Actual Geometry Research Articles

Geometric feature extraction and its profile accuracy evaluation for pockets on curved aircraft skin from scanned point clouds

Abstract Dimension inspection is crucial for aircraft skin manufacturing and assembly. To meet weight loss and other functional requirements, large numbers of shallow pockets are distributed on the surface of thin-walled aircraft skin. It is difficult to evaluate the profile accuracy of the pockets, as the aircraft skin is composed of curved surfaces and its actual geometry is inconsistent with the nominal model. This study proposes a method to evaluate the profile and position accuracy for the pockets on aircraft skin utilizing point clouds obtained by 3D scanners. Firstly, the feature contour lines are identified and extracted from the scanned aircraft skin surface point clouds by adopting the local curvature-aware method and minimum bounding rectangle algorithm. Then, an algorithm is proposed to mitigate the contour identification deviations of the segmented area by employing the shortest geodesic distance and transition zone section projection, so as to enhance the measurement accuracy. Finally, the viability of the proposed method for evaluating pockets on aircraft skin is verified by the simulation, and the reliability and robustness of the proposed method are verified by the simulation and experiment. Experimental results show that the measurement accuracy of the pocket can be improved from 0.5 mm to 0.0505 mm, compared with traditional specialized conformation fixture methods.

High-Frequency Modeling and Analysis of Single-Layer NiZn Ferrite Inductors for EMI Filtering in Power Electronics Applications

In the high-frequency (HF) region, specifically within the 150 kHz to 30 MHz range for conducting electromagnetic interference (EMI) modeling, NiZn inductors exhibit enhanced efficiency due to their low core losses and stable permeability. Consequently, the accurate modeling of NiZn ferrite toroidal inductors is essential, given their widespread applications in the HF domain, with the aim of addressing existing knowledge gaps. Previous inductor models often relied on the perfect electric conductor (PEC) assumption, which simplifies the analysis but does not fully represent the electromagnetic behavior of the cores to which the PEC assumption cannot be applied. This study investigates the actual electromagnetic behavior of NiZn cores, treating them as dielectrics, which diverges from the traditional PEC-based models. Furthermore, this research fully considers the actual geometry of the inductors, proposing a comprehensive and precise analytical model for NiZn ferrite toroidal inductors. The impact of various winding methods on core capacitance is also explored. The paper provides a detailed explanation of the physical significance underlying the proposed model. A comparative analysis of both modeling methods is presented, and the efficacy of the suggested approach is validated through simulations and experimental results in several distinct scenarios.

Remote Inspection of Bridges with the Integration of Scanning Total Station and Unmanned Aerial Vehicle Data

Remote visual inspections are valuable tools for maintaining bridges in safe operation. In the case of old structures with incomplete documentation, the verification of dimensions is also an essential aspect. This paper presents an attempt to use a Scanning Total Station (STS) and Unmanned Aerial Vehicle (UAV) for the inspection and inventory of bridge dimensions. The STS’s measurements are conducted by applying two methods: the direct method using a total station (TS) and advanced geometric analyses of the collected point cloud. The UAV’s measurements use a Structure from Motion (SfM) method. Verification tests were conducted on a steel truss railway bridge over the largest river in Poland. The measurements concerned both the basic dimensions of the bridge and the details of a selected truss connection. The STS identified a significant deviation in the actual geometry of the measured connection and the design documentation. The UAV’s inspection confirmed these findings. The integration of STS and UAV technologies has demonstrated significant advantages, including STS’s high accuracy in direct measurements, with deviations within acceptable engineering tolerances (below a few mm), and the UAV’s efficiency in covering large areas, achieving over 90% compliance with reference dimensions. This combined approach not only reduces operating costs and enhances safety by minimizing the need for heavy machinery or scaffolding but also provides a more comprehensive understanding of the structural condition.

Research on wheel–rail impact dynamics due to combined rail weld irregularities and polygonal wheel effects considering 3D contact geometry

The geometric irregularities of rail welds and polygonal wheels are common defects observed in high-speed railways, leading to the generation of high-frequency impact forces and vibrations in the wheel–rail contact system. This research establishes a novel vehicle-track coupled dynamic model that incorporates a 3D wheel–rail contact model using meshing grid and conjugate gradient methods to study the high-magnitude wheel–rail impact forces caused by rail weld irregularities and polygonal wheel combinations. The primary objective of this study is to develop a precise 3D contact model that incorporates the actual geometry of wheel and rail surface irregularities into the calculation of vehicle-track dynamic interactions. The study evaluates the effects of 3D rail weld irregularities and polygonal wheels on wheel–rail dynamic interaction by comparing results with those obtained from a conventional vehicle-track coupled model that considers a 2D contact model. The results show that the lengths and depths of polygonal wheels and rail weld irregularities, as well as vehicle speeds, significantly increase the wheel/rail dynamic impact forces. The results also indicate that the widening of irregularities not only significantly affects the wheel–rail contact force but also has an important influence on the contact stiffness.

Analysis of The Flow-Field Distorsions Induced by Pneumatic Pressure Probes In Test Bench Experiments On Centrifugal Compressors: Are We Testing Right?

Abstract Experimental testing at the test rig still plays a key role in the development of new centrifugal compressor designs for industrial applications. Although a wide set of different probes is used as per common practice, the overall impact of the probes? dimensions on the stage performance and rangeability is often assumed to be negligible. In this study, we aimed at quantifying the intrusiveness effects of pneumatic pressure probes on the flow-field inside a vaned diffuser using a model stage of an industrial centrifugal compressor, for which different experimental setups were tested at the University of Florence test rig. Performance and rangeability were initially assessed using a conventional set of pneumatic probes inserted in the flow path. Then, comparative analyses were realized through dedicated tests by either removing all probes at the diffuser inlet or introducing only a single pressure probe in the upstream section and varying its angular position in the measuring section. Experiments revealed an impact of upstream probes much higher than expected, with a decrease in efficiency and a substantial reduction of stall margin. Moving from this experimental evidence, accurate 3D CFD simulations of the entire stage were carried out including the actual geometry of the probes for two probes configurations and three operating points. Simulations highlighted the effect probes? wakes on downstream vanes and the induced blockage effect, which both appear in line with experimental evidence. As a handout, a recommendation on the optimal probe positioning is suggested.

2D PIC modeling of the helical scrape-off layer current driven by hybrid divertor biased targets in tokamak plasmas

Abstract The heat flux control of the divertor plate via strike-point splitting generated by biased targets was proposed in the HL-2A tokamak (Cui et al 2021 Fusion Eng. Des. 173 112963). To understand the helical scrape-off layer (SOL) currents driven by hybrid biasing, two SOL current models (model A and B) are employed. Model A is a simplified 2D model that focuses on investigating the effect of biasing on the sheath and elucidating the fundamental physical mechanism of bias-driven SOL current paths. The potential, charge density, electric field and current densities are calculated. Model B takes into account the actual tokamak geometry and computes the resonant magnetic perturbations (RMPs) generated by bias-driven linear decay currents. Additionally, strike-point splitting is observed in the HL-2A tokamak, indicating that the SOL currents generated by hybrid biasing are capable of generating strong RMPs and consequently influence the magnetic topology. These results confirm the potential of heat/particle flux control by hybrid divertor biased targets.

Acoustic materials based on the Gosper curve

In this work, slotted acoustic materials based on a space filling curve called the Peano-Gosper curve are proposed and investigated. The slits in such materials form a complex pattern because they are divided by walls built along lines generated by the Gosper curve algorithm. The pattern can be twisted around an axis normal to its surface to increase the tortuosity inside the material, and therefore, modify its acoustic properties, which can be controlled by the turning angle or pitch of the twist. A highly efficient semi-analytical model has been developed to accurately predict the acoustic properties, in particular the sound absorption of such materials. It only requires a representative part of the pattern, or better, scanning the surface of the fabricated material so that the actual geometry and dimensions (in particular slit widths) are well reproduced in a two-dimensional finite element mesh generated on a representative fluid domain. The mesh is used to solve a dedicated Poisson problem and determine a few key parameters, and the rest of the modelling is based on analytical formulas. Material samples with straight and twisted slit patterns were 3D printed and then measured in an impedance tube to confirm semi-analytical sound absorption predictions.

Optimization of fast-ion diagnostic sets in tokamaks and stellarators using diagnostic weight functions.

The fast-ion phase-space distribution function in the magnetic fusion devices is always underdiagnosed, and every new fast-ion diagnostic should be carefully assessed before installation to minimize redundancies in measurements and maximize the information from the yet undiagnosed part of the fast-ion phase space distribution function. Here, we present a novel method of assessing the added value of a considered fast-ion diagnostic, taking actual geometry and an existing set of fast-ion diagnostics into account. The new method is based on a reformulation of the diagnostic weight functions in constants of motion (COM). We compare the proposed method with the previous approach using Monte Carlo simulations.

Development of a kinematic model for a free kinematic forming process to compute the tool trajectory

AbstractIn the production of hybrid composites made of thermoplast and metal sheets, certain limitations in the linear forming process can be overcome through a free kinematic forming process. This process involves distributing the thermoplast press mass using a tumbling or cyclic rolling movement of the forming tool. Due to this special kinematics, only a small part of the tool is ever in engagement with the workpiece, so the component is formed incrementally. Therefore, the final geometry does not have to be created in one stroke but can be carried out step by step in several partial strokes. In order to determine the optimal trajectory of the forming tool, the kinematic interplay between the workpiece, forming tool, and toolpath should be numerically captured in a mathematical model. The specific toolpath depends on the component being formed, as well as the actual geometry of the forming tool. In this research, the free kinematic forming process is modeled and the optimal toolpath is determined using a genetic algorithm. The optimal toolpath enables a uniform distribution of the thermoplast to a specified thickness and collisions between the upper and lower tool are avoided. This enables key insights into the free kinematic forming process and opens up further avenues of research for this innovative and future‐oriented manufacturing concept.

Comprehensive Analysis of the Gradient Porous Transport Layer for the Proton-Exchange Membrane Electrolyzer.

A reasonable porous transport layer (PTL) is crucial to decreasing the mass-transfer loss in proton-exchange membrane water electrolyzers (PEMWEs). In this study, it was experimentally demonstrated that the gradient porosity PTL is beneficial in improving the performance of electrolyzers. The research comprehensively investigates the impact of gradient porosity PTL structures on the performance of the PEMWE, considering mass transfer and interfacial contact. It offers insights into the two-phase (oxygen-water) flow transport mechanisms within the PTLs using a 2D numerical model based on the actual PTL geometry. At the microscopic level, it analyzes how the interfacial contact impacts proton and electron transport mechanisms, affecting not only the contact resistance but also the number of effective catalytic sites for the oxygen evolution reaction. Experimental results demonstrate that the cis-gradient porosity PTL leads to a performance enhancement of 9.3% at 2.2 A/cm2. Numerical simulations reveal that the drivers of oxygen transport include the surface tension of the fibers and the pressure drop influenced by the local PTL porosity. Further analysis indicates that the lower oxygen saturation in the bottom region of the PTL with cis-gradient porosity favors a lower oxygen coverage area in the catalyst layers (CL) since the narrower pore space and higher capillary pressure increase the number of water flow paths into the CL. Overall, this study provides valuable insights for designing high-performance PTLs for use in electrolyzers.

Using Experiments, 3D Scanning, and CFD to Analyze the Variance in Energy Losses Through Pipe Elbows

Pipe bends, or elbows, cause energy loss in pipelines due to the flow conditions they create. This energy loss has traditionally been approximated based on published minor loss coefficients, known as k-factors. However, the energy losses of elbows can vary based on geometric characteristics, which may not be accounted for in the published k-factors. The purpose of this research was to quantify the variance in energy loss resulting from elbows with geometric differences and to determine appropriate methods for approximating these variances using computational fluid dynamics (CFD). Eight polyvinyl chloride (PVC) elbows were physically tested in a hydraulic laboratory to determine the individual loss coefficients. The resulting data show that the minor loss coefficient k for two short-radius elbows of the same nominal size can vary by up to 51%. The same tests on two of the elbows were repeated using CFD, in which they were modeled two different ways: 1) using the ideal geometry and 2) using the actual geometry. The actual geometry was captured using 3D scanning. Each geometry was used in a series of simulations, and the results were compared to the experimental data. The CFD simulations were able to reproduce similar variances between the two elbows as displayed in the physical tests, although they were unable to reproduce the same k-factors. When compared to the experimental k-factor data, using the actual geometries captured by 3D scanning was not consistently more accurate than using idealized geometries.

Unsupervised machine learning application in the selection of measurement strategy on Coordinate Measuring Machine

It is indisputable that some type of coordinate measurement system (CMS) is generally used to assess the quality of dimensional and geometric characteristics. Considering the required accuracy, flexibility, and speed of measurement, a CMM with a scanning sensor may offer the best performance. These measurement systems are very complex, and many factors affect the reliability of the measurement results. A Metrologist’s choice represents the greatest variability in the measurement strategy. Previous research has shown that the measurement results can be changed up to 100 % by choosing a different measurement strategy when evaluating the form error. This paper conducts a detailed study of the impact of the measurement strategy on the cylindricity error when measuring eleven workpieces with the same nominal characteristics, but different real characteristics described by roughness and the reference value of cylindricity. To examine the influence and importance of certain factors and their levels, design of experiment (DoE) and unsupervised machine learning techniques of PCA (Principal Component Analysis) and Multiple Correspondence Analysis (MCA), were used. The results suggest that depending on the real geometry of the workpiece, different factors with different percentages influence the output characteristic. The objective was to choose a uniform measurement strategy when measuring cylindricity on the CMM, while the prior information about the actual geometry of the workpiece is lacking.

Near-threshold fatigue crack propagation in a Ni-based single crystal superalloy affected by crystallographic anisotropy

Fatigue crack propagation in the near-threshold regime was investigated experimentally and numerically in a Ni-based single crystal superalloy, namely, CMSX-4. Fatigue crack propagation tests were conducted at room temperature using four types of specimens with different primary and secondary crystallographic orientations. The results reveal that the crystallographic orientations strongly affect the fatigue crack propagation behavior, including the crack paths, fatigue crack propagation rates, and fatigue threshold. Crystal plasticity finite element analysis was conducted to quantify the slip activity of an octahedral slip system in front of the crack tip, considering the actual 3D geometry of the crack plane and elastic–plastic anisotropy. The fatigue damage parameter, considering the slip activities of the individual octahedral slip systems, provides reasonable explanation for the fatigue crack propagation rates and crack paths in the near-threshold regime, regardless of the crystallographic orientation. Furthermore, these damage parameters are equivalent at the fatigue thresholds for all specimens with different crystallographic orientation.

Characterization of the Three-Dimensional Flowfield over a Truncated Linear Aerospike

The work focuses on the characterization of the flowfield over a truncated linear aerospike by combining theoretical grounds, numerical simulations and experimental tests. The experimental investigations are carried out on a test rig designed at Politecnico di Torino for advanced nozzle testing. Fully three-dimensional CFD analyses are performed on the actual geometry of the experimental nozzle model. At low nozzle pressure ratios (nprs) the analysis combines numerical simulations and experimental testing, which are also used for validating the CFD results. At higher nprs, the flowfield characterization is performed only by three-dimensional CFD analyses. In addition to the validation of the numerical method, the edge effects at different nprs have been observed.

Space–time isogeometric analysis of tire aerodynamics with complex tread pattern, road contact, and tire deformation

AbstractThe space–time (ST) computational method “ST-SI-TC-IGA” and recently-introduced complex-geometry isogeometric analysis (IGA) mesh generation methods have enabled high-fidelity computational analysis of tire aerodynamics with near-actual tire geometry, road contact, tire deformation, and aerodynamic influence of the car body. The tire geometries used in the computations so far included the longitudinal and transverse grooves. Here, we bring the tire geometry much closer to an actual tire geometry by using a complex, asymmetric tread pattern. The complexity of the tread pattern required an updated version of the NURBS Surface-to-Volume Guided Mesh Generation (NSVGMG) method, which was introduced recently and is robust even in mesh generation for complex shapes with distorted boundaries. The core component of the ST-SI-TC-IGA is the ST Variational Multiscale (ST-VMS) method, and the other key components are the ST Slip Interface (ST-SI) and ST Topology Change (ST-TC) methods and the ST Isogeometric Analysis (ST-IGA). They all play a key role. The ST-TC, uniquely offered by the ST framework, enables moving-mesh computation even with the topology change created by the contact between the tire and the road. It deals with the contact while maintaining high-resolution flow representation near the tire.The computational analysis we present is the first of its kind and shows the effectiveness of the ST-SI-TC-IGA and NSVGMG in tire aerodynamic analysis with complex tread pattern, road contact, and tire deformation.

Evaluation of the Transfemoral Bone-Implant Interface Properties Using Vibration Analysis.

Evaluating the bone-implant interface (BII) properties of osseointegrated transfemoral (TFA) implants is important for early failure detection and prescribing loads during rehabilitation. The objective of this work is to derive and validate a 1D finite element (FE) model of the Osseointegrated Prosthetic Limb (OPL) TFA system that can: (1) model its dynamic behaviour and (2) extract the BII properties. The model was validated by: (1) comparing the 1D FE formulation to the analytical and 3D FE solutions for a simplifiedcylinder, (2) comparing the vibration modes of the actual TFA geometry using 1D and 3D FE models, and (3) evaluating the BII properties for three extreme conditions (LOW, INTERMEDIATE, and HIGH) generated using 3D FE and experimental (where the implant was embedded, using different adhesives, in synthetic femurs) signals for additional validation. The modes predicted by the 1D FE model converged to the analytical and the 3D FE solutions for the cylinder. The 1D model also matched the 3D FE solution with a maximum frequency difference of 2.02% for the TFA geometry. Finally, the 1D model extracted the BII stiffness and the system's damping properties for the three conditions generated using the 3DFE simulations and the experimental INTERMEDIATE and HIGH signals. The agreement between the 1D FE and the 3D FE solutions for the TFA geometry indicates that the 1D model captures the system's dynamic behaviour. Distinguishing between the different BII conditions demonstrates the 1D model's potential usefor the non-invasive clinical evaluation of the TFA BII properties.

Interactive planning of GNSS monitoring applications with virtual reality

In conventional GNSS planning software, the local circumstances at the antenna locations are hardly covered. Due to uniform cut-off angles in the elevation of the satellite orbits, the quality investigations are often not representative at inhomogeneous areas (e.g. vicinity of mountains or buildings). An experimental software was developed in Unity with ray-tracing approaches to evaluate the satellite constellation on the basis of actual on-site geometry with virtual reality. The software has been tested in a real-life use case for the simulation of GNSS measurements at an Austrian water dam. Furthermore, the results have been validated by actual GNSS measurements on-site.

Analysis of load distribution on the plate and lateral hinge of a valgus opening high tibial osteotomy during weight-bearing: a finite element analysis

IntroductionValgus high tibial osteotomy (HTO) is indicated for managing isolated medial knee osteoarthritis in a young patient with a metaphyseal deformity of the proximal tibia. In a medial opening HTO, maintaining the integrity of the lateral hinge is crucial for ensuring proper healing and correction retention. Using a locked plate to stabilize an HTO is common practice, allowing for earlier weight-bearing. The objective of this study was therefore to measure and track the mechanical load distribution on a locked fixation plate and the lateral hinge of an HTO using a finite element (FE) model simulating single-leg stance loading. HypothesisThe working hypothesis was that during weight-bearing, the plate and the lateral hinge absorb stress asymmetrically, predominantly on the plate. Material and methodsA numerical model of an HTO stabilized with a locked plate was developed based on the actual geometry of a healthy proximal tibia (using Autodesk Fusion 360 and Altair HyperWorks software). In this finite element simulation of loading, a mesh convergence study was conducted to optimize the accuracy of the numerical model results. The primary outcome measure was the maximum stress value in the affected areas (Von Mises stress, in MPa) of the plate and the lateral hinge. ResultsThe maximum stress intensity in the plate was approximately 20.29 MPa. The maximum stress intensity in the bony hinge was about 5.6 MPa. The results of the mesh convergence study for the hinge and the plate enabled defining the most suitable model for future FE studies: a 4 mm mesh for all model elements except for the high-stress area in the plate and the hinge, which were meshed with a 0.7 mm element size. This adaptation provided greater precision in the study. DiscussionThere is a distribution and allocation of stress both on the plate and the hinge, underlining the significance of the plate and the absolute necessity of preserving the hinge. Predictably, the plate absorbs the majority of the load, more than three times that of the hinge. ConclusionThe hypothesis is confirmed; however, additional studies would be necessary to validate these numerical results: an experimental component on instrumented cadaveric bones, as well as comparative studies of different fixation plates. Level of EvidenceV, expert opinion; controlled laboratory study.

CFD approach for determining the losses in two-phase flows through the last stage of condensing steam turbine

Analyzing and simulating wet steam flows within steam turbines holds significant importance, especially due to the presence of a liquid phase in the low-pressure stages of the turbine, resulting in consequential losses that demand careful consideration. Considering these conditions, this study employs advanced predictive CFD models to simulate the wet steam flow within the actual 3D geometry of the final stage in a 200 MW steam turbine, which is observed in the least research due to the complexity of modeling and analysis of three-dimensional flows. This advancement promises more precise and reliable results. Employing the ANSYS CFX software, this study engages in numerical simulations of steady-state compressible two-phase flow. Furthermore, the study offers practical equations to quantify the losses within the entire stage, which serves as a valuable metric for assessing loss levels and offers a benchmark for design improvements aimed at loss reduction. Based on the results, 10 % of losses occur along the stator and 1 % along the rotor, and a total of 11 % of losses occur along the entire stage. Finally, the efficiency of the stage is calculated to be 89 %. Steam condensation strengthens the shock waves, changes their location, diminishes Mach number and the flow velocity, and alters the flow angle. It reduces the efficiency of the turbine by 1.27 % and also reduces the work done by the turbine by 13.97 %. This emphasizes the significant influence of condensation on flow characteristics, emphasizing the necessity of conducting comprehensive investigations into this phenomenon.

Searching optimal process parameters for desired layer geometry in wire-laser directed energy deposition based on machine learning

ABSTRACT The quantitative prediction of more process parameter variables for fewer layer geometry variables is challenging in wire-laser DED. This study’s novelty is combining machine learning models with a non-dominated sorting genetic algorithm-II (NSGA-II) to predict process parameters for desired layer geometries accurately. Thirty single-layer deposition experiments are conducted to obtain response data of layer geometries to process parameters. Two support vector regression (SVR) models are trained by these data to predict the layer height and width, respectively, and the mean absolute percentage errors (MAPEs) of these models are 4.16% and 1.76%. A reverse system, consisting of both SVR models and the NSGA-II algorithm, is designed to search the optimal process parameters for the desired layer geometries. The maximum MAPE between the actual layer geometry deposited by the predicted process parameters and the desired layer geometry is less than 5.5%, providing solid confirmation of this methodology’s reliability.