Matching Items (62)
Description
Uncertainty quantification is critical for engineering design and analysis. Determining appropriate ways of dealing with uncertainties has been a constant challenge in engineering. Statistical methods provide a powerful aid to describe and understand uncertainties. This work focuses on applying Bayesian methods and machine learning in uncertainty quantification and prognostics among all the statistical methods. This study focuses on the mechanical properties of materials, both static and fatigue, the main engineering field on which this study focuses. This work can be summarized in the following items: First, maintaining the safety of vintage pipelines requires accurately estimating the strength. The objective is to predict the reliability-based strength using nondestructive multimodality surface information. Bayesian model averaging (BMA) is implemented for fusing multimodality non-destructive testing results for gas pipeline strength estimation. Several incremental improvements are proposed in the algorithm implementation. Second, the objective is to develop a statistical uncertainty quantification method for fatigue stress-life (S-N) curves with sparse data.Hierarchical Bayesian data augmentation (HBDA) is proposed to integrate hierarchical Bayesian modeling (HBM) and Bayesian data augmentation (BDA) to deal with sparse data problems for fatigue S-N curves. The third objective is to develop a physics-guided machine learning model to overcome limitations in parametric regression models and classical machine learning models for fatigue data analysis. A Probabilistic Physics-guided Neural Network (PPgNN) is proposed for probabilistic fatigue S-N curve estimation. This model is further developed for missing data and arbitrary output distribution problems. Fourth, multi-fidelity modeling combines the advantages of low- and high-fidelity models to achieve a required accuracy at a reasonable computation cost. The fourth objective is to develop a neural network approach for multi-fidelity modeling by learning the correlation between low- and high-fidelity models. Finally, conclusions are drawn, and future work is outlined based on the current study.
ContributorsChen, Jie (Author) / Liu, Yongming (Thesis advisor) / Chattopadhyay, Aditi (Committee member) / Mignolet, Marc (Committee member) / Ren, Yi (Committee member) / Yan, Hao (Committee member) / Arizona State University (Publisher)
Created2022
Description
Aging-related damage and failure in structures, such as fatigue cracking, corrosion, and delamination, are critical for structural integrity. Most engineering structures have embedded defects such as voids, cracks, inclusions from manufacturing. The properties and locations of embedded defects are generally unknown and hard to detect in complex engineering structures. Therefore, early detection of damage is beneficial for prognosis and risk management of aging infrastructure system.
Non-destructive testing (NDT) and structural health monitoring (SHM) are widely used for this purpose. Different types of NDT techniques have been proposed for the damage detection, such as optical image, ultrasound wave, thermography, eddy current, and microwave. The focus in this study is on the wave-based detection method, which is grouped into two major categories: feature-based damage detection and model-assisted damage detection. Both damage detection approaches have their own pros and cons. Feature-based damage detection is usually very fast and doesn’t involve in the solution of the physical model. The key idea is the dimension reduction of signals to achieve efficient damage detection. The disadvantage is that the loss of information due to the feature extraction can induce significant uncertainties and reduces the resolution. The resolution of the feature-based approach highly depends on the sensing path density. Model-assisted damage detection is on the opposite side. Model-assisted damage detection has the ability for high resolution imaging with limited number of sensing paths since the entire signal histories are used for damage identification. Model-based methods are time-consuming due to the requirement for the inverse wave propagation solution, which is especially true for the large 3D structures.
The motivation of the proposed method is to develop efficient and accurate model-based damage imaging technique with limited data. The special focus is on the efficiency of the damage imaging algorithm as it is the major bottleneck of the model-assisted approach. The computational efficiency is achieved by two complimentary components. First, a fast forward wave propagation solver is developed, which is verified with the classical Finite Element(FEM) solution and the speed is 10-20 times faster. Next, efficient inverse wave propagation algorithms is proposed. Classical gradient-based optimization algorithms usually require finite difference method for gradient calculation, which is prohibitively expensive for large degree of freedoms. An adjoint method-based optimization algorithms is proposed, which avoids the repetitive finite difference calculations for every imaging variables. Thus, superior computational efficiency can be achieved by combining these two methods together for the damage imaging. A coupled Piezoelectric (PZT) damage imaging model is proposed to include the interaction between PZT and host structure. Following the formulation of the framework, experimental validation is performed on isotropic and anisotropic material with defects such as cracks, delamination, and voids. The results show that the proposed method can detect and reconstruct multiple damage simultaneously and efficiently, which is promising to be applied to complex large-scale engineering structures.
Non-destructive testing (NDT) and structural health monitoring (SHM) are widely used for this purpose. Different types of NDT techniques have been proposed for the damage detection, such as optical image, ultrasound wave, thermography, eddy current, and microwave. The focus in this study is on the wave-based detection method, which is grouped into two major categories: feature-based damage detection and model-assisted damage detection. Both damage detection approaches have their own pros and cons. Feature-based damage detection is usually very fast and doesn’t involve in the solution of the physical model. The key idea is the dimension reduction of signals to achieve efficient damage detection. The disadvantage is that the loss of information due to the feature extraction can induce significant uncertainties and reduces the resolution. The resolution of the feature-based approach highly depends on the sensing path density. Model-assisted damage detection is on the opposite side. Model-assisted damage detection has the ability for high resolution imaging with limited number of sensing paths since the entire signal histories are used for damage identification. Model-based methods are time-consuming due to the requirement for the inverse wave propagation solution, which is especially true for the large 3D structures.
The motivation of the proposed method is to develop efficient and accurate model-based damage imaging technique with limited data. The special focus is on the efficiency of the damage imaging algorithm as it is the major bottleneck of the model-assisted approach. The computational efficiency is achieved by two complimentary components. First, a fast forward wave propagation solver is developed, which is verified with the classical Finite Element(FEM) solution and the speed is 10-20 times faster. Next, efficient inverse wave propagation algorithms is proposed. Classical gradient-based optimization algorithms usually require finite difference method for gradient calculation, which is prohibitively expensive for large degree of freedoms. An adjoint method-based optimization algorithms is proposed, which avoids the repetitive finite difference calculations for every imaging variables. Thus, superior computational efficiency can be achieved by combining these two methods together for the damage imaging. A coupled Piezoelectric (PZT) damage imaging model is proposed to include the interaction between PZT and host structure. Following the formulation of the framework, experimental validation is performed on isotropic and anisotropic material with defects such as cracks, delamination, and voids. The results show that the proposed method can detect and reconstruct multiple damage simultaneously and efficiently, which is promising to be applied to complex large-scale engineering structures.
ContributorsChang, Qinan (Author) / Liu, Yongming (Thesis advisor) / Mignolet, Marc (Committee member) / Chattopadhyay, Aditi (Committee member) / Yan, Hao (Committee member) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2019
Description
Coordination and control of Intelligent Agents as a team is considered in this thesis.
Intelligent agents learn from experiences, and in times of uncertainty use the knowl-
edge acquired to make decisions and accomplish their individual or team objectives.
Agent objectives are defined using cost functions designed uniquely for the collective
task being performed. Individual agent costs are coupled in such a way that group ob-
jective is attained while minimizing individual costs. Information Asymmetry refers
to situations where interacting agents have no knowledge or partial knowledge of cost
functions of other agents. By virtue of their intelligence, i.e., by learning from past
experiences agents learn cost functions of other agents, predict their responses and
act adaptively to accomplish the team’s goal.
Algorithms that agents use for learning others’ cost functions are called Learn-
ing Algorithms, and algorithms agents use for computing actuation (control) which
drives them towards their goal and minimize their cost functions are called Control
Algorithms. Typically knowledge acquired using learning algorithms is used in con-
trol algorithms for computing control signals. Learning and control algorithms are
designed in such a way that the multi-agent system as a whole remains stable during
learning and later at an equilibrium. An equilibrium is defined as the event/point
where cost functions of all agents are optimized simultaneously. Cost functions are
designed so that the equilibrium coincides with the goal state multi-agent system as
a whole is trying to reach.
In collective load transport, two or more agents (robots) carry a load from point
A to point B in space. Robots could have different control preferences, for example,
different actuation abilities, however, are still required to coordinate and perform
load transport. Control preferences for each robot are characterized using a scalar
parameter θ i unique to the robot being considered and unknown to other robots.
With the aid of state and control input observations, agents learn control preferences
of other agents, optimize individual costs and drive the multi-agent system to a goal
state.
Two learning and Control algorithms are presented. In the first algorithm(LCA-
1), an existing work, each agent optimizes a cost function similar to 1-step receding
horizon optimal control problem for control. LCA-1 uses recursive least squares as
the learning algorithm and guarantees complete learning in two time steps. LCA-1 is
experimentally verified as part of this thesis.
A novel learning and control algorithm (LCA-2) is proposed and verified in sim-
ulations and on hardware. In LCA-2, each agent solves an infinite horizon linear
quadratic regulator (LQR) problem for computing control. LCA-2 uses a learning al-
gorithm similar to line search methods, and guarantees learning convergence to true
values asymptotically.
Simulations and hardware implementation show that the LCA-2 is stable for a
variety of systems. Load transport is demonstrated using both the algorithms. Ex-
periments running algorithm LCA-2 are able to resist disturbances and balance the
assumed load better compared to LCA-1.
Intelligent agents learn from experiences, and in times of uncertainty use the knowl-
edge acquired to make decisions and accomplish their individual or team objectives.
Agent objectives are defined using cost functions designed uniquely for the collective
task being performed. Individual agent costs are coupled in such a way that group ob-
jective is attained while minimizing individual costs. Information Asymmetry refers
to situations where interacting agents have no knowledge or partial knowledge of cost
functions of other agents. By virtue of their intelligence, i.e., by learning from past
experiences agents learn cost functions of other agents, predict their responses and
act adaptively to accomplish the team’s goal.
Algorithms that agents use for learning others’ cost functions are called Learn-
ing Algorithms, and algorithms agents use for computing actuation (control) which
drives them towards their goal and minimize their cost functions are called Control
Algorithms. Typically knowledge acquired using learning algorithms is used in con-
trol algorithms for computing control signals. Learning and control algorithms are
designed in such a way that the multi-agent system as a whole remains stable during
learning and later at an equilibrium. An equilibrium is defined as the event/point
where cost functions of all agents are optimized simultaneously. Cost functions are
designed so that the equilibrium coincides with the goal state multi-agent system as
a whole is trying to reach.
In collective load transport, two or more agents (robots) carry a load from point
A to point B in space. Robots could have different control preferences, for example,
different actuation abilities, however, are still required to coordinate and perform
load transport. Control preferences for each robot are characterized using a scalar
parameter θ i unique to the robot being considered and unknown to other robots.
With the aid of state and control input observations, agents learn control preferences
of other agents, optimize individual costs and drive the multi-agent system to a goal
state.
Two learning and Control algorithms are presented. In the first algorithm(LCA-
1), an existing work, each agent optimizes a cost function similar to 1-step receding
horizon optimal control problem for control. LCA-1 uses recursive least squares as
the learning algorithm and guarantees complete learning in two time steps. LCA-1 is
experimentally verified as part of this thesis.
A novel learning and control algorithm (LCA-2) is proposed and verified in sim-
ulations and on hardware. In LCA-2, each agent solves an infinite horizon linear
quadratic regulator (LQR) problem for computing control. LCA-2 uses a learning al-
gorithm similar to line search methods, and guarantees learning convergence to true
values asymptotically.
Simulations and hardware implementation show that the LCA-2 is stable for a
variety of systems. Load transport is demonstrated using both the algorithms. Ex-
periments running algorithm LCA-2 are able to resist disturbances and balance the
assumed load better compared to LCA-1.
ContributorsKAMBAM, KARTHIK (Author) / Zhang, Wenlong (Thesis advisor) / Nedich, Angelia (Thesis advisor) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2018
Description
Advanced material systems refer to materials that are comprised of multiple traditional constituents but complex microstructure morphologies, which lead to their superior properties over conventional materials. This dissertation is motivated by the grand challenge in accelerating the design of advanced material systems through systematic optimization with respect to material microstructures or processing settings. While optimization techniques have mature applications to a large range of engineering systems, their application to material design meets unique challenges due to the high dimensionality of microstructures and the high costs in computing process-structure-property (PSP) mappings. The key to addressing these challenges is the learning of material representations and predictive PSP mappings while managing a small data acquisition budget. This dissertation thus focuses on developing learning mechanisms that leverage context-specific meta-data and physics-based theories. Two research tasks will be conducted: In the first, we develop a statistical generative model that learns to characterize high-dimensional microstructure samples using low-dimensional features. We improve the data efficiency of a variational autoencoder by introducing a morphology loss to the training. We demonstrate that the resultant microstructure generator is morphology-aware when trained on a small set of material samples, and can effectively constrain the microstructure space during material design. In the second task, we investigate an active learning mechanism where new samples are acquired based on their violation to a theory-driven constraint on the physics-based model. We demonstrate using a topology optimization case that while data acquisition through the physics-based model is often expensive (e.g., obtaining microstructures through simulation or optimization processes), the evaluation of the constraint can be far more affordable (e.g., checking whether a solution is optimal or equilibrium). We show that this theory-driven learning algorithm can lead to much improved learning efficiency and generalization performance when such constraints can be derived. The outcomes of this research is a better understanding of how physics knowledge about material systems can be integrated into machine learning frameworks, in order to achieve more cost-effective and reliable learning of material representations and predictive models, which are essential to accelerate computational material design.
ContributorsCang, Ruijin (Author) / Ren, Yi (Thesis advisor) / Liu, Yongming (Committee member) / Jiao, Yang (Committee member) / Nian, Qiong (Committee member) / Zhuang, Houlong (Committee member) / Arizona State University (Publisher)
Created2018
Interoperability of geometric dimension & tolerance data between CAD systems through ISO STEP AP 242
Description
There is very little in the way of prescriptive procedures to guide designers in tolerance specification. This shortcoming motivated the group at Design Automation Lab to automate tolerancing of mechanical assemblies. GD&T data generated by the Auto-Tolerancing software is semantically represented using a neutral Constraint Tolerance Feature (CTF) graph file format that is consistent with the ASME Y14.5 standard and the ISO STEP Part 21 file. The primary objective of this research is to communicate GD&T information from the CTF file to a neutral machine readable format. The latest STEP AP 242 (ISO 10303-242) “Managed model based 3D engineering“ aims to support smart manufacturing by capturing semantic Product Manufacturing Information (PMI) within the 3D model and also helping with long-term archiving of the product information. In line with the recommended practices published by CAx Implementor Forum, this research discusses the implementation of CTF to AP 242 translator. The input geometry available in STEP AP 203 format is pre-processed using STEP-NC DLL and 3D InterOp. While the former is initially used to attach persistent IDs to the topological entities in STEP, the latter retains the IDs during translation to ACIS entities for consumption by other modules in the Auto-tolerancing module. The associativity of GD&T available in CTF file to the input geometry is through persistent IDs. C++ libraries used for the translation to STEP AP 242 is provided by StepTools Inc through the STEP-NC DLL. Finally, the output STEP file is tested using available AP 242 readers and shows full conformance with the STEP standard. Using the output AP 242 file, semantic GDT data can now be automatically consumed by downstream applications such as Computer Aided Process Planning (CAPP), Computer Aided Inspection (CAI), Computer Aided Tolerance Systems (CATS) and Coordinate Measuring Machines (CMM).
ContributorsVenkiteswaran, Adarsh (Author) / Shah, Jami J. (Thesis advisor) / Hardwick, Martin (Committee member) / Davidson, Joseph K. (Committee member) / Arizona State University (Publisher)
Created2016
Performance evaluation and characterization of lithium-ion cells under simulated PHEVs' drive cycles
Description
Increasing demand for reducing the stress on fossil fuels has motivated automotive industries to shift towards sustainable modes of transport through electric and hybrid electric vehicles. Most fuel efficient cars of year 2016 are hybrid vehicles as reported by environmental protection agency. Hybrid vehicles operate with internal combustion engine and electric motors powered by batteries, and can significantly improve fuel economy due to downsizing of the engine. Whereas, Plug-in hybrids (PHEVs) have an additional feature compared to hybrid vehicles i.e. recharging batteries through external power outlets. Among hybrid powertrains, lithium-ion batteries have emerged as a major electrochemical storage source for propulsion of vehicles.
In PHEVs, batteries operate under charge sustaining and charge depleting mode based on torque requirement and state of charge. In the current article, 26650 lithium-ion cells were cycled extensively at 25 and 50 oC under charge sustaining mode to monitor capacity and cell impedance values followed by analyzing the Lithium iron phosphate (LiFePO4) cathode material by X-ray diffraction analysis (XRD). High frequency resistance measured by electrochemical impedance spectroscopy was found to increase significantly under high temperature cycling, leading to power fading. No phase change in LiFePO4 cathode material is observed after 330 cycles at elevated temperature under charge sustaining mode from the XRD analysis. However, there was significant change in crystallite size of the cathode active material after charge/discharge cycling with charge sustaining mode. Additionally, 18650 lithium-ion cells were tested under charge depleting mode to monitor capacity values.
In PHEVs, batteries operate under charge sustaining and charge depleting mode based on torque requirement and state of charge. In the current article, 26650 lithium-ion cells were cycled extensively at 25 and 50 oC under charge sustaining mode to monitor capacity and cell impedance values followed by analyzing the Lithium iron phosphate (LiFePO4) cathode material by X-ray diffraction analysis (XRD). High frequency resistance measured by electrochemical impedance spectroscopy was found to increase significantly under high temperature cycling, leading to power fading. No phase change in LiFePO4 cathode material is observed after 330 cycles at elevated temperature under charge sustaining mode from the XRD analysis. However, there was significant change in crystallite size of the cathode active material after charge/discharge cycling with charge sustaining mode. Additionally, 18650 lithium-ion cells were tested under charge depleting mode to monitor capacity values.
ContributorsBadami, Pavan Pramod (Author) / Kannan, Arunachala Mada (Thesis advisor) / Huang, Huei Ping (Thesis advisor) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2016
Description
A process plan is an instruction set for the manufacture of parts generated from detailed design drawings or CAD models. While these plans are highly detailed about machines, tools, fixtures and operation parameters; tolerances typically show up in less formal manner in such plans, if at all. It is not uncommon to see only dimensional plus/minus values on rough sketches accompanying the instructions. On the other hand, design drawings use standard GD&T (Geometrical Dimensioning and tolerancing) symbols with datums and DRFs (Datum Reference Frames) clearly specified. This is not to say that process planners do not consider tolerances; they are implied by way of choices of fixtures, tools, machines, and operations. When converting design tolerances to the manufacturing datum flow, process planners do tolerance charting, that is based on operation sequence but the resulting plans cannot be audited for conformance to design specification.
In this thesis, I will present a framework for explicating the GD&T schema implied by machining process plans. The first step is to derive the DRFs from the fixturing method in each set-up. Then basic dimensions for the features to be machined in each set up are determined with respect to the extracted DRF. Using shop data for the machines and operations involved, the range of possible geometric variations are estimated for each type of tolerances (form, size, orientation, and position). The sequence of manufacturing operations determines the datum flow chain. Once we have a formal manufacturing GD&T schema, we can analyze and compare it to tolerance specifications from design using the T-map math model. Since the model is based on the manufacturing process plan, it is called resulting T-map or m-map. Then the process plan can be validated by adjusting parameters so that the m-map lies within the T-map created for the design drawing. How the m-map is created to be compared with the T-map is the focus of this research.
In this thesis, I will present a framework for explicating the GD&T schema implied by machining process plans. The first step is to derive the DRFs from the fixturing method in each set-up. Then basic dimensions for the features to be machined in each set up are determined with respect to the extracted DRF. Using shop data for the machines and operations involved, the range of possible geometric variations are estimated for each type of tolerances (form, size, orientation, and position). The sequence of manufacturing operations determines the datum flow chain. Once we have a formal manufacturing GD&T schema, we can analyze and compare it to tolerance specifications from design using the T-map math model. Since the model is based on the manufacturing process plan, it is called resulting T-map or m-map. Then the process plan can be validated by adjusting parameters so that the m-map lies within the T-map created for the design drawing. How the m-map is created to be compared with the T-map is the focus of this research.
ContributorsHaghighi, Payam (Author) / Shah, Jami J. (Thesis advisor) / Davidson, Joseph K. (Committee member) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2015
Description
ABSTRACT
A large fraction of the total energy consumption in the world comes from heating and cooling of buildings. Improving the energy efficiency of buildings to reduce the needs of seasonal heating and cooling is one of the major challenges in sustainable development. In general, the energy efficiency depends on the geometry and material of the buildings. To explore a framework for accurately assessing this dependence, detailed 3-D thermofluid simulations are performed by systematically sweeping the parameter space spanned by four parameters: the size of building, thickness and material of wall, and fractional size of window. The simulations incorporate realistic boundary conditions of diurnally-varying temperatures from observation, and the effect of fluid flow with explicit thermal convection inside the building. The outcome of the numerical simulations is synthesized into a simple map of an index of energy efficiency in the parameter space which can be used by stakeholders to quick look-up the energy efficiency of a proposed design of a building before its construction. Although this study only considers a special prototype of buildings, the framework developed in this work can potentially be used for a wide range of buildings and applications.
A large fraction of the total energy consumption in the world comes from heating and cooling of buildings. Improving the energy efficiency of buildings to reduce the needs of seasonal heating and cooling is one of the major challenges in sustainable development. In general, the energy efficiency depends on the geometry and material of the buildings. To explore a framework for accurately assessing this dependence, detailed 3-D thermofluid simulations are performed by systematically sweeping the parameter space spanned by four parameters: the size of building, thickness and material of wall, and fractional size of window. The simulations incorporate realistic boundary conditions of diurnally-varying temperatures from observation, and the effect of fluid flow with explicit thermal convection inside the building. The outcome of the numerical simulations is synthesized into a simple map of an index of energy efficiency in the parameter space which can be used by stakeholders to quick look-up the energy efficiency of a proposed design of a building before its construction. Although this study only considers a special prototype of buildings, the framework developed in this work can potentially be used for a wide range of buildings and applications.
ContributorsJain, Gaurav (Author) / Huang, Huei-Ping (Thesis advisor) / Ren, Yi (Committee member) / Oswald, Jay (Committee member) / Arizona State University (Publisher)
Created2016
Description
Metal castings are selectively machined-based on dimensional control requirements. To ensure that all the finished surfaces are fully machined, each as-cast part needs to be measured and then adjusted optimally in its fixture. The topics of this thesis address two parts of this process: data translations and feature-fitting clouds of points measured on each cast part. For the first, a CAD model of the finished part is required to be communicated to the machine shop for performing various machining operations on the metal casting. The data flow must include GD&T specifications along with other special notes that may be required to communicate to the machinist. Current data exchange, among various digital applications, is limited to translation of only CAD geometry via STEP AP203. Therefore, an algorithm is developed in order to read, store and translate the data from a CAD file (for example SolidWorks, CREO) to a standard and machine readable format (ACIS format - *.sat). Second, the geometry of cast parts varies from piece to piece and hence fixture set-up parameters for each part must be adjusted individually. To predictively determine these adjustments, the datum surfaces, and to-be-machined surfaces are scanned individually and the point clouds reduced to feature fits. The scanned data are stored as separate point cloud files. The labels associated with the datum and to-be-machined (TBM) features are extracted from the *.sat file. These labels are further matched with the file name of the point cloud data to identify data for the respective features. The point cloud data and the CAD model are then used to fit the appropriate features (features at maximum material condition (MMC) for datums and features at least material condition (LMC) for TBM features) using the existing normative feature fitting (nFF) algorithm. Once the feature fitting is complete, a global datum reference frame (GDRF) is constructed based on the locating method that will be used to machine the part. The locating method is extracted from a fixture library that specifies the type of fixturing used to machine the part. All entities are transformed from its local coordinate system into the GDRF. The nominal geometry, fitted features, and the GD&T information are then stored in a neutral file format called the Constraint Tolerance Feature (CTF) Graph. The final outputs are then used to identify the locations of the critical features on each part and these are used to establish the adjustments for its setup prior to machining, in another module, not part of this thesis.
ContributorsRamnath, Satchit (Author) / Shah, Jami J. (Thesis advisor) / Davidson, Joseph (Committee member) / Hansford, Dianne (Committee member) / Arizona State University (Publisher)
Created2016
Description
When manufacturing large or complex parts, often a rough operation such as casting is used to create the majority of the part geometry. Due to the highly variable nature of the casting process, for mechanical components that require precision surfaces for functionality or assembly with others, some of the important features are machined to specification. Depending on the relative locations of as-cast to-be-machined features and the amount of material at each, the part may be positioned or ‘set up’ on a fixture in a configuration that will ensure that the pre-specified machining operations will successfully clean up the rough surfaces and produce a part that conforms to any assigned tolerances. For a particular part whose features incur excessive deviation in the casting process, it may be that no setup would yield an acceptable final part. The proposed Setup-Map (S-Map) describes the positions and orientations of a part that will allow for it to be successfully machined, and will be able to determine if a particular part cannot be made to specification.
The Setup Map is a point space in six dimensions where each of the six orthogonal coordinates corresponds to one of the rigid-body displacements in three dimensional space: three rotations and three translations. Any point within the boundaries of the Setup-Map (S-Map) corresponds to a small displacement of the part that satisfies the condition that each feature will lie within its associated tolerance zone after machining. The process for creating the S-Map involves the representation of constraints imposed by the tolerances in simple coordinate systems for each to-be-machined feature. Constraints are then transformed to a single coordinate system where the intersection reveals the common allowable ‘setup’ points. Should an intersection of the six-dimensional constraints exist, an optimization scheme is used to choose a single setup that gives the best chance for machining to be completed successfully. Should no intersection exist, the particular part cannot be machined to specification or must be re-worked with weld metal added to specific locations.
The Setup Map is a point space in six dimensions where each of the six orthogonal coordinates corresponds to one of the rigid-body displacements in three dimensional space: three rotations and three translations. Any point within the boundaries of the Setup-Map (S-Map) corresponds to a small displacement of the part that satisfies the condition that each feature will lie within its associated tolerance zone after machining. The process for creating the S-Map involves the representation of constraints imposed by the tolerances in simple coordinate systems for each to-be-machined feature. Constraints are then transformed to a single coordinate system where the intersection reveals the common allowable ‘setup’ points. Should an intersection of the six-dimensional constraints exist, an optimization scheme is used to choose a single setup that gives the best chance for machining to be completed successfully. Should no intersection exist, the particular part cannot be machined to specification or must be re-worked with weld metal added to specific locations.
ContributorsKalish, Nathan (Author) / Davidson, Joseph K. (Thesis advisor) / Shah, Jami J. (Thesis advisor) / Ren, Yi (Committee member) / Arizona State University (Publisher)
Created2016