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The development is presented of a tooling system that makes a controlled sinusoidal oscillation simulating a dynamic chip removal condition. It also measures the machining forces in two mutually perpendicular directions without any cross sensitivity.
Dynamic reproduction accuracy of machine tools with programmed control
Earth’s magnetosphere is continuously impacted by solar wind and interplanetary magnetic field (IMF) disturbances, such as shocks, discontinuities, magnetic clouds and more. Understanding how such disturbances propagate from the Sun and what is their impact on the different magnetospheric domains is key to understanding and forecasting energy transfer from the solar wind to Earth. The large number of overlapping solar wind and magnetospheric missions carrying magnetometers and the recent advances in communications and data storage technologies have enabled an unprecedented quantity of high-fidelity magnetic field data captured by in-situ spacecraft to be available at the click of a button. However, this massive quantity of available data can prove unwieldy for researchers, limiting the identification of interesting phenomena and disturbances to a relatively small percentage of the total dataset. Several techniques have been previously developed for automated identification of specific types of magnetic anomalies, but these methods are typically mission-specific and can be difficult to generalize. We present initial results for a generic method of automated anomaly detection in magnetic field measurements based on dimensionality reduction and unsupervised clustering via machine learning. The benefit of our technique is its high degree of generalizability and flexibility which make it a most useful data survey tool for a wide range of magnetic field datasets. This method can also be applied simultaneously to other observed time-series properties like plasma density, pressure, and velocity for more accurate event identification. Additionally, the application of this method to data captured by multiple spacecraft enables the simultaneous identification of disturbances and the determination of their propagation characteristics. Initial evaluation of this technique has been performed using data from Magnetospheric MultiScale (MMS) and THEMIS-ARTEMIS missions, providing a testbed scenario for the future Heliophysics Environmental and Radiation Measurement Experiment Suite (HERMES) platform instruments that will measure solar wind and IMF properties from lunar orbit onboard the Gateway station.
Earth’s magnetosphere is continuously impacted by solar wind and interplanetary magnetic field (IMF) disturbances, such as shocks, discontinuities, magnetic clouds and more. Understanding how such disturbances propagate from the Sun and what is their impact on the different magnetospheric domains is key to understanding and forecasting energy transfer from the solar wind to Earth. The large number of overlapping solar wind and magnetospheric missions carrying magnetometers and the recent advances in communications and data storage technologies have enabled an unprecedented quantity of high-fidelity magnetic field data captured by in-situ spacecraft to be available at the click of a button. However, this massive quantity of available data can prove unwieldy for researchers, limiting the identification of interesting phenomena and disturbances to a relatively small percentage of the total dataset. Several techniques have been previously developed for automated identification of specific types of magnetic anomalies, but these methods are typically mission-specific and can be difficult to generalize. We present initial results for a generic method of automated anomaly detection in magnetic field measurements based on dimensionality reduction and unsupervised clustering via machine learning. The benefit of our technique is its high degree of generalizability and flexibility which make it a most useful data survey tool for a wide range of magnetic field datasets. This method can also be applied simultaneously to other observed time-series properties like plasma density, pressure, and velocity for more accurate event identification. Additionally, the application of this method to data captured by multiple spacecraft enables the simultaneous identification of disturbances and the determination of their propagation characteristics. Initial evaluation of this technique has been performed using data from Magnetospheric MultiScale (MMS) and THEMIS-ARTEMIS missions, providing a testbed scenario for the future Heliophysics Environmental and Radiation Measurement Experiment Suite (HERMES) platform instruments that will measure solar wind and IMF properties from lunar orbit onboard the Gateway station.
Attempts were made to develop a dynamic metal working machine tool system using probability information on external factors and independent disturbances of the parameters. The problem was optimized in two stages: (1) creation of mathematical models under conditions determined by input influences, and (2) processing the results of calculations obtained on such models. Data were obtained on the patterns of distribution of dynamic quality characteristics of the tool, vibration frequencies and amplitudes, attenuation coefficients, and duration of a transition process. These data were obtained using a digital computer, statistical test methods, or logical possibility trees.
The alternate methods of conducting a man-machine interface evaluation are classified as static and dynamic, and are evaluated. A dynamic evaluation tool is presented to provide for a determination of the effectiveness of the man-machine interface in terms of the sequence of operations (task and task sequences) and in terms of the physical characteristics of the interface. This dynamic checklist approach is recommended for shuttle and shuttle payload man-machine interface evaluations based on reduced preparation time, reduced data, and increased sensitivity of critical problems.
In recent times, there has been a growing interest in resilience-based design. Resilience-based design operates on the concept that failures and unexpected events will happen, and when they occur, complex engineered systems should be able to operate within acceptable bounds and recover reasonably. Humans can contribute to the resilience of a system by quickly detecting unforeseen events and taking corrective measures. To this effect, researchers have proposed guidelines and design approaches that can help promote human-system resilience. However, there is no early design stage tool to validate if a system is indeed resilient after applying these guidelines and design methods. In this research, we integrate the Human Error and Functional Failure Reasoning (HEFFR) framework into the fmdtools toolkit to enable designers to model the combined (machine, human, and joint) failures, including their propagation and dynamic effects, during early design stages. This integrated tool also allows designers to model the effects of performance shaping factors, team dynamics, and human-machine interactions in systems of systems. A demonstrative example of a remotely operated rover is explored to demonstrate how this approach can be applied to understand resilience in complex engineered systems with human interactions.
Probabilistic risk assessment (PRA) is a method for assessing and integrating the risk of failure in a multivariate system. While it is often applied by engineers designing complex machines, it could also be applied to humans to assess the probability of a health “failure” treating diseases as the multiple “variables” and the human as the “complex machine.” The Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) was developed to apply PRA to assess medical risk for exploration spaceflight and inform the design of medical systems for space flight. The NASA engineering community utilizes event-driven and fault tree probabilistic techniques to classify risk in the space flight environment by leveraging the inherent knowledge of complex space flight system design and testing to quantify risk. However, in harmonizing the risk of human space flight, answering the question of “How do we balance astronaut health, performance and resource risks with other engineering risks on exploration space missions?” remains a profoundly challenging and largely qualitative practice. The Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) is one aspect of the Human Research Program’s efforts to represent space fight human health and performance risks quantitatively.
Reactive molecular dynamics (MD) is a powerful tool for atomistic-scale modeling of a diverse range of chemical processes. However, scaling these simulations to large systems and long times scales remains a challenge because of the complexity of the potential energy function required. The authors previously developed a heuristic approach, called REACTER, that incorporates reactivity in MD simulations in a less general but much more computationally efficient manner. REACTER uses standard, fixed valence force fields as the underlying potentialenergy surface for describing all interatomic interactions but adds a procedure for enforcing user-defined reactions that occur when certain geometric constraints on relative atomic positions are satisfied. Further, these bonding changes can be accepted or rejected with a probability related tothe local thermal energy. This work seeks to generalize this approach by replacing the set of user defined geometric constraints and energetic criteria with a committor function that specifies the probability of a reaction occurring on the basis of the local atomic configuration. The committor function is a useful mathematical tool for modeling rare events but, unfortunately, is very difficult to compute for realistic systems in a general way. This work describes a method for approximating the committor function using a machine learning approach, specifically a deep neural network trained with data from reactive MD and DFT-based dynamics simulations. This network is coupled to the existing REACTER protocol, as implemented in the LAMMPS MD package, and used to make on-the-fly predictions of reaction probabilities without the more extensive user input previously required. The new method is demonstrated using the polymerization of polystyrene as a case study. Although very dependent on the quality and quantity of training data, machine-learned committor functions show promise as a method for incorporating reaction probability from higher level calculations into highly scalable MD simulations.
The IVTS is a large software system designed to support user-controlled verification analysis and testing activities for programs written in the HAL/S language. The system is composed of a user interface and user command language, analysis tools and an organized data base of host system files. The analysis tools are of four major types: (1) static analysis, (2) symbolic execution, (3) dynamic analysis (testing), and (4) documentation enhancement. The IVTS requires a split HAL/S compiler, divided at the natural separation point between the parser/lexical analyzer phase and the target machine code generator phase. The IVTS uses the internal program form (HALMAT) between these two phases as primary input for the analysis tools. The dynamic analysis component requires some way to 'execute' the object HAL/S program. The execution medium may be an interpretive simulation or an actual host or target machine.
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.
Study suggests ways of reducing chatte, increasing productivity, and reducing tool wear. Report also describes static and dynamic cutting tests and tool materials and finishes.
Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.
Mesh adaption is a powerful tool for efficient unstructured-grid computations but causes load imbalance among processors on a parallel machine. A dynamic load balancing method is presented that balances the workload across all processors with a global view. After each parallel tetrahedral mesh adaption, the method first determines if the new mesh is sufficiently unbalanced to warrant a repartitioning. If so, the adapted mesh is repartitioned, with new partitions assigned to processors so that the redistribution cost is minimized. The new partitions are accepted only if the remapping cost is compensated by the improved load balance. Results indicate that this strategy is effective for large-scale scientific computations on distributed-memory multiprocessors.
As automation and advanced technologies are introduced into transport systems ranging from the Next Generation Air Transportation System termed NextGen, to the advanced surface transportation systems as exemplified by the Intelligent Transportations Systems, to future systems designed for space exploration, there is an increased need to validly predict how the future systems will be vulnerable to error given the demands imposed by the assistive technologies. One formalized approach to study the impact of assistive technologies on the human operator in a safe and non-obtrusive manner is through the use of human performance models (HPMs). HPMs play an integral role when complex human-system designs are proposed, developed, and tested. One HPM tool termed the Man-machine Integration Design and Analysis System (MIDAS) is a NASA Ames Research Center HPM software tool that has been applied to predict human-system performance in various domains since 1986. MIDAS is a dynamic, integrated HPM and simulation environment that facilitates the design, visualization, and computational evaluation of complex man-machine system concepts in simulated operational environments. The paper will discuss a range of aviation specific applications including an approach used to model human error for NASA s Aviation Safety Program, and what-if analyses to evaluate flight deck technologies for NextGen operations. This chapter will culminate by raising two challenges for the field of predictive HPMs for complex human-system designs that evaluate assistive technologies: that of (1) model transparency and (2) model validation.
This paper presents a methodology for debugging the performance of message-passing programs on both tightly coupled and loosely coupled distributed-memory machines. The AIMS (Automated Instrumentation and Monitoring System) toolkit, a suite of software tools for measurement and analysis of performance, is introduced and its application illustrated using several benchmark programs drawn from the field of computational fluid dynamics. AIMS includes (i) Xinstrument, a powerful source-code instrumentor, which supports both Fortran77 and C as well as a number of different message-passing libraries including Intel's NX Thinking Machines' CMMD, and PVM; (ii) Monitor, a library of timestamping and trace -collection routines that run on supercomputers (such as Intel's iPSC/860, Delta, and Paragon and Thinking Machines' CM5) as well as on networks of workstations (including Convex Cluster and SparcStations connected by a LAN); (iii) Visualization Kernel, a trace-animation facility that supports source-code clickback, simultaneous visualization of computation and communication patterns, as well as analysis of data movements; (iv) Statistics Kernel, an advanced profiling facility, that associates a variety of performance data with various syntactic components of a parallel program; (v) Index Kernel, a diagnostic tool that helps pinpoint performance bottlenecks through the use of abstract indices; (vi) Modeling Kernel, a facility for automated modeling of message-passing programs that supports both simulation -based and analytical approaches to performance prediction and scalability analysis; (vii) Intrusion Compensator, a utility for recovering true performance from observed performance by removing the overheads of monitoring and their effects on the communication pattern of the program; and (viii) Compatibility Tools, that convert AIMS-generated traces into formats used by other performance-visualization tools, such as ParaGraph, Pablo, and certain AVS/Explorer modules.
Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.