On-the-fly laser machining: a case study for in situ balancing of rotative parts

On-the-fly laser machining is defined as a process that aims to generate pockets/patches on target components that are rotated or moved at a constant velocity. Since it is a nonintegrated process (i.e., linear/rotary stage system moving the part is independent of that of the laser), it can be deployed to/into large industrial installations to perform in situ machining, i.e., without the need of disassembly. This allows a high degree of flexibility in its applications (e.g., balancing) and can result in significant cost savings for the user (e.g., no dis(assembly) cost). This paper introduces the concept of on-the-fly laser machining encompassing models for generating user-defined ablated features as well as error budgeting to understand the sources of errors on this highly dynamic process. Additionally, the paper presents laser pulse placement strategies aimed at increasing the surface finish of the targeted component by reducing the area surface roughness that are possible for on-the-fly laser machining. The overall concept was validated by balancing a rotor system through ablation of different pocket shapes by the use of a Yb:YAG pulsed fiber laser. In this respect, first, two different laser pulse placement strategies (square and hexagonal) were introduced in this research and have been validated on Inconel 718 target material; thus, it was concluded that hexagonal pulse placement reduces surface roughness by up to 17% compared to the traditional square laser pulse placement. The concept of on-the-fly laser machining has been validated by ablating two different features (4 × 60 mm and 12 × 4 mm) on a rotative target part at constant speed (100 rpm and 86 rpm) with the scope of being balanced. The mass removal of the ablated features to enable online balancing has been achieved within < 4 mg of the predicted value. Additionally, the error modeling revealed that most of the uncertainties in the dimensions of the feature/pocket originate from the stability of the rotor speed, which led to the conclusion that for the same mass of material to be removed it is advisable to ablate features (pockets) with longer circumferential dimensions, i.e., stretched and shallower pockets rather than compact and deep

Optimisation of material properties for the modelling of large deformation manufacturing processes using a finite element model of the Gleeble compression test

The finite element modelling of manufacturing processes often requires a large amount of large plastic strain flow stress data in order to represent the material of interest over a wide range of temperatures and strain rates. Compression data generated using a Gleeble thermo-mechanical simulator is difficult to interpret due to the complex temperature and strain fields, which exist within the specimen during the test. In this study, a non-linear optimisation process is presented, which includes a finite element model of the compression process to accurately determine the constants of a five-parameter Norton–Hoff material model. The optimisation process is first verified using a reduced three-parameter model and then the full five-parameter model using a known set of constants to produce the target data, from which the errors are assessed. Following this, the optimisation is performed using experimental target data starting from a set of constants derived from the test data using an initial least-squares fit and also an arbitrary starting point within the parameter space. The results of these tests yield coefficients differing by a maximum of less than 10% and significantly improve the representation of the flow stress of the material

Evaluating the robustness of objective pilling classification with the two-dimensional discrete wavelet transform

Previously, we proposed a new method of frequency domain analysis based on the two-dimensional discrete wavelet transform to objectively measure pilling intensity in sample fabric images. We have further evaluated this method, and our results indicate that it is robust to small horizontal and/or vertical translations and to significant variations in the brightness of the image under analysis, and is sensitive to rotation and to dilation of the image. These results suggest that as long as precautions are taken to ensure fabric test samples are imaged under consistent conditions of weave/knit pattern alignment (rotation) and apparent interyarn pitch (dilation), the method will yield repeatable results. <br /

Defects and boundary layers in non-Euclidean plates

We investigate the behavior of non-Euclidean plates with constant negative Gaussian curvature using the F\"oppl-von K\'arm\'an reduced theory of elasticity. Motivated by recent experimental results, we focus on annuli with a periodic profile. We prove rigorous upper and lower bounds for the elastic energy that scales like the thickness squared. In particular we show that are only two types of global minimizers -- deformations that remain flat and saddle shaped deformations with isolated regions of stretching near the edge of the annulus. We also show that there exist local minimizers with a periodic profile that have additional boundary layers near their lines of inflection. These additional boundary layers are a new phenomenon in thin elastic sheets and are necessary to regularize jump discontinuities in the azimuthal curvature across lines of inflection. We rigorously derive scaling laws for the width of these boundary layers as a function of the thickness of the sheet

Image based simulation of one-dimensional compression tests on carbonate sand

High factors of safety and conservative methods are commonly used on foundation design on shelly carbonate soils. A better understanding of the behavior of this material is, thus, critical for more sustainable approaches for the design of a number of offshore structures and submarine pipelines. In particular, understanding the physical phenomena taking place at the microscale has the potential to spur the development of robust computational methods. In this study, a one-dimensional compression test was performed inside an X-ray scanner to obtain 3D images of the evolving internal structure of a shelly carbonate sand. A preliminary inspection of the images through five loading increments has shown that the grains rearrange under loading and in some cases cracks develop at the contacts. In order to replicate of the experiments in the numerical domain, the 3D image of the soil prior to loading was imported into a micro Finite Element (µFE) framework. This image-based modelling tool enables measurements of the contact force and stress map inside the grains while making use of the real microstructure of the soil. The potential of the µFE model to contribute insights into yield initiation within the grain is demonstrated here. This is of particular interest to better understand the breakage of shelly grains underpinning their highly compressive behavior

Object knowledge modulates colour appearance

We investigated the memory colour effect for colour diagnostic artificial objects. Since knowledge about these objects and their colours has been learned in everyday life, these stimuli allow the investigation of the influence of acquired object knowledge on colour appearance. These investigations are relevant for questions about how object and colour information in high-level vision interact as well as for research about the influence of learning and experience on perception in general. In order to identify suitable artificial objects, we developed a reaction time paradigm that measures (subjective) colour diagnosticity. In the main experiment, participants adjusted sixteen such objects to their typical colour as well as to grey. If the achromatic object appears in its typical colour, then participants should adjust it to the opponent colour in order to subjectively perceive it as grey. We found that knowledge about the typical colour influences the colour appearance of artificial objects. This effect was particularly strong along the daylight axis

Use of MMG signals for the control of powered orthotic devices: Development of a rectus femoris measurement protocol

Copyright © 2009 Rehabilitation Engineering and Assistive Technology Society (RESNA). This is an Author's Accepted Manuscript of an article published in Assistive Technology, 21(1), 1 - 12, 2009, copyright Taylor & Francis, available online at: http://www.tandfonline.com/10.1080/10400430902945678.A test protocol is defined for the purpose of measuring rectus femoris mechanomyographic (MMG) signals. The protocol is specified in terms of the following: measurement equipment, signal processing requirements, human postural requirements, test rig, sensor placement, sensor dermal fixation, and test procedure. Preliminary tests of the statistical nature of rectus femoris MMG signals were performed, and Gaussianity was evaluated by means of a two-sided Kolmogorov-Smirnov test. For all 100 MMG data sets obtained from the testing of two volunteers, the null hypothesis of Gaussianity was rejected at the 1%, 5%, and 10% significance levels. Most skewness values were found to be greater than 0.0, while all kurtosis values were found to be greater than 3.0. A statistical convergence analysis also performed on the same 100 MMG data sets suggested that 25 MMG acquisitions should prove sufficient to statistically characterize rectus femoris MMG. This conclusion is supported by the qualitative characteristics of the mean rectus femoris MMG power spectral densities obtained using 25 averages

Development of a stochastic computational fluid dynamics approach for offshore wind farms

In this paper, a method for stochastic analysis of an offshore wind farm using computational fluid dynamics (CFD) is proposed. An existing offshore wind farm is modelled using a steady-state CFD solver at several deterministic input ranges and an approximation model is trained on the CFD results. The approximation model is then used in a Monte-Carlo analysis to build joint probability distributions for values of interest within the wind farm. The results are compared with real measurements obtained from the existing wind farm to quantify the accuracy of the predictions. It is shown that this method works well for the relatively simple problem considered in this study and has potential to be used in more complex situations where an existing analytical method is either insufficient or unable to make a good prediction

Quantifying the evolution of soil fabric during shearing using directional parameters

Over the past 50 years, experimental studies have repeatedly demonstrated that the mechanical behaviour of sand is sensitive to the material fabric, that is, the arrangement of the grains. Up until now there have been relatively few attempts to describe this fabric quantitatively. Much of our understanding of the link between the particle movements and interactions and the macro-scale response of granular materials, including sand, comes from discrete-element modelling and experiments on ‘analogue’ sands with simple, idealised shapes. This paper investigates methods of quantifying the directional fabric of a real sand and its evolution under loading. Statistical analyses of the distribution of fabric directional data in terms of particle, contact normal, branch vector and void orientations were carried out at different stages of shearing deformation. The data show that the initial particle orientation fabric that develops during the deposition of the material tends to persist during shearing, while in the post-peak regime the contact normals seem to be reoriented along the direction of the major principal stress. Different patterns were observed within the shear band, as both the particles and the contact normal vectors appeared to rotate along the shear plane

Algorithm 873: LSTRS: MATLAB Software for Large-Scale Trust-Region Subproblems and Regularization

A MATLAB 6.0 implementation of the LSTRS method is presented. LSTRS was described in Rojas et al. [2000]. LSTRS is designed for large-scale quadratic problems with one norm constraint. The method is based on a reformulation of the trust-region subproblem as a parameterized eigenvalue problem, and consists of an iterative procedure that finds the optimal value for the parameter. The adjustment of the parameter requires the solution of a large-scale eigenvalue problem at each step. LSTRS relies on matrix-vector products only and has low and fixed storage requirements, features that make it suitable for large-scale computations. In the MATLAB implementation, the Hessian matrix of the quadratic objective function can be specified either explicitly, or in the form of a matrix-vector multiplication routine. Therefore, the implementation preserves the matrix-free nature of the method. A description of the LSTRS method and of the MATLAB software, version 1.2, is presented. Comparisons with other techniques and applications of the method are also included. A guide for using the software and examples are provided.34