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At least 649 records · Page 36

All sources NASA NTRS DOE OSTI

DOE OSTI2018

Ultrafast Sharpening of a Hard-Alloy Tool

The sharpening of hard-alloy cutting tools affects their life and reliability and the quality of the machined surface. In the case of imported tools for high-precision machining, the rounding radius of the cutting edge after sharpening is 10–15 µm. That permits machining with chip thickness no less than 20–30 µm. This limit is often critical, since the machining precision of some important components is 3–5 µm. In addition, such sharpening shortens the potential tool life. If sharpening is improved so that the rounding radius of the cutting edge is 3–5 µm, the machining precision is enhanced and tool life is extended. That improves machining [2].

42 ENGINEERING↗

DOE OSTI2018

Controlling the State of Machine Tools

Globally, manufacturers make great efforts to maintain the performance of industrial equipment. Developers and researchers are interested in automated approaches to maintaining the performance of equipment, especially at enterprises with high degrees of computerization and comprehensive information systems. In the present work, a new approach is outlined: an autonomous control system for maintaining the condition of metal-cutting machines. This approach is based on prior work in the field and permits maintenance on the basis of autonomous control of the state of machine tools. The structure of a system with the following generalized control functions is presented: decision making; and the issuing of commands on the basis of built-in resources. The formulation of control decisions employs the theory of fuzzy sets and fuzzy logic. By means of the ANFIS fuzzy network system, the autonomy of state control of the machine tool may be assessed. Criticality assessment of the condition of machine tools and their components is important in making decisions as to the setup of systems controlling the condition of equipment at enterprises, with assessment of their efficiency. In the monitoring subsystem, provision is made for assessment of the diagnostic results, prediction, and the generation of control decisions so as to prevent disruptions of machine-tool operation.

42 ENGINEERING↗

DOE OSTI2019

Preventing Faults in Machine Tools for Critical Cooperative and Distributed Industrial Productions

A critically important high-tech industrial enterprise forms part of a territorially distributed cooperative production system. Precise optimization of management decisions regarding fault prevention in its stock of machine tools is very important. Up-to-date tools for management decisions must be used for that purpose. Those tools must support the basic management functions and include software for high-level mathematical models of machine-tool operation (models of the state of the equipment and a model of its use in the course of production) and a model of the economic potential of the enterprises.

42 ENGINEERING↗

DOE OSTI2024

Agrivoltaic Decision Tools for Perennial and Field Crop Farmers

This article describes a series of spreadsheet-based tools to help farmers estimate costs, revenues, and yields from agricultural production under different configurations of agrivoltaic installations for field and perennial crops. Crop-specific log books allow farmers to project changes in activity-level costs from the field due to agrivoltaic installations. The whole-farm tool helps farmers aggregate activity-level net returns up to the farm level to calculate projections of trade-offs between crop production with or without agrivoltaic installations. We present tools for lettuce and cranberries, but the tools are comprehensive and inclusive and so can be modified for other perennial and field crops.

14 SOLAR ENERGY↗

NASA NTRS2013

An Evaluation of Operational Airspace Sectorization Integrated System (OASIS) Advisory Tool

In January 2013, a human-in-the-loop evaluation of the Operational Airspace Sectorization Integrated System (OASIS) was conducted in the Airspace Operations Laboratory of the Human Systems Integration Division (Code TH) in conjunction with the Aviation Systems Division (Code AF). The development of OASIS is a major activity of the Dynamic Airspace Configuration (DAC) research focus area within the Aeronautics Research Mission Directorate (ARMD) Airspace Systems Program. OASIS is an advisory tool to assist Federal Aviation Administration (FAA) En Route Area Supervisors in their planning of sector combinedecombine operations as well as opening closing of Data-side (D-side) control positions. These advisory solutions are tailored to the predicted traffic demand over the next few hours. During the experiment, eight retired FAA personnel served as participants for a part-task evaluation of OASIS functionality, covering the user interface as well as the underlying algorithm. Participants gave positive feedback on both the user interface and the algorithm solutions for airspace configuration, including an excellent average rating of 94 on the tool usability scales. They also suggested various enhancements to the OASIS tool, which will be incorporated into the next tool development cycle for the full-scale human-in-the-loop evaluation to be conducted later this year.

decision support tools↗

NASA NTRS2013

Tool Use Within NASA Software Quality Assurance

As space mission software systems become larger and more complex, it is increasingly important for the software assurance effort to have the ability to effectively assess both the artifacts produced during software system development and the development process itself. Conceptually, assurance is a straightforward idea - it is the result of activities carried out by an organization independent of the software developers to better inform project management of potential technical and programmatic risks, and thus increase management's confidence in the decisions they ultimately make. In practice, effective assurance for large, complex systems often entails assessing large, complex software artifacts (e.g., requirements specifications, architectural descriptions) as well as substantial amounts of unstructured information (e.g., anomaly reports resulting from testing activities during development). In such an environment, assurance engineers can benefit greatly from appropriate tool support. In order to do so, an assurance organization will need accurate and timely information on the tool support available for various types of assurance activities. In this paper, we investigate the current use of tool support for assurance organizations within NASA, and describe on-going work at JPL for providing assurance organizations with the information about tools they need to use them effectively.

software assurance↗

DOE OSTI2015

Developing a 300C Analog Tool for EGS

This paper covers the development of a 300°C geothermal well monitoring tool for supporting future EGS (enhanced geothermal systems) power production. This is the first of 3 tools planed. This is an analog tool designed for monitoring well pressure and temperature. There is discussion on 3 different circuit topologies and the development of the supporting surface electronics and software. There is information on testing electronic circuits and component. One of the major components is the cable used to connect the analog tool to the surface.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

Tool-Based Case Studies on Strategic Deployment of Untapped Micro-Pumped Hydro Storage in Michigan

With most classical hydropower sites already utilized and the global push for rapid integration of renewable energy sources accelerating, there is a critical need to identify alternative energy storage solutions. Pumped hydro energy storage, which accounts for the vast majority of global grid-scale storage, remains one of the most cost-effective and long-duration storage technologies available. Hence, this study presents a novel tool designed to assess the untapped potential of inland lakes and reservoirs for micro-PSH, using Michigan’s relatively flat landscape as a case study due to its extensive but underutilized water infrastructure. To ensure accuracy and reliability, the tool incorporates extensive data gathered from authorized sources, covering more than 420 water facilities and potential reservoirs in the state. The tool evaluates key parameters such as horizontal and vertical distances, volume, and the total storage capacity of each reservoir. Its robust assessment framework integrates these metrics to evaluate each site’s potential. The tool’s intuitive interface and geospatial visualizations support actionable insights for planners and scalable deployment of distributed storage infrastructure.

13 HYDRO ENERGY↗

DOE OSTI2024

Investigating Formal Methods Tools and their Applicability for Hardware Vulnerability Remediation

Formal methods use mathematical logic and equations to prove that a system or code is secure. In this poster, I examine existing formal methods tools and their application for projects working to remediate vulnerabilities in hardware and hardware description language. This poster is focused on the tools ReWire and AutoGenILA and I hope to evaluate their benefits and weaknesses with the intention of creating an internal report on the application and weaknesses of existing formal methods tools and identifying gaps for future formal methods tool creation.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Fleet Tools; NREL (National Renewable Energy Laboratory)

From beverage distributors to shipping companies and federal agencies, industry leaders turn to the National Renewable Energy Laboratory (NREL) to help green their fleet operations. Cost, efficiency, and reliability are top priorities for fleets, and NREL partners know the lab’s portfolio of tools can pinpoint fuel efficiency and emissions-reduction strategies that also support operational the bottom line. NREL is one of the nation’s foremost leaders in medium- and heavy-duty vehicle research and development (R&D) and the go-to source for credible, validated transportation data. NREL developers have drawn on this expertise to create tools grounded in the real-world experiences of commercial and government fleets. Operators can use this comprehensive set of technology- and fuel-neutral tools to explore and analyze equipment and practices, energy-saving strategies, and other operational variables to ensure meaningful performance, financial, and environmental benefits.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Multi‐objective optimization for cost‐efficient and resilient machining under tool wear

Abstract With the onset and rapid growth of smart manufacturing, there is a constant increase in the demand for automation technologies to enhance productivity while providing uninterrupted, cost‐efficient, and resilient machining. Traditional manufacturing systems, however, suffer from several losses due to machine faults and degradation. Specifically, tool wear directly impacts the precision and quality of the milled parts, which causes an increase in the scrap production. Hence, more attempts are required to meet the desired quota of successful parts, which in turn results in wasted material, longer delays, further tool degradation, and higher energy, machining, and labor costs. As such, this paper develops a multi‐objective optimization framework to generate the optimal control set points (e.g., feed rate and width of cut) that minimize the total cost of machining operations resulting from multiple contradictory cost functions (e.g., material, energy, tardiness, machining, labor, and tool) in the presence of tool wear. Notably, we estimate the total expected cost in dollars, which provides automatic and intuitive weighting in this multi‐objective formulation. The optimization framework is tested on a high‐fidelity face milling model that has been validated on real data from industry. Results show significant dollar savings of up to as compared to the default control scheme.

Wilson, James P.↗

DOE OSTI2018

Regulatory Tools for Controlling Gene Expression in Cyanobacteria

Cyanobacteria are attractive hosts for converting carbon dioxide and sunlight into desirable chemical products. To engineer these organisms and manipulate their metabolic pathways, the biotechnology community has developed genetic tools to control gene expression. Many native cyanobacterial promoters and related sequence elements have been used to regulate genes of interest, and heterologous tools that use non-native small molecules to induce gene expression have been demonstrated. Overall, IPTG-based induction systems seem to be leaky and initially demonstrate small dynamic ranges in cyanobacteria. Consequently, a variety of other induction systems have been optimized to enable tighter control of gene expression. Tools require significant optimization because they function quite differently in cyanobacteria when compared to analogous use in model heterotrophs. We hypothesize that these differences are due to fundamental differences in physiology between organisms. This review is not intended to summarize all known products made in cyanobacteria nor the performance (titer, rate, yield) of individual strains, but instead will focus on the genetic tools and the inherent aspects of cellular physiology that influence gene expression in cyanobacteria.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗

DOE OSTI2023

SyReNN: A tool for analyzing deep neural networks

Deep Neural Networks (DNNs) are rapidly gaining popularity in a variety of important domains. Unfortunately, modern DNNs have been shown to be vulnerable to a variety of attacks and buggy behavior. This has motivated recent work in formally analyzing the properties of such DNNs. Furthermore, this paper introduces SyReNN, a tool for understanding and analyzing a DNN by computing its symbolic representation. The key insight is to decompose the DNN into linear functions. Our tool is designed for analyses using low-dimensional subsets of the input space, a unique design point in the space of DNN analysis tools. We describe the tool and the underlying theory, then evaluate its use and performance on three case studies: computing Integrated Gradients, visualizing a DNN’s decision boundaries, and repairing buggy DNNs.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2017

Effects of High Current Pulsed Electron Beam Irradiation on the Mechanical Properties and Cutting Performance of TiAlN-Coated Tools

Commercial TiAlN-coated carbide tools were post-treated using the high current pulsed electron beam irradiation method. The influence of the energy density of the electron beam on the morphology, phase composition, surface roughness and Vickers hardness were investigated. The higher energy density imposed on TiAlN-coated carbide tools resulted in a flatter and harder modified surface. After the beam irradiation, the XRD diffraction peak intensity of the hardening phase (Ti,Al)N was changed, and the diffraction peak position was shifted; these changes are attributed to the improved microhardness of the irradiated coatings. Investigations on the cutting experiments of turning Ti-6Al-4V alloy showed that the irradiated TiAlN-coated carbide tool exhibited longer cutting life and better wear resistance than those of an unirradiated tool. This improvement is attributed to the combined effect of low surface roughness and high microhardness that resulted from the high current pulse electron beam irradiation.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Finite Element Simulation and Optimization of Gas-Quenching Process for Tool Steels

Various gas-quenching processes, including marquenching, were investigated to optimize gas-quenching processes in terms of distortion and hardness by means of numerical and experimental analyses. The temperature, microstructure, hardness, and distortion during the various gas-quenching processes of a tool steel block were simulated using a finite element method based on a coupled thermo-metallurgical–mechanical model. The predicted temperature, hardness, and distortion agreed well with the experimental data. The tool steel block (200 × 150 × 70 mm{sup 3}) quenched under 10 bar pressure of nitrogen gas (Case 2) had higher hardness due to the higher martensite fraction and larger distortion owing to the higher thermal stress induced by faster cooling, compared to the block quenched under 2 bar pressure of nitrogen gas (Case 1). The tool steel block marquenched under 10 bar pressure of nitrogen gas interrupted by isothermal holding at 500 °C (Case 3) had 30% smaller distortion with a negligible loss of hardness compared to Case 2. Furthermore, the simulation results could provide an optimized process condition to minimize distortion of the gas-quenched tool steel block while satisfying the hardness requirement.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Effect of Tool Temperature on Microstructure and Properties of Tailored Hot Stamping Components

Traditional boron steel hot stamping technology can achieve components with full martensite and tensile strength of 1500 MPa. However, fully martensitic hot stamped components exhibit very low level of ductility and are rarely used in energy absorbing structures. Hot stamping with segmented heating and cooling tool can obtain multiphase quenched structures and the tailored mechanical properties. Hot stamping experiment of U-shape component was performed with segmented heating and cooling tool. Mechanical properties of the formed component were measured, and scanning electron microscope and color tint etching were used to quantify the quenched phases achieved under different tool temperatures. The results showed that hardness value decreased from 470 to 230 HV and tensile strength reduced about 50% from 1406 to 730 MPa and elongation increased from 4.19 to 10.20% as tool temperatures increased from 25 to 500 °C. Meanwhile, martensite decreased from 85 to 30% and bainite increased from 12 to 55%, and there was also a small increase in ferrite. In order to get the influence of quenched phases on the strength and hardness of tailored hot stamped component, linear fitting optimization was used to establish mathematical models for area fraction of quenched phases and strength and hardness.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗