Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “machining”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Thermal Management for a Novel Non-Heavy Rare-Earth Interior Permanent Magnet Machine

The work presents a thermal management solution for a novel non-heavy rare-earth permanent magnet machine being developed at Oak Ridge National Laboratory. The motor has been designed to minimize losses while maximizing performance for a range of speeds and power ratings. The novel motor design reduces rare-earth magnet usage, thereby avoiding supply chain issues. The motor component heat losses are established for operating windows and desired performance. These heat losses, along with windage losses, are being used to develop cooling solutions for different components of this machine. A novel thermal management solution for stators and rotors has been developed, and progress is presented in this paper. The stator cooling is achieved with the help of water-ethylene glycol flowing over the finned aluminum stator jacket, and rotor cooling with automatic transmission fluid passing through novel channels designed in the rotor laminations. The attempt is to establish effective cooling of the stator winding, laminations, and rotor magnets. A 3D conjugate heat transfer model has been developed for overall thermal analysis to establish a down- selected thermal management solution for the machine. The model, in addition to estimated component heat losses, includes windage losses and its impact on rotor and stator cooling. Overall, the work presents a workable thermal solution for the interior permanent magnet machine with potential for further improvements. Future work will involve establishing end winding and refinement of other end parts of the machine with the aim of establishing a robust thermal management solution. The work will also focus on different shapes (e.g., round, non-round, presence of wedges) of rotor-stator gaps and investigate windage losses and their impact on thermal management for higher rotational speeds for the machine.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Practical CO2—WAG Field Operational Designs Using Hybrid Numerical-Machine-Learning Approaches

Machine-learning technologies have exhibited robust competences in solving many petroleum engineering problems. The accurate predictivity and fast computational speed enable a large volume of time-consuming engineering processes such as history-matching and field development optimization. The Southwest Regional Partnership on Carbon Sequestration (SWP) project desires rigorous history-matching and multi-objective optimization processes, which fits the superiorities of the machine-learning approaches. Although the machine-learning proxy models are trained and validated before imposing to solve practical problems, the error margin would essentially introduce uncertainties to the results. In this paper, a hybrid numerical machine-learning workflow solving various optimization problems is presented. By coupling the expert machine-learning proxies with a global optimizer, the workflow successfully solves the history-matching and CO2 water alternative gas (WAG) design problem with low computational overheads. The history-matching work considers the heterogeneities of multiphase relative characteristics, and the CO2-WAG injection design takes multiple techno-economic objective functions into accounts. This work trained an expert response surface, a support vector machine, and a multi-layer neural network as proxy models to effectively learn the high-dimensional nonlinear data structure. The proposed workflow suggests revisiting the high-fidelity numerical simulator for validation purposes. The experience gained from this work would provide valuable guiding insights to similar CO2 enhanced oil recovery (EOR) projects.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
NASA NTRS2004

Fault Tolerant State Machines

State machines are commonly used to control sequential logic in FPGAs and ASKS. An errant state machine can cause considerable damage to the device it is controlling. For example in space applications, the FPGA might be controlling Pyros, which when fired at the wrong time will cause a mission failure. Even a well designed state machine can be subject to random errors us a result of SEUs from the radiation environment in space. There are various ways to encode the states of a state machine, and the type of encoding makes a large difference in the susceptibility of the state machine to radiation. In this paper we compare 4 methods of state machine encoding and find which method gives the best fault tolerance, as well as determining the resources needed for each method.

encoding↗
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 NTRSDate not supplied

Electrifying Aircraft Propulsion: Thermal Issues of Megawatt Scale Power Dense Electric Machines and Material Solutions

Aircraft are the last major mode of transportation to undergo electrification for many reasons, where the underlying reason is the sensitivity of aircraft performance to mass. This sensitivity demands that efficient, megawatt (MW)-scale high specific power density powertrains be developed to impact regional, single aisle and larger aircraft that account for the majority of fuel burn in commercial aviation. Developing MW-scale high specific power electric powertrains (machines, cables/busbars and power electronics) remains a significant challenge. While advanced power semiconductors have enabled higher voltages, densities, and operational frequencies this also leads to passing high current through smaller volumes when considering electric machines and power electronics. This poses significant thermal challenges. This is particularly true for electric machines that strive to surpass 13 kW/kg, which studies have shown to be desirable for electric aircraft propulsion. The necessity of handling high current densities to achieve MW power levels dictates that greater than 10kW of waste heat will be generated. Moreover, most of the heat is generated in the stator winding which is a mixture of electrical conductor (copper or aluminum), potting material, magnet wire (electrical) insulation and high voltage electrical insulation. Although the electrical conductor is a fantastic thermal conductor, it is also the source of the heat (carrying the electrical current) and is thermally isolated by the other materials. Simply letting the machine run at increased temperatures is an attractive idea, however the reality is that most of the suitable electric insulations and potting material candidates are not likely to satisfactorily operate at higher temperatures with reasonable life expectancies. The likelihood of developing new polymers that can satisfy the necessary functions (mechanical and electrical), operate at higher temperatures with acceptable lifetime in the near term is small. This has led the researchers at the NASA Glenn Research Center to examine electrically insulative materials in high power destiny electric machines, their thermal environment, and what solutions are realistic from a materials point of view. This presentation will touch on both the thermal challenges of electric machines and NASA Glenn’s research into material solutions.

Electric Aircraft Propulsion↗
NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗
DOE OSTI2022

Monotonic Gaussian Process for Physics-Constrained Machine Learning With Materials Science Applications

Physics-constrained machine learning is emerging as an important topic in the field of machine learning for physics. One of the most significant advantages of incorporating physics constraints into machine learning methods is that the resulting model requires significantly less data to train. By incorporating physical rules into the machine learning formulation itself, the predictions are expected to be physically plausible. Gaussian process (GP) is perhaps one of the most common methods in machine learning for small datasets. In this paper, we investigate the possibility of constraining a GP formulation with monotonicity on three different material datasets, where one experimental and two computational datasets are used. The monotonic GP is compared against the regular GP, where a significant reduction in the posterior variance is observed. The monotonic GP is strictly monotonic in the interpolation regime, but in the extrapolation regime, the monotonic effect starts fading away as one goes beyond the training dataset. Imposing monotonicity on the GP comes at a small accuracy cost, compared to the regular GP. The monotonic GP is perhaps most useful in applications where data are scarce and noisy, and monotonicity is supported by strong physical evidence.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Exploiting Machine Learning in Multiscale Modelling of Materials

Recent developments in efficient machine learning algorithms have spurred significant interest in the materials community. The inherently complex and multiscale problems in Materials Science and Engineering pose a formidable challenge. The present scenario of machine learning research in Materials Science has a clear lacunae, where efficient algorithms are being developed as a separate endeavour, while such methods are being applied as ‘black-box’ models by others. The present article aims to discuss pertinent issues related to the development and application of machine learning algorithms for various aspects of multiscale materials modelling. The authors present an overview of machine learning of equivariant properties, machine learning-aided statistical mechanics, the incorporation of ab initio approaches in multiscale models of materials processing and application of machine learning in uncertainty quantification. In addition to the above, the applicability of Bayesian approach for multiscale modelling will be discussed. Critical issues related to the multiscale materials modelling are also discussed.

42 ENGINEERING↗
DOE OSTI2024

Recycling of CF-ABS machining waste for large format additive manufacturing

Large format additive manufacturing (LFAM) necessitates the use of short fiber thermoplastic composites, such as carbon fiber filled acrylonitrile butadiene styrene, to enable printing. Currently, when LFAM parts are machined into their final shape, the machining scrap (i.e., small flake like particles and offcuts) is landfilled. Previous studies have demonstrated the viability of recycling end-of-life LFAM parts by shredding and optionally re-compounding the material back into pellets. However, there is little understanding of the value and performance of recycled material made from LFAM machining scrap, which if pursued could motivate more broad recycling of this waste stream. In this study, recycled in-process machining scrap is explored as an LFAM feedstock source. Herein, it is found that the primary degradation mechanism of the recycled material is significant fiber length attrition during surface machining. While this fiber attrition negatively impacts the mechanical performance of the material in the print direction, it seems that the changes in processing behaviors and print quality, namely the surface roughness of the printed structure associated with shorter fiber lengths, is beneficial to interlayer adhesion. The tensile strength and elastic modulus of the recycled material, in the print direction, decreased 11% and 31% respectively compared to the pristine material. However, in the layer-wise direction it was found that the recycled material exhibited no significant change in elastic modulus and a significant 21% increase in tensile strength – a surprising result. In conclusion, this work indicates that machining waste could be a viable material stream for recycled LFAM feedstock materials.

42 ENGINEERING↗
DOE OSTI2026

Subseasonal Forecasting and MJO Teleconnections in Machine Learning Weather Prediction Models

Abstract In recent years, machine‐learning (ML) models trained on reanalysis data have rivaled physics‐based forecast models in terms of performance skill for global weather forecasting. With increased rollout stability, the question of how these models perform for subseasonal to seasonal (S2S, week 3–8) forecasting has emerged. In this study we run a large set of subseasonal hindcasts over 2004–2023 to evaluate two ML weather forecast models at the S2S time scale, SFNO‐HENS (Nvidia, fully ML) and NeuralGCM (Google Research, hybrid). Corresponding hindcasts from the European Centre for Medium‐Range Weather Forecasts (ECMWF) are used as a baseline for comparison to a physics‐based model. Because our focus is on predicting moisture transport over the Western United States between October and March, we evaluate the models' prediction skill for the Madden‐Julian Oscillation (MJO) and its associated teleconnections in the North Pacific. We find that both ML models are competitive with the ECWMF model, with comparable skill in predicting the North Pacific large‐scale circulation and the MJO at week 3 and beyond. Even though overall the mid‐latitude subseasonal prediction skill remains low, the ML models exhibit interesting behavior such as a realistic propagation of the MJO across the Maritime Continent and realistic teleconnections. A SFNO‐HENS sensitivity experiment with altered initial conditions in the tropics demonstrates the stability of the model, and it illustrates the capability of ML models to represent important physical processes of the atmosphere at the S2S time scale. Plain Language Summary Predicting weather patterns and precipitation a few weeks in advance (subseasonal time scale) is of great interest for stakeholders such as water managers in the Southwest United States (US), where arid conditions prevail. Subseasonal forecasts from traditional weather forecast models exhibit low skill in the region, limiting their applicability. Here we examine whether the recent breakthrough in weather forecasting made with machine learning/artificial intelligence models can translate to improved subseasonal forecasts. Recently‐developed machine learning models exhibit comparable skill to a state‐of‐the‐art physics‐based model for predicting weather patterns in the North Pacific/North America region, and associated moisture transport. The same applies to their skill in predicting the tropical pattern, the Madden‐Julian Oscillation, and its important remote perturbations over the midlatitude East Pacific and Southwest US. Additionally, a perturbation experiment carried out with one of the machine learning models illustrates their ability to not only predict the evolution of atmospheric fields, but also to learn and represent physical processes such as tropics‐extratropics Rossby wave propagation. Key Points Two machine learning weather forecast models exhibit state‐of‐the‐art prediction skill at the subseasonal time scale in the Pacific sector The models equal ECWMF in terms of Madden‐Julian oscillation (MJO) prediction skill, and they accurately predict the MJO propagation and associated teleconnections The two machine‐learning models represent key physical processes for subseasonal prediction, despite being trained for weather forecasting

Peings, Yannick↗
DOE OSTI2021

Decoding defect statistics from diffractograms via machine learning

Abstract Diffraction techniques can powerfully and nondestructively probe materials while maintaining high resolution in both space and time. Unfortunately, these characterizations have been limited and sometimes even erroneous due to the difficulty of decoding the desired material information from features of the diffractograms. Currently, these features are identified non-comprehensively via human intuition, so the resulting models can only predict a subset of the available structural information. In the present work we show (i) how to compute machine-identified features that fully summarize a diffractogram and (ii) how to employ machine learning to reliably connect these features to an expanded set of structural statistics. To exemplify this framework, we assessed virtual electron diffractograms generated from atomistic simulations of irradiated copper. When based on machine-identified features rather than human-identified features, our machine-learning model not only predicted one-point statistics (i.e. density) but also a two-point statistic (i.e. spatial distribution) of the defect population. Hence, this work demonstrates that machine-learning models that input machine-identified features significantly advance the state of the art for accurately and robustly decoding diffractograms.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Rotor Magnet Fault Analysis in Permanent Magnet AC Machines Under Load Conditions - All Electric Transportation Systems

This paper studies the performance of a Permanent Magnet (PM) alternating-current (AC) machine when subjected to faults under load conditions. The effect of varying load torques, and unbalances are found to be potential causes of rotor faults, inducing physical magnet defects or broken rotor-PMs. The consequent and immediate impact on the machine quantities is observed through anomalous change in torque-speed characteristics and other vital signatures such as machine back-EMF/flux and motor current signatures (MCS). The present research study develops and illustrates a method to diagnose physical magnet defects (fault) in PMAC machines by estimating the machine torque/back-EMF constant, Ke. The constant Ke is a measure of magnet strength exhibiting the health of rotor PMs, indicative of faults. Advanced research studies and investigations are carried out to establish motor approximations and signature-based analysis as significant viable tools for diagnosing machine faults even under load conditions.

alternating current↗
DOE OSTI2023

A Comparison of Outer Rotor Radial and Axial Flux Machines for Application in Electric Vehicles

Axial flux machines have attracted a lot of interest in the recent years as potential high torque low weight candidates for use as traction motors in electric vehicles (EV). This paper compares axial and radial flux machines for electric vehicle applications. An external rotor radial flux machine with a Halbach array surface permanent magnet rotor and concentrated windings is chosen as a baseline to compare with axial flux designs. Both axial and radial flux motors are sized to meet the EV same requirements. Multi-objective design optimization using differential evolution minimizing loss and volume is carried out for both types of machines. Hundreds of candidate designs for each type of machine are analyzed, pareto fronts are identified and compared. The potential advantages of axial flux machines are evaluated and quantified.

Rallabandi, Vandana↗
DOE OSTI2023

State Machine Operation of Complex Systems

Operation of complex systems which depend on one or more other systems with many process variables often operate in more than one state. For each state there may be a variety of parameters of interest, and for each of these, one may require different alarm limits, different archiving needs, and have different critical parameters. Relying on operators to reliably change 10s-1000s of parameters for each system for each state is unreasonable. Not changing these parameters results in alarms being ignored or disabled, critical changes missed, and/or possible data archiving problems. To reliably manage the operation of complex systems, such as cryomodules (CMs), Fermilab is implementing state machines for each CM and an over-arching state machine for the PIP-II superconducting linac (SCL). The state machine transitions and operating parameters are stored/restored to/from a configuration database. Proper implementation of the state machines will not only ensure safe and reliable operation of the CMs, but will help ensure reliable data quality. A description of PIP-II SCL, details of the state machines, and lessons learned from limited use of the state machines in recent CM testing will be discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Decision Science for Machine Learning (DeSciML)

The increasing use of machine learning (ML) models to support high-consequence decision making drives a need to increase the rigor of ML-based decision making. Critical problems ranging from climate change to nonproliferation monitoring rely on machine learning for aspects of their analyses. Likewise, future technologies, such as incorporation of data-driven methods into the stockpile surveillance and predictive failure analysis for weapons components, will all rely on decision-making that incorporates the output of machine learning models. In this project, our main focus was the development of decision scientific methods that combine uncertainty estimates for machine learning predictions, with a domain-specific model of error costs. Other focus areas include uncertainty measurement in ML predictions, designing decision rules using multiobjecive optimization, the value of uncertainty reduction, and decision-tailored uncertainty quantification for probability estimates. By laying foundations for rigorous decision making based on the predictions of machine learning models, these approaches are directly relevant to every national security mission that applies, or will apply, machine learning to data, most of which entail some decision context.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Application of Quantum Machine Learning to High Energy Physics Analysis at LHC using IBM Quantum Computer Simulators and IBM Quantum Computer Hardware

One of the major objectives of the experimental programs at the LHC is the discovery of new physics. This requires the identification of rare signals in immense backgrounds. Using machine learning algorithms greatly enhances our ability to achieve this objective. With the progress of quantum technologies, quantum machine learning could become a powerful tool for data analysis in high energy physics. In this study, using IBM gate-model quantum computing systems, we employ the quantum variational classifier method and the quantum kernel estimator method in two recent LHC flagship physics analyses: $t\bar{t}H$ (Higgs boson production in association with a top quark pair) and $H\rightarrow\mu\mu$ (Higgs boson decays to two muons). We have obtained early results with 10 qubits on the IBM quantum simulator and the IBM quantum hardware. On the quantum simulator, the quantum machine learning methods perform similarly to classical algorithms such as SVM (support vector machine) and BDT (boosted decision tree), which are often employed in LHC physics analyses. On the quantum hardware, the quantum machine learning methods have shown promising discrimination power, comparable to that on the quantum simulator. This study demonstrates that quantum machine learning has the ability to differentiate between signal and background in realistic physics datasets.

Chan, Jay↗
NASA NTRS1978

Formal modeling of virtual machines

Systematic software design can be based on the development of a 'hierarchy of virtual machines', each representing a 'level of abstraction' of the design process. The reported investigation presents the concept of 'data space' as a formal model for virtual machines. The presented model of a data space combines the notions of data type and mathematical machine to express the close interaction between data and control structures which takes place in a virtual machine. One of the main objectives of the investigation is to show that control-independent data type implementation is only of limited usefulness as an isolated tool of program development, and that the representation of data is generally dictated by the control context of a virtual machine. As a second objective, a better understanding is to be developed of virtual machine state structures than was heretofore provided by the view of the state space as a Cartesian product.

Cremers, A. B.↗
NASA NTRS1989

Human factors model concerning the man-machine interface of mining crewstations

The U.S. Bureau of Mines is developing a computer model to analyze the human factors aspect of mining machine operator compartments. The model will be used as a research tool and as a design aid. It will have the capability to perform the following: simulated anthropometric or reach assessment, visibility analysis, illumination analysis, structural analysis of the protective canopy, operator fatigue analysis, and computation of an ingress-egress rating. The model will make extensive use of graphics to simplify data input and output. Two dimensional orthographic projections of the machine and its operator compartment are digitized and the data rebuilt into a three dimensional representation of the mining machine. Anthropometric data from either an individual or any size population may be used. The model is intended for use by equipment manufacturers and mining companies during initial design work on new machines. In addition to its use in machine design, the model should prove helpful as an accident investigation tool and for determining the effects of machine modifications made in the field on the critical areas of visibility and control reach ability.

Rider, James P.↗