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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗
NASA NTRS1988

Sine-Bar Attachment For Machine Tools

Sine-bar attachment for collets, spindles, and chucks helps machinists set up quickly for precise angular cuts that require greater precision than provided by graduations of machine tools. Machinist uses attachment to index head, carriage of milling machine or lathe relative to table or turning axis of tool. Attachment accurate to 1 minute or arc depending on length of sine bar and precision of gauge blocks in setup. Attachment installs quickly and easily on almost any type of lathe or mill. Requires no special clamps or fixtures, and eliminates many trial-and-error measurements. More stable than improvised setups and not jarred out of position readily.

Mann, Franklin D.↗
NASA NTRS1992

Speed-Selector Guard For Machine Tool

Simple guardplate prevents accidental reversal of direction of rotation or sudden change of speed of lathe, milling machine, or other machine tool. Custom-made for specific machine and control settings. Allows control lever to be placed at only one setting. Operator uses handle to slide guard to engage or disengage control lever. Protects personnel from injury and equipment from damage occurring if speed- or direction-control lever inadvertently placed in wrong position.

Shakhshir, Roda J.↗
NASA NTRS1989

A fatigue study of electrical discharge machine (EDM) strain-gage balance materials

A fatigue study was undertaken to determine how much electrical-discharge-machine (EDM) processing affected the fatigue life of balance materials: EDM and regular milling-machine (MM) samples were compared. Simulation of a typical balance stress configuration was devised for the fatigue testing in order to obtain results more closely related to balance situations. The fatigue testing of the EDM and MM specimens has indicated that the EDM technique does indeed reduce the fatigue life of 15-5PH steel, the first balance material tested. This conclusion was based on comparisons of the specimen fatigue lives with theoretical and manufacturer's data. Hence the EDM surface effects are detrimental to the fatigue life of this balance material.

Rhew, Ray D.↗
NASA NTRS1991

Procedure for computer-controlled milling of accurate surfaces of revolution for millimeter and far-infrared mirrors

A simple method for milling accurate off-axis parabolic mirrors with a computer-controlled milling machine is discussed. For machines with a built-in circle-cutting routine, an exact paraboloid can be milled with few computer commands and without the use of the spherical or linear approximations. The proposed method can be adapted easily to cut off-axis sections of elliptical or spherical mirrors.

Emmons, Louisa↗
NASA NTRS1999

Development of a Revolutionary High Speed Spindle

This report presents the development of a hydraulic motor driven spindle system to be employed for high speed machining of composite materials and metals. The spindle system is conceived to be easily retrofitted into conventional milling machines. The need for the hydraulic spindle arises because of the limitations placed on conventional electric motor driven spindles by the low cutting power and the presence of vibrational phenomena associated with voltage frequency at high rotational speeds. Also, the electric motors are usually large and expensive when power requirements are moderately high. In contrast, hydraulic motor driven spindles promise a distinct increase in spindle life over the conventional electric motor driven spindles. In this report, existing technologies applicable to spindle holder for severe operating conditions were reviewed, conceptual designs of spindle holder system were developed and evaluated, and a detailed design of an acceptable concept was conducted. Finally, a rapid prototype of the design was produced for design evaluation.

Agba, Emmanuel I.↗
NASA NTRS1981

AIRCL: A programmed system for generating NC tapes for airplane models. User's manual

A computer program is presented which calculates the cutter location file needed to machine models of airplane wings or wing-fuselage combinations on numerically controlled machine tools. Input to the program is a data file consisting of coordinates on the fuselage and wing. From this data file, the program calculates tool offsets, determines the intersection between wing and fuselage tool paths, and generates additional information needed to machine the fuselage and/or wing. Output from the program can be post processed for use on a variety of milling machines. Information on program structure and methodology is given as well as the user's manual for implementation of the program.

Akgerman, N.↗
NASA NTRS2000

Fracture Tests of Etched Components Using a Focused Ion Beam Machine

Many optical MEMS device designs involve large arrays of thin (0.5 to 1 micron components subjected to high stresses due to cyclic loading. These devices are fabricated from a variety of materials, and the properties strongly depend on size and processing. Our objective is to develop standard and convenient test methods that can be used to measure the properties of large numbers of witness samples, for every device we build. In this work we explore a variety of fracture test configurations for 0.5 micron thick silicon nitride membranes machined using the Reactive Ion Etching (RIE) process. Testing was completed using an FEI 620 dual focused ion beam milling machine. Static loads were applied using a probe. and dynamic loads were applied through a piezo-electric stack mounted at the base of the probe. Results from the tests are presented and compared, and application for predicting fracture probability of large arrays of devices are considered.

Kuhn, Jonathan, L.↗
NASA NTRS2011

Fabric circuits and method of manufacturing fabric circuits

A flexible, fabric-based circuit comprises a non-conductive flexible layer of fabric and a conductive flexible layer of fabric adjacent thereto. A non-conductive thread, an adhesive, and/or other means may be used for attaching the conductive layer to the non-conductive layer. In some embodiments, the layers are attached by a computer-driven embroidery machine at pre-determined portions or locations in accordance with a pre-determined attachment layout before automated cutting. In some other embodiments, an automated milling machine or a computer-driven laser using a pre-designed circuit trace as a template cuts the conductive layer so as to separate an undesired portion of the conductive layer from a desired portion of the conductive layer. Additional layers of conductive fabric may be attached in some embodiments to form a multi-layer construct.

Chu, Andrew W.↗
NASA NTRS1983

Machining Three Prongs on a Shaft

Simple tool reduces set-up and machining time by more than 70 percent. Unorthodox tooling arrangement used to machine three prongs on end of specialpurpose wrench. Modified carbide-tipped spot-facing tool rotated at 1,400 to 1,600 revolutions per minute in small milling machine and applied to work piece, held with its corners in spaces of three-cornered collect.

Hewitt, C.↗
NASA NTRS1987

Laser Scanner for Tile-Cavity Measurement

Irregular surfaces mapped and digitized for numerical-control machinery. Fast, accurate laser scanning system measures size and shape of cavity without making any physical contact with cavity and walls. Measurements processed into control signals for numerically controlled machining of tile or block to fit cavity. System generates map of grid points representing cavity and portion of outer surface surrounding cavity. Map data used to control milling machine, which cuts tile or block to fit in cavity.

Yoshino, Stanley Y.↗
NASA NTRS2022

(Preliminary) Effects of Ball Milling Zeolite Powders for Use in Additively Manufactured Solid Sorbents

Zeolite 13X is favorable to be used as an adsorbent in carbon dioxide (CO2) removal from the spacecraft cabin air. Reducing the size of the zeolite particles and particle size distribution is thought to increase the capacity of CO2 adsorption of the zeolite 13X powder, and potentially increase its manufacturability as a paste for additive manufacturing or slip casting. This paper will go into detail on the process of using ball milling in order to reduce particle size and particle size distribution of commercial zeolite 13X powder, as well as to characterize CO2 adsorption and manufacturability of the milled powder. Both dry and wet ball milling was analyzed during the experiment. Studies were also ran on the amount of time the powder was milled, rotational speed of the milling machine, ball to powder ratio, ball to jar ratio, and ethanol to powder ratio. The processed powder was then characterized through laser diffraction, SEM, and surface measurement techniques to show that particle size and particle size distribution could be reduced, and to show the effect of the reduced particle size and particle size distribution on CO2 adsorption and manufacturability.

zeolite↗
NASA NTRS1974

Apparatus for cutting elastomeric materials

Sharp thin cutting edge is held in head of milling machine designed for metal working. Controls of machine are used to position cutting edge in same plane as vibrating specimen. Controls then are operated, making blade come into contact with specimen, to cut it into shapes and sizes desired. Cut surfaces appear mirror-smooth; vibrating mechanism causes no visible striations.

Corbett, A. B.↗
NASA NTRS1978

Fabrication of sea-floor models

Sea-floor models are fabricated simply and inexpensively by utilizing milling machine programmed with data tapes from ocean sounding surveys, and cement vermiculite mixture.

Hale, G. L.↗
NASA NTRS1979

Low-cost boring mill

Portable unit and special fixture serve as boring mill. Machine, fabricated primarily from scrap metal, was designed and set up in about 12 working days. It has reduced setup and boring time by 66 percent as compared with existing boring miles, thereby making latter available for other jobs. Unit can be operated by one man.

Hibdon, R. A.↗
NASA NTRS1980

"Grinding" cavities in polyurethane foam

Grinding tool installed on conventional milling machine cuts precise cavities in foam blocks. Method is well suited for prototype or midsize production runs and can be adapted to computer control for mass production. Method saves time and materials compared to bonding or hot wire techniques.

Brower, J. R.↗
NASA NTRS1984

Tool Support Ring

Tool support ring requires only single repositioning to give broaching tool access to series of 66 holes located on circle. Permits use of tools designed for hand-held use (such as electric drill) where less portable setup (such as milling machine) otherwise required.

Smith, D. F.↗