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DOE OSTI2018

Sources of Uncertainty in Modeled Land Carbon Storage within and across Three MIPs: Diagnosis with Three New Techniques

Terrestrial carbon cycle models have incorporated increasingly more processes as a means to achieve more-realistic representations of ecosystem carbon cycling. Despite this, there are large across-model variations in the simulation and projection of carbon cycling. Several model intercomparison projects (MIPs), for example, the fifth phase of the Coupled Model Intercomparison Project (CMIP5) (historical simulations), Trends in Net Land–Atmosphere Carbon Exchange (TRENDY), and Multiscale Synthesis and Terrestrial Model Intercomparison Project (MsTMIP), have sought to understand intermodel differences. Here in this study, the authors developed a suite of new techniques to conduct post-MIP analysis to gain insights into uncertainty sources across 25 models in the three MIPs. First, terrestrial carbon storage dynamics were characterized by a three-dimensional (3D) model output space with coordinates of carbon residence time, net primary productivity (NPP), and carbon storage potential. The latter represents the potential of an ecosystem to lose or gain carbon. This space can be used to measure how and why model output differs. Models with a nitrogen cycle generally exhibit lower annual NPP in comparison with other models, and mostly negative carbon storage potential. Second, a transient traceability framework was used to decompose any given carbon cycle model into traceable components and identify the sources of model differences. The carbon residence time (or NPP) was traced to baseline carbon residence time (or baseline NPP related to the maximum carbon input), environmental scalars, and climate forcing. Third, by applying a variance decomposition method, the authors show that the intermodel differences in carbon storage can be mainly attributed to the baseline carbon residence time and baseline NPP (>90% in the three MIPs). The three techniques developed in this study offer a novel approach to gain more insight from existing MIPs and can point out directions for future MIPs. Finally, since this study is conducted at the global scale for an overview on intermodel differences, future studies should focus more on regional analysis to identify the sources of uncertainties and improve models at the specified mechanism level.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2015

TU-CD-207-03: Time Evolution of Texture Parameters of Subtracted Images Obtained by Contrast-Enhanced Digital Mammography (CEDM)

Purpose: To evaluate the time evolution of texture parameters, based on the gray level co-occurrence matrix (GLCM), in subtracted images of 17 patients (10 malignant and 7 benign) subjected to contrast-enhanced digital mammography (CEDM). The goal is to determine the sensitivity of texture to iodine uptake at the lesion, and its correlation (or lack of) with mean-pixel-value (MPV). Methods: Acquisition of clinical images followed a single-energy CEDM protocol using Rh/Rh/48 kV plus external 0.5 cm Al from a Senographe DS unit. Prior to the iodine-based contrast medium (CM) administration a mask image was acquired; four CM images were obtained 1, 2, 3, and 5 minutes after CM injection. Temporal series were obtained by logarithmic subtraction of registered CM minus mask images.Regions of interest (ROI) for the lesion were drawn by a radiologist and the texture was analyzed. GLCM was evaluated at a 3 pixel distance, 0° angle, and 64 gray-levels. Pixels identified as registration errors were excluded from the computation. 17 texture parameters were chosen, classified according to similarity into 7 groups, and analyzed. Results: In all cases the texture parameters within a group have similar dynamic behavior. Two texture groups (associated to cluster and sum mean) show a strong correlation with MPV; their average correlation coefficient (ACC) is r{sup 2}=0.90. Other two groups (contrast, homogeneity) remain constant with time, that is, a low-sensitivity to CM uptake. Three groups (regularity, lacunarity and diagonal moment) are sensitive to CM uptake but less correlated with MPV; their ACC is r{sup 2}=0.78. Conclusion: This analysis has shown that, at least groups associated to regularity, lacunarity and diagonal moment offer dynamical information additional to the mean pixel value due to the presence of CM at the lesion. The next step will be the analysis in terms of the lesion pathology. Authors thank PAPIIT-IN105813 for support. Consejo Nacional de Ciencia Y Tecnologia, PAPIIT-IN105813.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

Discharge dynamics and plasma density recovery by on/off switches of additional gas

Measurement of the plasma density is investigated to study plasma dynamics by adding reactive gas (O{sub 2}) or rare gas (He) in Ar plasmas. When the O{sub 2} or He gas is added, plasma density is suddenly decreased, while the plasma density recovers slowly with gas off. It is found that the recovery time is strongly dependent on the gas flow rate, and it can be explained by effect of gas residence time. When the He gas is off in the Ar plasma, the plasma density is overshot compared to the case of the O{sub 2} gas pulsing due to enhanced ionizations by metastable atoms. Analysis and calculation for correlation between the plasma density dynamics and the gas pulsing are also presented in detail.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2019

An integrated analytical and experimental study of contact acoustic nonlinearity at rough interfaces of fatigue cracks

This paper presents an analytical model that describes the relationship between interface stiffness and separation of rough interfaces such as fatigue cracks. The contact acoustic nonlinearity at the interface is simulated by a quasi-static model based on Hertzian contact theory. The model is validated using the results of dynamic acoustoelastic testing (DAET) with a Rayleigh wave probe on fatigue cracks in two aluminum alloy samples. One novel aspect of this work is that all the required geometrical parameters for the model are acquired directly from the aperture profile of real cracks extracted from their scanning electron microscopy (SEM) images. Also, the separation of the crack faces during dynamic perturbation is independently measured using a 3D laser Doppler vibrometer (LDV). In addition, using DAET allows for an unprecedented direct comparison between experimental and analytical results. Overall, this is because unlike conventional nonlinear ultrasonic tests that are based on measuring the amplitude of higher harmonics, DAET outputs directly the strain-dependency of transmission and time delay of ultrasonic waves propagating across the interface. The model is found in good qualitative agreement with the experimental results, although the predictions tend to underestimate the variation of transmission coefficient and time delay. We conduct a sensitivity analysis to investigate the influence of different assumptions and simplifications on model predictions.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Methodology and Tool for the Physical Security Analysis of Micro and Advanced Reactors

This work proposes a dynamic evaluation methodology to relax the conservatism in physical security evaluation, by leveraging an ongoing work in the Light Water Reactor Sustainability pathway. This methodology is implemented in a dynamic risk assessment tool named Event Modeling Risk Assessment using Linked Diagrams (EMRALD). The work extends EMRALD’s capability to support a sandbox feature where analysts can easily create attack scenarios and modify advanced/small modular reactor (A/SMR) security and safety features using templates. This approach saves time and cost since the analysis does not require creating detailed computer-aided design models, as is commonly required in commercial force-on-force software tools. EMRALD is completely free to use at https://emraldapp.inl.gov. We have developed basic templates including physical barriers, intrusion sensors, physical areas, and safety actions, that can be downloaded from EMRALD’s GitHub site: https://github.com/idaholab/EMRALD. These templates use generic data commonly used for training purposes, which do not reflect any actual operating nuclear reactor. Users may adjust the data in the templates with their own dataset and/or create new templates in EMRALD. The proposed methodology combines security and safety by assessing sabotage effects up to the radiological consequence to the public instead of merely the core damage state. This practice follows the industry standard for advanced non-light-water reactors currently proposed for endorsement by the Nuclear Regulatory Commission. The combination of security and safety is expressed in an achievability-consequence chart. EMRALD can be used to generate data for this chart. A hypothetical case study using a representative sodium-cooled fast reactor (SFR) facility is presented in this report to demonstrate this methodology. This case study does not contain any actual nuclear plant information. This work will benefit A/SMR vendors and utilities to implement security by design during the reactor design iteration phase, such that they do not have to perform upgrades and retrofits to the reactor after it is installed to improve its physical protection system. The tool may also be used to analyze domestic or foreign reactor designs to support the International Nuclear Security Techniques for Advanced Reactors (INSTAR) bilateral missions. Future works are planned to implement the methodology on a reference SFR reactor and a reference high-temperature gas-cooled reactor to obtain insights and lessons-learned for the A/SMR community.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Multiphase Species Transport Modeling for Molten Salt Reactors in the System Analysis Module: Generation, Decay, Deposition, and Extraction of Insoluble Fission Products

With the increase of interests in the design and deployment of advanced reactor systems, a desire for simulation tools supporting system analysis of reactor operation and safety is rising. Molten salt reactors (MSRs), one of the advanced reactor systems, utilize liquid fused salt fuel as both coolant and fuel. During operation, MSR generates insoluble fission products, including noble metals and gases. The buildup of these species in fuel salt presents safety concerns as they may deposit on surfaces of critical components and produce excessive decay heat, causing the failure of system components. Timely removal of these noble metals and gases would ensure the safe operation of the reactor system. The dynamic nature of salt fuel system, involving the generation, decay, deposition, and extraction of noble metals and gases, calls for robust species transport models to facilitate system analysis and monitoring, and design of efficient species removal components. This paper concentrates on the development of a computational framework for species transport, consisting of multiphase transport model formulation, mass transfer between phases, numerical implementation in MOOSE environment, verification through Method of Manufacture Solutions (MMS) and validation against experimental data from the Molten Salt Reactor Experiment (MSRE). Integrating this framework into the System Analysis Module (SAM) code further enhances SAM’s capabilities for advanced reactor analysis in the future.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Towards elastic in situ analysis for high-performance computing simulations

In situ analysis and visualization have grown increasingly popular for enabling direct access to data from high-performance computing (HPC) simulations. As a simulation progresses and interesting physical phenomena emerge, however, the data produced may become increasingly complex, and users may need to dynamically change the type and scale of in situ analysis tasks being carried out and consequently adapt the amount of resources allocated to such tasks. To date, none of the production in situ analysis frameworks offer such an elasticity feature, and for good reason: the assumption that the number of processes could vary during run time would force developers to rethink software and algorithms at every level of the in situ analysis stack. In this paper we present Colza, a data staging service with elastic in situ visualization capabilities. We demonstrate the use of Colza with the Deep Water Impact and the AMR-Wind simulations, coupling them with the ParaView Catalyst and Ascent in situ libraries, and show that Colza enables dynamic rescaling of these widely-used frameworks with no interruption to the simulation or staging service. Here, we highlight the challenges of enabling such elasticity, which requires overcoming these frameworks' reliance on MPI, using distinct engineering approaches, namely dependency injection and dependency overload. To the best of our knowledge, this work is the first to enable elastic in situ visualization capabilities for HPC applications on top of existing production analysis tools.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Coupling flux balance analysis with reactive transport modeling through machine learning for rapid and stable simulation of microbial metabolic switching

Integrating genome-scale metabolic networks with reactive transport models (RTMs) provides a detailed description of the dynamic changes in microbial growth and metabolism. Despite promising demonstrations in the past, computational inefficiency has been pointed out as a critical issue to overcome because it requires repeated application of linear programming (LP) to obtain flux balance analysis (FBA) solutions in every time step and spatial grid. To address this challenge, we propose a new simulation method where we train and validate artificial neural networks (ANNs) using randomly sampled FBA solutions and incorporate the resulting surrogate FBA model (represented as algebraic equations) into RTMs as source/sink terms. We demonstrate the efficiency of our method via a case study of Shewanella oneidensis MR-1. During aerobic growth on lactate, S. oneidensis produces metabolic byproducts (such as pyruvate and acetate), which are subsequently consumed as alternative carbon sources when the preferred nutrients are depleted. To effectively simulate these complex dynamics, we used a cybernetic approach that models metabolic switches as the outcome of dynamic competition among multiple growth options. In both zero-dimensional batch and one-dimensional column configurations, the ANN-based surrogate models achieved substantial reduction of computational time by several orders of magnitude compared to the original LP-based FBA models. Moreover, the ANN models produced robust solutions without any special measures to prevent numerical instability. These developments significantly promote our ability to utilize genome-scale networks in complex, multi-physics, and multi-dimensional ecosystem modeling.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2015

Correlations between quasi-coherent fluctuations and the pedestal evolution during the inter-edge localized modes phase on DIII-D

Direct measurements of the pedestal recovery during an edge-localized mode cycle provide evidence that quasi-coherent fluctuations (QCFs) play a role in the inter-ELM pedestal dynamics. Using fast Thomson scattering measurements, the pedestal density and temperature evolutions are probed on sub-millisecond time scales to show a fast recovery of the density gradient compared to the temperature gradient. The temperature gradient appears to provide a drive for the onset of quasi-coherent fluctuations (as measured with the magnetic probe and the density diagnostics) localized in the pedestal. The amplitude evolution of these QCFs tracks the temperature gradient evolution including its saturation. Such correlation suggests that these QCFs play a key role in limiting the pedestal temperature gradient. The saturation of the QCFs coincides with the pressure gradient reaching the kinetic-ballooning mode (KBM) critical gradient as predicted by EPED1. Furthermore, linear microinstability analysis using GS2 indicates that the steep gradient is near the KBM threshold. Thus, the modeling and the observations together suggest that QCFs are consistent with dominant KBMs, although microtearing cannot be excluded as subdominant.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Flow-induced vibration analysis of a helical coil steam generator experiment using large eddy simulation

This paper describes a numerical study of flow-induced vibration in a helical coil steam generator experiment conducted at Argonne National Laboratory in the 1980s. In the experiment, a half-scale sector model of a steam generator helical coil tube bank was subjected to still and flowing air and water, and the vibrational characteristics were recorded. The research detailed in this document utilizes the multi-physics simulation toolkit SHARP developed at Argonne National Laboratory, in cooperation with Lawrence Livermore National Laboratory, to simulate the experiment. SHARP uses the spectral element code Nek5000 for fluid dynamics analysis and the finite element code DIABLO for structural analysis. The flow around the coil tubes is modeled in Nek5000 by using a large eddy simulation turbulence model. Transient pressure data on the tube surfaces is sampled and transferred to DIABLO for the structural simulation. The structural response is simulated in DIABLO via an implicit time-marching algorithm and a combination of continuum elements and structural shells. Tube vibration data (acceleration and frequency) are sampled and compared with the experimental data. Currently, only one-way coupling is used, which means that pressure loads from the fluid simulation are transferred to the structural simulation but the resulting structural displacements are not fed back to the fluid simulation

CFD↗

DOE OSTI2015

Identification and quantification analysis of nonlinear dynamics properties of combustion instability in a diesel engine

The cycling combustion instabilities in a diesel engine have been analyzed based on chaos theory. The objective was to investigate the dynamical characteristics of combustion in diesel engine. In this study, experiments were performed under the entire operating range of a diesel engine (the engine speed was changed from 600 to 1400 rpm and the engine load rate was from 0% to 100%), and acquired real-time series of in-cylinder combustion pressure using a piezoelectric transducer installed on the cylinder head. Several methods were applied to identify and quantitatively analyze the combustion process complexity in the diesel engine including delay-coordinate embedding, recurrence plot (RP), Recurrence Quantification Analysis, correlation dimension (CD), and the largest Lyapunov exponent (LLE) estimation. The results show that the combustion process exhibits some determinism. If LLE is positive, then the combustion system has a fractal dimension and CD is no more than 1.6 and within the diesel engine operating range. We have concluded that the combustion system of diesel engine is a low-dimensional chaotic system and the maximum values of CD and LLE occur at the lowest engine speed and load. This means that combustion system is more complex and sensitive to initial conditions and that poor combustion quality leads to the decrease of fuel economy and the increase of exhaust emissions.

42 ENGINEERING↗

DOE OSTI2023

Novel angular velocity estimation technique for plasma filaments

Magnetic field aligned filaments such as blobs and edge localized mode filaments carry significant amounts of heat and particles to the plasma facing components and they decrease their lifetime. The dynamics of these filaments determine at least a part of the heat and particle loads. These dynamics can be characterized by their translation and rotation. In this paper, we present an analysis method novel for fusion plasmas, which can estimate the angular velocity of the filaments on frame-by-frame time resolution. After pre-processing, the frames are two-dimensional (2D) Fourier-transformed, then the resulting 2D Fourier magnitude spectra are transformed to log-polar coordinates, and finally the 2D cross-correlation coefficient function (CCCF) is calculated between the consecutive frames. The displacement of the CCCF’s peak along the angular coordinate estimates the angle of rotation of the most intense structure in the frame. Further, the proposed angular velocity estimation method is tested and validated for its accuracy and robustness by applying it to rotating Gaussian-structures. The method is also applied to gas-puff imaging measurements of filaments in National Spherical Torus Experiment plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Enhanced resting-state dynamics of the hemoglobin signal as a novel biomarker for detection of breast cancer

Purpose: The work presented here demonstrates an application of diffuse optical tomography (DOT) to the problem of breast-cancer diagnosis. The potential for using spatial and temporal variability measures of the hemoglobin signal to identify useful biomarkers was studied. Methods: DOT imaging data were collected using two instrumentation platforms the authors developed, which were suitable for exploring tissue dynamics while performing a simultaneous bilateral exam. For each component of the hemoglobin signal (e.g., total, oxygenated), the image time series was reduced to eight scalar metrics that were affected by one or more dynamic properties of the breast microvasculature (e.g., average amplitude, amplitude heterogeneity, strength of spatial coordination). Receiver-operator characteristic (ROC) analyses, comparing groups of subjects with breast cancer to various control groups (i.e., all noncancer subjects, only those with diagnosed benign breast pathology, and only those with no known breast pathology), were performed to evaluate the effect of cancer on the magnitudes of the metrics and of their interbreast differences and ratios. Results: For women with known breast cancer, simultaneous bilateral DOT breast measures reveal a marked increase in the resting-state amplitude of the vasomotor response in the hemoglobin signal for the affected breast, compared to the contralateral, noncancer breast. Reconstructed 3D spatial maps of observed dynamics also show that this behavior extends well beyond the tumor border. In an effort to identify biomarkers that have the potential to support clinical aims, a group of scalar quantities extracted from the time series measures was systematically examined. This analysis showed that many of the quantities obtained by computing paired responses from the bilateral scans (e.g., interbreast differences, ratios) reveal statistically significant differences between the cancer-positive and -negative subject groups, while the corresponding measures derived from individual breast scans do not. ROC analyses yield area-under-curve values in the 77%–87% range, depending on the metric, with sensitivity and specificity values ranging from 66% to 91%. An interesting result is the initially unexpected finding that the hemodynamic-image metrics are only weakly dependent on the tumor burden, implying that the DOT technique employed is sensitive to tumor-induced changes in the vascular dynamics of the surrounding breast tissue as well. Computational modeling studies serve to identify which properties of the vasomotor response (e.g., average amplitude, amplitude heterogeneity, and phase heterogeneity) principally determine the values of the metrics and their codependences. Findings from the modeling studies also serve to clarify the influence of spatial-response heterogeneity and of system-design limitations, and they reveal the impact that a complex dependence of metric values on the modeled behaviors has on the success in distinguishing between cancer-positive and -negative subjects. Conclusions: The authors identified promising hemoglobin-based biomarkers for breast cancer from measures of the resting-state dynamics of the vascular bed. A notable feature of these biomarkers is that their spatial extent encompasses a large fraction of the breast volume, which is mainly independent of tumor size. Tumor-induced induction of nitric oxide synthesis, a well-established concomitant of many breast cancers, is offered as a plausible biological causal factor for the reported findings.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2018

A framework for the identification of full-field structural dynamics using sequences of images in the presence of non-ideal operating conditions

Recent developments in the ability to automatically and efficiently extract natural frequencies, damping ratios, and full-field mode shapes from video of vibrating structures has great potential for reducing the resources and time required for performing experimental and operational modal analysis at very high spatial resolution. Furthermore, these techniques have the added advantage that they can be implemented remotely and in a non-contact fashion. Emerging full-field imaging techniques therefore have potential to allow the identification of the modal properties of structures in regimes that used to be challenging. For instance, these techniques suggest that the high spatial resolution structural identification could be performed on an aircraft during flight using a ground or aircraft-based imager. They also have the potential to identify the dynamics of microscopic systems. In order to realize this capability it will be necessary to develop techniques that can extract full-field structural dynamics in the presence of non-ideal operating conditions. In this work, we develop a framework for the deployment of emerging algorithms that allow the automatic extraction of high-resolution, full-field modal parameters in the presence of non-ideal operating conditions. One of the most notable non-ideal operating conditions is the rigid body motion of both the structure being measured as well as the imager performing the measurement. We demonstrate an instantiation of the framework by showing how it can be used to address, in-plane, translational, rigid body motion. The development of a frame-to-frame keypoint–based technique for identifying full-field structural dynamics in the presence of either rigid body motion is presented and demonstrated in the context of the framework for the deployment of full-field structural identification techniques in the presence of non-ideal operating conditions. It is expected that this framework will ultimately help enable the collection of full-field structural dynamics using measurement platforms including unmanned aerial vehicles, robotic telescopes, satellites, imagers mounted in high-vibration environments (seismic, industrial, harsh weather), characterization of microscopic structures, and human-carried imagers. If imager-based structural identification techniques mature to the point that they can be used in non-ideal field conditions, it could open up the possibility that the structural health monitoring community will be able to think beyond monitoring individual structures, to full-field structural integrity monitoring at the city scale.

Dasari, Sudeep↗

DOE OSTI2025

Experimental analysis of gas dynamics in the reactor cavity section of a High-Temperature Gas-Cooled Reactor during an accident scenario

Here, this study investigates the behavior of a High-Temperature Gas-Cooled Reactor (HTGR) during a break of the helium pressure boundary event. Understanding the gas dynamics that occur during a break could help develop safety systems that reduce the probability of air entering the reactor core. To achieve this objective, experimental studies were conducted in a scaled-down HTGR experimental facility to provide information on the air-helium gas mixture within the confinement building and the impact of the ventilation system on the helium/air gas concentration following the depressurization event. The study evaluated different configurations, including active ventilation time scales, break sizes, and locations. The analysis of the active ventilation time revealed that a ventilation time of 22 seconds produced positive results, and smaller break sizes resulted in longer depressurization times, which improved the ventilation process. The orientation and elevation of the breaks had little effect on the oxygen concentration in the cavity but did impact the gas velocities.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

UV–Vis–NIR Reflectance Spectroscopy and Chemometrics for Monitoring Pu Directly on an Ion Exchange Column

Here, we present a fiber-optic UV–vis–NIR reflectance spectroscopy method for direct, noninvasive monitoring of Pu(IV) in a glass ion exchange column during dynamic loading and elution in a glovebox. A movable probe enables spatially resolved spectral acquisition along the column axis, capturing distinct features associated with Pu(IV) nitrate complexes during loading and free ions during elution. Principal component analysis was applied to extract the dominant spectral variance and resolve relative concentration profiles without requiring precise knowledge of optical penetration depth or species identity. This in situ approach reveals spatial gradients and speciation dynamics in real time, which provides actionable insight into Pu(IV) ion migration, resin saturation, and breakthrough behavior under evolving flow conditions. The method offers a practical, fiber-compatible strategy to monitor glass column–based separations for Pu and other lanthanides or actinides and to characterize metal–resin interactions in flow-through systems.

actinide↗

DOE OSTI2015

Diffusive dynamics of nanoparticles in ultra-confined media

Differential dynamic microscopy (DDM) was used to investigate the diffusive dynamics of nanoparticles of diameter 200 400 nm that were strongly confined in a periodic square array of cylindrical nanoposts. The minimum distance between posts was 1.3 5 times the diameter of the nanoparticles. The image structure functions obtained from the DDM analysis were isotropic and could be fit by a stretched exponential function. The relaxation time scaled diffusively across the range of wave vectors studied, and the corresponding scalar diffusivities decreased monotonically with increased confinement. The decrease in diffusivity could be described by models for hindered diffusion that accounted for steric restrictions and hydrodynamic interactions. The stretching exponent decreased linearly as the nanoparticles were increasingly confined by the posts. Altogether, these results are consistent with a picture in which strongly confined nanoparticles experience a heterogeneous spatial environment arising from hydrodynamics and volume exclusion on time scales comparable to cage escape, leading to multiple relaxation processes and Fickian but non-Gaussian diffusive dynamics.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Digital force prediction for milling

This paper presents a fully digital, integrated approach for milling force prediction with arbitrary end mill-work material combinations. The approach includes: 1) structured light scanning to identify the end mill’s cutting edge macro-geometry along the tool axis; 2) structured light scanning to measure the cutting edge cross-sectional rake and relief profiles; 3) finite element analysis of orthogonal cutting to determine the force model coefficients that relate the force to chip area using the work material’s constitutive model and tool’s rake and relief profiles; and 4) time domain simulation with inputs that include the measured cutting edge macro-geometry, finite element-based force model, and measured structural dynamics. Milling force predictions are compared to in-process measurements to validate the method.

42 ENGINEERING↗