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Precise recesses in fragile metal honeycomb blocks formed in special electrical-discharge machining process. Special tooling used, and recesses bored with workpiece in nonstandard alignment. Cutting electrode advances into workpiece along x axis to form pocket of rectangular cross section. Deionized water flows from fitting, along honeycomb tubes of workpiece, to electrode/workpiece interface.
For commercial, military, and aerospace applications, low-cost, small, reliable, and lightweight gas and liquid hermetically sealed valves with post initiation on/off capability are highly desirable for pressurized systems. Applications include remote fire suppression, single-use system-pressurization systems, spacecraft propellant systems, and in situ instruments. Current pyrotechnic- activated rupture disk hermetic valves were designed for physically larger systems and are heavy and integrate poorly with portable equipment, aircraft, and small spacecraft and instrument systems. Additionally, current pyrotechnically activated systems impart high g-force shock loads to surrounding components and structures, which increase the risk of damage and can require additional mitigation. The disclosed mechanism addresses the need for producing a hermetically sealed micro-isolation valve for low and high pressure for commercial, aerospace, and spacecraft applications. High-precision electrical discharge machining (EDM) parts allow for the machining of mated parts with gaps less than a thousandth of an inch. These high-precision parts are used to support against pressure and extrusion, a thin hermetically welded diaphragm. This diaphragm ruptures from a pressure differential when the support is removed and/or when the plunger is forced against the diaphragm. With the addition of conventional seals to the plunger and a two-way actuator, a derivative of this design would allow nonhermetic use as an on/off or metering valve after the initial rupturing of the hermetic sealing disk. In addition, in a single-use hermetically sealed isolation valve, the valve can be activated without the use of potential leak-inducing valve body penetrations. One implementation of this technology is a high-pressure, high-flow-rate rupture valve that is self-rupturing, which is advantageous for high-pressure applications such as gas isolation valves. Once initiated, this technology is self-energizing and requires low force compared to current pyrotechnic-based burst disk hermetic valves. This is a novel design for producing a single-use, self-rupturing, hermetically sealed valve for isolation of pressurized gas and/or liquids. This design can also be applied for single-use disposable valves for chemical instruments. A welded foil diaphragm is fully supported by two mated surfaces that are machined to micron accuracies using EDM. To open the valve, one of the surfaces is moved relative to the other to (a) remove the support creating an unsupported diaphragm that ruptures due to over pressure, and/or (b) produce tension in the diaphragm and rupture it.
NASA Lewis Research Center's Life Prediction Branch, in partnership with Sonix, Inc., and Cleveland State University, recently advanced the development of, refined, and commercialized an advanced nondestructive evaluation (NDE) inspection method entitled the Single Transducer Thickness-Independent Ultrasonic Imaging Method. Selected by R&D Magazine as one of the 100 most technologically significant new products of 1996, the method uses a single transducer to eliminate the superimposing effects of thickness variation in the ultrasonic images of materials. As a result, any variation seen in the image is due solely to microstructural variation. This nondestructive method precisely and accurately characterizes material gradients (pore fraction, density, or chemical) that affect the uniformity of a material's physical performance (mechanical, thermal, or electrical). Advantages of the method over conventional ultrasonic imaging include (1) elimination of machining costs (for precision thickness control) during the quality control stages of material processing and development and (2) elimination of labor costs and subjectivity involved in further image processing and image interpretation. At NASA Lewis, the method has been used primarily for accurate inspections of high temperature structural materials including monolithic ceramics, metal matrix composites, and polymer matrix composites. Data were published this year for platelike samples, and current research is focusing on applying the method to tubular components. The initial publicity regarding the development of the method generated 150 requests for further information from a wide variety of institutions and individuals including the Federal Bureau of Investigation (FBI), Lockheed Martin Corporation, Rockwell International, Hewlett Packard Company, and Procter & Gamble Company. In addition, NASA has been solicited by the 3M Company and Allison Abrasives to use this method to inspect composite materials that are manufactured by these companies.
Portable routing machine for cutting precise weld joints required by nonstandard pipe sections used in the field for transfer of cryogenic fluids. This tool is adaptable for various sizes of pipes and has a selection of router bits for different joint configurations.
Improved scarfing tool consists of a mount-table, roller-guided assembly. It converts a conventional routing machine for relatively precise field preparation of pipes for welding.
A hot wire anemometer probe is described that includes a ceramic body supporting two conductive rods parallel to each other. The body has a narrow edge surface from which the rods protrude. A probe wire is welded to the rods and extends along the edge surface. A ceramic adhesive is used to secure the probe wire to the surface so that the probe wire is rigid. A method for fabricating the probe is also described in which the body is molded and precisely shaped by machining techniques before the probe wires are installed.
The effects caused by reflector surface pillows and aperture cables on RF performance were determined. The test uses models that were designed to be replicas of a quad aperture at the proper F/D = 1.50 as provided in the LSST point design. Separate pillow models were machined from solid aluminum sections that simulated the surface contour pillows but on an exaggerated basis. The worse case pillow heights lamda/20 and lamda/5 were machined onto the precision reflector. In addition to the pillow effects, the scattering effects of aperture (Hoop/Column cables) cables were determined. Therefore, simulated quartz and graphite cables were tested with the smooth, lamda/20, and lamda/5 reflector models.
Rolling element bearings are a precision, yet simple, machine element of great utility. A brief history of rolling element bearings is reviewed and the type of rolling element bearings, their geometry and kinematics, as well as the materials they are made from and the manufacturing processes they involve are described. Unloaded and unlubricated rolling element bearings, loaded but unlubricated rolling element bearings and loaded and lubricated rolling element bearings are considered. The recognition and understanding of elastohydrodynamic lubrication covered, represents one of the major development in rolling element bearings.
This article describes a single transducer ultrasonic imaging method that eliminates the effect of plate thickness variation in the image. The method thus isolates ultrasonic variations due to material microstructure. The use of this method can result in significant cost savings because the ultrasonic image can be interpreted correctly without the need for machining to achieve precise thickness uniformity during nondestructive evaluations of material development. The method is based on measurement of ultrasonic velocity. Images obtained using the thickness-independent methodology are compared with conventional velocity and c-scan echo peak amplitude images for monolithic ceramic (silicon nitride), metal matrix composite and polymer matrix composite materials. It was found that the thickness-independent ultrasonic images reveal and quantify correctly areas of global microstructural (pore and fiber volume fraction) variation due to the elimination of thickness effects. The thickness-independent ultrasonic imaging method described in this article is currently being commercialized under a cooperative agreement between NASA Lewis Research Center and Sonix, Inc.
We present the metrology requirements and metrology implementation necessary to prove out the reflector technology for the Constellation X(C-X) spectroscopy X-ray telescope (SXT). This segmented, 1.6m diameter highly nested Wolter-1 telescope presents many metrology and alignment challenges. In particular, these mirrors have a stringent imaging error budget as compared to their intrinsic stiffness; This is required for Constellation-X to have sufficient effective area with the weight requirement. This has implications for the metrology that can be used. A variety of contract and noncontact optical profiling and interferometric methods are combined to test the formed glass substrates before replication and the replicated reflector segments.The reflectors are tested both stand-alone and in-situ in an alignment tower.Some of these methods have not been used on prior X-ray telescopes and some are feasible only because of the segmented approach used on the SXT. Methods discussed include high precision coordinate measurement machines using very low force or optical probe axial interferometric profiling azimuthal circularity profiling and use of advanced null optics such as conical computer generated hologram (CGHs).
A proposed inchworm actuator, to be designed and fabricated according to the principles of microelectromechanical systems (MEMS), would effect linear motion characterized by steps as small as nanometers and an overall range of travel of hundreds of microns. Potential applications for actuators like this one include precise positioning of optical components and active suppression of noise and vibration in scientific instruments, conveyance of wafers in the semiconductor industry, precise positioning for machine tools, and positioning and actuation of micro-surgical instruments. The inchworm motion would be generated by a combination of piezoelectric driving and electrostatic clamping. The actuator (see figure), would include a pair of holders (used for electrostatic clamping), a slider (the part that would engage in the desired linear motion), a driver, a piezoelectric stack under the driver, and a pair of polymer beams centrally clamped to the flexure beam via a T bar. The holders would be held stationary. One end of the piezoelectric stack would be held stationary; the other end would be connected to the bottom of the driver, which would be free to move up and down. All of these components except the piezoelectric stack and the polymer beams would be micromachined from a 500- m-thick silicon wafer by deep reactive-ion etching. The inchworm motion would be perpendicular to the broad faces of the wafer (perpendicular to the plane of the figure). The combination of the polymer beams and the centrally clamped flexure beam would spring-bias the slider into a position such that, in the absence of electrostatic clamping, the gap between the slider on the one hand and both the driver and the holder on the other hand would be no more than a few microns. This arrangement would make it possible to electrostatically pull the slider into contact with either the holders or the driver at a clamping force of the order of 1 N by applying a reasonably small voltage (of the order of 100 V).
INTRODUCTION: Renal stones are thought to be a risk for spaceflight due to urine chemistry changes, induced by microgravity. Asymptomatic stone can have significant medical and mission impact.For9 years astronauts travelling to the International Space Station (ISS) have received pre-and post-flight renal ultrasound, according to a specialized renal ultrasound protocol, to look for renal calcifications or mineralized renal material (MRM).A new ultrasound machine was put in service halfway through the screening program. METHODS: MRM screening data from pre-and post-flight were compared, to look for changes in MRM burden. Pre-and post-flight scans from 42 subjects were compared. Studies were further stratified by old versus new machine. Measures were modeled using the analysis of variance (ANOVA) as defined by the interaction between pre-to postflight, and machine-to-machine. RESULTS: There was no observed statistical change seen in MRM burden pre-to postflight using the new higher-resolution ultrasound machine. DISCUSSION: The new machine gives more precise measurements and allows us to differentiate MRMs from other bright objects seen on ultrasound, such as small blood vessels. These data imply that spaceflight does not increase the risk of renal stone formation, at least out to the length of ISS missions. This data will be used to update NASA’s Human System Risk Board’s risk tracking documents, in-flight Concept of Operations, and our Clinical Practice Guideline.
Advances in optical testing are as important as advances in optical fabrication, because one can make only what one can measure, particularly for unconventional prescriptions, like aspheric and freeform optics. A new, high-precision metrology capability is utilized to close the gap between interferometric testing and lower precision, contact-probe-based coordinate measuring machines or laser tracker/radar metrology to accurately measure surfaces with large figure error. This nearly universal optical testing method employs an ultra-precision coordinate measuring machine equipped with a non-contact probe. It was developed to characterize a broad spectrum of optical surfaces including ones with high slopes, impossible to measure using traditional interferometric testing. Optical components, covering a wide range of prescriptions, such as large convex conics, high-sloped aspherics, grazing-incidence x-ray optics, and highly deformed flats, were successfully measured. The resulting data were reduced using custom-developed routines to determine the optic’s alignment, surface departure from design, and the as-built optical prescription. This information guided the fabrication and modeling of these optical components
A first end surface of a coiled compression spring at its relaxed length is machined to a plane transverse to the spring axis. The spring is then placed in a press structure having first and second opposed planar support surfaces, with the machined spring end surface bearing against the first support surface, the unmachined spring end surface bearing against a planar first surface of a lateral force compensation member, and an opposite, generally spherically curved surface of the compensation member bearing against the second press structure support surface. The spring is then compressed generally to its loaded length, and a circumferentially spaced series of marks, lying in a plane parallel to the second press structure support surface, are formed on the spring coil on which the second spring end surface lies. The spring is then removed from the press structure, and the second spring end surface is machined to the mark plane. When the spring is subsequently compressed to its loaded length the precisely parallel relationship between the machined spring end surfaces substantially eliminates undesirable lateral deflection of the spring.
A first end surface of a coiled compression spring at its relaxed length is machined to a plane transverse to the spring axis. The spring is then placed in a press structure having first and second opposed planar support surfaces, with the machined spring end surface bearing against the first support surface, the unmachined spring end surface bearing against a planar first surface of a lateral force compensation member, and an opposite, generally spherically curved surface of the compensation member bearing against the second press structure support surface. The spring is then compressed generally to its loaded length, and a circumferentially spaced series of marks, lying in a plane parallel to the second press structure support surface, are formed on the spring coil on which the second spring end surface lies. The spring is then removed from the press structure, and the second spring end surface is machined to the mark plane. When the spring is subsequently compressed to its loaded length the precisely parallel relationship between the machined spring end surfaces substantially eliminates undesirable lateral deflection of the spring.
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.
Technology handbook for machinists, mechanics, and technicians - shock absorbers and protective devices, machining, metal forming, welding and brazing, and precision tools
A low accuracy in the force calculation per time step of a few percent for each particle pair is sufficient for collisionless N-body simulations. Higher accuracy is made meaningless by the dominant discreteness noise in the form of two-body relaxation, which can be reduced only by increasing the number of particles. Since an N-body simulation is a Monte Carlo procedure in which each particle-particle force is essentially random, i.e., carries an error of about 1000 percent, the only requirement is a systematic averaging-out of these intrinsic errors. We illustrate these assertions with two specific examples in which individual pairwise forces are deliberately allowed to carry significant errors: tree-codes on supercomputers and algorithms on special-purpose machines with low-precision hardware.