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A Supervised Machine Learning Model for Tool Condition Monitoring in Smart Manufacturing
Get PDFIn the current industry 4.0 scenario, good quality cutting tools result in a good surface finish, minimum vibrations, low power consumption, and reduction of machining time. Monitoring tool wear plays a crucial role in manufacturing quality components. In addition to tool monitoring, wear prediction assists the manufacturing systems in making tool-changing decisions. This paper introduces an industrial use case supervised machine learning model to predict the turning tool wear. Cutting forces, the surface roughness of a specimen, and flank wear of tool insert are measured for corresponding spindle speed, feed rate, and depth of cut. Those turning test datasets are applied in machine learning for tool wear predictions. The test was conducted using SNMG TiN Coated Silicon Carbide tool insert in turning of EN8 steel specimen. The dataset of cutting forces, surface finish, and flank wear is extracted from 200 turning tests with varied spindle speed, feed rate, and depth of cut. Random forest regression, Support vector regression, K Nearest Neighbour regression machine learning algorithms are used to predict the tool wear. R squared, the technique shows the random forest machine learning model predicts the tool wear of 91.82% of accuracy validated with the experimental trials. The experimental results exhibit flank wear is mainly influenced by the feed rate followed by the spindle speed and depth of cut. The reduction of flank wear with a lower feed rate can be achieved with a good surface finish of the workpiece. The proposed model may be helpful in tool wear prediction and making tool-changing decisions, which leads to achieving good quality machined components. Moreover, the machine learning model is adaptable for industry 4.0 and cloud environments for intelligent manufacturing systems
Sensor Based System Identification in Real Time for Noise Covariance Deficient Models
Get PDFSystem identification methods have extensive application in the aerospace industry’s experimental stability and control studies. Accurate aerodynamic modeling and system identification are necessary because they enable performance evaluation, flight simulation, control system design, fault detection, and model aircraft’s complex non-linear behavior. Various estimation methods yield different levels of accuracies with varying complexity and computational time requirements. The primary motivation of such studies is the accurate quantification of process noise. This research evaluates the performance of two recursive parameter estimation methods, viz.; First is the Fourier Transform Regression (FTR). The second approach describes the Extended version of Recursive Least Square (EFRLS), where E.F. refers to the Extended Forgetting factor. Also, the computational viability of these methods was analyzed for real-time application in aerodynamic parameter estimation for both linear and non-linear systems. While the first method utilizes the frequency domain to evaluate aerodynamic parameters, the second method works when noise covariances are unknown. The performance of both methods was assessed by benchmarking against parameter estimates from established methods like Extended Kalman Filter (EKF), Unscented Kalman Filter (UNKF), and Output Error Method (OEM)
A Motion Estimation based Algorithm for Encoding Time Reduction in HEVC
Get PDFHigh Efficiency Video Coding (HEVC) is a video compression standard that offers 50% more efficiency at the expense of high encoding time contrasted with the H.264 Advanced Video Coding (AVC) standard. The encoding time must be reduced to satisfy the needs of real-time applications. This paper has proposed the Multi- Level Resolution Vertical Subsampling (MLRVS) algorithm to reduce the encoding time. The vertical subsampling minimizes the number of Sum of Absolute Difference (SAD) computations during the motion estimation process. The complexity reduction algorithm is also used for fast coding the coefficients of the quantised block using a flag decision. Two distinct search patterns are suggested: New Cross Diamond Diamond (NCDD) and New Cross Diamond Hexagonal (NCDH) search patterns, which reduce the time needed to locate the motion vectors. In this paper, the MLRVS algorithm with NCDD and MLRVS algorithm with NCDH search patterns are simulated separately and analyzed. The results show that the encoding time of the encoder is decreased by 55% with MLRVS algorithm using NCDD search pattern and 56% with MLRVS using NCDH search pattern compared to HM16.5 with Test Zone (TZ) search algorithm. These results are achieved with a slight increase in bit rate and negligible deterioration in output video quality
Technology Forecasting of Unmanned Aerial Vehicle Technologies through Hierarchical S Curves
Get PDFThis study aims to propose a technology forecasting approach based on hierarchical S-curves. The proposed approach uses holistic forecasting by evaluating the S-curves of sub-technologies as well as the main technology under concern. A case study of unmanned aerial vehicle (UAV) technologies is conducted to demonstrate how the proposed approach works in practice. This is the first study that applies hierarchical S-curves to technology forecasting of unmanned aerial vehicle technologies in the literature. The future trend of the UAV technologies is analysed in detail through a hierarchical S-curve approach. Hierarchical S-curves are also utilised to investigate the sub-technologies of the UAV. In addition, the technology development life cycle of technology is assessed by using the three indexes namely, (1) the current technological maturity ratio (TMR), (2) estimating the number of potential patents that could be granted in the future (PPA), and (3) forecasting the expected remaining life (ERL). The results of this study indicate that the UAV technologies and their sub-technologies are at the growth stage in the technology life cycle, and most of the developments in UAV technology will have been completed by 2048. Hence, these technologies can be considered emerging technologies
Investigation of the Gum Stock Behavior of Polyurethane Crosslinking Matrix by Adding Triol Diol Mixtures for the Application of Composite Solid Rocket Propellants
Get PDFThe addition of some advanced additives to improve the mechanical properties of polyurethane (PU) polymeric matrix, which acts as a binder system in composite solid rocket propellants (CSRPs), is a target for the energetic materials researchers. In this investigation, 45 compositions of different crosslinked PU matrices were produced to demonstrate the effect of adding crosslinking mixture (CM) on the mechanical capabilities of polyurethane gum stock. The crosslinking mixture (CM) is composed of a triol crosslinker, trimethylolpropane (TMP), and a chain extender, 1,4-butanediol
(BD). For comparison, traditional PU samples without crosslinking additives were formulated. As a prepolymer, HTPB was used with a curing agent (HMDI). The research was carried out with different ratios of TMP to BD, different curing ratios (NCO/OH=0.7, 0.9, and 1.1), and crosslinking mixture contents in the range of 0-5 wt.%. The mechanical characteristics of all the cured formulations were measured. It was demonstrated that changing the ratio of TMP to BD has a significant impact on the mechanical performance causing a wide range of elongation and strength qualities. Increasing the wt.% of triol crosslinker in the sample enhanced the tensile strength, whereas the strain has been decreased. The addition of diol chain extender increased the strain rate of the samples. The mechanical parameters were adjusted simply by employing the crosslinking ingredients to get exceptional mechanical characteristics at each NCO/OH curing ratios. Also it was concluded that PU samples of curing ratio (NCO/OH= 0.7-0.9) with TMP:BD (1:1) showed a promising results and could be used according to the requirements of the rocket system designers
A Secure, Configurable, Wireless System for Transfer of Sensor Data from Aircraft to Ground
Get PDFModern aircraft are complex systems, equipped with hundreds of embedded sensors that record a wide repertoire of data during flight, such as crucial engine and airframe parameters, status of flight control system, air conditioning system, landing gear, life-saving and emergency systems. The data from the sensors is stored in the Flight Data Recorder. Maintenance personnel routinely transfer this sensor data to a ground terminal device to analyze it for aircraft health and performance monitoring purposes. Manual methods of extracting sensor data can be tedious and error-prone when large fleets of aircraft are involved. This paper presents a novel system to extract sensor data from aircraft to a ground terminal, wirelessly. The wireless system is implemented using unique, configurable wireless transmitter receivers (WTRs) designed for this purpose. The hardware for the wireless transfer of data was designed, interfaced with a modern aircraft’s system, and tested with the aircraft on the ground and another flying object. The data from the aircraft’s Flight Data Recorder was successfully transmitted and received wirelessly by the ground terminal, over a distance of 50 meters (with aircraft on ground) and 10 Kilometers (with a flying object), in a secure mode with zero packet loss. The WTRs have also qualified the requisite tests for airborne certification
A Novel Loss Tolerant Data Transmission Schemes for Airborne Telemetry System of a Long Range Aerospace Vehicle
Get PDFThe on-board telemetry system of an aerospace vehicle sends the vehicle performance parameters to the ground receiving station at all instances of its trajectory. During the course of its trajectory, the communication channel of a long range vehicle, experiences various phenomena such as plume attenuation, stage separation, manoeuvring of a vehicle and RF blackout, causing loss of valuable telemetry data. The loss of communication link is inevitable due to these harsh conditions even when using the space diversity of ground receiving systems. Conventional telemetry systems do not provide redundant data for long range aerospace vehicles. This research work proposes an innovative delay data transmission, frame switchover and multiple frames data transmission schemes to improve the availability of telemetry data at ground receiving stations. The proposed innovative schemes are modelled using VHDL and extensive simulations have been performed to validate the results. The functionally simulated net list has been synthesised with 130 nm ACTEL flash based FPGA and verified on telemetry hardware
Task Scheduling in Fog Node within the Tactical Cloud
Get PDFFog computing architecture competent to support the mission-oriented network-centric warfare provides the framework for a tactical cloud in this work. The tactical cloud becomes situation-aware of the war from the information relayed by fog nodes (FNs) on the battlefield. This work aims to sustain the network of FNs by maintaining the operational efficiency of the FNs on the battlefield at the tactical edge. The proposed solution monitors and predicts the likely overloading of an FN using the long short-term memory model through a buddy FN at the fog server (FS). This paper also proposes randomised task scheduling (RTS) algorithm to avert the likely overloading of an FN by pre-empting tasks from the FN and scheduling them to another FN. The experimental results demonstrate that RTS with linear complexity has a schedulability measure 8% - 26% higher than that of other base scheduling algorithms. The results show that the LSTM model has low mean absolute error compared to other time-series forecasting models
Kinematic Analyses of Metallic Plate Perforation by Penetrators with Various Nose Geometries
Get PDFThis study analyses kinematics of a metallic plate perforation by a penetrator with truncated ogive nose geometry to find solutions also to blunt, conical, ogive, and hemi-spherical nosed penetrators. Plugging, ductile hole enlargement, dishing, and petal forming failure modes are used in the analyses. Acceleration throughout perforation is calculated by using the related failure mode, analytical model, and the target-penetrator interaction geometry. Depending on the failure model; back lip and front lip formation during ductile hole enlargement, plug formation during plugging, and deflection of target plate during dishing is also analysed. Analyses are based on projectile’s equation of motion, momentum and energy equations, and projectile-target plate interactions. The analyses results for selected cases, with the impact velocity range 215-863 m/s, are compared with the test data. The residual velocity estimation for a strike velocity is close to the related test data with an error of 0.3-2.2 %, except for conical nosed penetrators at impact velocities approaching the ballistic limit velocit
Response of a Thin Flat Scored Metallic Disc Under Pressure Impulse
Get PDFThis paper presents the large deformation, and failure response of a thin flat scored metallic disc (FSMD) subjected to a pressure impulse as experienced in a break-away disc or an explosion vent. The response of this thin FSMD is numerically simulated for a loading rate and validated with an experiment, where a good agreement is found on plastic strains, burst pressure, and deformation pattern. The loading rate and several geometric parameters of FSMD significantly influence its response. Therefore, the influence of loading rate ( P& ), score depth and width-todisc thickness ratio (t 1 /t and b/t), diameter-to-disc thickness ratio (D/t), score length-to-disc radius ratio (l/R), score pattern, and score geometry on the deformation and failure response of the thin FSMD is thoroughly investigated. The studies demonstrate that 1) the failure initiation point shifts from disc centre to between 1/5th and 1/3rd radius for loading rates ≤ 25 MPa/s; 2) the responses such as burst pressure, burst time, central deflection, and equivalent strain are i) sensitive to the loading rates up to 100 MPa/s, ii) sensitive to score’s depth, only up to 0.6t and insensitive to score’s width, iii) significantly unaffected for the number of scores N > 8, iv) stabilised for l/R > 0.5 and D/t > 250, v) almost the same for semi-circular, rectangular and triangular score geometries, and vi) very minimal for the number of scores N = 3; and 3) the failure do not initiate and propagate along all scores for N > 4 in the disc