7,803 research outputs found

    Meso-scale FDM material layout design strategies under manufacturability constraints and fracture conditions

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    In the manufacturability-driven design (MDD) perspective, manufacturability of the product or system is the most important of the design requirements. In addition to being able to ensure that complex designs (e.g., topology optimization) are manufacturable with a given process or process family, MDD also helps mechanical designers to take advantage of unique process-material effects generated during manufacturing. One of the most recognizable examples of this comes from the scanning-type family of additive manufacturing (AM) processes; the most notable and familiar member of this family is the fused deposition modeling (FDM) or fused filament fabrication (FFF) process. This process works by selectively depositing uniform, approximately isotropic beads or elements of molten thermoplastic material (typically structural engineering plastics) in a series of pre-specified traces to build each layer of the part. There are many interesting 2-D and 3-D mechanical design problems that can be explored by designing the layout of these elements. The resulting structured, hierarchical material (which is both manufacturable and customized layer-by-layer within the limits of the process and material) can be defined as a manufacturing process-driven structured material (MPDSM). This dissertation explores several practical methods for designing these element layouts for 2-D and 3-D meso-scale mechanical problems, focusing ultimately on design-for-fracture. Three different fracture conditions are explored: (1) cases where a crack must be prevented or stopped, (2) cases where the crack must be encouraged or accelerated, and (3) cases where cracks must grow in a simple pre-determined pattern. Several new design tools, including a mapping method for the FDM manufacturability constraints, three major literature reviews, the collection, organization, and analysis of several large (qualitative and quantitative) multi-scale datasets on the fracture behavior of FDM-processed materials, some new experimental equipment, and the refinement of a fast and simple g-code generator based on commercially-available software, were developed and refined to support the design of MPDSMs under fracture conditions. The refined design method and rules were experimentally validated using a series of case studies (involving both design and physical testing of the designs) at the end of the dissertation. Finally, a simple design guide for practicing engineers who are not experts in advanced solid mechanics nor process-tailored materials was developed from the results of this project.U of I OnlyAuthor's request

    In-situ crack and keyhole pore detection in laser directed energy deposition through acoustic signal and deep learning

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    Cracks and keyhole pores are detrimental defects in alloys produced by laser directed energy deposition (LDED). Laser-material interaction sound may hold information about underlying complex physical events such as crack propagation and pores formation. However, due to the noisy environment and intricate signal content, acoustic-based monitoring in LDED has received little attention. This paper proposes a novel acoustic-based in-situ defect detection strategy in LDED. The key contribution of this study is to develop an in-situ acoustic signal denoising, feature extraction, and sound classification pipeline that incorporates convolutional neural networks (CNN) for online defect prediction. Microscope images are used to identify locations of the cracks and keyhole pores within a part. The defect locations are spatiotemporally registered with acoustic signal. Various acoustic features corresponding to defect-free regions, cracks, and keyhole pores are extracted and analysed in time-domain, frequency-domain, and time-frequency representations. The CNN model is trained to predict defect occurrences using the Mel-Frequency Cepstral Coefficients (MFCCs) of the lasermaterial interaction sound. The CNN model is compared to various classic machine learning models trained on the denoised acoustic dataset and raw acoustic dataset. The validation results shows that the CNN model trained on the denoised dataset outperforms others with the highest overall accuracy (89%), keyhole pore prediction accuracy (93%), and AUC-ROC score (98%). Furthermore, the trained CNN model can be deployed into an in-house developed software platform for online quality monitoring. The proposed strategy is the first study to use acoustic signals with deep learning for insitu defect detection in LDED process.Comment: 36 Pages, 16 Figures, accepted at journal Additive Manufacturin

    Digital Image Correlation for Measuring Full-Field Residual Stresses in Wire and Arc Additive Manufactured Components

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    This study aims to demonstrate the capability of the digital image correlation (DIC) technique for evaluating full-field residual stresses in wire and arc-additive-manufactured (WAAM) components. Investigations were carried out on WAAM steel parts (wall deposited on a substrate) with two different wall heights: 24 mm and 48 mm. Mild steel solid wire AWS ER70S-6 was used to print WAAM walls on substrates that were rigidly clamped to H-profiles. DIC was used to monitor the bending deformation of WAAM parts during unclamping from the H-profiles, and residual stresses were calculated from the strain field captured during unclamping. Residual stresses determined from the proposed DIC-based method were verified with an analytical model and validated by the results from established residual stress measurement techniques, i.e., the contour method and X-ray diffraction.</jats:p

    Introductory Chapter: Acoustic Emission

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    TOWARDS AN UNDERSTANDING OF EFFORTFUL FUNDRAISING EXPERIENCES: USING INTERPRETATIVE PHENOMENOLOGICAL ANALYSIS IN FUNDRAISING RESEARCH

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    Physical-activity oriented community fundraising has experienced an exponential growth in popularity over the past 15 years. The aim of this study was to explore the value of effortful fundraising experiences, from the point of view of participants, and explore the impact that these experiences have on people’s lives. This study used an IPA approach to interview 23 individuals, recognising the role of participants as proxy (nonprofessional) fundraisers for charitable organisations, and the unique organisation donor dynamic that this creates. It also bought together relevant psychological theory related to physical activity fundraising experiences (through a narrative literature review) and used primary interview data to substantiate these. Effortful fundraising experiences are examined in detail to understand their significance to participants, and how such experiences influence their connection with a charity or cause. This was done with an idiographic focus at first, before examining convergences and divergences across the sample. This study found that effortful fundraising experiences can have a profound positive impact upon community fundraisers in both the short and the long term. Additionally, it found that these experiences can be opportunities for charitable organisations to create lasting meaningful relationships with participants, and foster mutually beneficial lifetime relationships with them. Further research is needed to test specific psychological theory in this context, including self-esteem theory, self determination theory, and the martyrdom effect (among others)

    Predictive Maintenance of Critical Equipment for Floating Liquefied Natural Gas Liquefaction Process

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    Predictive Maintenance of Critical Equipment for Liquefied Natural Gas Liquefaction Process Meeting global energy demand is a massive challenge, especially with the quest of more affinity towards sustainable and cleaner energy. Natural gas is viewed as a bridge fuel to a renewable energy. LNG as a processed form of natural gas is the fastest growing and cleanest form of fossil fuel. Recently, the unprecedented increased in LNG demand, pushes its exploration and processing into offshore as Floating LNG (FLNG). The offshore topsides gas processes and liquefaction has been identified as one of the great challenges of FLNG. Maintaining topside liquefaction process asset such as gas turbine is critical to profitability and reliability, availability of the process facilities. With the setbacks of widely used reactive and preventive time-based maintenances approaches, to meet the optimal reliability and availability requirements of oil and gas operators, this thesis presents a framework driven by AI-based learning approaches for predictive maintenance. The framework is aimed at leveraging the value of condition-based maintenance to minimises the failures and downtimes of critical FLNG equipment (Aeroderivative gas turbine). In this study, gas turbine thermodynamics were introduced, as well as some factors affecting gas turbine modelling. Some important considerations whilst modelling gas turbine system such as modelling objectives, modelling methods, as well as approaches in modelling gas turbines were investigated. These give basis and mathematical background to develop a gas turbine simulated model. The behaviour of simple cycle HDGT was simulated using thermodynamic laws and operational data based on Rowen model. Simulink model is created using experimental data based on Rowen’s model, which is aimed at exploring transient behaviour of an industrial gas turbine. The results show the capability of Simulink model in capture nonlinear dynamics of the gas turbine system, although constraint to be applied for further condition monitoring studies, due to lack of some suitable relevant correlated features required by the model. AI-based models were found to perform well in predicting gas turbines failures. These capabilities were investigated by this thesis and validated using an experimental data obtained from gas turbine engine facility. The dynamic behaviours gas turbines changes when exposed to different varieties of fuel. A diagnostics-based AI models were developed to diagnose different gas turbine engine’s failures associated with exposure to various types of fuels. The capabilities of Principal Component Analysis (PCA) technique have been harnessed to reduce the dimensionality of the dataset and extract good features for the diagnostics model development. Signal processing-based (time-domain, frequency domain, time-frequency domain) techniques have also been used as feature extraction tools, and significantly added more correlations to the dataset and influences the prediction results obtained. Signal processing played a vital role in extracting good features for the diagnostic models when compared PCA. The overall results obtained from both PCA, and signal processing-based models demonstrated the capabilities of neural network-based models in predicting gas turbine’s failures. Further, deep learning-based LSTM model have been developed, which extract features from the time series dataset directly, and hence does not require any feature extraction tool. The LSTM model achieved the highest performance and prediction accuracy, compared to both PCA-based and signal processing-based the models. In summary, it is concluded from this thesis that despite some challenges related to gas turbines Simulink Model for not being integrated fully for gas turbine condition monitoring studies, yet data-driven models have proven strong potentials and excellent performances on gas turbine’s CBM diagnostics. The models developed in this thesis can be used for design and manufacturing purposes on gas turbines applied to FLNG, especially on condition monitoring and fault detection of gas turbines. The result obtained would provide valuable understanding and helpful guidance for researchers and practitioners to implement robust predictive maintenance models that will enhance the reliability and availability of FLNG critical equipment.Petroleum Technology Development Funds (PTDF) Nigeri

    Cost-effective non-destructive testing of biomedical components fabricated using additive manufacturing

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    Biocompatible titanium-alloys can be used to fabricate patient-specific medical components using additive manufacturing (AM). These novel components have the potential to improve clinical outcomes in various medical scenarios. However, AM introduces stability and repeatability concerns, which are potential roadblocks for its widespread use in the medical sector. Micro-CT imaging for non-destructive testing (NDT) is an effective solution for post-manufacturing quality control of these components. Unfortunately, current micro-CT NDT scanners require expensive infrastructure and hardware, which translates into prohibitively expensive routine NDT. Furthermore, the limited dynamic-range of these scanners can cause severe image artifacts that may compromise the diagnostic value of the non-destructive test. Finally, the cone-beam geometry of these scanners makes them susceptible to the adverse effects of scattered radiation, which is another source of artifacts in micro-CT imaging. In this work, we describe the design, fabrication, and implementation of a dedicated, cost-effective micro-CT scanner for NDT of AM-fabricated biomedical components. Our scanner reduces the limitations of costly image-based NDT by optimizing the scanner\u27s geometry and the image acquisition hardware (i.e., X-ray source and detector). Additionally, we describe two novel techniques to reduce image artifacts caused by photon-starvation and scatter radiation in cone-beam micro-CT imaging. Our cost-effective scanner was designed to match the image requirements of medium-size titanium-alloy medical components. We optimized the image acquisition hardware by using an 80 kVp low-cost portable X-ray unit and developing a low-cost lens-coupled X-ray detector. Image artifacts caused by photon-starvation were reduced by implementing dual-exposure high-dynamic-range radiography. For scatter mitigation, we describe the design, manufacturing, and testing of a large-area, highly-focused, two-dimensional, anti-scatter grid. Our results demonstrate that cost-effective NDT using low-cost equipment is feasible for medium-sized, titanium-alloy, AM-fabricated medical components. Our proposed high-dynamic-range strategy improved by 37% the penetration capabilities of an 80 kVp micro-CT imaging system for a total x-ray path length of 19.8 mm. Finally, our novel anti-scatter grid provided a 65% improvement in CT number accuracy and a 48% improvement in low-contrast visualization. Our proposed cost-effective scanner and artifact reduction strategies have the potential to improve patient care by accelerating the widespread use of patient-specific, bio-compatible, AM-manufactured, medical components

    Compatibility and challenges in machine learning approach for structural crack assessment

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    Structural health monitoring and assessment (SHMA) is exceptionally essential for preserving and sustaining any mechanical structure’s service life. A successful assessment should provide reliable and resolute information to maintain the continuous performance of the structure. This information can effectively determine crack progression and its overall impact on the structural operation. However, the available sensing techniques and methods for performing SHMA generate raw measurements that require significant data processing before making any valuable predictions. Machine learning (ML) algorithms (supervised and unsupervised learning) have been extensively used for such data processing. These algorithms extract damage-sensitive features from the raw data to identify structural conditions and performance. As per the available published literature, the extraction of these features has been quite random and used by academic researchers without a suitability justification. In this paper, a comprehensive literature review is performed to emphasise the influence of damage-sensitive features on ML algorithms. The selection and suitability of these features are critically reviewed while processing raw data obtained from different materials (metals, composites and polymers). It has been found that an accurate crack prediction is only possible if the selection of damage-sensitive features and ML algorithms is performed based on available raw data and structure material type. This paper also highlights the current challenges and limitations during the mentioned sections

    Optimising acoustic cavitation for industrial application

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    The ultrasonic horn is one of the most commonly used acoustic devices in laboratories and industry. For its efficient application to cavitation mediated process, the cavitation generated at its tip as a function of its tip-vibration amplitudes still needed to be studied in detail. High-speed imaging and acoustic detection are used to investigate the cavitation generated at the tip of an ultrasonic horn, operating at a fundamental frequency, f0, of 20 kHz. Tip-vibration amplitudes are sampled at fine increments across the range of input powers available. The primary bubble cluster under the tip is found to undergo subharmonic periodic collapse, with concurrent shock wave emission, at frequencies of f0/m, with m increasing through integer values with increasing tip-vibration amplitude. The contribution of periodic shock waves to the noise spectra of the acoustic emissions is confirmed. Transitional input powers for which the value of m is indistinct, and shock wave emission irregular and inconsistent, are identified through Vrms of the acoustic detector output. For cavitation applications mediated by bubble collapse, sonications at transitional powers may lead to inefficient processing. The ultrasonic horn is also deployed to investigate the role of shock waves in the fragmentation of intermetallic crystals, nominally for ultrasonic treatment of Aluminium melt, and in a novel two-horn configuration for potential cavitation enhancement effects. An experiment investigating nitrogen fixation via cavitation generated by focused ultrasound exposures is also described. Vrms from the acoustic detector is again used to quantify the acoustic emissions for comparison to the sonochemical nitrite yield and for optimisation of sonication protocols at constant input energy. The findings revealed that the acoustic cavitation could be enhanced at constant input energy through optimisation of the pulse duration and pulse interval. Anomalous results may be due to inadequate assessment for the nitrate generated. The studies presented in this thesis have illustrated means of improving the cavitation efficiency of the used acoustic devices, which may be important to some selected industrial processes
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