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Physics-guided logistic classification for tool life modeling and process parameter optimization in machining

This paper describes a physics-guided logistic classification method for tool life modeling and process parameter optimization in machining. Tool life is modeled using a classification method since the exact tool life cannot be measured in a typical production environment where tool wear can only be directly measured when the tool is replaced. Here, in this study, laboratory tool wear experiments are used to simulate tool wear data normally collected during part production. Two states are defined: tool not worn (class 0) and tool worn (class 1). The non-linear reduction in tool life with cutting speed is modeled by applying a logarithmic transformation to the inputs for the logistic classification model. A method for interpretability of the logistic model coefficients is provided by comparison with the empirical Taylor tool life model. The method is validated using tool wear experiments for milling. Results show that the physics-guided logistic classification method can predict tool life using limited datasets. A method for pre-process optimization of machining parameters using a probabilistic machining cost model is presented. The proposed method offers a robust and practical approach to tool life modeling and process parameter optimization in a production environment.

Machine learning↗

Anvil Tool in the Advanced Weather Interactive Processing System

Meteorologists from the 45th Weather Squadron (45 WS) and Spaceflight Meteorology Group (SMG) have identified anvil forecasting as one of their most challenging tasks when predicting the probability of violations of the lightning Launch Commit Criteria and Space Shuttle Flight Rules. As a result, the Applied Meteorology Unit (AMU) created a graphical overlay tool for the Meteorological Interactive Data Display Systems (MIDDS) to indicate the threat of thunderstorm anvil clouds, using either observed or model forecast winds as input. In order for the Anvil Tool to remain available to the meteorologists, the AMU was tasked to transition the tool to the Advanced Weather interactive Processing System (AWIPS). This report describes the work done by the AMU to develop the Anvil Tool for AWIPS to create a graphical overlay depicting the threat from thunderstorm anvil clouds. The AWIPS Anvil Tool is based on the previously deployed AMU MIDDS Anvil Tool. SMG and 45 WS forecasters have used the MIDDS Anvil Tool during launch and landing operations. SMG's primary weather analysis and display system is now AWIPS and the 45 WS has plans to replace MIDDS with AWIPS. The Anvil Tool creates a graphic that users can overlay on satellite or radar imagery to depict the potential location of thunderstorm anvils one, two, and three hours into the future. The locations are based on an average of the upper-level observed or forecasted winds. The graphic includes 10 and 20 nm standoff circles centered at the location of interest, in addition to one-, two-, and three-hour arcs in the upwind direction. The arcs extend outward across a 30 degree sector width based on a previous AMU study which determined thunderstorm anvils move in a direction plus or minus 15 degrees of the upper-level (300- to 150-mb) wind direction. This report briefly describes the history of the MIDDS Anvil Tool and then explains how the initial development of the AWIPS Anvil Tool was carried out. After testing was performed by SMG, 45 WS, and AMU, a number of needed improvements were identified. A bug report document was created that showed the status of each bug and desired improvement. This report lists the improvements that were made to increase the accuracy and user-friendliness of the tool. Final testing was carried out and documented and then the final version of the software and Users Guide was provided to SMG and the 45 WS. Several possible future improvements to the tool are identified that would increase the flexibility of the tool. This report contains a brief history of the development of the Anvil Tool in MIDDS, and then describes the transition and development of software to AWIPS.

Barrett, Joe, III↗

Developing Concepts of Operations Using Multi-Step Tool Techniques With Large Language Models

The National Aeronautics and Space Administration (NASA) Air Mobility Pathfinders (AMP) project is developing and evaluating concepts of operations (ConOps) for safe, secure, and scalable Urban Air Mobility (UAM) operations. The AMP project’s Operational Concepts, Architecture, and Requirements Integration (OCARI) Team is using a Model Based System Engineering (MBSE) approach for integration, interoperability, and traceability of Advanced Air Mobility (AAM) ecosystems centered around urban air taxi services. The team’s goal is to define structures and behaviors needed for system feasibility, readiness, and interoperability, establish a UAM knowledge base, and trace and validate assumptions and requirements relevant to AAM. NASA Langley Research Center (LaRC) is spearheading an innovative digital engineering approach to integrate, communicate, and facilitate the research of multi-modal transportation systems. The Knowledge-based Digital Platform (KbDP) is a concept being developed that ties the workflows of Project Managers (PM), Principal Investigators (PI), and System Engineers together across organizational boundaries. It does so through the management of an information database defined by mathematical, data science, and system engineering principles. Machine Learning (ML) algorithms play a key role in this concept by extracting meaningful knowledge from relational and graph databases, document repositories, and system artifacts, which the human user leverages to greatly improve the efficiency and effectiveness of their research. Recent advancements in the field of Large Language Models (LLMs), specifically models trained for tool use, such as Command-R , now allow for the reliable implementation of single-step and multi-step tool-centric systems. These techniques provide the LLM with a set of tools, in our case Python functions, that can be called on to answer a much wider range of questions compared to LLMs implemented using a traditional single-source or Retrieval Augmented Generation (RAG) approach. Through this method, the LLM can pull information from multiple data sources, such as relational or graph databases, document repositories, application programming interfaces (APIs), and SysML artifacts depending on the user’s question. The LLM can also output the information in a variety of different formats, using output generation tools, such as CSV, UML, or SysML artifacts. Additionally, tools can be assigned roles and can work together to provide answers to queries in an “agent” like approach, similar to that implemented by Microsoft’s AutoGen framework where different agents can converse with each other to accomplish tasks. Previously, our team developed a chatbot system with “agent like” functionality in the form of different “modes” the user could select from a user interface (UI), this architecture can be seen on the left in figure 1. Three different modes were implemented, the first mode allowed the LLM to utilize the structures and algorithms within a graph database to trace UAM requirements. The second mode gave the LLM access to a vector search capable of providing relevant information from thousands of document pages related to UAM ConOps and requirements. The third mode served as a general assistant where users could enter open-ended questions and custom prompts to utilize the LLM for different use-cases. This system improved the process surrounding generating and analyzing information related to UAM requirements, however, the implementation provided a clunky user experience. Users were required to know what mode to select within the UI in advance before entering their question to the selected tool. Moreover, the different tools were isolated from each other, they lacked bidirectional links that would allow for tools to collaborate to generate better responses. Our team is working on a new architecture, seen on the right in the below figure, with the goal to address many of the UX shortcomings of our original system while improving the accuracy and depth of responses from the LLM. This new system will automatically select the appropriate tool to use based off the user’s question. Each tool will be capable of calling on any of the other tools available to the LLM, resulting in a collaborative pipeline where tools can pass data between other tools until enough data is received to generate an answer to the user’s question. Using a locally deployed, open-source, LLM, the NASA OCARI team, in collaboration with Collins Aerospace, will implement a prototype application that will bridge knowledge across multiple sources to assist System Engineers (SEs) with requirements discovery and tracing, research question and use case identification, and assumption validation. Such a system will also allow SEs to more easily, and intuitively, explore the AAM ecosystem, ultimately improving the efficiency and effectiveness of the SE's research and decision-making processes surrounding ConOps development and validation. In this session, our team will provide a video demonstration of our new prototype architecture in action. We will also present an overview of our prototype system architecture and talk about its advantages over traditional LLM deployments along with how those advantages can provide additional value to the field of System Engineering.

systems engineering↗

Flow in the Proximity of the Pin-Tool in Friction Stir Welding and Its Relation to Weld Homogeneity

In the Friction Stir Welding (FSW) process a rotating pin inserted into a seam literally stirs the metal from each side of the seam together. It is proposed that the flow in the vicinity of the pin-tool comprises a primary rapid shear over a cylindrical envelope covering the pin-tool and a relatively slow secondary flow taking the form of a ring vortex about the tool circumference. This model is consistent with a plastic characterization of metal flow, where discontinuities in shear flow are allowed but not viscous effects. It is consistent with experiments employing several different kinds of tracer: atomic markers, shot, and wire. If a rotating disc with angular velocity w is superposed on a translating continuum with linear velocity omega, the trajectories of tracer points become circular arcs centered upon a point displaced laterally a distance v/omega from the center of rotation of the disc in the direction of the advancing side of the disc. In the present model a stream of metal approaching the tool (taken as the coordinate system of observation) is sheared at the slip surface, rapidly rotated around the tool, sheared again on the opposite side of the tool, and deposited in the wake of the tool. Local shearing rates are high, comparable to metal cutting in this model. The flow patterns in the vicinity of the pin-tool determine the level of homogenization and dispersal of contaminants that occurs in the FSW process. The approaching metal streams enfold one another as they are rotated around the tool. Neglecting mixing they return to the same lateral position in the wake of the tool preserving lateral tracer positions as if the metal had flowed past the tool like an extrusion instead of being rotated around it. (The seam is, however, obliterated.) The metal stream of thickness approximately that of the tool diameter D is wiped past the tool at elevated temperatures drawn out to a thickness of v/2(omega) in the wiping zone. Mixing distances in the wiping zone are multiplied in the unfolded metal. Inhomogeneities on a smaller scale than the mixing length are obliterated, but structure on a larger scale may be transmitted to the wake of a FSW weld.

Nunes, Arthur C., Jr.↗

Programming Tools: Status, Evaluation, and Comparison

In this tutorial I will first describe the characteristics of scientific applications and their developers, and describe the computing environment in a typical high-performance computing center. I will define the user requirements for tools that support application portability and present the difficulties to satisfy them. These form the basis of the evaluation and comparison of the tools. I will then describe the tools available in the market and the tools available in the public domain. Specifically, I will describe the tools for converting sequential programs, tools for developing portable new programs, tools for debugging and performance tuning, tools for partitioning and mapping, and tools for managing network of resources. I will introduce the main goals and approaches of the tools, and show main features of a few tools in each category. Meanwhile, I will compare tool usability for real-world application development and compare their different technological approaches. Finally, I will indicate the future directions of the tools in each category.

Cheng, Doreen Y.↗

Template for Systems Engineering Tools Trade Study

A discussion of Systems Engineering tools brings out numerous preferences and reactions regarding tools of choice as well as the functions those tools are to perform. A recent study of Systems Engineering Tools for a new Program illustrated the need for a generic template for use by new Programs or Projects to determine the toolset appropriate for their use. This paper will provide the guidelines new initiatives can follow and tailor to their specific needs, to enable them to make their choice of tools in an efficient and informed manner. Clearly, those who perform purely technical functions will need different tools than those who perform purely systems engineering functions. And, everyone has tools they are comfortable with. That degree of comfort is frequently the deciding factor in tools choice rather than an objective study of all criteria and weighting factors. This paper strives to produce a comprehensive list of criteria for selection with suggestions for weighting factors based on a number of assumptions regarding the given Program or Project. In addition, any given Program will begin with assumptions for its toolset based on Program size, tool cost, user base and technical needs. In providing a template for tool selection, this paper will guide the reader through assumptions based on Program need; decision criteria; potential weighting factors; the need for a compilation of available tools; the importance of tool demonstrations; and finally a down selection of tools. While specific vendors cannot be mentioned in this work, it is expected that this template could serve other Programs in the formulation phase by alleviating the trade study process of some of its subjectivity.

Michelle D Bailey↗

Tool for Two Types of Friction Stir Welding

A tool that would be useable in both conventional and self-reacting friction stir welding (FSW) has been proposed. The tool would embody both a prior tooling concept for self-reacting FSW and an auto-adjustable pin-tool (APT) capability developed previously as an augmentation for conventional FSW. Some definitions of terms are prerequisite to a meaningful description of the proposed tool. In conventional FSW, depicted in Figure 1, one uses a tool that includes (1) a rotating shoulder on top (or front) of the workpiece and (2) a rotating pin that protrudes from the shoulder into the depth of the workpiece. The main axial force exerted by the tool on the workpiece is reacted through a ridged backing anvil under (behind) the workpiece. When conventional FSW is augmented with an APT capability, the depth of penetration of the pin into the workpiece is varied in real time by a position- or force-control system that extends or retracts the pin as needed to obtain the desired effect. In self-reacting (also known as self-reacted) friction stir welding (SR-FSW), there are two rotating shoulders: one on top (or front) and one on the bottom (or back) of the workpiece. In this case, a threaded shaft protrudes from the tip of the pin to beyond the back surface of the workpiece. The back shoulder is held axially in place against tension by a nut on the threaded shaft. The main axial force exerted on the workpiece by the tool and front shoulder is reacted through the back shoulder and the threaded shaft, back into the FSW machine head, so that a backing anvil is no longer needed. A key transmits torque between the bottom shoulder and the threaded shaft, so that the bottom shoulder rotates with the shaft. A tool for SRFSW embodying this concept was reported in "Mechanism for Self-Reacted Friction Stir Welding" (MFS-31914), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 53. In its outward appearance, the proposed tool (see Figure 2) would fit the above description of an SR-FSW tool. In this case, the FSW machine would have an APT capability and the pin would be modified to accept a bottom shoulder. The APT capability could be used to vary the distance between the front and back shoulders in real time to accommodate process and workpiece-thickness variations. The tool could readily be converted to a conventional FSW tool, with or without APT capability, by simply replacing the modified pin with a conventional FSW pin.

Carter, Robert↗

The Way Point Planning Tool: Real Time Flight Planning for Airborne Science

Airborne real time observation are a major component of NASA's Earth Science research and satellite ground validation studies. For mission scientist, planning a research aircraft mission within the context of meeting the science objective is a complex task because it requires real time situational awareness of the weather conditions that affect the aircraft track. Multiple aircraft are often involved in the NASA field campaigns the coordination of the aircraft with satellite overpasses, other airplanes and the constantly evolving dynamic weather conditions often determine the success of the campaign. A flight planning tool is needed to provide situational awareness information to the mission scientist and help them plan and modify the flight tracks successfully. Scientists at the University of Alabama Huntsville and the NASA Marshal Space Flight Center developed the Waypoint Planning Tool (WPT), an interactive software tool that enables scientist to develop their own flight plans (also known as waypoints), with point and click mouse capabilities on a digital map filled with time raster and vector data. The development of this Waypoint Planning Tool demonstrates the significance of mission support in responding to the challenges presented during NASA field campaigns. Analyses during and after each campaign helped identify both issues and new requirements, initiating the next wave of development. Currently the Waypoint Planning Tool has gone through three rounds of development and analysis processes. The development of this waypoint tool is directly affected by the technology advances on GIS/Mapping technologies. From the standalone Google Earth application and simple KML functionalities to the Google Earth Plugin and Java Web Start/Applet on web platform, as well as to the rising open source GIS tools with new JavaScript frameworks, the Waypoint planning Tool has entered its third phase of technology advancement. The newly innovated, cross-platform, modular designed JavaScript-controled Waypoint tool is planned to be integrated with the NASA Airborne Science Mission Tool Suite. Adapting new technologies for the Waypoint Planning Tool ensures its success in helping scientist reach their mission objectives. This presentation will discuss the development process of the Waypoint Planning Tool in responding to field campaign challenges, identifying new information technologies, and describing the capabilities and features of the Waypoint Planning Tool with the real time aspect, interactive nature, and the resultant benefits to the airborne science community.

He, Yubin↗

Development of Waypoint Planning Tool in Response to NASA Field Campaign Challenges

Airborne real time observations are a major component of NASA's Earth Science research and satellite ground validation studies. For mission scientists, planning a research aircraft mission within the context of meeting the science objectives is a complex task because it requires real time situational awareness of the weather conditions that affect the aircraft track. Multiple aircrafts are often involved in NASA field campaigns. The coordination of the aircrafts with satellite overpasses, other airplanes and the constantly evolving, dynamic weather conditions often determines the success of the campaign. A flight planning tool is needed to provide situational awareness information to the mission scientists, and help them plan and modify the flight tracks. Scientists at the University of Alabama-Huntsville and the NASA Marshall Space Flight Center developed the Waypoint Planning Tool, an interactive software tool that enables scientists to develop their own flight plans (also known as waypoints) with point -and-click mouse capabilities on a digital map filled with real time raster and vector data. The development of this Waypoint Planning Tool demonstrates the significance of mission support in responding to the challenges presented during NASA field campaigns. Analysis during and after each campaign helped identify both issues and new requirements, and initiated the next wave of development. Currently the Waypoint Planning Tool has gone through three rounds of development and analysis processes. The development of this waypoint tool is directly affected by the technology advances on GIS/Mapping technologies. From the standalone Google Earth application and simple KML functionalities, to Google Earth Plugin and Java Web Start/Applet on web platform, and to the rising open source GIS tools with new JavaScript frameworks, the Waypoint Planning Tool has entered its third phase of technology advancement. The newly innovated, cross ]platform, modular designed JavaScript ]controlled Way Point Tool is planned to be integrated with NASA Airborne Science Mission Tool Suite. Adapting new technologies for the Waypoint Planning Tool ensures its success in helping scientists reach their mission objectives. This presentation will discuss the development processes of the Waypoint Planning Tool in responding to field campaign challenges, identify new information technologies, and describe the capabilities and features of the Waypoint Planning Tool with the real time aspect, interactive nature, and the resultant benefits to the airborne science community.

He, Matt↗

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗

Multi-Process Tooling

Decisions made early in the automotive design process influence material selection, which in turn dictates process selection and tool design. Because of tool build time and cost of tooling, the original path is not easily altered, even if there is compelling evidence that another material or process would be beneficial. This project focused on tool design that is agile enough to allow its use in multiple processes—injection, injection compression, and extrusion-compression. This tool design allows for the manufacture of components with the most efficient process or materials, without building multiple, single-process tools. The primary purpose of the Multi-Process Tool project was to physically demonstrate that a single, well-designed tool could be used to manufacture parts with a variety of materials that require different processes. A multi-process tool would be beneficial to providing data for any changes to the process since materials and processes can be interchanged without incurring additional tool cost(s). Battery tray parts, (representative of a multi-process tool, were successfully manufactured using various types of materials, such as fiber reinforced (carbon fiber and/or glass fibers, recycled carbon fibers), amorphous (PP, TPU), semi-crystalline (PA6, PA66), and crystalline (thermoset epoxy resin) polymers. Processing of the parts was achieved by injection molding, compression molding, compression overmolding, and injection overmolding. Specimens extracted from various locations on the battery tray parts were evaluated for mechanical properties (flexure and interlaminar shear strength properties). The results show that the tool can be used to produce parts from a wide range of materials and processes with no degradation of the physical or cosmetic properties.

42 ENGINEERING↗

Software Tools for Energy Storage Valuation and Design

Abstract Purpose of Review As the application space for energy storage systems (ESS) grows, it is crucial to valuate the technical and economic benefits of ESS deployments. Since there are many analytical tools in this space, this paper provides a review of these tools to help the audience find the proper tools for their energy storage analyses. Recent Findings There are many software tools for valuating ESS. These tools can be classified into two groups: (1) power system simulation and planning tools for analyzing the technical contributions of ESSs, and (2) techno-economic analysis tools for valuating the economic benefits of ESS deployment and specifying the optimal design of energy systems that include ESSs. While many of the tools, developed by the national laboratories, are free to use, the commercial tools are also of great importance in meeting the customers’ specific needs. Summary This paper provides a review of software tools for ESS valuation and design. A review of analysis tools for evaluating the technical impacts of energy storage deployments is also provided, as well as a discussion of development trends for valuation and design tools.

Nguyen, Tu A. (ORCID:0000000181148063)↗

A global assessment of policy tools to support climate adaptation

Governments, businesses, and civil society organizations have diverse policy tools to incentivize adaptation. Policy tools can shape the type and extent of adaptation, and therefore, function either as barriers or enablers for reducing risk and vulnerability. Using data from a systematic review of academic literature on global adaptation responses to climate change (n = 1549 peer-reviewed articles), we categorize the types of policy tools used to shape climate adaptation. We apply qualitative and quantitative analyses to assess the contexts where particular tools are used, along with equity implications for groups targeted by the tools, and the tools’ relationships with transformational adaptation indicators such as the depth, scope, and speed of adaptation. We find diverse types of tools documented across sectors and geographic regions. We also identify a mismatch between the tools that consider equity and those that yield more transformational adaptations. Direct regulations, plans, and capacity building are associated with higher depth and scope of adaptation (thus transformational adaptation), while economic instruments, information provisioning, and networks are not; the latter tools, however, are more likely to target marginalized groups in their design and implementation. We identify multiple research gaps, including a need to assess instrument mixes rather than single tools and to assess adaptations that result from policy implementation. Key policy insights Information-based approaches, networks, and economic instruments are the most frequently documented adaptation policy tools worldwide. Direct regulations, plans, and capacity building are associated with higher depth and scope of adaptation, and thus more transformational adaptation. Capacity building, economic instruments, networks, and information provisioning approaches are more likely to target specific marginalized groups and thus equity challenges. There are many regions and sectors where certain tools are not widely documented (e.g. regulations and plans in Africa and Asia), representing a key research gap.

54 ENVIRONMENTAL SCIENCES↗

Influence of Tool Runout on Force Measurement During Internal Void Monitoring for Friction Stir Welding of 6061-T6 Aluminum

Abstract The goal of this research was to examine how altering the amount of friction stir tool eccentricity while controlling the amount of slant in the tool shoulder (drivers of oscillatory process forces) effects the generation of process force transients during sub-surface void interaction. The knowledge gained will help improve the accuracy of force-based void monitoring methods that have the potential to reduce the need for post-weld inspection. Process force transients during sub-surface void formation were examined for multiple tools with varying magnitudes of kinematic runout. The eccentric motion of the tool produced oscillations in the process forces at the tools rotational frequency that became distorted when features (flats) on the tool probe interacted with voided volumes, generating an amplitude in the force signals at three times the tool rotational frequency (for three-flat tools). A larger tool eccentricity generates a larger amplitude in the force signals at the tool’s rotational frequency that holds a larger potential to create a distortion during void interaction. It was determined that once void becomes large enough to produce an interaction that generates an amplitude at the third harmonic larger than 30% of the amplitude at the rotational frequency in a weld with no interaction (amplitude solely at rotational frequency), the trailing edge of the tool shoulder cannot fully consolidate the void, i.e., it will remain in the final weld. Additionally, once the void exceeds a certain size, the amplitudes of the third harmonics saturate at 70% of the amplitude at the rotational frequency during full consolidation. The interaction between the eccentric probe and sub-surface void was isolated by ensuring any geometric imperfection in the shoulder (slant) with respect to the rotational axis was removed. The results suggest that geometric imperfections (eccentricity and slant) with respect to the tool’s rotational axis must be known when developing a void monitoring method from force transients of this nature.

Engineering↗

Core-Cutoff Tool

A tool makes a cut perpendicular to the cylindrical axis of a core hole at a predetermined depth to free the core at that depth. The tool does not damage the surrounding material from which the core was cut, and it operates within the core-hole kerf. Coring usually begins with use of a hole saw or a hollow cylindrical abrasive cutting tool to make an annular hole that leaves the core (sometimes called the plug ) in place. In this approach to coring as practiced heretofore, the core is removed forcibly in a manner chosen to shear the core, preferably at or near the greatest depth of the core hole. Unfortunately, such forcible removal often damages both the core and the surrounding material (see Figure 1). In an alternative prior approach, especially applicable to toxic or fragile material, a core is formed and freed by means of milling operations that generate much material waste. In contrast, the present tool eliminates the damage associated with the hole-saw approach and reduces the extent of milling operations (and, hence, reduces the waste) associated with the milling approach. The present tool (see Figure 2) includes an inner sleeve and an outer sleeve and resembles the hollow cylindrical tool used to cut the core hole. The sleeves are thin enough that this tool fits within the kerf of the core hole. The inner sleeve is attached to a shaft that, in turn, can be attached to a drill motor or handle for turning the tool. This tool also includes a cutting wire attached to the distal ends of both sleeves. The cutting wire is long enough that with sufficient relative rotation of the inner and outer sleeves, the wire can cut all the way to the center of the core. The tool is inserted in the kerf until its distal end is seated at the full depth. The inner sleeve is then turned. During turning, frictional drag on the outer core pulls the cutting wire into contact with the core. The cutting force of the wire against the core increases with the tension in the wire and, hence, with the frictional drag acting on the outer sleeve. As the wire cuts toward the center of the core, the inner sleeve rotates farther with respect to the outer sleeve. Once the wire has cut to the center of the core, the tool and the core can be removed from the hole. The proper choice of cutting wire depends on the properties of the core material. For a sufficiently soft core material, a nonmetallic monofilament can be used. For a rubber-like core material, a metal wire can be used. For a harder core material, it is necessary to use an abrasive wire, and the efficiency of the tool can be increased greatly by vacuuming away the particles generated during cutting. For a core material that can readily be melted or otherwise cut by use of heat, it could be preferable to use an electrically heated cutting wire. In such a case, electric current can be supplied to the cutting wire, from an electrically isolated source, via rotating contact rings mounted on the sleeves.

Gheen, Darrell↗

Users Guide for the Anvil Threat Corridor Forecast Tool V1.7.0 for AWIPS

The Applied Meteorology Unit (AMU) originally developed the Anvil Threat Sector Tool for the Meteorological Interactive Data Display System (MIDDS) and delivered the capability in three phases beginning with a feasibility study in 2000 and delivering the operational final product in December 2003. This tool is currently used operationally by the 45th Weather Squadron (45 WS) Launch Weather Officers (LWO) and Spaceflight Meteorology Group (SMG) forecasters. Phase I of the task established the technical feasibility of developing an objective, observations-based tool for short-range anvil forecasting. The AMU was subsequently tasked to develop short-term anvil forecasting tools to improve predictions of the threat of triggered lightning to space launch and landing vehicles. Under the Phase II effort, the AMU developed a nowcasting anvil threat sector tool, which provided the user with a threat sector based on the most current radiosonde upper wind data from a co-located or upstream station. The Phase II Anvil Threat Sector Tool computes the average wind speed and direction in the layer between 300 and 150 mb from the latest radiosonde for a user-designated station. The following threat sector properties are consistent with the propagation and lifetime characteristics of thunderstorm anvil clouds observed over Florida and its coastal waters (Short et al. 2002): a) 20 n mi standoff circle, b) 30 degree sector width, c) Orientation given by 300 to 150 mb average wind direction, d) 1-, 2-, and 3- hour arcs in upwind direction, and e) Arc distances given by 300 to 150 mb average wind speed. Figure 1 is an example of the MIDDS Anvil Threat Sector tool overlaid on a visible satellite image at 2132 UTC 13 May 2001. Space Launch Complex 39A was selected as the center point and the Anvil Threat Sector was determined from upper-level wind data at 1500 UTC in the preconvective environment. Narrow thunderstorm anvil clouds extend from central Florida to the space launch and landing facilities at the Kennedy Space Center (KSC) and Cape Canaveral Air Force Station (CCAFS) and beyond. The anvil clouds were generated around 1930 UTC (1430 EDT) by thunderstorm activity over central Florida and transported 90 n mi east-northeastward within 2 hours, as diagnosed by the anvil forecast tool. Phase III, delivered in February 2003, built upon the results of Phase II by enhancing the Anvil Threat Sector Tool with the capability to use national model forecast winds for depiction of potential anvil lengths and orientations over the KSC/CCAFS area with lead times from 3 through 168 hours (7 days). In September 2003, AMU customers requested the capability to use data from the KSC 50 MHz Doppler Radar Wind Profiler (DRWP) in the Anvil Threat Sector Tool and this capability was delivered by the AMU in December 2003. In March 2005, the AMU was tasked to migrate the MIDDS Anvil Threat Sector Tool capabilities onto the Advanced Weather Interactive Processing System (AWIPS) as the Anvil Threat Corridor Forecast Tool.

Bauman, William H., III↗

Space Launch System Liftoff and Separation Dynamics Analysis Tool Chain

A flexible, hierarchical tool chain that is being applied to NASA’s Space Launch System (SLS) for critical dynamics phenomena is described. This tool chain, called CLVTOPS, is used to investigate lateral liftoff movement of the vehicle as it departs and clears the mobile launch tower and separation of the two solid rocket boosters without collision with the core stage and payload. The toolset’s architecture was configured to take advantage of a modern software engineering approach for maximum flexibility and utilization of open-source simulations and associated tools. As opposed to a “monolithic” approach, scripting languages were used to “bind” together a tool chain to configure and organize input data, execute and produce analysis results, and post-process these results to facilitate a rapid, iterative analysis process to quickly address issues and pursue alternatives with emphasis on analysis automation. Key capabilities in the tool chain include processing and mining of very large data sets, a wide range of graphical depictions, and high-fidelity, physics-based simulations. The paper begins with a problem description and the motivation for liftoff and separation dynamics analysis followed by a historical survey of dynamics analyses for previous NASA human-rated launch vehicles. Details of the tool chain and its components are then introduced and divided, first, into description of the scripting language architecture used to “bind” the simulation tools, programs, and scripts together and, second, the physics models and simulations. Representative analyses and data products for liftoff and booster separation dynamics are shown in order to provide in-depth insight into the tool chain’s capabilities. Supporting activities such as simulation tool chain verification, version archiving and data management, and training are addressed. The paper concludes with case examples on how the tool chain can be tailored to related aerospace dynamics analyses, both large and small. The flexibility and versatility of this tool chain in supporting analyses of such a diverse range of aerospace applications demonstrates the feasibility of applying these patterns and techniques for tool construction to other aerospace simulations.

6DOF↗

Verification and Validation of START: A Spent Nuclear Fuel Routing and Decision Support Tool

The Stakeholder Tool for Assessing Radioactive Transportation (START) is a web-based geospatial decision-support tool being developed by the US Department of Energy’s Office of Integrated Waste Management (IWM) to support federal interim storage for spent nuclear fuel (SNF) and associated transportation. START provides many functions for the IWM program including: serving as a communications tool for conveying geospatial data and information, an options analysis tool for exploring potential transport modes and routes for transporting SNF from nuclear power plants to future federal interim storage facilities, an emergency response planning tool for Tribes and States to identify training needs along potential SNF transport corridors, an environmental analysis tool for estimating potential radiation dose exposure from incident-free and incident-case SNF transport conditions, and a systems analysis support tool providing route-related inputs for system throughput analysis. As part of the START development process, a verification and validation (V&V) effort is being undertaken. In the initial V&V phase, several outputs of the START tool were checked such as the total distance, population and population densities within the buffer zone, and incident free dose. The V&V process is fluid as it will be utilized after each version change to ensure that the core functionalities of the tool are maintained and the results are consistent with the previous versions. Efforts have also been put into developing scripts to aid in the process of automating certain sections of the V&V work. As some of the V&V efforts use Environmental Systems Research Institute’s (ESRI) tools upon which the START framework is built, the START data were compared against outputs from tools like Quantum Geographic Information System (QGIS) for buffer zone populations and route lengths to ensure independence of the V&V process. Good agreement was observed between the START results and the independent V&V studies with the majority of the differences falling between 1% and 5% for populations within the buffer zone and route distance. This presentation describes the development and design of the START tool, V&V methods employed for various metrics of interest and their respective results, and future plans.

START, transportation, GIS, V&V↗