Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Establishment of a color tolerance for yarn-dyed fabrics from different color-depth yarns

Yarn-dyed fabric is often woven from warp and weft yarns in the same color depth to ensure a uniform color appearance. The difference in color depth between warp and weft tends to result in the uneven color of the yarn-dyed fabric. This article aims to establish a color tolerance for yarn-dyed fabric that can be woven with a qualified color appearance but from the warp and weft yarns in different color depths. A total of 27 yarn-dyed fabric samples in three color series (red, yellow, and blue) were evaluated by using the yarn-dyed fabric from warp and weft yarns in the same color depth of 2% (on weight of fabric, owf) as the standard. Visual assessment and instrumental measurement of color were carried out to establish the color tolerance ellipse that was defined as CMC (Color Measurement Committee) color differences (2:1) of no more than 1.00. It was found that the color strengths (K/S) and color differences (ΔE_CMC(2:1)) of these fabric samples for each color series had linear relationships with the color depths of warp and weft yarns. The color tolerance ellipses indicated that, even though the warp and weft yarns had an apparent color difference, they could be woven in fabrics with relatively uniform color appearance and meet the requirements for yarn-dyed fabric. This work provided valuable insight into the production of qualified yarn-dyed fabrics from unqualified dyed yarns.     

Influence of temperature on acoustic emission source location accuracy in underground structure

An acoustic emission (AE) experiment was carried out to explore the AE location accuracy influenced by temperature. A hollow hemispherical specimen was used to simulate common underground structures. In the process of heating with the flame, the pulse signal of constant frequency was stimulated as an AE source. Then AE signals received by each sensor were collected and used for comparing localization accuracy at different temperatures. Results show that location errors of AE keep the same phenomenon in the early and middle heating stages. In the later stage of heating, location errors of AE increase sharply due to the appearance of cracks. This provides some beneficial suggestions on decreasing location errors of structural cracks caused by temperature and improves the ability of underground structure disaster prevention and control.     

Mixing enhancement mechanism of combined H2–Water jets in supersonic crossflows in a combustor with an expanded section

To obtain the mixing enhancement mechanism of H₂–Water combined jets in supersonic crossflows in a combustor with expanded section for rotating detonation ramjet, the flow field shape and spray structure were studied by experimental and numerical methods. The Eulerian–Lagrangian method was used to investigate the diffusion mechanism and H₂–Water interaction law of combined jets with different sequences. At the same time, high-speed photography and the schlieren technique were used to capture the flow field. The effects of jet pressure drop, orifice diameter, orifice spacing, incoming Mach number, and other parameters on the penetration depth of water jets were studied. The results of experiment and simulation show that using H₂–Water combined jets, the penetration depth of the jet spray can be greatly increased and the jet mixing effect can be significantly improved, which will contribute to the engine's ignition and stable combustion. In the case of pre-water/post-H₂, the penetration depth of the hydrogen jet is greater. In the case of pre-H₂/post-water, the hydrogen jet raises the water spray mainly by protecting the integrity of the water column.     

Study on the non-uniform contact during ELID groove grinding

This paper introduces the potential feasibility that ELID (electrolytic in-process dressing) grinding replaces superfinishing in bearing manufacturing, but ELID grinding will bring new challenges. Different regions present distinguish surface profile due to the non-uniform contact in ELID groove grinding. However, few reports explaining the non-uniform contact are available. This article explores the mechanisms of the non-uniform contact during ELID groove grinding. Experiments on the non-uniform contact between bearing raceway and grinding wheel have been carried out under different conditions. The results show that non-uniform contact exists in ELID groove grinding process and it exerts influence on the profile of the raceway surface. Non-uniform contact influences the Rsk and Rku value all the time, but it influences the Ra value occasionally. Improvement strategies of eliminating the non-uniform contact are also discussed based on the experimental study.     

Stereo matching cost computation based on nonsubsampled contourlet transform

A new matching cost computation method based on nonsubsampled contourlet transform (NSCT) for stereo image matching is proposed in this paper. Firstly, stereo image is decomposed into high frequency sub-band images at different scales and along different directions by NSCT. Secondly, by utilizing coefficients in high frequency domain and grayscales in RGB color space, the computation model of weighted matching cost between two pixels is designed based on the gestalt laws. Lastly, two types of experiments are carried out with standard stereopairs in the Middlebury benchmark. One of the experiments is to confirm optimum values of NSCT scale and direction parameters, and the other is to compare proposed matching cost with nine known matching costs. Experimental results show that the optimum values of scale and direction parameters are respectively 2 and 3, and the matching accuracy of the proposed matching cost is twice higher than that of traditional NCC cost.     

利用量块和百分表提高钳工锉配工件测量的精度和效率

在钳工锉配中,测量贯穿整个加工过程,千分尺和游标卡尺等传统测量方式往往不能满足加工要求。创新使用量块、百分表和正弦规进行测量,既提高了测量的效率和准确性,又保证工件的加工精度,缩短了加工工时,高质量地完成工件的加工。     

Corrosion resistance of Al–Cr-slag containing chromium–corundum refractories to slags with different basicity

Al–Cr slag is the solid waste generated by the smelting of Cr metal. It presents a range of environmental hazards. This study addressed the corrosion resistance of Al–Cr slag containing chromium–corundum refractories to slags with different basicity. Herein, we provide suggestions for the use of Cr–corundum of different basicity in kilns. Al–Cr slag, brown fused Al₂O₃, and chrome green were used as the raw materials, with pure calcium aluminate cement being used as a binder. The brick samples, prepared using different blends of chrome green and corundum, were fired at 1600?°C, and subsequently subjected to a slag corrosion test. After corrosion by slag of different basicity, the phase composition and microstructure of the sample were analyzed by X-ray diffraction, energy dispersive spectrometer and scanning electron microscopy. There were two major findings. First, Cr–corundum brick made from Al–Cr slag has a better slag corrosion resistance than that made from Cr₂O₃ and brown fused Al₂O₃. Second, Cr–corundum brick made from Al–Cr slag has superior corrosion resistance to slag with a CaO:SiO₂ ratio of 2:1.     

Accuracy of wind energy forecasts in Great Britain and prospects for improvement

The metric representing the wind energy forecast error, when reported as a percent, is calculated quite differently than the error metrics for electricity transmission, electricity load, or in other industries such as manufacturing when they are also reported as a percent. The resulting calculated metric is quite different from what would be reported if the method utilized elsewhere was employed. This paper examines the possible forecast assessment and operational challenges associated with this finding. Concerning the prospects for improvement, the errors reported in MW of energy have a systematic component. With this insight, we developed a model to improve accuracy.     

Efficient Low Dissipative High Order Schemes for Multiscale MHD Flows, II: Minimization of ∇·B Numerical Error

An adaptive numerical dissipation control in a class of high order filter methods for compressible MHD equations is systematically discussed. The filter schemes consist of a divergence-free preserving high order spatial base scheme with a filter approach which can be divergence-free preserving depending on the type of filter operator being used, the method of applying the filter step, and the type of flow problem to be considered. Some of these filter variants provide a natural and efficient way for the minimization of the divergence of the magnetic field (∇·B) numerical error in the sense that commonly used divergence cleaning is not required. Numerical experiments presented emphasize the performance of the ∇·B numerical error. Many levels of grid refinement and detailed comparison of the filter methods with several commonly used compressible MHD shock-capturing schemes will be illustratedA condensed version appears in the Proceedings of the International Conference on High Performance Scientific Computing, March 10-14, 2003, Hanoi, Vietnam. This is a revised version of a longer internal report, Feb. 19, 2004. The longer internal report was published as a RIACS Technical Report TR03.10, July 2003, NASA Ames Research Center