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Results for “Machining simulation”

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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Insights into the structure and dynamics of K + ions at the muscovite–water interface from machine learning potential simulations

The surfaces of many minerals are covered by naturally occurring cations that become partially hydrated and can be replaced by hydronium or other cations when the surface is exposed to water or an aqueous solution. These ion exchange processes are relevant to various chemical and transport phenomena, yet elucidating their microscopic details is challenging for both experiments and simulations. Here, in this work, we make a first step in this direction by investigating the behavior of the native K + ions at the interface between neat water and the muscovite mica (001) surface with ab-initio -based machine learning molecular dynamics and enhanced sampling simulations. Our results show that the desorption of the surface K + ions in pure ion-free water has a significant free energy barrier irrespective of their local surface arrangement. In contrast, facile K + diffusion between mica’s ditrigonal cavities characterized by different Al/Si orderings is observed. This behavior suggests that the K + ions may favor a dynamic disordered surface arrangement rather than complete desorption when exposed to deionized water.

Ab-initio molecular dynamics↗
DOE OSTI2022

A Realistic Full-Scale 3D Modeling of Turning Using Coupled Smoothed Particle Hydrodynamics and Finite Element Method for Predicting Cutting Forces

Computational modelling is an effective technique for understanding the complex physics of machining. Large deformations, material separation, and high computational requirements are the key challenges faced while simulating machining. This work introduces a full-scale three-dimensional model of turning operations using a combined approach based on the Smoothed Particle Hydrodynamics (SPH) and Finite Element (FE) methods. By exploiting the advantages of each method, this approach leads to high-fidelity coupled SPH-FE machining models. Cutting forces and chip morphology are the primary results of interest. The machining models are validated with the results of turning experiments. Two-dimensional machining model underpredicts the cutting force and feed force by approximately 49% and 70%, respectively. Moreover, passive force cannot be predicted using the two-dimensional model. On the other hand, with the three-dimensional models developed in this manuscript, the difference between the total simulated force and experimentally measured force is ∼17%. The chip morphologies correlate with experiments in terms of the direction of the chip movement and the “long” continuous chips observed while turning Al 6061. This work expands the realm of machining simulations from two-dimensional orthogonal machining or sectional three-dimensional model to a full-scale realistic simulation. The encouraging simulation results show the potential to study more complex phenomena, such as machining stability and tool path modulation.

42 ENGINEERING↗
DOE OSTI2023

Vision-based localization for cooperative robot-CNC hybrid manufacturing

Wire and arc additive manufacturing (WAAM) has shown promise in recent years for producing large-scale parts with higher deposition rates than other additive processes. WAAM is often combined with subtractive machining to form a hybrid manufacturing process. This hybrid process can be realized by retrofitting computer numerical control (CNC) machines with deposition heads, adding spindles and deposition heads to robots, or developing part localization methods to transfer parts from an additive cell to a CNC machine. Here, a novel, robot-CNC hybrid configuration is introduced where a maneuverable robot is placed in front of a CNC machine to deposit material within the machine envelop. Furthermore, this method removes the need for part localization and the extensive machine modifications required for retrofitting; however, the problem of robot localization is also added. In this work, the effects of error in vision-based, contactless robot localization on machining parameters in a robot-machine hybrid process were studied. Performance was characterized on an implementation of this system using classical computer vision techniques. In addition, machining simulations were conducted to evaluate the effects of image-induced error on chip thickness, material removal rate, and machining allowance. Initial tests show that computer vision could adequately locate a robot for the hybrid WAAM process within .5 mm.

Hybrid manufacturing↗
DOE OSTI2021

Enabling Combustion Science Simulations for Future Exascale Machines

Reacting flow simulations for combustion applications require extensive computing capabilities. Leveraging the AMReX library, the Pele suite of combustion simulation tools targets the largest supercomputers available and future exascale machines. We introduce PeleC, the compressible solver in the Pele suite, and detail its capabilities, including complex geometry representation, chemistry integration, and discretization. We present a comparison of development efforts using both OpenACC and AMReX's C++ performance portability framework for execution on multiple GPU architectures. We discuss relevant details that have allowed PeleC to achieve high performance and scalability. PeleC's performance characteristics are measured through relevant simulations on multiple supercomputers. The success of PeleC's design for exascale is exhibited through demonstration of a 160 billion cell simulation and weak scaling onto 100\% of Summit, an NVIDIA-based GPU supercomputer at Oak Ridge National Laboratory. Our results provide confidence that PeleC will enable future combustion science simulations with unprecedented fidelity.

combustion↗
DOE OSTI2025

Introducing the DREAMS Project: DaRk mattEr and Astrophysics with Machine Learning and Simulations

We introduce the DaRk mattEr and Astrophysics with Machine learning and Simulations (DREAMS) project, an innovative approach to understanding the astrophysical implications of alternative dark matter (DM) models and their effects on galaxy formation and evolution. The DREAMS project will ultimately comprise thousands of cosmological hydrodynamic simulations that simultaneously vary over DM physics, astrophysics, and cosmology in modeling a range of systems—from galaxy clusters to ultra-faint satellites. Such extensive simulation suites can provide adequate training sets for machine-learning-based analyses. This paper introduces two new cosmological hydrodynamical suites of warm dark matter (WDM), each comprising 1024 simulations generated using the arepo code. One suite consists of uniform-box simulations covering a ${(25\,{h}^{-1}\,{\rm{Mpc}})}^{3}$ volume, while the other consists of Milky Way zoom-ins with sufficient resolution to capture the properties of classical satellites. For each simulation, the WDM particle mass is varied along with the initial density field and several parameters controlling the strength of baryonic feedback within the IllustrisTNG model. We provide two examples, separately utilizing emulators and convolutional neural networks, to demonstrate how such simulation suites can be used to disentangle the effects of DM and baryonic physics on galactic properties. The DREAMS project can be extended further to include different DM models, galaxy formation physics, and astrophysical targets. In this way, it will provide an unparalleled opportunity to characterize uncertainties on predictions for small-scale observables, leading to robust predictions for testing the particle physics nature of DM on these scales.

cosmological parameters↗
DOE OSTI2023

Exploring model complexity in machine learned potentials for simulated properties

Abstract Machine learning (ML) enables the development of interatomic potentials with the accuracy of first principles methods while retaining the speed and parallel efficiency of empirical potentials. While ML potentials traditionally use atom-centered descriptors as inputs, different models such as linear regression and neural networks map descriptors to atomic energies and forces. This begs the question: what is the improvement in accuracy due to model complexity irrespective of descriptors? We curate three datasets to investigate this question in terms of ab initio energy and force errors: (1) solid and liquid silicon, (2) gallium nitride, and (3) the superionic conductor Li $$_{10}$$ 10 Ge(PS $$_{6}$$ 6 ) $$_{2}$$ 2 (LGPS). We further investigate how these errors affect simulated properties and verify if the improvement in fitting errors corresponds to measurable improvement in property prediction. By assessing different models, we observe correlations between fitting quantity (e.g. atomic force) error and simulated property error with respect to ab initio values. Graphical abstract

Rohskopf, A. (ORCID:0000000227128296)↗
NASA NTRS2007

ShareSync: A Solution for Deterministic Data Sharing over Ethernet

As part of upgrading the Contact Dynamics Simulation Laboratory (CDSL) at the NASA Marshall Space Flight Center (MSFC), a simple, cost effective method was needed to communicate data among the networked simulation machines and I/O controllers used to run the facility. To fill this need and similar applicable situations, a generic protocol was developed, called ShareSync. ShareSync is a lightweight, real-time, publish-subscribe Ethernet protocol for simple and deterministic data sharing across diverse machines and operating systems. ShareSync provides a simple Application Programming Interface (API) for simulation programmers to incorporate into their code. The protocol is compatible with virtually all Ethernet-capable machines, is flexible enough to support a variety of applications, is fast enough to provide soft real-time determinism, and is a low-cost resource for distributed simulation development, deployment, and maintenance. The first design cycle iteration of ShareSync has been completed, and the protocol has undergone several testing procedures including endurance and benchmarking tests and approaches the 2001ts data synchronization design goal for the CDSL.

Dunn, Daniel J., II↗
NASA NTRS1994

Technology for robotic surface inspection in space

This paper presents on-going research in robotic inspection of space platforms. Three main areas of investigation are discussed: machine vision inspection techniques, an integrated sensor end-effector, and an orbital environment laboratory simulation. Machine vision inspection utilizes automatic comparison of new and reference images to detect on-orbit induced damage such as micrometeorite impacts. The cameras and lighting used for this inspection are housed in a multisensor end-effector, which also contains a suite of sensors for detection of temperature, gas leaks, proximity, and forces. To fully test all of these sensors, a realistic space platform mock-up has been created, complete with visual, temperature, and gas anomalies. Further, changing orbital lighting conditions are effectively mimicked by a robotic solar simulator. In the paper, each of these technology components will be discussed, and experimental results are provided.

Volpe, Richard↗