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NASA NTRS2022

Hybrid data-driven and model-informed online tool wear detection in milling machines

Precision machining tool wear is responsible for low product throughput and quality. Monitoring the tool wear online is vital to prevent degradation in machining quality. However, direct real-time tool wear measurement is not practical. This paper presents residual-based anomaly detection models, combining a hybrid model comprised of a physics-based model and a data-driven model (a decision tree or a neural network) to predict signals of interest (e.g., power or forces) under nominal conditions, followed by Page’s cumulative sum test for detecting tool wear on-line using the computer numerical control machine measurements. The most informative features are ranked using dynamic programming and its approximation variants from real-time measurements and machine settings, such as the width of cut, depth of cut, feed rate and spindle speed, that serve as inputs to the predictive models. The baseline nominal model is incrementally updated with experimental data via a gradient boosted adaptation model to generate the residuals that account for discrepancies between the actual machine data under normal conditions and the baseline nominal model predictions. The hybrid model is validated against 20 Mazak milling machine experimental tests and one Haas run-to-failure experiment. The proposed anomaly detector is applied to synthetic data from simulations of the physics-based model at different operating conditions, measurement noise levels, and tool wear levels, and the methods were able to achieve an overall 92% accuracy in data with 1% noise. The anomaly detection methods based on hybrid model reduced the false alarms of either the data-driven or physical-based models alone, and are found to be capable of good online detection of tool wear.

Online anomaly detection↗

NASA NTRS2013

High-Reliability Waveguide Vacuum/Pressure Window

The NASA Deep Space Network (DSN) uses commercial waveguide windows on the output waveguide of Ka-band (32 GHz) low-noise amplifiers. Mechanical failure of these windows resulted in an unacceptable loss in tracking time. To address this issue, a new Ka-band WR-28 waveguide window has been designed, fabricated, and tested. The window uses a slab of low-loss, low-dielectric constant foam that is bonded into a 1/2-wave-thick waveguide/flange. The foam is a commercially available, rigid, closed-cell polymethacrylimide. It has excellent electrical properties with a dielectric constant of 1.04, and a loss tangent of 0.01. It is relatively strong with a tensile strength of 1 MPa. The material is virtually impermeable to helium. The finished window exhibits a leak rate of less than 3x10(exp -3)cu cm/s with helium. The material is also chemically resistant and can be cleaned with acetone. The window is constructed by fabricating a window body by brazing a short length of WR-28 copper waveguide into a standard rectangular flange, and machining the resulting part to a thickness of 4.6 mm. The foam is machined to a rectangular shape with a dimension of 7.06x3.53 mm. The foam is bonded into the body with a two-part epoxy. After curing, the excess glue and foam are knife-trimmed by hand. The finished window has a loss of less than 0.08 dB (2%) and a return loss of greater than 25 dB at 32 GHz. This meets the requirements for the DSN application. The window is usable for most applications over the entire 26-to-40-GHz waveguide band. The window return loss can be tuned to a required frequency by var y in g the thickness of the window slightly. Most standard waveguide windows use a thin membrane of material bonded into a recess in a waveguide flange, or sandwiched between two flanges with a polymer seal. Designs using the recessed window are prone to mechanical failure over time due to constraints on the dimensions of the recess that allow the bond to fail. Designs using the sandwich method are often permeable to helium, which prohibits the use of helium leak detection. At the time of this reporting, 40 windows have been produced. Twelve are in operation with a combined operating time of over 30,000 hours without a failure.

Britcliffe, Michael J.↗

NASA NTRS1978

Filtration effects on ball bearing life and condition in a contaminated lubricant

Ball bearings were fatigue tested with a noncontaminated lubricant and with a contaminated lubricant under four levels of filtration. The test filters had absolute particle removal ratings of 3, 30, 49, and 105 microns. Aircraft turbine engine contaminants were injected into the filter's supply line at a constant rate of 125 milligrams per bearing hour. Bearing life and running track condition generally improved with finer filtration. The experimental lives of 3 and 30 micron filter bearings were statistically equivalent, approaching those obtained with the noncontaminated lubricant bearings. Compared to these bearings, the lives of the 49 micron bearings were statistically lower. The 105 micron bearings experienced gross wear. The degree of surface distress, weight loss, and probable failure mode were dependent on filtration level, with finer filtration being clearly beneficial.

Loewenthal, S. H.↗

NASA NTRS1978

Filtration effects on ball bearing life and condition in a contaminated lubricant

Ball bearings were fatigue tested with a noncontaminated MIL-L-23699 lubricant and with a contaminated MIL-L-23699 lubricant under four levels of filtration. The test filters had absolute particle removal ratings of 3, 30, 49, and 105 microns. Aircraft turbine engine contaminants were injected into the filter's supply line at a constant rate of 125 milligrams per bearing hour. Bearing life and running track condition generally improved with finer filtration. The experimental lives of 3- and 30-micron filter bearings were statistically equivalent, approaching those obtained with the noncontaminated lubricant bearings. Compared to these bearings, the lives of the 49-micron bearings were statistically lower. The 105-micron bearings experienced gross wear. The degree of surface distress, weight loss, and probable failure mode were dependent on filtration level, with finer filtration being clearly beneficial.

Loewenthal, S. H.↗

NASA NTRS2001

Nonvolatile Memory Solution for Near-Term NASA Missions

Nonvolatile memory (NVM) system that could reliably function in extreme environments is one of the most critical components for many spacecrafts being developed for NASA missions to be launched in next four to seven years. NVM supports the computer system in saving and updating critical state data required for a warm restart after power cycling or in case of a power bus failure. It also provides a power independent mass storage capacity for the scientific data gathered by the instruments. In some cases the window for gathering such data is very small and occurs only once in a given mission. Commercially popular and fully developed Flash NVM technology is inappropriate for many reasons such as the limited read write cycles with slower access speeds, radiation intolerance, higher Single Event Upsets (SEU) rates, etc. It is desirable to have an NVM system based upon a robust cell technology making it immune to the SEUs and with sufficient radiation hardness. Availability of such NVM system seems to be still 5 to 10 years in the future. Meanwhile, it is possible to provide an interim hybrid solution by combining the existing rad-hard technologies. Additional information is contained in the original extended abstract.

Patel, J. U.↗

NASA NTRS2000

Directionally Solidified Ceramics Produced

Produced Multiphase, interpenetrating structures are an alternative route to obtaining structural ceramic materials with adequate strength, toughness, and stability for high-temperature aerospace applications. The eutectic architecture, a continuous-reinforcing phase within a higher volume phase or matrix, can be described as a naturally occurring, in situ composite. The phases of a eutectic are thermodynamically compatible at high homologous temperatures. Strong and stable materials have been produced. Toughness, however, remains a technical obstacle. The potential for producing materials with enhanced toughness along with adequate strength and stability was demonstrated using the laser-heated float zone (LHFZ) growth method at the NASA Glenn Research Center at Lewis Field. LHFZ growth at Glenn provides a means to efficiently produce and record the underlying growth phenomena associated with two-phase structures. To initiate directional solidification, a seed of single-crystal sapphire (<0001> direction) was lowered onto the molten liquid until wetting occurred and then withdrawn at a constant rate. Neither the crystal nor the source rod was rotated. The materials produced were tested mechanically in tension, and the resulting microstructure was examined with a scanning electron microscope. Both the inherent properties of the constituent phases and the properties of the interface between them affect the mechanical behavior and the fracture surfaces. The following scanning electron micrographs show the microstructures of two different materials that were tested to failure in tension. In the left micrograph, the flat fracture surface is typical of a material that is strong but has low toughness. In the right micrograph, the crack is effectively deflected at the interface between the two phases, achieving higher toughness at moderately lower strength levels. Conducting mechanical tests to determine the high temperature properties of these materials is the next step in determining their eventual suitability.

Farmer, Serene C.↗

NASA NTRS2008

A Gyroless Safehold Control Law Using Angular Momentum as an Inertial Reference Vector

A novel safehold control law was developed for the nadir-pointing Vegetation Canopy Lidar (VCL) spacecraft, necessitated by a challenging combination of constraints. The instrument optics did not have a recloseable cover to protect them form potentially catastrophic damage if they were exposed to direct sunlight. The baseline safehold control law relied on a single-string inertial reference unit. A gyroless safehold law was developed to give a degree of robustness to gyro failures. Typical safehold solutions were not viable; thermal constraints made spin stabilization unsuitable, and an inertial hold based solely on magnetometer measurements wandered unaceptably during eclipse. The novel approach presented here maintains a momentum bias vector not for gyroscopic stiffness, but to use as an inertial reference direction during eclipse. The control law design is presented. The effect on stability of the rank-deficiency of magnetometer-based rate derivation is assessed. The control law's performance is evaluated by simulation.

Stoneking, Eric↗

NASA NTRS1996

Pilot-in-the-Loop Analysis of Propulsive-Only Flight Control Systems

Longitudinal control system architectures are presented which directly couple flight stick motions to throttle commands for a multi-engine aircraft. This coupling enables positive attitude control with complete failure of the flight control system. The architectures chosen vary from simple feedback gains to classical lead-lag compensators with and without prefilters. Each architecture is reviewed for its appropriateness for piloted flight. The control systems are then analyzed with pilot-in-the-loop metrics related to bandwidth required for landing. Results indicate that current and proposed bandwidth requirements should be modified for throttles only flight control. Pilot ratings consistently showed better ratings than predicted by analysis. Recommendations are made for more robust design and implementation. The use of Quantitative Feedback Theory for compensator design is discussed. Although simple and effective augmented control can be achieved in a wide variety of failed configurations, a few configuration characteristics are dominant for pilot-in-the-loop control. These characteristics will be tested in a simulator study involving failed flight controls for a multi-engine aircraft.

Chou, Hwei-Lan↗

NASA NTRS1996

Nucleation and Crystallization of Globular Proteins: What we Know and What is Missing

Recently. much progress has been made in understanding the nucleation and crystallization of globular proteins, including the formation of compositional and structural crystal defects, Insight into the interactions of (screened) protein macro-ions in solution, obtained from light scattering, small angle X-ray scattering and osmotic pressure studies. can guide the search for crystallization conditions. These studies show that the nucleation of globular proteins is governed by the same principles as that of small molecules. However, failure to account for direct and indirect (hydrodynamic) protein interactions in the solutions results in unrealistic aggregation scenarios. Microscopic studies of numerous proteins reveal that crystals grow by the attachment of growth units through the same layer-spreading mechanisms as inorganic crystals. Investigations of the growth kinetics of hen-egg-white lysozyme (HEWL) reveal non-steady behavior under steady external conditions. Long-term variations in growth rates are due to changes in step-originating dislocation groups. Fluctuations on a shorter timescale reflect the non-linear dynamics of layer growth that results from the interplay between interfacial kinetics and bulk transport. Systematic gel electrophoretic analyses suggest that most HEWL crystallization studies have been performed with material containing other proteins at percent levels. Yet, sub-percent levels of protein impurities impede growth step propagation and play a role in the formation of structural/compositional inhomogeneities. In crystal growth from highly purified HEWL solutions, however, such inhomogeneities are much weaker and form only in response to unusually large changes in growth conditions. Equally important for connecting growth conditions to crystal perfection and diffraction resolution are recent advances in structural characterization through high-resolution Bragg reflection profiling and X-ray topography.

Rosenberger, F.↗

NASA NTRS2007

Medical Monitoring during Short Radius Centrifugation in Bed-rested Subjects

The artificial gravity pilot project was designed to investigate the efficacy of daily exposure to a Gz acceleration gradient for counteracting the physiologic decrements induced by prolonged bed rest. A short radius centrifuge was used to produce a Gz gradient such that 1 g was applied at the level of the subject s heart and 2.5 g at the feet. For inclusion in the study, subjects were required to complete a 75-minute screening spin on the centrifuge. During the study, each active treatment subject was scheduled for a 60-minute spin each day for 20 consecutive days. During centrifugation, subjects were continuously monitored by a physician for signs and symptoms of pre-syncope, motion sickness, arrhythmias, joint/muscle pain and any other unanticipated problems. The physician was also present to provide emergency care in the case of a medical emergency. Cameras mounted on the centrifuge were used to provide a means of observing the subject s face and torso. Audio communication was continuously maintained. Other monitoring tools included two-lead EKG tracings, pulse oximetry, intermittent sphygmomanometer readings, lights in the peripheral visual field, and continuous blood pressure readout from a tonometry device. Thirty screening runs were attempted using twenty-seven subjects. Seven of these runs were terminated early for symptoms of pre-syncope, motion sickness, or GI distress. A total of eight subjects completed the active treatment arm of the study. Of the 160 centrifuge runs that were scheduled for these eight treatment subjects, 152 were completed, seven were terminated early, and one was not attempted. Of the seven early terminations, four were related to symptoms of pre-syncope, one to leg pain, one to GI discomfort, and one to equipment failure. Three terminations for adverse symptoms occurred on the first treatment day. Three terminations occurred on day nineteen of treatment and within 24 hours after scheduled soleus and quadriceps muscle biopsies. We have summarized the relative usefulness of the information obtained by the various monitoring modalities in making a decision to terminate a centrifuge run. The video and audio communication information was essential to the decision-making process. Heart rate and EKG tracings are considered valuable, even though no spins were terminated due to significant arrhythmias. The tonometer device was generally not reliable in this application. Our observations suggest that subjects may be less tolerant of centrifugation just after starting bed rest and after invasive procedures.

Reinertson, Randal↗

NASA NTRS2018

Sediment Starvation Destroys New York City Marshes' Resistance to Sea Level Rise

New York City (NYC) is representative of many vulnerable coastal urban populations, infrastructures, and economies threatened by global sea level rise. The steady loss of marshes in NYC's Jamaica Bay is typical of many urban estuaries worldwide. Essential to the restoration and preservation of these key wetlands is an understanding of their sedimentation. Here we present a reconstruction of the history of mineral and organic sediment fluxes in Jamaica Bay marshes over three centuries, using a combination of density measurements and a detailed accretion model. Accretion rate is calculated using historical land use and pollution markers, through a wide variety of sediment core analyses including geochemical, isotopic, and paleobotanical analyses. We find that, since 1800 CE, urban development dramatically reduced the input of marsh stabilizing mineral sediment. However, as mineral flux decreased, organic matter flux increased. While this organic accumulation increase allowed vertical accumulation to outpace sea level, reduced mineral content causes structural weakness and edge failure. Marsh integrity now requires mineral sediment addition to both marshes and subsurface channels and borrow pits, a solution applicable to drowning estuaries worldwide. Integration of marsh mineral/organic accretion history with modeling provides parameters for marsh preservation at specific locales with sea level rise.

organic flux↗

NASA NTRS2020

Evaluation of Fatigue Damage Accumulation Functions for Delamination Initiation and Propagation

The present report follows on the cohesive fatigue damage model methodology proposed in NASA-TP-2018-219838. In that report, an empirical function describing the incremental damage due to cyclic loading was used to calculate fatigue damage within a cohesive formulation. The form of the function was developed such that, when integrated at a constant stress amplitude from no damage to failure, it produces a life versus load response that is consistent with an S-N diagram. Therefore, the parameters of the damage model could be obtained by fitting the model predictions to an S-N diagram. The finite element analyses performed demonstrate that the cohesive fatigue accumulation function provides a link between the S-N diagram that describes crack initiation, and the Paris law that characterizes the rate of crack propagation. However, when the model was proposed, it was not known whether the form of the damage accumulation function associated with a desired S-N diagram is unique and, if not, if the link between S-N and the Paris law is unique and independent of the fatigue function selected. In the effort described herein, several alternative forms of the damage function that reproduce the desired features of S-N diagrams were found and evaluated. The effects of each of these functions on the predicted parameters of the Paris law and the propagation threshold are discussed. The results indicate that the predicted exponent m of the Paris law is indeed independent of the damage accumulation function. However, different functions predict different values for the pre-factor C of the Paris law. Therefore, the proper damage accumulation function must be selected by comparison with experiments. One of the new damage accumulation functions proposed herein was found to be particularly useful for analysis because of the ease with which the model parameters can be determined with a minimal amount of experimental information. The effectiveness of the proposed methodology and damage function was demonstrated by conducting analyses of a double cantilever beam test, a mixed-mode bending test, and a three-point bending test of a skin/doubler specimen. The results indicate that the same set of model parameters can provide accurate predictions of the rate of fatigue crack propagation for a variety of material interfaces, mode mixities, load levels, and stress ratios.

Cohesive elements↗

NASA NTRS2006

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗

NASA NTRS1984

Analysis of local delaminations and their influence on composite laminate behavior

An equation was derived for the strain energy release rate, G, associated with local delamination growth from a matrix ply crack. The critical GC for edge delamination onset in 25/902s graphite epoxy laminates was measured and used in this equation to predict local delamination onset strains in 25/90ns, n = 4, 6, 8 laminates. A simple technique for predicting strain concentrations in the primary load bearing plies near local delaminations was developed. These strain concentrations were responsible for reduced laminate nominal failure strains in laminates containing local delaminations. The influence of edge delamination and matrix crack tip delamination on laminate stiffness and strength was compared.

Obrien, T. K.↗

NASA NTRS1985

Analysis of local delaminations and their influence on composite laminate behavior

Obrien, T. K.↗

NASA NTRS1992

Pilot-in-the-loop analysis of propulsive-only flight control systems

Longitudinal control system architectures which directly couple flight stick motions to throttle commands for a multi-engine aircraft are presented. This coupling enables positive attitude control with complete failure of the flight control system. The architectures chosen vary from simple feedback gains to classical lead-lag compensators with and without prefilters. Each architecture is reviewed for its appropriateness for piloted flight. The control systems are then analyzed with pilot-in-the-loop metrics related to bandwidth required for landing. Results indicate that current and proposed bandwidth requirements should be modified for throttles-only flight control. Pilot ratings consistently showed better ratings than predicted by analysis. Recommendations are made for more robust design and implementation. The use of quantitative feedback theory for compensator design is discussed. Although simple and effective augmented control can be achieved in a wide variety of failed configurations, a few configuration characteristics are dominant for pilot-in-the-loop control.

Chou, Hwei-Lan↗

NASA NTRS1973

A simulator investigation of the influence of engine response characteristics on the approach and landing for an externally blown flap aircraft. Part 1: Description of the simulation and discussion of results

Investigation of the influence of engine response characteristics on approach and landing operations of a powered lift aircraft were carried out in a piloted ground-based simulator. The aircraft simulated was a four engine, externally-blown jet-flap configuration having an 80 pound wing loading and .56 thrust to weight ratio. Results indicate that for ideal operating conditions and minimal pilot reaction delay, substantial reductions in engine-out wave-off altitude increment and touchdown sink rate for engine-out landings can be achieved with the fast engine compared to the slow engine response. However, delays in pilot reaction of one to two seconds diminish the advantage of rapid thrust response. A need exists for some form of automatic cueing of the pilot or automatic engine control to enable the potential of rapid thrust response to be realized in improving safety in the event of an engine failure.

Franklin, J. A.↗

NASA NTRS1994

Flight test of takeoff performance monitoring system

The Takeoff Performance Monitoring System (TOPMS) is a computer software and hardware graphics system that visually displays current runway position, acceleration performance, engine status, and other situation advisory information to aid pilots in their decision to continue or to abort a takeoff. The system was developed at the Langley Research Center using the fixed-base Transport Systems Research Vehicle (TSRV) simulator. (The TSRV is a highly modified Boeing 737-100 research airplane.) Several versions of the TOPMS displays were evaluated on the TSRV B-737 simulator by more than 40 research, United States Air Force, airline and industry and pilots who rated the system satisfactory and recommended further development and testing. In this study, the TOPMS was flight tested on the TSRV. A total of 55 takeoff and 30 abort situations were investigated at 5 airfields. TOPMS displays were observed on the navigation display screen in the TSRV research flight deck during various nominal and off-nominal situations, including normal takeoffs; reduced-throttle takeoffs; induced-acceleration deficiencies; simulated-engine failures; and several gross-weight, runway-geometry, runway-surface, and ambient conditions. All tests were performed on dry runways. The TOPMS software executed accurately during the flight tests and the displays correctly depicted the various test conditions. Evaluation pilots found the displays easy to monitor and understand. The algorithm provides pretakeoff predictions of the nominal distances that are needed to accelerate the airplane to takeoff speed and to brake it to a stop; these predictions agreed reasonably well with corresponding values measured during several fully executed and aborted takeoffs. The TOPMS is operational and has been retained on the TSRV for general use and demonstration.

Middleton, David B.↗