Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “machining processes”

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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Accelerating Machine Learning Inference with GPUs in ProtoDUNE Data Processing

Abstract We study the performance of a cloud-based GPU-accelerated inference server to speed up event reconstruction in neutrino data batch jobs. Using detector data from the ProtoDUNE experiment and employing the standard DUNE grid job submission tools, we attempt to reprocess the data by running several thousand concurrent grid jobs, a rate we expect to be typical of current and future neutrino physics experiments. We process most of the dataset with the GPU version of our processing algorithm and the remainder with the CPU version for timing comparisons. We find that a 100-GPU cloud-based server is able to easily meet the processing demand, and that using the GPU version of the event processing algorithm is two times faster than processing these data with the CPU version when comparing to the newest CPUs in our sample. The amount of data transferred to the inference server during the GPU runs can overwhelm even the highest-bandwidth network switches, however, unless care is taken to observe network facility limits or otherwise distribute the jobs to multiple sites. We discuss the lessons learned from this processing campaign and several avenues for future improvements.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Additive Friction Stir Deposition of a Tantalum–Tungsten Refractory Alloy

Additive friction stir deposition (AFSD) is a solid-state metal additive manufacturing technique, which utilizes frictional heating and plastic deformation to create large deposits and parts. Much like its cousin processes, friction stir welding and friction stir processing, AFSD has seen the most compatibility and use with lower-temperature metals, such as aluminum; however, there is growing interest in higher-temperature materials, such as titanium and steel alloys. In this work, we explore the deposition of an ultrahigh-temperature refractory material, specifically, a tantalum–tungsten (TaW) alloy. The solid-state nature of AFSD means refractory process temperatures are significantly lower than those for melt-based additive manufacturing techniques; however, they still pose difficult challenges, especially in regards to AFSD tooling. In this study, we perform initial deposition trials of TaW using twin-rod-style AFSD with a high-temperature tungsten–rhenium-based tool. Many challenges arise because of the high temperatures of the process and high mechanical demand on AFSD machine hardware to process the strong refractory alloy. Despite these challenges, successful deposits of the material were produced and characterized. Mechanical testing of the deposited material shows improved yield strength over that of the annealed reference material, and this strengthening is mostly attributed to the refined recrystallized microstructure typical of AFSD. These findings highlight the opportunities and challenges associated with ultrahigh-temperature AFSD, as well as provide some of the first published insights into twin-rod-style AFSD process behaviors.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Vision-based localization for cooperative robot-CNC hybrid manufacturing

Wire and arc additive manufacturing (WAAM) has shown promise in recent years for producing large-scale parts with higher deposition rates than other additive processes. WAAM is often combined with subtractive machining to form a hybrid manufacturing process. This hybrid process can be realized by retrofitting computer numerical control (CNC) machines with deposition heads, adding spindles and deposition heads to robots, or developing part localization methods to transfer parts from an additive cell to a CNC machine. Here, a novel, robot-CNC hybrid configuration is introduced where a maneuverable robot is placed in front of a CNC machine to deposit material within the machine envelop. Furthermore, this method removes the need for part localization and the extensive machine modifications required for retrofitting; however, the problem of robot localization is also added. In this work, the effects of error in vision-based, contactless robot localization on machining parameters in a robot-machine hybrid process were studied. Performance was characterized on an implementation of this system using classical computer vision techniques. In addition, machining simulations were conducted to evaluate the effects of image-induced error on chip thickness, material removal rate, and machining allowance. Initial tests show that computer vision could adequately locate a robot for the hybrid WAAM process within .5 mm.

Hybrid manufacturing↗
DOE OSTI2022

Molecular-orbital-based machine learning for open-shell and multi-reference systems with kernel addition Gaussian process regression

We introduce a novel machine learning strategy, kernel addition Gaussian process regression (KA-GPR), in molecular-orbital-based machine learning (MOB-ML) to learn the total correlation energies of general electronic structure theories for closed- and open-shell systems by introducing a machine learning strategy. The learning efficiency of MOB-ML(KA-GPR) is the same as the original MOB-ML method for the smallest criegee molecule, which is a closed-shell molecule with multi-reference characters. In addition, the prediction accuracies of different small free radicals could reach the chemical accuracy of 1 kcal/mol by training on one example structure. Accurate potential energy surfaces for the H10 chain (closed-shell) and water OH bond dissociation (open-shell) could also be generated by MOB-ML(KA-GPR). To explore the breadth of chemical systems that KA-GPR can describe, we further apply MOB-ML to accurately predict the large benchmark datasets for closed- (QM9, QM7b-T, and GDB-13-T) and open-shell (QMSpin) molecules.

Chemistry↗
DOE OSTI2021

IoT Devices and Applications for Wire-Based Hybrid Manufacturing Machine Tools

Hybrid manufacturing machine tools have the potential to be a disruptive technology as they can leverage the benefits of both additive and subtractive manufacturing by incorporating both processes on the same machine while limiting the downsides of the individual processes. Since these machines use two very disparate manufacturing processes and hybrid manufacturing is an emerging technology, it will be useful to monitor data coming from the machine and apply it to improve the manufacturing process, the operation of the machine, and to integrate the machine into the larger digital framework of Industrial Internet of Things (IoT). The present work discusses IoT devices that would be beneficial to add to a hybrid machine tool as well as applications for those devices. The proposed methods discussed in this work have not been experimentally implemented on a hybrid machine tool and so there are no performance data available yet. The hybrid machine tool used as a basis to generate these IoT applications is the Mazak VC-500A/5x AM Hot Wire Deposition, which is a 5-axis machine tool incorporated with a wire feedstock 4kW laser deposition system. Methodologies and applications will be outlined for machine health and process monitoring. Other areas covered include process benchmarking, secure networking options for the proposed IoT framework, and hybrid process improvement. Limitations of these methods and future work for new sensor devices and application areas is also discussed.

Thien, Austen↗
DOE OSTI2021

Classification and regression models of audio and vibration signals for machine state monitoring in precision machining systems

Here we present a data-driven method for monitoring machine status in manufacturing processes. Audio and vibration data from precision machining are used for inference in two operating scenarios: (a) variable machine health states (anomaly detection); and (b) settings of machine operation (state estimation). Audio and vibration signals are first processed through Fast Fourier Transform and Principal Component Analysis to extract transformed and informative features. These features are then used in the training of classification and regression models for machine state monitoring. Specifically, three classifiers (K-nearest neighbors, convolutional neural networks and support vector machines) and two regressors (support vector regression and neural network regression) were explored, in terms of their accuracy in machine state prediction. It is shown that the audio and vibration signals are sufficiently rich in information about the machine that 100% state classification accuracy could be accomplished. Data fusion was also explored, showing overall superior accuracy of data-driven regression models.

42 ENGINEERING↗
DOE OSTI2023

Predicting chatter using machine learning and acoustic signals from low-cost microphones

Machining chatter is a phenomenon resulting from self-oscillation between a machining tool and workpiece. This self-oscillation results in variation on the machined product that reduces the ability to meet desired specifications. Chatter is a widely studied topic as it directly relates to the quality of machined products. Here, this study details the application of a Random Forest (RF) classifier with Recursive Feature Elimination (RFE) to machining audio collected by a single microphone during down-milling operations. This approach allows straightforward feature elimination that results in an easily understood set of analyzed dimensions. Stability is predicted solely based on the classification output of the RF classifier. Our approach proves highly predictive with consistent machining setup and a small sample set. We also review transferability between machining setups and present key findings. Our RF approach demonstrates the ability to analyze and classify chatter through a low-cost approach with limited training data required. The motivation for using a single microphone is to enable detection on machines without other sensors, such as accelerometers, present in the machining setup. The value of the in-process sensor and chatter classifier is highlighted because the machining setup included asymmetric dynamics that reduced the accuracy of the traditional analytical stability solution. We see a natural progression to deploying this audio-only methodology with real-time processing and classification using either a laptop or smartphone. This progression will allow visual indicators during the machining process that can alert machinists of progression into unstable machining processes.

42 ENGINEERING↗
DOE OSTI2022

Machine learning with knowledge constraints for process optimization of open-air perovskite solar cell manufacturing

Perovskite photovoltaics (PV) have achieved rapid development in the past decade in terms of power conversion efficiency of small-area lab-scale devices; however, successful commercialization still requires further development of low-cost, scalable, and high-throughput manufacturing techniques. One of the critical challenges of developing a new fabrication technique is the high-dimensional parameter space for optimization, but machine learning (ML) can readily be used to accelerate perovskite PV scaling. Herein, we present an ML-guided framework of sequential learning for manufacturing process optimization. We apply our methodology to the Rapid Spray Plasma Processing (RSPP) technique for perovskite thin films in ambient conditions. With a limited experimental budget of screening 100 process conditions, we demonstrated an efficiency improvement to 18.5% as the best-in-our-lab device fabricated by RSPP, and we also experimentally found 10 unique process conditions to produce the top-performing devices of more than 17% efficiency, which is 5 times higher rate of success than the control experiments with pseudo-random Latin hypercube sampling. Our model is enabled by three innovations: (a) flexible knowledge transfer between experimental processes by incorporating data from prior experimental data as a probabilistic constraint; (b) incorporation of both subjective human observations and ML insights when selecting next experiments; (c) adaptive strategy of locating the region of interest using Bayesian optimization first, and then conducting local exploration for high-efficiency devices. Furthermore, in virtual benchmarking, our framework achieves faster improvements with limited experimental budgets than traditional design-of-experiments methods (e.g., one-variable-at-a-time sampling). This framework shows the capability of incorporating researchers’ domain knowledge into the ML-guided optimization loop; therefore, it has the potential to facilitate the wider adoption of ML in scaling to perovskite PV manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2024

Machine-learning based approach to examine ecological processes influencing the diversity of riverine dissolved organic matter composition

Dissolved organic matter (DOM) assemblages in freshwater rivers are formed from mixtures of simple to complex compounds that are highly variable across time and space. These mixtures largely form due to the environmental heterogeneity of river networks and the contribution of diverse allochthonous and autochthonous DOM sources. Most studies are, however, confined to local and regional scales, which precludes an understanding of how these mixtures arise at large, e.g., continental, spatial scales. The processes contributing to these mixtures are also difficult to study because of the complex interactions between various environmental factors and DOM. Here we propose the use of machine learning (ML) approaches to identify ecological processes contributing toward mixtures of DOM at a continental-scale. We related a dataset that characterized the molecular composition of DOM from river water and sediment with Fourier-transform ion cyclotron resonance mass spectrometry to explanatory physicochemical variables such as nutrient concentrations and stable water isotopes ( 2 H and 18 O). Using unsupervised ML, distinctive clusters for sediment and water samples were identified, with unique molecular compositions influenced by environmental factors like terrestrial input and microbial activity. Sediment clusters showed a higher proportion of protein-like and unclassified compounds than water clusters, while water clusters exhibited a more diversified chemical composition. We then applied a supervised ML approach, involving a two-stage use of SHapley Additive exPlanations (SHAP) values. In the first stage, SHAP values were obtained and used to identify key physicochemical variables. These parameters were employed to train models using both the default and subsequently tuned hyperparameters of the Histogram-based Gradient Boosting (HGB) algorithm. The supervised ML approach, using HGB and SHAP values, highlighted complex relationships between environmental factors and DOM diversity, in particular the existence of dams upstream, precipitation events, and other watershed characteristics were important in predicting higher chemical diversity in DOM. Our data-driven approach can now be used more generally to reveal the interplay between physical, chemical, and biological factors in determining the diversity of DOM in other ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Experimental Setup and Learning-Based AI Model for Developing Accurate PV Inverter Models

The integration of power electronics-based interfaces presents challenges due to the absence of detailed models and the high computational complexity. Generic models used in system studies lack accuracy in capturing converter dynamics. This paper proposes a data-driven approach developed from experimental setup data. This approach enhances accuracy in photovoltaic inverter modeling. We used two types of PV inverters in the experiment. The recorded experimental data undergo processing through a machine learning model. Results from the model trained through machine learning is also presented.

artificial intelligence↗
DOE OSTI2023

Barium stars as tracers of s -process nucleosynthesis in AGB stars: II. Using machine learning techniques on 169 stars

Barium (Ba) stars are characterised by an abundance of heavy elements made by the slow neutron capture process (s-process). This peculiar observed signature is due to the mass transfer from a stellar companion, bound in a binary stellar system, to the Ba star observed today. The signature is created when the stellar companion is an asymptotic giant branch (AGB) star. We aim to analyse the abundance pattern of 169 Ba stars using machine learning techniques and the AGB final surface abundances predicted by the FRUITY and Monash stellar models. We developed machine learning algorithms that use the abundance pattern of Ba stars as input to classify the initial mass and metallicity of each Ba star’s companion star using stellar model predictions. We used two algorithms. The first exploits neural networks to recognise patterns, and the second is a nearest-neighbour algorithm that focuses on finding the AGB model that predicts the final surface abundances closest to the observed Ba star values. In the second algorithm, we included the error bars and observational uncertainties in order to find the best-fit model. The classification process was based on the abundances of Fe, Rb, Sr, Zr, Ru, Nd, Ce, Sm, and Eu. We selected these elements by systematically removing s-process elements from our AGB model abundance distributions and identifying the elements whose removal had the biggest positive effect on the classification. We excluded Nb, Y, Mo, and La. Our final classification combined the output of both algorithms to identify an initial mass and metallicity range for each Ba star companion. With our analysis tools, we identified the main properties for 166 of the 169 Ba stars in the stellar sample. The classifications based on both stellar sets of AGB final abundances show similar distributions, with an average initial mass of M = 2.23 M ⊙ and 2.34 M ⊙ and an average [Fe/H] = –0.21 and –0.11, respectively. We investigated why the removal of Nb, Y, Mo, and La improves our classification and identified 43 stars for which the exclusion had the biggest effect. We found that these stars have statistically significant and different abundances for these elements compared to the other Ba stars in our sample. We discuss the possible reasons for these differences in the abundance patterns.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing

The Physics-Guided Machine Learning (PGML) for Improved Aerostructure Manufacturing project objective is to automatically tune machining parameter predictions from physics-based models using process data and Bayesian machine learning. The intent is to enable a step change in aerospace manufacturing by combining machine learning, physics-based process models, and sensors/data in a comprehensive digital environment that simultaneously considers the computer numerically controlled (CNC) machining center capabilities, the workpiece material and geometry, and the workpiece support (fixturing). The project hypothesis is that this combination will enable improved performance in machining operations.

42 ENGINEERING↗
DOE OSTI2021

Iterative hybrid manufacture of a titanium alloy component

Here, this paper describes an iterative hybrid (additive + subtractive) manufacturing approach for a titanium alloy (Ti6Al4V) part using a laser hotwire directed energy deposition system (LHWDED) and a traditional four-axis milling machine tool. The term iterative hybrid manufacturing is used to described hybrid manufacturing where the additive and subtractive operations occur in multiple stages rather than sequentially. It is currently common to produce an entire part by sequential hybrid manufacturing by additively manufacturing (AM) an entire preform geometry that then requires post processing by another machine tool to create final part features. By contrast, a part produced by iterative hybrid manufacturing (IHM) does not produce the entire preform geometry in a single AM process. Instead, a portion of the entire preform geometry is manufactured by an AM process, then that portion is transferred to another machine tool which creates features in that portion, and then that machined portion is transferred back to the AM machine to complete another AM process. There is no limit to the number of iterations that an IHM process can have. IHM offers several advantages over sequential hybrid manufacturing such as the use of shorter and stiffer subtractive tooling, better access to part geometries that require subtractive processes, and the separation of the AM heat source from the subtractive machine tool. A titanium alloy demonstration part was successfully manufactured by IHM with three iterations using a shared pallet system between the AM machine tool and the subtractive machine tool.

Hybrid manufacturing↗
DOE OSTI2022

SplitML

SplitML (Signal Processing Library for Interference rejecTion by Machine Learning) is a code repository for a set of tools for interference rejection in complex time-domain signals. The goal of the tools is to provide machine learning modeling capabilities for rejecting interference. Recent related machine learning algorithms for signal processing have focused mostly on speech enhancement or multi-speaker speech separation; the tools in SplitML will extend these innovations to generic time-domain signals of interest. SplitML includes tools for generating synthetic noisy signals, code for customized machine learning models applicable to interference rejection, and tools for evaluating such algorithms against standard signal processing techniques. These components are written in Python, a high-level programming language that takes advantage of the Python ecosystem of high-quality open-source packages for machine learning and signal processing.

Klein, Natalie↗
DOE OSTI2020

Process Image Analysis using Big Data, Machine Learning, and Computer Vision

The development of algorithms for machine learning and data analysis for the 3013 MIS corrosion surveillance program is a collaborative effort by SRNL, USC and GT. For corrosion detection, LCM image data is extracted from large binary files, with software written to convert the data to physical attributes (i.e. height, color and grayscale values; all as functions of a location in a plane projection). The user interface for the software permits selective downloading of binary data and interrogation of attributes. User input thresholds are used to flag attributes of interest. Machine learning algorithms, developed for this application, are used to determine whether the features are the result of corrosion. To address the fundamental mechanisms of corrosion, machine learning algorithms are being developed to derive interatomic potential force-fields from ab-initio DFT calculations. The goal is to apply molecular modeling on a large enough scale to guide the design of resistant materials.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗