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At least 91 records · Page 5

Polarimetric microwave scattering from known randomly rough surfaces

Scattering from rough surfaces is reviewed, and artificial randomly rough surfaces are described. Measurements were made from 4 to 18 GHz for the 4 linear polarization states. The target consists of a metalized randomly rough surface constructed from known surface statistical information. The surface was generated using surface generation routines on the computer, and then the data was converted for the machining of the surface on a computer controlled mill. Bistatic and monostatic measurements were acquired at incident angles from 25 to 60 deg. At the 13.5 to 18 GHz frequencies, the effects of backscatter enhancement and depolarization effects can be studied in a regime which does not satisfy Kirchoff or small perturbation assumptions. This allows scattering mechanisms to be introduced into models, which may show missing elements in the more standard formulations. At lower frequency bands such as 4 to 8.5 GHz the scattering behavior was also examined to see the behavior as assumptions of other formulations are satisfied.

Nance, C. E.↗

Interactive cutting path analysis programs

The operation of numerically controlled machine tools is interactively simulated. Four programs were developed to graphically display the cutting paths for a Monarch lathe, Cintimatic mill, Strippit sheet metal punch, and the wiring path for a Standard wire wrap machine. These programs are run on a IMLAC PDS-ID graphic display system under the DOS-3 disk operating system. The cutting path analysis programs accept input via both paper tape and disk file.

Weiner, J. M.↗

Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods

Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Handschuh, Robert F.↗

Surface texture characterization by angular distributions of scattered light

Work at the National Bureau of Standards to develop an on-line optical measurement device and attendant algorithms for automated optical scattering measurements of machined metal surfaces are described. The surfaces could be milled, ground or lapped, and the system is intended to categorize the resulting surface characteristics. The optical device consists of a He-Ne laser which is shone on a surface. The scattered light is captured by a semicircular array of 87 detector elements rotated over the scanned area. The light signals are processed through a digital voltmeter and then an A/D converter. The signals are then stored for later comparisons with optical scattering data obtained by optical instruments used with stylus instruments for characterizing surface topographies. A theoretical model has been defined which relates light scattering and the characteristics of the surface roughness. Initial experimental results with a sinusoidal surface have indicated that although the system can follow the trend of the roughness, the roughness amplitude is as yet uncertainly defined and the computations require excessive time.

Gilsinn, D. E.↗

Confessions of a robot lobotomist

Since its inception, numerically controlled (NC) machining methods have been used throughout the aerospace industry to mill, drill, and turn complex shapes by sequentially stepping through motion programs. However, the recent demand for more precision, faster feeds, exotic sensors, and branching execution have existing computer numerical control (CNC) and distributed numerical control (DNC) systems running at maximum controller capacity. Typical disadvantages of current CNC's include fixed memory capacities, limited communication ports, and the use of multiple control languages. The need to tailor CNC's to meet specific applications, whether it be expanded memory, additional communications, or integrated vision, often requires replacing the original controller supplied with the commercial machine tool with a more powerful and capable system. This paper briefly describes the process and equipment requirements for new controllers and their evolutionary implementation in an aerospace environment. The process of controller retrofit with currently available machines is examined, along with several case studies and their computational and architectural implications.

Gottshall, R. Marc↗

Continuous internal channels formed in aluminum fusion welds

Process produces continuous internal channel systems on a repeatable basis in 2014-T6 aluminum. Standard machining forms the initial channel, which is filled with tungsten carbide powder. TIG machine fusion welding completes formation of the channel. Chem-mill techniques enlarge it to the desired size.

Gault, J.↗

Preliminary investigation of a NiAl composite prepared by cryomilling

An attempt has been made to improve the high temperature mechanical strength of the B2 cubic crystal structure intermetallic NiAl by dispersion strengthening. Prealloyed Ni-51 at. pct Al was cryomilled with a Y2O3 addition to form an yttria dispersoid within the intermetallic matrix. Following milling, the powder was hot extruded to full density and machined into test coupons. Compression testing between 1200 and 1400 K indicated that the cryogenic process yielded the strongest NiAl based material tested to date. Creep resistance was six times better than NiAl and twice that of a NiAl particulate composite containing 10 vol pct TiB2. Surprisingly, transmission electron microscopy revealed that the second phase was inhomogeneously distributed. Furthermore, X-ray analysis indicated that the second phase was not Y2O3 but rather AlN.

Whittenberger, J. Daniel↗

Description of photovoltaic village power systems in the United States and Africa

The paper describes the designs, hardware, and installations of NASA photovoltaic power systems in the village of Schuchuli in Arizona and Tangaye in Upper Volta, Africa. The projects were designed to demonstrate that current photovoltaic system technology can provide electrical power for domestic services for small, remote communities. The Schuchuli system has a 3.5 kW peak solar array which provides power for water pumping, a refrigerator for each family, lights, and community washing and sewing machines. The 1.8 kW Tangaye system provides power for pumping, flour milling, and lights in the milling building. Both are stand-alone systems operated by local personnel, and they are monitored by NASA to measure design adequacy and refine future designs.

Ratajczak, A. F.↗

Spring Internship 2018 at the Prototype Development Lab: A place of Dreamers and Makers

This paper covers the role of the design process and the methodology of creating a trophy during my Spring 2018 Internship at the Prototype Development Laboratory at the Kennedy Space Center. In the course of this project I used many new machines and materials while trying to deliver a professional product for a competition that invites college student teams from across the country. The machines covered in this paper include the wood chop saw, CNC mill, water jet, laser engraver, and the 3D printer. This paper also serves as an assembly guide for the trophy.

Rueda, Juan F.↗

Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments

In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.

Post-Processing↗

Modeling of Fillets in Thin-Walled Structures for Dynamic Analysis

Relatively new developments in manufacturing methods have made it possible to produce machined parts with a wall thickness of less than 0.010". While the parts are being machined. Fillets of relatively large radius to thickness ratios are created by the milling tool. This paper discusses an accurate new technique for finite-element modeling of fillets for dynamic and stiffness analysis using efficient plate elements rather than more computationally intensive, high density solid meshes, A simple filleted cantilever beam of 0.040" thickness, 1.6" length, 1" depth, and 0.250" radius in the corner was modeled using both solid elements and several different plate element geometries. The finite element results were then compared with static and modal testing of a machined sample. The highest-scoring plate element technique uses a bridge of elements that is constructed through the tangent point of the Fillet radius such that the thickness of the element matches tile volume of the fillet. This model produces errors of less than 4.6 percent for static loading and less than 7.4 percent for modal analysis. This simple plate element technique will prove critical for efficient, timely, and accurate dynamic analysis of complex thin-walled structures.

Seugling, Richard M.↗

Description of photovoltaic village power systems in the United States and Africa

Photovoltaic power systems in remote villages in the United States and Africa are described. These projects were undertaken to demonstrate that existing photovoltaic system technology is capable of providing electrical power for basic domestic services for the millions of small, remote communities in both developed and developing countries. One system is located in the Papago Indian Village of Schuchuli in southwest Arizona (U. S.) and became operational 16 December 1978. The other system is located in Tangaye, a rural village in Upper Volta, Africa. It became operational 1 March 1979. The Schuchuli system has a 3.5 kW (peak) solar array which provides electric power for village water pumping, a refrigerator for each family, lights in the village buildings, and a community washing machine and sewing machine. The 1.8 kW (peak) Tangaye system provides power for community water pumping, flour milling and lights in the milling building. These are both stand-alone systems (i.e., no back-up power source) which are being operated and maintained by local personnel. Both systems are instrumented. Systems operations are being monitored by NASA to measure design adequacy and to refine designs for future systems.

Ratajczak, A. F.↗

Quantum-Assisted Variational Segmentation for Image-to-Image Wildfire Detection Using Satellite Data

The quantum computing community has been searching for suitable applications to demonstrate the potential of near-term quantum devices. Quantum machine learning is a potential candidate, particularly using models that cannot be efficiently simulated with classical computers [1, 2]. This work focuses on a transition phase of quantum computers where the quantum machine learning model is still simulable classically but projected not to be simulable as the size of the model grows. Ultimately quantum computers may have advantages for high-dimensional real-world problems. Due to the limited number of qubits in current noisy intermediate-scale quantum (NISQ) devices, the direct application of quantum computers in high dimensional data is not feasible. To remedy this problem, an encoder-decoder architecture can be utilized. The encoder model would transform the high-dimensional data into a compact representation, to a level that small quantum computers can be used today (or in the near future), and the decoder would take the quantum processed outputs back to the high-dimensional space. Addressing the two challenges of quantum machine learning, this work investigates a hybrid supervised generative model with a quantum Ising Born machine embedded as the latent distribution. The model contains four main parts (Figure 1.a.): (1) a U-NET architecture responsible for learning segmentation flow, (2) a Prior network responsible for learning an encoded latent distribution of the input data, (3) a Born machine which represents the latent distribution, and (4) a Posterior network in charge of learning the joint encoded latent distribution of inputs and target data. The initial model, proposed by [3], is optimized by (1) maximizing the overlap of the prior and posterior latent distributions, and (2) minimizing the segmentation loss. The proposed model is designed to be investigated in a simulation environment applied to the real-world application of wildfire segmentation. Specifically, the model is designed to solve the patchy wildfire segmentations of Moderate Resolution Imaging Spectroradiometer (MODIS) by taking the MODIS observations and using Visible Infrared Imaging Radiometer Suite’s (VIIRS) consistent wildfire product as the target. The model solves patchy wildfire segmentations and provides insight into the epistemic errors sourced from model variation. The model utilizes the Born machine as a QUBO solver to represent the latent space as a Bernoulli distribution. The proposed configuration allows the variational segmentation model to leverage the true quantum probabilistic nature and derive a more expressive latent configuration, increasing the model performance in describing wildfire segmentations. The quantum probabilistic information of the Born machine is directly incorporated in the Kullback-Leibler divergence loss in the prior and posterior distributions, forcing the Bernoulli latent distribution to maximize the overlap of input and joint input-target distributions. The proposed model is then trained and compared with a baseline only consisting of direct Bernoulli latent distribution with no Born machine representing the latent space. The models are evaluated based on the segmentation metrics, such as precision, recall, intersect of union, with uncertainty boundaries accounting for the stochastic nature of the model. Our findings show that even in low latent-dimensional space (due to the limit in computational power of the classical quantum simulator), we are able to effectively capture the latent representation and hence the model performs better than the baseline. The findings are a projection for scaling the model into higher dimensional latent space with the Born machine surpassing the baseline performance. Figure 1. Sub-figure (a) demonstrates the architecture for the training phase. The model consists of a Prior and Posterior network that encode inputs and joint input-target data into compact representations, respectively. The Born machine represents the latent distribution, and the U-NET branch learns the segmentation patterns of the data. The stochasticity is introduced to the U-NET through its last layer to create meaningful but stochastic segmentations. Sub-figure (b) represents the inference phase where the model takes the stochastic behavior from the prior network and injects that into the U-NET. Each attempt of inference will generate different but similar segmentations from the same distribution of the wildfire event. REFERENCES [1] Coyle, B., Mills, D., Danos, V., & Kashefi, E. (2020). The Born supremacy: quantum advantage and training of an Ising Born machine. npj Quantum Information, 6(1), 1-11. [2] Liu, J. G., & Wang, L. (2018). Differentiable learning of quantum circuit born machines. Physical Review A, 98(6), 062324. [3] Kohl, S., Romera-Paredes, B., Meyer, C., De Fauw, J., Ledsam, J. R., Maier-Hein, K., ... & Ronneberger, O. (2018). A probabilistic u-net for segmentation of ambiguous images. Advances in neural information processing systems, 31.

quantum machine learning↗

Virtual Manufacturing Techniques Designed and Applied to Manufacturing Activities in the Manufacturing Integration and Technology Branch

One of the identified goals of EM3 is to implement virtual manufacturing by the time the year 2000 has ended. To realize this goal of a true virtual manufacturing enterprise the initial development of a machinability database and the infrastructure must be completed. This will consist of the containment of the existing EM-NET problems and developing machine, tooling, and common materials databases. To integrate the virtual manufacturing enterprise with normal day to day operations the development of a parallel virtual manufacturing machinability database, virtual manufacturing database, virtual manufacturing paradigm, implementation/integration procedure, and testable verification models must be constructed. Common and virtual machinability databases will include the four distinct areas of machine tools, available tooling, common machine tool loads, and a materials database. The machine tools database will include the machine envelope, special machine attachments, tooling capacity, location within NASA-JSC or with a contractor, and availability/scheduling. The tooling database will include available standard tooling, custom in-house tooling, tool properties, and availability. The common materials database will include materials thickness ranges, strengths, types, and their availability. The virtual manufacturing databases will consist of virtual machines and virtual tooling directly related to the common and machinability databases. The items to be completed are the design and construction of the machinability databases, virtual manufacturing paradigm for NASA-JSC, implementation timeline, VNC model of one bridge mill and troubleshoot existing software and hardware problems with EN4NET. The final step of this virtual manufacturing project will be to integrate other production sites into the databases bringing JSC's EM3 into a position of becoming a clearing house for NASA's digital manufacturing needs creating a true virtual manufacturing enterprise.

Shearrow, Charles A.↗

Sikorsky interactive graphics surface design/manufacturing system

An interactive graphics system conceived to be used in the design, analysis, and manufacturing of aircraft components with free form surfaces was described. In addition to the basic surface definition and viewing capabilities inherent in such a system, numerous other features are present: surface editing, automated smoothing of control curves, variable milling patch boundary definitions, surface intersection definition and viewing, automatic creation of true offset surfaces, digitizer and drafting machine interfaces, and cutter path optimization. Documented costs and time savings of better than six to one are being realized with this system. The system was written in FORTRAN and GSP for use on IBM 2250 CRT's in conjunction with an IBM 370/158 computer.

Robbins, R.↗

Multistage Electrophoretic Separators

A multistage electrophoresis apparatus has been invented for use in the separation of cells, protein molecules, and other particles and solutes in concentrated aqueous solutions and suspensions. The design exploits free electrophoresis but overcomes the deficiencies of prior free-electrophoretic separators by incorporating a combination of published advances in mathematical modeling of convection, sedimentation, electro-osmotic flow, and the sedimentation and aggregation of droplets. In comparison with other electrophoretic separators, these apparatuses are easier to use and are better suited to separation in relatively large quantities characterized in the art as preparative (in contradistinction to smaller quantities characterized in the art as analytical). In a multistage electrophoretic separator according to the invention, an applied vertical steady electric field draws the electrically charged particles of interest from within a cuvette to within a collection cavity that has been moved into position of the cuvette. There are multiple collection cavities arranged in a circle; each is aligned with the cuvette for a prescribed short time. The multistage, short-migration-path character of the invention solves, possibly for the first time, the fluid-instability problems associated with free electrophoresis. The figure shows a prototype multistage electrophoretic separator that includes four sample stations and five collection stages per sample. At each sample station, an aqueous solution or suspension containing charged species to be separated is loaded into a cuvette, which is machined into a top plate. The apparatus includes a lower plate, into which 20 collection cavities have been milled. Each cavity is filled with an electrophoresis buffer solution. For the collection of an electrophoretic fraction, the lower plate is rotated to move a designated collection cavity into alignment with the opening of the cuvette. An electric field is then applied between a non-gassing electrode in the collection cavity and an electrolyte compartment, which is separated from the cuvette by a semipermeable membrane. The electrolyte is refreshed by circulation by use of a peristaltic pump. In subsequent steps, the lower plate is rotated to collect other electrophoretic fractions. Later, the collected fractions are removed from the collection cavities through ports that have threaded plugs. The base of the apparatus contains power supplies and a computer interface. The design includes provisions for monitoring and feedback control of cavity position, electric field, and temperature. The operation of the apparatus can easily be automated, as demonstrated by use of software that has already been written for this purpose.

Thomas, Nathan↗

Composite beam cap fabricator experiment definition study, volume 1

The Composite Beam Cap Fabricator (CBCF), a part of a family of machines that was designed to develop and augment the technology of space fabrication (the automatic production of basic structural members in space is described. The major components of the CBCF are described. The mill weighs approximately 1400 pounds and its size is approximately 6 feet by 2 feet by 2 feet. It is a microprocessor under a low cost-of-concept type of contract. Consequently, all components are made of commercially available hardware. Neither weight nor volume constraints were considered during the development of the machine. For example, over 3/4 of the volume enclosed by the controller units is empty.

Source record↗