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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Integration of discrete-event dynamics and machining dynamics for machine tool: Modeling, analysis and algorithms

Machining dynamics research lays a solid foundation for machining operations by providing stable combinations of spindle speed and depth of cut. Furthermore, machine learning has been applied to predict tool life as a function of cutting speed. However, the existing research does not consider the discrete-event dynamics in machine shop, i.e., the machine tool needs to process a series of parts in queue under various practical production requirements. This paper addresses the integration of discrete-event dynamics and machining dynamics to achieve cost savings in machining. A learning-based cost function is first proposed for the studied integrated optimization problem of machine tool. The proposed cost function utilizes the predicted tool life under different stable cutting speeds for further optimizing speed selection of machine tool to deal with the discrete-event dynamics in machine shop. Then, according to the practical production requirements, effective mathematical optimization models are developed for the related integrated optimization problems with the consideration of cost, makespan and due date, respectively. Numerical results show the effectiveness of our proposed methods and also the potential to be used in practice.

Ma, Mason↗
DOE OSTI2020

A Generic Advanced Computing Framework for Executing Windows-based Dynamic Contingency Analysis Tool in Parallel on Cluster Machines

Dynamic contingency analysis tool (DCAT) has been developed to assess the impact and likelihood of extreme contingencies and potential cascading events across their systems and interconnections. By including more customized protection models and corrective actions into the Windows-based commercial tools, DCAT can help operators understand the cascading behavior and find mitigation approaches to reduce the risk of cascading outages in a more realistic manner. In order to further enhance the capability of DCAT, this paper presents a design of an advanced computing framework that enables DCAT to run on a cluster machine to improve its computational performance. This framework is generic and can be applied to other Windows-based simulation tools to fill the technical gap of applying advanced computing technology to vendors' Windows-based tools. The preliminary tests using medium to large power systems have shown the effectiveness of this framework and its potential for accelerating the adoption of advanced computing in utilities.

Advanced computing, dynamic contingency analysis, ↗
DOE OSTI2024

Process damping identification using Bayesian learning and time domain simulation

Process damping can provide improved machining productivity by increasing the stability limit at low spindle speeds. However, existing methods for identifying process damping models experimentally require specialized setups and/or multiple cutting tests. While the phenomenon is well known, the modeling challenges limit pre-process parameter selection that leverages the potential increases in material removal rates. This paper proposes a physics-informed Bayesian method that can identify the cutting force and process damping models from a limited set of test cuts without requiring direct measurements of cutting force or vibration. The method uses time domain simulation to incorporate process damping and provide a basis for test selection. Here, new strategies for efficient sampling and dimensionality reduction are applied to lower computation time and minimize the effect of model error. The proposed method is demonstrated and the identified cutting and damping force coefficients are compared to values obtained using machining tests and least-squares fitting.

42 ENGINEERING↗
DOE OSTI2020

Chatter Stability of Machining Operations

Here, this paper reviews the dynamics of machining and chatter stability research since the first stability laws were introduced by Tlusty and Tobias in the 1950s. The paper aims to introduce the fundamentals of dynamic machining and chatter stability, as well as the state of the art and research challenges, to readers who are new to the area. First, the unified dynamic models of mode coupling and regenerative chatter are introduced. The chatter stability laws in both the frequency and time domains are presented. The dynamic models of intermittent cutting, such as milling, are presented and their stability solutions are derived by considering the time-periodic behavior. The complexities contributed by highly intermittent cutting, which leads to additional stability pockets, and the contribution of the tool's flank face to process damping are explained. The stability of parallel machining operations is explained. The design of variable pitch and serrated cutting tools to suppress chatter is presented. The paper concludes with current challenges in chatter stability of machining which remains to be the main obstacle in increasing the productivity and quality of manufactured parts.

42 ENGINEERING↗
DOE OSTI2021

Rethinking production of machine tool bases: Polymer additive manufacturing and concrete

Cast iron and steel weldments are the most common machine tool base elements. However, both construction methods have associated disadvantages for domestic machine tool manufacturers. Here, this paper documents the investigation of an alternative method for machine tool base production using concrete to fill an additively manufactured polymer mold, where the motion components are attached to the concrete base after the initial concrete curing. Modal testing results for a three-axis, vertical spindle prototype indicate high damping and stiffness can be achieved using the concrete base construction. Advantages are reduced cost and lead time compared to traditional methods.

Additive manufacturing↗
DOE OSTI2020

Data-Driven Security Assessment of Power Grids Based on Machine Learning Approach: Preprint

Data-driven security assessment provides key indicators on power system stability using simulations on scheduling models, as opposed to dynamic simulations that are more time-consuming. This paper investigates data-driven security assessment of power grids based on machine learning. Multivariate random forest regression is used as the machine learning algorithm due to its high robustness to the input data. Three stability issues are analyzed using the proposed machine learning tool, including transient stability, frequency stability and small signal stability. The estimation values from machine learning tool are compared with those from dynamic simulations. Results show that the proposed machine learning tool can effectively predict the stability margins for the three stability metrics.

14 SOLAR ENERGY↗
DOE OSTI2022

Multi-tool optimization for computer controlled optical surfacing

With the rapid development of precision technologies, the demand of high-precision optical surfaces has drastically increased. These optical surfaces are mainly fabricated with computer controlled optical surfacing (CCOS). In a CCOS process, a target surface removal profile is achieved by scheduling the dwell time for a set of machine tools. The optimized dwell time should be positive and smooth to ensure convergence to the target while considering CNC dynamics. The total run time of each machine tool is also expected to be balanced to improve the overall processing efficiency. In the past few decades, dwell time optimization for a single machine tool has been extensively developed. While the methods are applicable to multi-tool scenarios, they fail to consider the overall contributions of multiple tools simultaneously. In this paper, we conduct a systematic study on the strategies for multi-tool dwell time optimization and propose an innovative method for simultaneously scheduling dwell time for multiple tools for the first time. First, the influential factors to the positiveness and smoothness of dwell time solutions for a single machine tool are analyzed. The compensation strategies that minimize the residual while considering the CNC dynamics limit are then proposed. Afterwards, these strategies are extended to the proposed multi-tool optimization that further balances the run time of machine tools. Finally, the superiority of each strategy is carefully studied via simulation and experiment. The experiment is performed by bonnet polishing a 60 mm × 60 mm mirror with three tools of different diameters ( i.e., 12 mm, 8 mm, and 5 mm). The figure error of the mirror is reduced from 45.42 nm to 11.18 nm root mean square in 13.28 min. Moreover, the measured polishing result well coincides with the estimation, which proves the effectiveness of the proposed method.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A Prediction Method for Catchment Efficiency Loss due to Coaxial Nozzle Wear in Powder Fed Directed Energy Deposition Systems

Abstract Powder fed laser directed energy deposition systems show significant promise and their widespread adoption could greatly advance manufacturing technology; however, a significant amount of gas atomized metal powder is wasted during material deposition. As contaminated powder must be collected and disposed of as hazardous waste, this process is often criticized for its low catchment efficiency. This presents potential implementation and scaling issues, as widespread use of this technology would directly increase the amount of contaminated powder in need of safe disposal. A direct contribution to this waste issue was identified in past work as wearing exterior and interior surfaces on a replaceable nozzle component within the additive head of such a system integrated into a hybrid manufacturing machine tool. A computational fluid dynamics simulation is developed specifically for use within the manufacturing process by predicting catchment efficiency losses before a deposition operation is performed. The model is robust enough to calculate a catchment efficiency estimate within a reasonable transition time before deposition and is designed to replace visual estimation of nozzle deterioration by the machine operator. Both of two previously identified wear modes are represented in the simulation. Their effects on powder stream geometry are discussed in detail and the results are compared with in-situ measurements of powder stream geometry and concentrations. The resulting work contributes to the growing understanding of using prediction and prevention methods on catchment efficiency related part defects within these systems.

DeWitte, Lisa↗
DOE OSTI2022

Autodifferentiable Ensemble Kalman Filters

Data assimilation is concerned with sequentially estimating a temporally evolving state. This task, which arises in a wide range of scientific and engineering applications, is particularly challenging when the state is high-dimensional and the state-space dynamics are unknown. This paper introduces a machine learning framework for learning dynamical systems in data assimilation. Here, our auto-differentiable ensemble Kalman filters (AD-EnKFs) blend ensemble Kalman filters for state recovery with machine learning tools for learning the dynamics. In doing so, AD-EnKFs leverage the ability of ensemble Kalman filters to scale to high-dimensional states and the power of automatic differentiation to train high-dimensional surrogate models for the dynamics. Numerical results using the Lorenz-96 model show that AD-EnKFs outperform existing methods that use expectation-maximization or particle filters to merge data assimilation and machine learning. In addition, AD-EnKFs are easy to implement and require minimal tuning.

autodifferentiation↗
DOE OSTI2023

Computer-controlled finishing via dynamically constraint position-velocity-time scheduler

In a Computer Numerical Controlled (CNC) finishing process, the target material removal from an optical surface is guided by the convolution between the influence function of a machine tool and its dwell time at certain points over the surface. To reduce dynamics stressing and increase machining efficiency, the dwell time must be converted to varying velocities, which are the actual inputs to the machine tool controller. Conventionally, the conversion assumed constant acceleration and relied on linear motion interpolation, which caused discontinuities in velocities. This unsmooth motion affects the material removal distribution, and, thus, the accuracy of the finished surface shape. Many modern CNC machines support the smoother, cubic-polynomial interpolated Position-Velocity-Time (PVT) motion mode; however, the conventional scheduler may fail to provide suitable velocities for the PVT. Here in this study answers this challenge by proposing a novel PVT-based velocity scheduler that achieves smooth motion while considering CNC dynamic limits. Firstly, the principle of the PVT is explained, and the PVT-based velocity scheduler is formulated. Secondly, a quadratic programming is used to optimize the velocities by imposing the CNC dynamic constraints and the C 1 continuities (zeroth and first derivatives are continuous) simultaneously. Thirdly, the smoothness and accuracy of the scheduled velocities are studied on different kinds of tool paths via simulation. Finally, a sub-0.3 nm level surface finishing experiment using ion beam figuring is demonstrated to verify the feasibility of the proposed method. The PVT-based scheduler and simulator code is open-sourced.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Linac_Gen: Integrating Machine Learning and Particle-in-Cell Methods for Enhanced Beam Dynamics at Fermilab

Here, we introduce Linac_Gen, a tool developed at Fermilab, which combines machine learning algorithms with Particle-in-Cell methods to advance beam dynamics in linacs. Linac_Gen employs techniques such as Random Forest, Genetic Algorithms, Support Vector Machines, and Neural Networks, achieving a tenfold increase in speed for phase-space matching in Linacs over traditional methods, through the use of genetic algorithms. Crucially, Linac_Gen's adept handling of 3D field maps elevates the precision and realism in simulating beam instabilities and resonances, marking a key advancement in the field. Benchmarked against established codes, Linac_Gen demonstrates not only improved efficiency and precision in beam dynamics studies but also in the design and optimization of Linac systems, as evidenced in its application to Fermilab's PIP-II Linac project. This work represents a notable advancement in accelerator physics, marrying ML with PIC methods to set new standards for efficiency and accuracy in accelerator design and research. Linac_Gen exemplifies a novel approach in accelerator technology, offering substantial improvements in both theoretical and practical aspects of beam dynamics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Linac_Gen: integrating machine learning and particle-in-cell methods for enhanced beam dynamics at Fermilab

Here, we introduce Linac_Gen, a tool developed at Fermilab, which combines machine learning algorithms with Particle-in-Cell methods to advance beam dynamics in linacs. Linac_Gen employs techniques such as Random Forest, Genetic Algorithms, Support Vector Machines, and Neural Networks, achieving a tenfold increase in speed for phase-space matching in linacs over traditional methods through the use of genetic algorithms. Crucially, Linac_Gen's adept handling of 3D field maps elevates the precision and realism in simulating beam instabilities and resonances, marking a key advancement in the field. Benchmarked against established codes, Linac_Gen demonstrates not only improved efficiency and precision in beam dynamics studies but also in the design and optimization of linac systems, as evidenced in its application to Fermilab's PIP-II linac project. This work represents a notable advancement in accelerator physics, marrying ML with PIC methods to set new standards for efficiency and accuracy in accelerator design and research. Linac_Gen exemplifies a novel approach in accelerator technology, offering substantial improvements in both theoretical and practical aspects of beam dynamics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

The Rise of Neural Networks for Materials and Chemical Dynamics

Machine learning (ML) is quickly becoming a premier tool for modeling chemical processes and materials. ML-based force fields, trained on large data sets of high-quality electron structure calculations, are particularly attractive due their unique combination of computational efficiency and physical accuracy. This Perspective summarizes some recent advances in the development of neural network-based interatomic potentials. Designing high-quality training data sets is crucial to overall model accuracy. One strategy is active learning, in which new data are automatically collected for atomic configurations that produce large ML uncertainties. Another strategy is to use the highest levels of quantum theory possible. Transfer learning allows training to a data set of mixed fidelity. A model initially trained to a large data set of density functional theory calculations can be significantly improved by retraining to a relatively small data set of expensive coupled cluster theory calculations. These advances are exemplified by applications to molecules and materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

The development of thermodynamically consistent and physics-informed equation-of-state model through machine learning

Ab initio molecular dynamics (AIMD) simulations have become an important tool used in the construction of equations of state (EOS) tables for warm dense matter. Due to computational costs, only a limited number of system state conditions can be simulated, and the remaining EOS surface must be interpolated for use in radiation-hydrodynamic simulations of experiments. In this work, we develop a thermodynamically consistent EOS model that utilizes a physics-informed machine learning approach to implicitly learn the underlying Helmholtz free-energy from AIMD generated energies and pressures. The model, referred to as PIML-EOS, was trained and tested on warm dense polystyrene producing a fit within a 1% relative error for both energy and pressure and is shown to satisfy both the Maxwell and Gibbs–Duhem relations. In addition, we provide a path toward obtaining thermodynamic quantities, such as the total entropy and chemical potential (containing both ionic and electronic contributions), which are not available from current AIMD simulations.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2023

Ultra-fast interpretable machine-learning potentials

Abstract All-atom dynamics simulations are an indispensable quantitative tool in physics, chemistry, and materials science, but large systems and long simulation times remain challenging due to the trade-off between computational efficiency and predictive accuracy. To address this challenge, we combine effective two- and three-body potentials in a cubic B-spline basis with regularized linear regression to obtain machine-learning potentials that are physically interpretable, sufficiently accurate for applications, as fast as the fastest traditional empirical potentials, and two to four orders of magnitude faster than state-of-the-art machine-learning potentials. For data from empirical potentials, we demonstrate the exact retrieval of the potential. For data from density functional theory, the predicted energies, forces, and derived properties, including phonon spectra, elastic constants, and melting points, closely match those of the reference method. The introduced potentials might contribute towards accurate all-atom dynamics simulations of large atomistic systems over long-time scales.

36 MATERIALS SCIENCE↗