electromagnetic specific power and greater than 98% efficiency at a nominal operating condition of 1.4 MW and 6800 RPM. In this paper, a design optimization algorithm for partially superconducting machines based on HEMM’s technologies is used to explore the possible performance of HEMM technology at other machine power levels and operating conditions. The design optimization algorithm is detailed in full and results for achievable geared and direct drive machine performance are presented.

Thomas F Tallerico↗