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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

User's manual for tooth contact analysis of face-milled spiral bevel gears with given machine-tool settings

Research was performed to develop a computer program that will: (1) simulate the meshing and bearing contact for face milled spiral beval gears with given machine tool settings; and (2) to obtain the output, some of the data is required for hydrodynamic analysis. It is assumed that the machine tool settings and the blank data will be taken from the Gleason summaries. The theoretical aspects of the program are based on 'Local Synthesis and Tooth Contact Analysis of Face Mill Milled Spiral Bevel Gears'. The difference between the computer programs developed herein and the other one is as follows: (1) the mean contact point of tooth surfaces for gears with given machine tool settings must be determined iteratively, while parameters (H and V) are changed (H represents displacement along the pinion axis, V represents the gear displacement that is perpendicular to the plane drawn through the axes of the pinion and the gear of their initial positions), this means that when V differs from zero, the axis of the pionion and the gear are crossed but not intersected; (2) in addition to the regular output data (transmission errors and bearing contact), the new computer program provides information about the contacting force for each contact point and the sliding and the so-called rolling velocity. The following topics are covered: (1) instructions for the users as to how to insert the input data; (2) explanations regarding the output data; (3) numerical example; and (4) listing of the program.

Litvin, Faydor L.↗
NASA NTRS1993

Milling dynamics. I - Attritor dynamics: Results of a cinematographic study

The motions of grinding media and powder in an attritor canister were studied by means of filming the agitated charge and frame-by-frame scrutiny of the footage. In conjunction with auxiliary experiments, this permitted semiquantitative analysis of the milling action. In particular, the mill can be divided into several regions characterized by different balances between direct impacts and rolling/sliding of the grinding media. Simple calculations suggest that impacts are more capable of effecting mechanical alloying (MA) than are rolling or sliding events in an attritor. Powder circulation within an operating mill was also investigated. Based on the results and the accompanying analysis, concepts for improved attritor design are presented.

Rydin, R. W.↗
NASA NTRS2001

Experimental Comparison of Face-Milled and Face-Hobbed Spiral Bevel Gears

An experimental comparison of face-milled and face-hobbed spiral bevel gears was accomplished. The two differently manufactured spiral bevel gear types were tested in a closed-loop facility at NASA Glenn Research Center. Strain, vibration, and noise testing were completed at various levels of rotational speed and load. Tests were conducted from static (slow-roll) to 12600 rpm and up to 269 N-m (2380 in.-lb) pinion speed and load conditions. The tests indicated that the maximum stress recorded at the root locations had nearly the same values, however the stress distribution was different from the toe to the heel. Also, the alternating stress measured was higher for the face-milled pinion than that attained for the face-hobbed pinion (larger minimum stress). The noise and vibration results indicated that the levels measured for the face-hobbed components were less than those attained for the face-milled gears tested.

Handschuh, Robert F.↗
NASA NTRS2002

Ion Milling of Sapphire

The ion figuring system at the Marshall Space Flight Center has been successfully used for at least three previous investigations into the ion milling of metals. The research was directed toward improving the surface quality of X-ray directing optics. These studies were performed on surfaces that were already hand polished to an excellent surface quality and were intended to remove the residual unwanted figure left by those techniques. The ion milling was typically carried out on test surfaces or mandrels that were several centimeters in width and length. The good thermal conductivity of the metal samples allowed the ion beam to be directed onto the sample for an indefinite period of time. This is not true of sapphire or most electrical insulators and problems have arisen in recent attempts to ion mill thin samples of sapphire. The failure and fracture of the material was likely due to thermal stresses and the relatively low thermal conductivity of sapphire (compared to most metals), These assumed stresses actually provided the key as to how they might be monitored. A thermal gradient in the sapphire sample will induce an effective index of refraction change and because of the shape constraint and the crystal structure and simple thermal expansion, this index change will be nonuniform across the sample. In all but simple cubic crystal structures, this leads to a spatially nonuniform optical retardance induced on any polarized optical beam traversing the sample, and it is this retardance that can be monitored using standard polarimetric procedures.

Don A. Gregory↗
NASA NTRS2005

Retrieving Storm Electric Fields From Aircraft Field Mill Data: Applications - Part 2

The Lagrange multiplier theory and "pitch down method" developed in Part I of this study are applied to complete the calibration of a Citation aircraft that is instrumented with six field mill sensors. When side constraints related to average fields are used, the method performs well in computer simulations. For mill measurement errors of 1 V/m and a 5 V/m error in the mean fair weather field function, the 3-D storm electric field is retrieved to within an error of about 12%. A side constraint that involves estimating the detailed structure of the fair weather field was also tested using computer simulations. For mill measurement errors of 1 V/m, the method retrieves the 3-D storm field to within an error of about 8% if the fair weather field estimate is typically within 1 V/m of the true fair weather field. Using this side constraint and data from fair weather field maneuvers taken on 29 June 2001, the Citation aircraft was calibrated. The resulting calibration matrix was then used to retrieve storm electric fields during a Citation flight on 2 June 2001. The storm field results are encouraging and agree favorably with the results obtained from earlier calibration analyses that were based on iterative techniques.

Koshak, W. J.↗
NASA NTRS2005

Retrieving Storm Electric Fields From Aircraft Field Mill Data. Part I: Theory

It is shown that the problem of retrieving storm electric fields from an aircraft instrumented with several electric field mill sensors can be expressed in terms of a standard Lagrange multiplier optimization problem. The method naturally removes aircraft charge from the retrieval process without having to use a high voltage stinger and linearly combined mill data values. It also allows a variety of user-supplied physical constraints (the so-called side constraints in the theory of Lagrange multipliers). Additionally, this paper introduces a novel way of performing the absolute calibration of an aircraft that has several benefits over conventional analyses. In the new approach, absolute calibration is completed by inspecting the time derivatives of mill and pitch data for a pitch down maneuver performed at high (greater than 1 km) altitude. In Part II of this study, the above methods are tested and then applied to complete a full calibration of a Citation aircraft.

Koshak, W. J.↗
NASA NTRS2006

Retrieving Storm Electric Fields from Aircrfaft Field Mill Data: Part II: Applications

The Lagrange multiplier theory developed in Part I of this study is applied to complete a relative calibration of a Citation aircraft that is instrumented with six field mill sensors. When side constraints related to average fields are used, the Lagrange multiplier method performs well in computer simulations. For mill measurement errors of 1 V m(sup -1) and a 5 V m(sup -1) error in the mean fair-weather field function, the 3D storm electric field is retrieved to within an error of about 12%. A side constraint that involves estimating the detailed structure of the fair-weather field was also tested using computer simulations. For mill measurement errors of 1 V m(sup -l), the method retrieves the 3D storm field to within an error of about 8% if the fair-weather field estimate is typically within 1 V m(sup -1) of the true fair-weather field. Using this type of side constraint and data from fair-weather field maneuvers taken on 29 June 2001, the Citation aircraft was calibrated. Absolute calibration was completed using the pitch down method developed in Part I, and conventional analyses. The resulting calibration matrices were then used to retrieve storm electric fields during a Citation flight on 2 June 2001. The storm field results are encouraging and agree favorably in many respects with results derived from earlier (iterative) techniques of calibration.

Koshak, William↗
NASA NTRS2006

Retrieving Storm Electric Fields from Aircraft Field Mill Data: Theory - Part 1

It is shown that the problem of retrieving storm electric fields from an aircraft instrumented with several electric field mill sensors can be expressed in terms of a standard Lagrange multiplier optimization problem. The method naturally removes aircraft charge from the retrieval process without having to use a high voltage stinger and linearly combined mill data values. It allows a variety of user-supplied physical constraints (the so-called side constraints in the theory of Lagrange multipliers) and also helps improve absolute calibration. Additionally, this paper introduces an alternate way of performing the absolute calibration of an aircraft that has some benefits over conventional analyses. It is accomplished by using the time derivatives of mill and pitch data for a pitch down maneuver performed at high (greater than 1 km) altitude. In Part II of this study, the above methods are tested and then applied to complete a full calibration of a Citation aircraft.

Koshak, W. J.↗
NASA NTRS2012

The Amino Acid Composition of the Sutter's Mill Carbonaceous Chondrite

In contrast to the Murchison meteorite which had a complex distribution of amino acids with a total C2 to Cs amino acid abundance of approx.14,000 parts-per-billion (ppb) [2], the Sutters Mill meteorite was found to be highly depleted in amino acids. Much lower abundances (approx.30 to 180 ppb) of glycine, beta-alanine, L-alanine and L-serine were detected in SM2 above procedural blank levels indicating that this meteorite sample experienced only minimal terrestrial amino acid contamination after its fall to Earth. Carbon isotope measurements will be necessary to establish the origin of glycine and beta-alanine in SM2. Other non-protein amino acids that are rare on Earth, yet commonly found in other CM meteorites such as aaminoisobutyric acid (alpha-AIB) and isovaline, were not identified in SM2. However, traces of beta-AIB (approx.1 ppb) were detected in SM2 and could be" extraterrestrial in origin. The low abundances of amino acids in the Sutter's Mill meteorite is consistent with mineralogical evidence that at least some parts of the Sutter's Mill meteorite parent body experienced extensive aqueous and/or thermal alteration.

Glavin, D. P.↗
NASA NTRS2013

Coordinated In Situ Analyses of Organic Nanoglobules in the Sutter's Mill Meteorite

The Sutter s Mill meteorite is a newly fallen carbonaceous chondrite that was collected and curated quickly after its fall [1]. Preliminary petrographic and isotopic investigations suggest affinities to the CM2 carbonaceous chondrites. The primitive nature of this meteorite and its rapid recovery provide an opportunity to investigate primordial solar system organic matter in a unique new sample. Organic matter in primitive meteorites and chondritic porous interplanetary dust particles (CP IDPs) is commonly enriched in D/H and N-15/N-14 relative to terrestrial values [2-4]. These anomalies are ascribed to the partial preservation of presolar cold molecular cloud material [2]. Some meteorites and IDPs contain gm-size inclusions with extreme H and N isotopic anomalies [3-5], possibly due to preserved primordial organic grains. The abundance and isotopic composition of C in Sutter's Mill were found to be similar to the Tagish Lake meteorite [6]. In the Tagish Lake meteorite, the principle carriers of large H and N isotopic anomalies are sub-micron hollow organic spherules known as organic nanoglobules [7]. Organic nanoglobules are commonly distributed among primitive meteorites [8, 9] and cometary samples [10]. Here we report in-situ analyses of organic nano-globules in the Sutter's Mill meteorite using UV fluorescence imaging, Fourier-transform infrared spectroscopy (FTIR), scanning transmission electron microscopy (STEM), NanoSIMS, and ultrafast two-step laser mass spectrometry (ultra-L2MS).

Nakamura--Messenger, K.↗
DOE OSTI2022

Dynamic force and stability prediction for milling using feed rate scheduling software and time-domain simulation

This paper describes: 1) the use of feed rate scheduling software to predict the radial depth of cut variation for three-axis milling toolpaths and; 2) the use of the radial depth profile in a time-domain simulation to predict dynamic cutting forces. The time-domain simulation, which also includes the tool tip frequency response functions and force model (which relates the cutting force components to the chip geometry) as inputs, enables dynamic force profiles to be predicted and parameter combinations that cause chatter to be identified. A ramp geometry is selected that provides constantly varying radial depth and force predictions are completed at multiple axial depths for comparison to measured forces. Both stable and unstable (chatter) milling conditions were observed with good agreement between time-domain simulation and measurement results. The value of combining the feed rate scheduling software and time-domain simulation is demonstrated.

42 ENGINEERING↗
DOE OSTI2026

Focused ion beam milling of polycrystalline diamond

Focused ion beam (FIB) technology has a large potential for precise milling of ultrahard materials such as diamond. However, studies of the sputtering of diamond with ion species and energies relevant to the FIB technology are scarce. Here, we report a systematic study of the sputtering of polycrystalline diamond surfaces with ion beams in a wide range of ion energies (2 - 30 keV), incident beam angles (0 - 80°), and ion masses (N, O, Ar, and Xe). Results show that the sputter yield is relatively insensitive to ion energy but strongly depends on the ion species and incident beam angles. Bombardment with O ions results in sputter yields that are significantly larger than ballistic predictions due to chemical etching effects. Characteristic surface ripples develop for oblique beam incidence angle irradiation. The critical beam tilt angle for the onset of ripple formation and the wavelength of the ripples depend on ion species and energies. Ripples appear to suppress ion reflection at high beam tilt angles and, hence, a peak in the sputter yield angular dependence. In conclusion, these results have direct implications for the development of process parameter maps for high-precision ion-beam milling of diamond.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Physics-informed KNN milling stability model with process damping effects

This paper describes a k-nearest neighbors, or KNN, model for milling stability including process damping effects. A physics-based, frequency domain milling stability solution is used to generate the training data, but does not incorporate process damping effects. The data set is then updated using limited tests to capture the process damping behavior. A “stair step” approach is used to select the test points, where a first spindle speed-axial depth combination is selected based on the physics-based stability map, subsequent tests are defined using the previous test result, and data points are updated by knowledge of process damping behavior and the test results. Furthermore, the KNN modeling approach demonstrates the ability to predict both stable and unstable results, including process damping behavior.

42 ENGINEERING↗
DOE OSTI2020

Glass transition temperature studies of planetary ball milled glasses: Accessing the rapidly cooled glassy state in Na 4 P 2 S 7-x O x , 0 ≤ x ≤ 7, Oxy-thio phosphate glasses

This paper details the very first in-depth study of the glass transition temperature (T g ) for planetary balled milled (PBM) Na 4 P 2 S 7-x O x (NaPSO), where 0 ≤ x ≤ 7, glasses. For 0 ≤ x ≤ 5, fully amorphous, homogeneous, and chemically reacted compositions can be prepared. For samples with 5 < x ≤ 7, partially amorphous but fully chemically reacted glass-ceramics can be produced. The reproducible, thermally cyclable onset T g and the onset crystallization temperature, T c , were investigated as a function of the composition and of the short-range order (SRO) structures of the glasses. Additionally, we examined the extreme sub-T g exothermic relaxations present due to the high energy milling processing and correspondingly high effective quenching rate. Using a differential scanning calorimeter (DSC) and scanning from well below the onset T g , the glasses are observed to relax exothermally below T g . The integrated relaxation enthalpy, ΔH rel , is ~ 0 for the x = 2 glass, but is significantly exothermic for lower and higher values of x. Once the high fictive state of these glasses has been erased by scanning to above the T g , but below the T c of the glass, the DSC scans of the glasses recover normal behavior for a normally cooled glass without any relaxation exotherm. The T g s of these glasses remain relatively constant for 0 ≤ x ≤ 3, but for glasses with 3 < x ≤ 5, T g increases sharply following the combined effects of the phosphate chain length increasing caused by the formation of bridging oxygens and the increasing concentration of more charge dense non-bridging oxygens (NBOs). For x > 5, both T g and Tc decrease sharply, becoming nearly identical at x = 7 where glass formation essentially ceases. For smaller values of x, T c increases with both chain length and the structural complexity of the composition but decreases sharply for glass-ceramics of x > 5.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Low-cost, constrained-motion dynamometer for milling force measurement

This paper describes the design and testing of a low-cost dynamometer for milling force measurement. The monolithic design is based on constrained-motion/flexure-based kinematics, where force is inferred from displacement measured using a low-cost optical interrupter (i.e., a knife edge that partially interrupts the beam in an emitter-detector pair). The time-dependent displacement of the dynamometer’s moving platform caused by the milling force is converted to the frequency domain, multiplied by the inverse of the single degree of freedom frequency response, and converted back to the time domain to obtain the time dependent cutting force. Lastly, comparisons with commercially available, piezoelectric-based force measurement are provided.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Identification of Critical Process Parameters for Knife Milling and Alternative Communication Strategies

An assessment of knife milling operations was performed to identify parameters that require consideration to model wear and degradation of knife blades. A quality-by-design (QbD) paradigm was followed to identify material and feedstock attributes, and processing parameters that impact the quality attributes of the blades used in the comminution of biomass into forms compatible with downstream operations. Based on analytical and experimental observations of knife and tool wear, a QbD model is proposed that considers three wear mechanisms (erosion, abrasion, and gouging) to predict volumetric wear of knife blades and sharpness. These factors, if properly applied, provide a science-based approach to predict the mechanical efficiency of the mill as a function of feedstock properties, knife blade material properties, and processing parameters (feed rate, speed, and design parameters).

09 BIOMASS FUELS↗
DOE OSTI2022

Analysis of Cutter Blade Wear in Rotary Shear Mills

Following development of an analytical abrasive wear model to predict wear of components in a rotary shear mill, the team used a finite element analysis (FEA) approach to calculate forces and loads acting on particles responsible for abrasive wear. The analytical model related critical rotary shear process parameters (shear geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness and elastic modulus) that enabled us to model the wear of shear cutters in a rotary shear milling system developed by Forest Concepts. With proper knowledge of the forces acting between abrasive particles and cutter components built into it, the model can accurately predict wear of the cutters and provides a quality by design (QbD) approach to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches. During this reporting period, researchers at Oak Ridge National Laboratory applied an FEA package to simulate the local stresses and forces between an abrasive silica particle and two rotary shear cutters as the distance between the cutters decreases. The output of the FEA was used to provide more accurate projections of the loads applied to the particles in the analytical wear model. Comparison of the FEA force calculations are in good agreement with the loads assumed in the analytical predictions.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Mid-infrared Study of Stones from the Sutters Mill Meteorite

The Sutter's Mill meteorite fell in northern California on April 22, 2012, and numerous pieces have been recovered and studied with several analytical techniques [1]. We present a Fourier-transform infrared (FTIR) spectroscopy analysis of fragments from several stones of the meteorite. Methods and analysis: Infrared spectra of samples SM2 and SM12 were recorded with a Nicolet iN10 MX FTIR microscope in the mid-IR range (4000-650/cm; spectral resolution 4/cm), while samples SM20 and SM30 were analyzed with a synchrotron-based Nicolet Continuum IR microscope in the same range. Samples were deposited on a clean glass slide, crushed with either a stainless steel roller tool or between 2 slides, and placed directly on the focal plane of the microscopes. Results: IR spectra of non-fusion crust samples show several absorption features associated with minerals such as olivines, phyllosilicates, carbonates (calcite and dolomite), and pyroxenes, as well as organics [2]. The carbonates display a main, broad band centered at 1433/cm, with additional bands at 2515/cm, 1797/cm, 882/cm, and 715/cm. Features associated with phyllosilicates include a symmetric Si-O stretching mode band centered at 1011/cm and several O-H stretching mode bands―a broad band centered at 3415/cm that is probably due to adsorbed H2O, and occasionally a much weaker, narrower feature centered near 3680/cm due to structural O-H. Features observed in the 2985-2855/cm range suggest the presence of aliphatic -CH3 and -CH2- groups. However, some of these bands show unusual relative intensities, mainly because of carbonate overtone bands that fall in the same spectral range, which can make the identification of C-H stretching bands problematic. The positions and relative strengths of the aliphatic -CH2- and -CH3 features, where they can be distinguished from overlapping carbonate bands, are consistent with those in interplanetary dust particles (IDPs) and Murchison. Finally, the absence of a strong C=O absorption feature near 1700/cm distinguishes the organics in the Sutter's Mill meteorite from that in most IDPs and in Murchison, but is consistent with the organic matter in Tagish Lake.

mid-infrared study↗