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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 OSTI2022

Physics-based modeling and information-theoretic sensor and settings selection for tool wear detection in precision machining

Precision machining of metals is an energy intensive process with applications and impacts across the manufacturing industry. The energy efficiency, product yield, and maintenance of the precision machine require a digital twin that can assist with prognostics and health management. In this report a physics-based model is developed and validated against face milling data, and then used for the timely and precise inference of machining faults that cannot be measured directly. Computer numerical control (CNC) measurements of power and force are used through this physics-based machining model to predict deviations of the outputs of power consumption and cutting forces during normal operation. A model-based fault detection and isolation methodology is applied to determine the optimal (traditional and available) sensor suite and the test settings (admissible input values) that improve the inference of tool wear in face milling. The optimal sensor suite and input test settings are obtained by solving a mixed integer non-linear program that optimizes information-theoretic metrics relevant to the detection and isolation of tool wear from steady-state or transient machining measurements. Dynamic time warping and k—NN classification are then used to validate the robustness of the optimal design for fault detection test design, including the optimal sensor suite.

42 ENGINEERING↗
DOE OSTI2022

Sensor selection and tool wear prediction with data‐driven models for precision machining

Abstract Estimation of tool wear in precision machining is vital in the traditional subtractive machining industry to reduce processing cost, improve manufacturing efficiency and product quality. In this vein, fusion of time and frequency‐domain features of commonly sensed signals can provide an early indication of tool wear and improve its prediction accuracy for prognostics and health management. This paper presents a data‐driven methodology and a complete tool chain for the inference of precision machining tool wear from fused machine measurements, such as cutting force, power, audio and vibration signals, and quantify the usefulness of each measurement. Indicators of tool wear are extracted from time‐domain signal statistics, frequency‐domain analysis, and time‐frequency domain analysis. Correlation coefficients between the extracted features (indicators) and the tool wear are used to select the most informative features. Principal Component Analysis and Partial Least‐Squares are used to reduce the dimensionality of the feature space. Regression models, including linear regression, support vector regression, Decision tree regression, neural network regression and Gaussian process regression, are used to predict the tool wear using data from a Haas milling machine performing spiral boss face milling. The performance of the regression models based on subsets of sensors validates the preliminary estimates about the saliency of the sensors. The experimental results show that the proposed methods can predict the machine tool wear precisely, with readily available sensor measurements. Neural network and Gaussian process regression were able to achieve good estimates of tool wear at different machine operating conditions. The most informative signal in predicting tool wear was shown to be the vibration signal. Time‐frequency domain features were the most informative features among the combination of features of three domains. In addition, using partial least squares components extracted from the original features of signals led to higher prediction accuracy.

Han, Seulki↗
NASA NTRS1983

Precision machining technology and metrology for AXAF study

The optical surfaces for the Advanced X-ray Astrophysical Facility (AXAF), was studied. The applicability of precision machining technology to the manufacture of the AXAF objective mirrors and the proposed and alternative methods for manufacturing and testing; (1) the AXAF technology mirrors and (2) the AXAF high resolution mirror assembly were reviewed. Surface shape and smoothness metrology for grazing incidence X-ray surfaces and the feasibility of applying heterodyne surface profilometry to nonflat surfaces were investigated. Three sets of scattering flats with known surface profiles and microtopographic character produced by precision machining and polished precision machine surfaces were analyzed.

Sanger, G. M.↗
DOE OSTI2024

Calculation of machine precision second order derivatives using dual-complex numbers

It is well known that both complex and dual numbers can be employed to obtain machine precision first-order derivatives; however, neither, on their own, can compute machine precision 2nd order derivatives. To address this limitation, it is demonstrated in this paper that combined dual-complex numbers can be used to compute machine precision 1st and 2nd order derivatives. The dual-complex approach is simpler than utilizing multicomplex or hyper-dual numbers as existing dual libraries can be used as is or easily augmented to accept complex numbers, and the complexity of developing, integrating, and deploying multicomplex or hyper-dual libraries is avoided. The efficacy of this approach is demonstrated for both univariate and multivariate functions. Finally, source code examples using the Python, Julia, and Mathematica languages are provided as supplemental material.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1972

Precision machining of steel decahedrons

Production of highly accurate decahedron prisms from hardened stainless steel is discussed. Prism is used to check angular alignment of mounting pads of strapdown inertial guidance system. Accuracies obtainable using recommended process and details of operation are described. Photographic illustration of production device is included.

Abernathy, W. J.↗
DOE OSTI2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

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.

42 ENGINEERING↗
NASA NTRS2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

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.

Online anomaly detection↗
NASA NTRS1996

Adaptive Machining Of Large, Somewhat Flexible Parts

Adaptive machining is method of machining large, somewhat flexible workpieces to close tolerances. Devised for machining precise weld lands on aft skirts of rocket nozzles, but underlying concept generally applicable to precise machining of any of large variety of workpieces deformed by thermal, gravitational, and/or machining forces. For example, in principle, method used to bore precise hole on unanchored end of long cantilever beam.

Gutow, David↗
DOE OSTI2024

Speeding up and reducing memory usage for scientific machine learning via mixed precision

Scientific machine learning (SciML) has emerged as a versatile approach to address complex computational science and engineering problems. Within this field, physics-informed neural networks (PINNs) and deep operator networks (DeepONets) stand out as the leading techniques for solving partial differential equations by incorporating both physical equations and experimental data. However, training PINNs and DeepONets require significant computational resources, including long computational times and large amounts of memory. In search of computational efficiency, training neural networks using half precision (float16) rather than the conventional single (float32) or double (float64) precision has gained substantial interest, given the inherent benefits of reduced computational time and memory consumed. However, we find that float16 cannot be applied to SciML methods, because of gradient divergence at the start of training, weight updates going to zero, and the inability to converge to a local minima. To overcome these limitations, we explore mixed precision, which is an approach that combines the float16 and float32 numerical formats to reduce memory usage and increase computational speed. Our experiments showcase that mixed precision training not only substantially decreases training times and memory demands but also maintains model accuracy. Here, we also reinforce our empirical observations with a theoretical analysis. The research has broad implications for SciML in various computational applications.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Observable optimization for precision theory: machine learning energy correlators

The practice of collider physics typically involves the marginalization of multi-dimensional collider data to uni-dimensional observables relevant for some physics task. In many cases, such as classification or anomaly detection, the observable can be arbitrarily complicated, such as the output of a neural network. However, for precision measurements, the observable must correspond to something computable systematically beyond the level of current simulation tools. In this work, we demonstrate that precision-theory-compatible observable space exploration can be systematized by using neural simulation-based inference techniques from machine learning. We illustrate this approach by exploring the space of marginalizations of the energy 3-point correlator to optimize sensitivity to the top quark mass. We first learn the energy-weighted probability density from simulation, then search in the space of marginalizations for an optimal triangle shape. Although simulations and machine learning are used in the process of observable optimization, the output is an observable definition which can be then computed to high precision and compared directly to data without any memory of the computations which produced it. We find that the optimal marginalization is isosceles triangles on the sphere with a side ratio approximately $1 : 1 : \sqrt{2}$ (i.e. right triangles) within the set of marginalizations we consider.

Jets and Jet Substructure↗
DOE OSTI2024

A new approach to the evaluation and solution of the relativistic kinetic dispersion relation and verification with continuum kinetic simulation

Here, the present work describes a new approach to evaluation and root finding for the kinetic dispersion relation of Langmuir waves, which is central to the analytical understanding of collisionless damping in plasmas. The plasma dispersion function is solved to machine precision using direct integration in the complex plane in combination with an analytic evaluation of the residue to account for the deformation along the Landau contour. To efficiently attain machine precision, the contour is displaced in the complex plane prior to integration, and numerical subtleties related to the placement of the contour are discussed. The approach is generic in that it applies to arbitrary distribution functions, with the present manuscript focused on relativistic cases. Detailed verification of results via direct kinetic simulation in a variety of configuration space dimensions is also presented. Finally, the technique is applied to the challenging case of highly relativistic (i.e. extremely hot) plasmas. Here we show both qualitative agreement with prior work, as well as the disappearance of the Landau root which would have significant implication for real-life observation or experiment.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2012

Ring Image Analyzer

Ring Image Analyzer software analyzes images to recognize elliptical patterns. It determines the ellipse parameters (axes ratio, centroid coordinate, tilt angle). The program attempts to recognize elliptical fringes (e.g., Newton Rings) on a photograph and determine their centroid position, the short-to-long-axis ratio, and the angle of rotation of the long axis relative to the horizontal direction on the photograph. These capabilities are important in interferometric imaging and control of surfaces. In particular, this program has been developed and applied for determining the rim shape of precision-machined optical whispering gallery mode resonators. The program relies on a unique image recognition algorithm aimed at recognizing elliptical shapes, but can be easily adapted to other geometric shapes. It is robust against non-elliptical details of the image and against noise. Interferometric analysis of precision-machined surfaces remains an important technological instrument in hardware development and quality analysis. This software automates and increases the accuracy of this technique. The software has been developed for the needs of an R&TD-funded project and has become an important asset for the future research proposal to NASA as well as other agencies.

Strekalov, Dmitry V.↗
DOE OSTI2023

Methods for the Automated Determination of Sustained Maximum Amplitudes in Oscillating Signals

Machine condition monitoring has been proven to reduce machine downtime and increase productivity. The state-of-the-art research uses vibration monitoring for tasks such as maintenance and tool wear prediction. A less explored aspect is how vibration monitoring might be used to monitor equipment sensitive to vibration. In a manufacturing environment, one example of where this might be needed is in monitoring the vibration of optical linear encoders used in high-precision machine tools and coordinate measuring machines. Monitoring the vibration of sensitive equipment presents a unique case for vibration monitoring because an accurate calculation of the maximum sustained vibration is needed, as opposed to extracting trends from the data. To do this, techniques for determining sustained peaks in vibration signals are needed. Here, this work fills this gap by formalizing and testing methods for determining sustained vibration amplitudes. The methods are tested on simulated signals based on experimental data. Results show that processing the signal directly with the novel Expire Timer method produces the smallest amounts of error on average under various test conditions. Additionally, this method can operate in real-time on streaming vibration data.

Industrial Internet of Things↗
NASA NTRS2018

Optimal Control Prediction Method for Control Allocation

This paper proposes a novel prediction method for online optimal control allocation that extends the volume of moments achievable with the Moore-Penrose generalized inverse to the entire Attainable Moment Set. This method formulates the control allocation problem using selected basis vectors and associated gains which reduces the optimization problem dimensions and provides physical insight into the resulting optimal solutions. The proposed algorithm finds the entire family of unique optimal control solutions along the desired moment vector from the origin to the boundary of the Attainable Moment Set. Numerical results for the Moore-Penrose prediction method show that the unique minimal controls obtained yield the desired moment with near machine precision accuracy while maintaining control effectors within specified position limits. This method has been fully validated against the unique solution obtained on the boundary of the Attainable Moment Set using the Durham Direct Allocation method. Minimal control solutions obtained for moments in the interior of the Attainable Moment Set, similarly yield the desired moment to near machine precision while providing control solutions that are smaller (i.e. 2-norm) than solutions found with traditional control allocation algorithms (e.g. interior point methods) applied to the minimal control problem. Numerical simulations using a Matlab® autocoded executable (MEX) for the representative real world problem of 3-moments with 20 individual control effectors and prescribed control position limits show a mean computation speed of approximately 125 Hz which is sufficient to enable real-time flight allocation.

Acheson, Michael J.↗
NASA NTRS2019

Efficient computation of optimal low thrust gravity perturbed orbit transfers

We have developed a new method for solving low-thrust fuel-optimal orbit transfer problems in the vicinity of a large body (planet or asteroid), considering a high-fidelity spherical harmonic gravity model. The algorithm is formulated via the indirect optimization method, leading to a two-point boundary value problem (TPBVP). We make use of a hyperbolic tangent smoothing law for performing continuation on the thrust magnitude to reduce the sharpness of the control switches in early iterations and thus promote convergence. The TPBVP is solved using the method of particular solutions (MPS) shooting method and Picard-Chebyshev numerical integration. Application of Picard-Chebyshev integration affords an avenue for increased efficiency that is not available with step-by-step integrators. We demonstrate that computing the particular solutions with only a low-fidelity force model greatly increases the efficiency of the algorithm while ultimately achieving near machine precision accuracy. A salient feature of the MPS is that it is parallelizable, and thus further speedups are available. It is also shown that, for near Earth orbits and over a small number of en-route revolutions around the Earth, only the zonal perturbation terms are required in the costate equations to obtain a solution that is accurate to machine precision and optimal to engineering precision. The proposed framework can be used for trajectory design around small asteroids and also for orbit debris rendezvous and removal tasks.

Junkins, John L.↗