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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
NASA NTRS2001

A Safety Risk Assessment Methodology for Decision Support Systems with an Application to the Expedite Departure Path Tool

In support of the NASA Advanced Air Transportation Technologies Project, the Volpe National Transportation Systems Center has developed a methodology to perform safety risk assessments for air traffic control/air traffic management decision Support systems and concepts. Changes in controller, pilot, and/or airline dispatcher tasks that are affected by the decision support system are related to associated hazards. These hazards are then assessed either qualitatively or quantitatively in terms of likelihood of occurring and the impact if they do occur. Those items that show a potential safety hazard level increase can then have research plans developed to address those safety risks areas. An application of this methodology will he demonstrated using the AATT decision support tool Expedite Departure Path.

Snyder, Phillip T.↗
NASA NTRS1996

Program Helps Specify Paths For Numerically Controlled Tools

ESDAPT computer program provides graphical programming environment for developing APT (Automatically Programmed Tool) programs for controlling numerically controlled machine tools. Establishes graphical user interface providing user with APT syntax-sensitive text-editing subprogram and windows for displaying geometry and tool paths. APT geometry statements also created by use of menus and screen picks. Written in C language, yacc, lex, and XView for use on Sun4-series computers running SunOS.

Premack, Timothy↗
NASA NTRS2001

Table-driven software architecture for a stitching system

Native code for a CNC stitching machine is generated by generating a geometry model of a preform; generating tool paths from the geometry model, the tool paths including stitching instructions for making stitches; and generating additional instructions indicating thickness values. The thickness values are obtained from a lookup table. When the stitching machine runs the native code, it accesses a lookup table to determine a thread tension value corresponding to the thickness value. The stitching machine accesses another lookup table to determine a thread path geometry value corresponding to the thickness value.

Thrash, Patrick J.↗
NASA NTRS1970

A method of numerically controlled machine part programming

Computer program is designed for automatically programmed tools. Preprocessor computes desired tool path and postprocessor computes actual commands causing machine tool to follow specific path. It is used on a Cincinnati ATC-430 numerically controlled machine tool.

Source record↗
NASA NTRSDate not supplied

Integration of Structural Analysis and Manufacturing Process Planning for Global Optimization with Automated Fiber Placement

Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.

Automated Fiber Placement↗
NASA NTRS2019

Development of a Design for Manufacturing Tool for Automated Fiber Placement Structures

Existing design processes for laminates constructed with automated fiber placement lack significant integration between the various software tools that compose the process. Tools for finite element analysis, computer aided drafting, stress analysis, tool path simulation, and manufacturing defect prediction are all critical parts of the design process. With traditional hand-layup laminates, the analysis performed with each of these tools could be fairly well decoupled from one another. However, for laminates generated by automated fiber placement, the disciplines can become significantly coupled, especially on structures with curvature. This gives rise to a need for integrated “design for manufacturing” software tools that are able to balance the competing objectives from each discipline. This paper describes the preliminary development of such a tool.

Noevere, August T.↗
NASA NTRS1968

Thread cutting with 3-axis N/C milling machine

TAPDIE, a generalized macro written for the APT numerical control system, cuts threads in stock too big for conventional machines or for which conventional methods are unsuitable. TAPDIE computes the machine tool path necessary and the information is passed on to a post-processor which produces a control tape.

Salley, G. C.↗
NASA NTRS1981

AIRCL: A programmed system for generating NC tapes for airplane models. User's manual

A computer program is presented which calculates the cutter location file needed to machine models of airplane wings or wing-fuselage combinations on numerically controlled machine tools. Input to the program is a data file consisting of coordinates on the fuselage and wing. From this data file, the program calculates tool offsets, determines the intersection between wing and fuselage tool paths, and generates additional information needed to machine the fuselage and/or wing. Output from the program can be post processed for use on a variety of milling machines. Information on program structure and methodology is given as well as the user's manual for implementation of the program.

Akgerman, N.↗
NASA NTRS1984

Intersection of parametric surfaces using lookup tables

When primitive structures in the form of parametric surfaces are combined and modified interactively to form complex intersecting surfaces, it becomes important to find the curves of intersection. One must distinguish between finding the shape of the intersection curve, which may only be useful for display purposes, and finding an accurate mathematical representation of the curve, which is important for any meaningful geometric modeling, analysis, design, or manufacturing involving the intersection. The intersection curve between two or more parametric surfaces is important in a variety of computer-aided design and manufacture areas. A few examples are shape design, analysis of groins, design of fillets, and computation of numerically controlled tooling paths. The algorithm presented here provides a mathematical representation of the intersection curve to a specified accuracy. It also provides the database that can simplify operations such as hidden-surface removal, surface rendering, profile identification, and interference or clearance computations.

Hanna, S. L.↗
NASA NTRS1984

An enhanced Oct-tree data structure and operations for solid modeling

Oct-trees are enhanced to increase the processing efficiency of geometric operations for interactive CAD use. Further enhancement is made to combine them with surface models for more precise boundary specification as needed by tool path generation in CAM applications.

Fujimura, K.↗
NASA NTRS1984

Using a commercial CAD system for simultaneous input to theoretical aerodynamic programs and wind-tunnel model construction

The Computer Aided Design (CAD) system's common geometry database was used to generate input for theoretical programs and numerically controlled (NC) tool paths for wind tunnel part fabrication. This eliminates the duplication of work in generating separate geometry databases for each type of analysis. Another advantage is that it reduces the uncertainty due to geometric differences when comparing theoretical aerodynamic data with wind tunnel data. The system was adapted to aerodynamic research by developing programs written in Design Analysis Language (DAL). These programs reduced the amount of time required to construct complex geometries and to generate input for theoretical programs. Certain shortcomings of the Design, Drafting, and Manufacturing (DDM) software limited the effectiveness of these programs and some of the Calma NC software. The complexity of aircraft configurations suggests that more types of surface and curve geometry should be added to the system. Some of these shortcomings may be eliminated as improved versions of DDM are made available.

Enomoto, F.↗
NASA NTRS1986

Forbidden Zones for Numerically-Controlled Machine Tools

Computer-controlled machine tool prevented from striking and damaging protruding members on workpiece by creating forbidden zone in control program. With aid of computer graphics, tool profile and coordinates of forbidden zone digitized and stored in computer memory as part of tool path.

Philpot, D.↗
NASA NTRS1991

Engineering specification and system design for CAD/CAM of custom shoes: UMC project effort

The goal of this project is to supplement the footwear design system of North Carolina State University (NCSU) with a software module to design and manufacture a combination sole. The four areas of concentration were: customization of NASCAD (NASA Computer Aided Design) to the footwear project; use of CENCIT data; computer aided manufacturing activities; and beginning work for the bottom elements of shoes. The task of generating a software module for producing a sole was completed with a demonstrated product realization. The software written in C was delivered to NCSU for inclusion in their design system for custom footwear known as LASTMOD. The machining process of the shoe last was improved using a spiral tool path approach.

Bao, Han P.↗
NASA NTRS1992

Simulating Welding-Robot Trajectories For Previewing

New method devised for generating welding-tool paths; parts of off-line-programmed test trajectories of computer-controlled welding robot. Reduces time necessary to set up simulation of welding process and eliminates some errors by reducing amount of repetition. Provides visual feedback similar to graphical simulation used in off-line-programming process after development of model.

Levitt, Maureen L.↗
NASA NTRS2016

In-Process Thermal Imaging of the Electron Beam Freeform Fabrication Process

Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF3) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF3 system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.

Taminger, Karen M.↗
NASA NTRS2017

Predictive Modeling of Fast-Curing Thermosets in Nozzle-Based Extrusion

This work presents an approach to modeling the dynamic spreading and curing behavior of thermosets in nozzle-based extrusions. Thermosets cover a wide range of materials, some of which permit low-temperature processing with subsequent high-temperature and high-strength working properties. Extruding thermosets may overcome the limited working temperatures and strengths of conventional thermoplastic materials used in additive manufacturing. This project aims to produce technology for the fabrication of thermoset-based structures leveraging advances made in nozzle-based extrusion, such as fused deposition modeling (FDM), material jetting, and direct writing. Understanding the synergistic interactions between spreading and fast curing of extruded thermosetting materials will provide essential insights for applications that require accurate dimensional controls, such as additive manufacturing [1], [2] and centrifugal coating/forming [3]. Two types of thermally curing thermosets -- one being a soft silicone (Ecoflex 0050) and the other being a toughened epoxy (G/Flex) -- served as the test materials in this work to obtain models for cure kinetics and viscosity. The developed models align with extensive measurements made with differential scanning calorimetry (DSC) and rheology. DSC monitors the change in the heat of reaction, which reflects the rate and degree of cure at different crosslinking stages. Rheology measures the change in complex viscosity, shear moduli, yield stress, and other properties dictated by chemical composition. By combining DSC and rheological measurements, it is possible to establish a set of models profiling the cure kinetics and chemorheology without prior knowledge of chemical composition, which is usually necessary for sophisticated mechanistic modeling. In this work, we conducted both isothermal and dynamic measurements with both DSC and rheology. With the developed models, numerical simulations yielded predictions of diameter and height of droplets, along with width and height of extruded lines cured at varied temperatures. Experimental results carried out on a goniometric platform and a nozzle-based 3D printer showed agreement with the numerical simulations. Finally, this presentation will show how the models are adaptable to the planning of tool paths and designs in additive manufacturing.

Xie, Jingjin↗
NASA NTRSDate not supplied

Experimental Considerations for Ground-based Testing of Lunar Construction Technologies

The Moon-to-Mars Planetary Autonomous Construction Technology (MMPACT) project, under NASA’s Game Changing Division (GCD) aims to research, develop, and demonstrate lunar surface construction capabilities[1].A fundamental step in lunar infrastructure development is to quantify the geotechnical properties of lunar regolith, such as shear strength (Mohr-Coulomb cohesion and angle of internal friction), com-pression and bearing properties, and angle of re-pose. Knowledge of these geotechnical properties enables the prediction of forces and displacements associated with lunar infrastructure development processes including excavation and constructing landing pads, habitats, shelters, and roadways. Through ground-based testing of autonomous lunar systems performed using relevant hardware (e.g., robotic arms) in appropriate lunar regolith simulants, the developed hardware/technology and tool paths can be validated. Such testing also generates data to give insight into the geotechnical regolith properties on the lunar surface.

Regolith↗
NASA NTRSDate not supplied

LUNAR REGOLITH:SMALL SCALE ROBOTIC SITE PREPARATION AND GEOTECHNICAL EXPERIMENTSWITH SCOOPS

NASA’s Moon-To-Mars Planetary Autonomous Construction Technology (MMPACT) project seeks to research, develop, and demonstrate lunar surface construction capabilities. Quantification of lunar regolith’s geotechnical properties allows for effective prediction of forces and displacement during excavation and construction and is critical to facilitating regolith sintering capabilities all of which benefit lunar infrastructure plans. Knowledge of shear strength, Mohr-Coulomb cohesion, angle of internal friction, bearing strength, bulk density, etc. is needed. The use of ground-based testing of various lunar simulants with relevant hardware (e.g., robotic arm tools) enables validation of technology choices, tool paths, and lunar surface construction activities. In addition, the use of Taguchi methods will minimize the number of needed experiments to explore critical input parameters.

R. P. Mueller↗