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1. Phase- shifted 3D Imaging of Rotating Milling/Drilling tools

   Guo, Xiangyu ; Lee, ChaBum ( October 2020 , American Society for Precision Engineering)

   Drilling and milling operations are material removal processes involved in everyday conventional productions, especially in the high-speed metal cutting industry. The monitoring of tool information (wear, dynamic behavior, deformation, etc.) is essential to guarantee the success of product fabrication. Many methods have been applied to monitor the cutting tools from the information of cutting force, spindle motor current, vibration, as well as sound acoustic emission. However, those methods are indirect and sensitive to environmental noises. Here, the in-process imaging technique that can capture the cutting tool information while cutting the metal was studied. As machinists judge whether a tool is worn-out by the naked eye, utilizing the vision system can directly present the performance of the machine tools. We proposed a phase shifted strobo-stereoscopic method (Figure 1) for three-dimensional (3D) imaging. The stroboscopic instrument is usually applied for the measurement of fast-moving objects. The operation principle is as follows: when synchronizing the frequency of the light source illumination and the motion of object, the object appears to be stationary. The motion frequency of the target is transferring from the count information of the encoder signals from the working rotary spindle. If small differences are added to the frequency, the objectmore »appears to be slowly moving or rotating. This effect can be working as the source for the phase-shifting; with this phase information, the target can be whole-view 3D reconstructed by 360 degrees. The stereoscopic technique is embedded with two CCD cameras capturing images that are located bilateral symmetrically in regard to the target. The 3D scene is reconstructed by the location information of the same object points from both the left and right images. In the proposed system, an air spindle was used to secure the motion accuracy and drilling/milling speed. As shown in Figure 2, two CCDs with 10X objective lenses were installed on a linear rail with rotary stages to capture the machine tool bit raw picture for further 3D reconstruction. The overall measurement process was summarized in the flow chart (Figure 3). As the count number of encoder signals is related to the rotary speed, the input speed (unit of RPM) was set as the reference signal to control the frequency (f0) of the illumination of the LED. When the frequency was matched with the reference signal, both CCDs started to gather the pictures. With the mismatched frequency (Δf) information, a sequence of images was gathered under the phase-shifted process for a whole-view 3D reconstruction. The study in this paper was based on a 3/8’’ drilling tool performance monitoring. This paper presents the principle of the phase-shifted strobe-stereoscopic 3D imaging process. A hardware set-up is introduced, , as well as the 3D imaging algorithm. The reconstructed image analysis under different working speeds is discussed, the reconstruction resolution included. The uncertainty of the imaging process and the built-up system are also analyzed. As the input signal is the working speed, no other information from other sources is required. This proposed method can be applied as an on-machine or even in-process metrology. With the direct method of the 3D imaging machine vision system, it can directly offer the machine tool surface and fatigue information. This presented method can supplement the blank for determining the performance status of the machine tools, which further guarantees the fabrication process.« less
2. Design and Assessment of Innovative Dual-Mode Rolling Isolation Systems

   https://doi.org/11244/321054  

   Hadikhan Tehrani, Mohammad ( August 2019 , The University of Oklahoma Libraries)

   Loss of operation or devastating damage to buildings and industrial structures, as well as equipment housed in them, has been observed due to earthquake-induced vibrations. A common source of operational downtime is due to the performance reduction of vital equipment, which are sensitive to the total transmitted acceleration. A well-known method of protecting such equipment is seismic isolation of the equipment itself (or a group of equipment), as opposed to the entire structure due to the lower cost of implementation. The first objective of this dissertation is assessing a rolling isolation system (RIS) based on existing design guidelines for telecommunications equipment. A discrepancy is observed between the required response spectrum (RRS) and the one and only accelerogram recommended in the guideline. Several filters are developed to generate synthetic accelerograms that are compatible with the RRS. The generated accelerograms are used for probabilistic assessment of a RIS that is acceptable per the guideline. This assessment reveals large failure probability due to displacement demands in excess of the displacement capacity of the RIS. When the displacement demands on an isolation system are in excess of its capacity, impacts result in spikes in transmitted acceleration. Therefore, the second objective of this dissertation ismore »to design impact prevention/mitigation mechanisms. A dual-mode system is proposed where the behavior changes when the displacement exceeds a predefined threshold. A new piecewise optimal control approach is developed and applied to find the best possible mechanism for the region beyond the threshold. By utilizing the designed curves obtained from the proposed optimal control procedure, a Kelvin-Voigt device is tuned for illustrative purposes. On the other hand, the preference for protecting equipment decreases as the earthquake intensity increases. In extreme seismic loading, the response mitigation of the primary structure (i.e., life safety and collapse prevention) is of greater concern than protecting isolated equipment. Therefore, the third objective of this dissertation is to develop an innovative dual-mode system that can behave as equipment isolation under low to moderate seismic loading and passively transition to behave as a vibration absorber for the primary structure under extreme seismic loading. To reduce the computational cost of simulating a large linear elastic structure with nonlinear attachments (i.e., equipment isolation with cubic hardening nonlinearity), a reduced order modeling method is introduced that can capture the behavior of such nonlinear coupled systems. The method is applied to study the feasibility of dual-mode vibration isolation/absorber. To this end, nonlinear transmissibility curves for the roof displacement and isolated mass total acceleration are developed from the steady-state responses of dual-mode systems using the harmonic balanced method. The final objective of this dissertation is to extend the reduced order modeling method developed for linear elastic structure with nonlinear attachment to inelastic structures (without attachments). The new inelastic model condensation (IMC) method uses the modal properties of the full structural model (in the elastic range) to construct a linear reduced order model in conjunction with a hysteresis model to capture the hysteretic inter-story restoring forces. The parameters of these hysteretic forces are easily tuned, in order to fit the inelastic behavior of the condensed structure to that of the full model under a variety of simple loading scenarios. The fidelity of structural models condensed in this way is demonstrated via simulation for different ground motion intensities on three different building structures with various heights. The simplicity, accuracy, and efficiency of this approach could significantly alleviate the computational burden of performance-based earthquake engineering.« less
3. Extreme mechanical tunability in suspended MoS2 resonator controlled by Joule heating

   https://doi.org/10.1038/s41699-023-00383-3  

   Chiout, Anis ; Brochard-Richard, Cléophanie ; Marty, Laetitia ; Bendiab, Nedjma ; Zhao, Meng-Qiang ; Johnson, A. T. Charlie ; Oehler, Fabrice ; Ouerghi, Abdelkarim ; Chaste, Julien ( March 2023 , npj 2D Materials and Applications)

   Nanomechanical resonators are built into phones, as filters or accelerometers, but they lack a knob to effectively tune the frequency at the nanoscale when it’s easy to tune on an octave the tone of a classical musical instrument like a guitar string. Moreover, the control of deformation in nanomaterials, as two-dimensional (2D) materials, to tailor their electronic properties, i.e., straintronic, opens up avenues for applications in force detection, bolometry or quantum emitters. An accurate control of the deformation within these materials is thus necessary to fully exploit their potential. The precise study of deformations in 2D materials involves measurements of vibration modes and nanomechanics. By using a suspended MoS₂membrane heated by the Joule effect, we induce a strong softening of the mechanical resonance frequency as a function of the electrothermal heating, over one octave. A simple electrical tension is used to modulate the thermal mechanical tuning. Its amplitude is very large, greater than 100% modulation for one volt, compared to other approaches on 2D or 1D materials and, moreover, a very wide frequency range is accessible. Finally, we have related a photo-induced softening of the membrane over very long times with the current measurements and a photothermal effect.
4. Volume averaging effect in nonlinear processes of focused laser fields

   Yao, Yuzhong Freund ( September 2021 , Journal of chemical physics)

   We report theoretical derivations and experimental results on the volume averaging effect of nonlinear processes in focused laser fields. This effect is considered detrimental in revealing the intensity dependence of a nonlinear process, caused by the intensity variation across the sampled volume of a focused laser. Following the treatment in the literature, we prove that if the signal dependence can be expressed as a simple power function of the laser intensity and if the detection region encompasses effectively the whole volume, volume average does not affect the final conclusion on the derived exponent. However, to reveal the detailed saturation effect of a multi-photon process, intensity selective scans involving spatial filters and displacement of the laser focus (z-scan) are required. Moreover, to fully capture the dependence of the signal on the variation of the laser intensity, the degree of spatial discrimination and the corresponding range of z-scan need to be modeled carefully. Limitations in the dynamic range of the detector or the laser power, however, can thwart the desired scan range, resulting in erroneous fitting exponents. Using our nanosecond laser with a non-ideal Gaussian beam profile, based on multiphoton ionization of argon atoms from a collimated molecular beam and from ambientmore »argon gas, we report experimental measurements of the beam waist and Rayleigh range, and compare the experimental intensity dependence of Ar+ with theoretical values. Agreements between theory and experiment are remarkable.« less
5. Modeling and Experimental Validation of Part-Level Thermal Profile in Fused Filament Fabrication

   https://doi.org/10.1115/MSEC2019-2897  

   Roy, Mriganka ; Yavari, Reza ; Zhou, Chi ; Wodo, Olga ; Rao, Prahalad ( June 2019 , ASME, Manufacturing Science and Engineering Conference)

   Part design and process parameters directly influence the spatiotemporal distribution of temperature and associated heat transfer in parts made using additive manufacturing (AM) processes. The temporal evolution of temperature in AM parts is termed herein as thermal profile or thermal history. The thermal profile of the part, in turn, governs the formation of defects, such as porosity and shape distortion. Accordingly, the goal of this work is to understand the effect of the process parameters and the geometry on the thermal profile in AM parts. As a step towards this goal, the objectives of this work are two-fold: (1) to develop and apply a finite element-based framework that captures the transient thermal phenomena in the fused filament fabrication (FFF) additive manufacturing of acrylonitrile butadiene styrene (ABS) parts, and (2) validate the model-derived thermal profiles with experimental in-process measurements of the temperature trends obtained under different feed rate settings (viz., the translation velocity, also called scan speed or deposition speed, of the extruder on the FFF machine). In the specific context of FFF, this foray is the critical first-step towards understanding how and why the thermal profile directly affects the degree of bonding between adjacent roads (linear track of deposited material),more »which in turn determines the strength of the part, as well as, propensity to form defects, such as delamination. From the experimental validation perspective, we instrumented a Hyrel Hydra FFF machine with three non-contact infrared temperature sensors (thermocouples) located near the nozzle (extruder) of the machine. These sensors measure the surface temperature of a road as it is deposited. Test parts are printed under three different settings of feed rate, and subsequently, the temperature profiles acquired from the infrared thermocouples are juxtaposed against the model-derived temperature profiles. Comparison of the experimental and model-derived thermal profiles confirms a high-degree of correlation therein, with maximum absolute error less than 10%. This work thus presents one of the first efforts in validation of thermal profiles in FFF via in-process sensing. In our future work, we will focus on predicting defects, such as delamination and inter-road porosity based on the thermal profile.

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