Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy

The current paper presents the simulated 3D Finite Element Model (FEM) and experimental validation while turning the Nimonic C-263 super alloy using a cemented carbide cutting tool. FEM machining simulations was carried out using a Lagrangian finite element based machining model to predict the tangential cutting force, temperature distribution at tool tip and the effective stress and strain. All simulations were performed according to the cutting conditions designed, using the orthogonal array. The work piece was considered as perfectly plastic and its shape was taken as a curved model. An experimental validation of the cutting process was conducted in order to verify the simulated results of tangential cutting force and temperature at tool tip and the comparison shows that the percentage error 6% was observed and the shear friction factor 0.6 indicates good agreement between the simulated results and the experiment results. As the cutting speed is increased from 22 m/min to 54 m/min at higher feed rate, a larger strain to an extent of up to 6.55 mm/mm, a maximum value of 810 MPa stress and higher temperature localization to an extent of 620 °C at tool tip were observed.     

Simulation of media behaviour in vibration assisted abrasive flow machining

Abrasive flow machining (AFM) is an abrasive-based precision finishing process used for achieving surface finish in micro and nano-level. The AFM polishes surfaces by extruding a visco-elastic media in contact with the workpiece. The media, also called a ‘flexible tool’, plays a key role in the performance of the process. Ultrasonic assisted abrasive flow machining (UAAFM) is a new variant of the AFM process in which the workpiece is subjected to mechanical vibration orthogonal to the media flow direction. In this process a high frequency, in the range of about 5–20 kHz, is given to the workpiece with the help of a piezo actuator and a specially designed fixture. The present work highlights on the possible behaviour of the tool (media) during UAAFM and its effect on the machining process through a computation based approach. Commercially available simulation tool was used to study the effect of the media in response to different set of machining conditions. The responses were evaluated in terms of changes in the fluid pressure, velocity profile of the fluid, temperature distribution in the working fluid and the possible wall shear on the work surface. A three-dimensional model was constructed for simulating the UAAFM process. The simulation shows that the abrasive particles tend to hit the target surface at an angle ‘θ’ which significantly affects the basic mechanisms involved and enhances the effectiveness of the process. The computed wall shear explains that the process will have higher finishing rate and hence the performance. The enhanced interaction of abrasive media in UAAFM while compared to simple AFM could be explained by the resultant pressure–velocity phenomena. Results show that while changes in the amplitude of applied vibration (10 μm and 50 μm) significantly affect the wall shear, the media velocity and pressure profiles are only marginally sensitive to this parameter. The simulation results also confirm that the rise in temperature during the process will not affect the media stability. Results have been discussed vis-a-vis the basic mechanism of the process through suitable illustrations.     

Taguchi-fuzzy multi output optimization (MOO) in high speed CNC turning of AISI P-20 tool steel

This paper presents the application of Taguchi method with logical fuzzy reasoning for multiple output optimization of high speed CNC turning of AISI P-20 tool steel using TiN coated tungsten carbide coatings. The machining parameters (cutting speed, feed rate, depth of cut, nose radius and cutting environment) are optimized with considerations of the multiple performance measures (surface roughness, tool life, cutting force and power consumption). Taguchi’s concepts of orthogonal arrays, signal to noise (S/N) ratio, ANOVA have been fuzzified to optimize the high speed CNC turning process parameters through a single comprehensive output measure (COM). The result analysis shows that cutting speed of 160 m/min, nose radius of 0.8 mm, feed of 0.1 mm/rev, depth of cut of 0.2 mm and the cryogenic environment are the most favorable cutting parameters for high speed CNC turning of AISI P-20 tool steel.     

Recurrent ANN for monitoring degraded behaviours in a range of workpiece thicknesses

This paper presents the use of artificial neural networks (ANN) to diagnose degraded behaviours in wire electrical discharge machining (WEDM). The detection in advance of the degradation of the cutting process is crucial since this can lead to the breakage of the cutting tool (the wire), reducing the process productivity and the required accuracy. Concerning this, previous investigations have identified different types of degraded behaviours in two commonly used workpiece thicknesses (50 and 100 mm). This goal was achieved by monitoring different functions of characteristic discharge variables. However, the thresholds achieved by these functions depended on the thickness of the workpiece. Consequently, the main objective of this work is to detect the degradation of the process when machining workpiece of different thicknesses using one unique empirical model. Since artificial neural network techniques are appropriate for stochastic and non-linear nature processes, its use is investigated here to cope with workpieces of different thicknesses. The results of this work show a satisfactory performance of the presented approach. The satisfactory performance is shown by two ratios: the validation ratio, which ranges between 85% and 100%, and the test ratio, which results between 75% and 100%.     

Bivariate quality control using two-stage intelligent monitoring scheme

In manufacturing industries, it is well known that process variation is a major source of poor quality products. As such, monitoring and diagnosis of variation is essential towards continuous quality improvement. This becomes more challenging when involving two correlated variables (bivariate), whereby selection of statistical process control (SPC) scheme becomes more critical. Nevertheless, the existing traditional SPC schemes for bivariate quality control (BQC) were mainly designed for rapid detection of unnatural variation with limited capability in avoiding false alarm, that is, imbalanced monitoring performance. Another issue is the difficulty in identifying the source of unnatural variation, that is, lack of diagnosis, especially when dealing with small shifts. In this research, a scheme to address balanced monitoring and accurate diagnosis was investigated. Design consideration involved extensive simulation experiments to select input representation based on raw data and statistical features, artificial neural network recognizer design based on synergistic model, and monitoring–diagnosis approach based on two-stage technique. The study focused on bivariate process for cross correlation function, ρ = 0.1–0.9 and mean shifts, μ = ±0.75–3.00 standard deviations. The proposed two-stage intelligent monitoring scheme (2S-IMS) gave superior performance, namely, average run length, ARL₁ = 3.18–16.75 (for out-of-control process), ARL₀ = 335.01–543.93 (for in-control process) and recognition accuracy, RA = 89.5–98.5%. This scheme was validated in manufacturing of audio video device component. This research has provided a new perspective in realizing balanced monitoring and accurate diagnosis in BQC.     

A 5 GHz LC-VCO frequency synthesizer for unlicensed band of WiMAX

This paper presents a low power and low phase noise CMOS integer-N frequency synthesizer based on the charge-pump Phase Locked Loop (PLL) topology. The frequency synthesizer can be used for IEEE 802.16 unlicensed band of WiMAX (World Interoperability for Microwave Access). The operation frequency of the proposed design is ranged from 5.13 to 5.22 GHz. The proposed Voltage-Controlled Oscillator (VCO) achieves low power consumption and low phase noise. The high speed divider is implemented by an optimal extended true single phase clock (E-TSPC) prescaler. It can achieve higher operating frequency and lower power consumption. A new frequency divider is also proposed to eliminate the hardware overhead of the S counter in the conventional programmable divider. The proposed frequency synthesizer consists of a phase-frequency detector (PFD), a charge pump, a low-pass loop filter, a VCO, and a frequency divider. The simulated phase noise of the proposed VCO is −121.6 dBc/Hz at 1 MHz offset from the carrier frequency. The proposed frequency synthesizer consumes 13.1 mW. The chip with an area of 1.048 × 1.076 mm² is fabricated in a TSMC 0.18 μm CMOS 1P6M technology process.     

Continuous blood pressure estimation based on multiple parameters from eletrocardiogram and photoplethysmogram by Back-propagation neural network

The cuff-less continuous blood pressure monitoring provides reliable and invaluable information about the individuals’ health condition. Conventional sphygmomanometer with a cuff measures only the value of the blood pressure intermittently and the measurement process is sometimes inconvenient. In this work, a systematic approach with multi-parameter fusion has been proposed to estimate the non-invasive beat-to-beat systolic and diastolic blood pressure with high accuracy. The methods involve real-time monitoring of the electrocardiogram (ECG) and photoplethysmogram (PPG), and extracting the R peak from the ECG and relevant feature parameters from the synchronous PPG. Also, it covers the creation of the topological model of back-propagation neural network that has fifteen neurons in the input layer, ten neurons in the single interlayer, and two neurons in the output layer, where all the neurons are fully connected. As for the results, the proposed method was validated on the volunteers. The reference blood pressure (BP) is from Finometer (MIDI, Finapres Medical System, Netherlands). The results showed that the mean ± S.D. for the estimated systolic BP (SBP) and diastolic BP (DBP) with the proposed method against reference were −0.41 ± 2.02 mmHg and 0.46 ± 2.21 mmHg, respectively. Thus, the continuous blood pressure algorithm based on Back-Propagation neural network provides a continuous BP with a high accuracy.     

A standard deviation based firefly algorithm for multi-objective optimization of WEDM process during machining of Indian RAFM steel

Non-conventional machining processes always suffer due to their low productivity and high cost. However, a suitable machining process should improve its productivity without compromising product quality. This implies the necessity to use efficient multi-objective optimization algorithm in non-conventional machining processes. In this present paper, an effective standard deviation based multi-objective fire-fly algorithm is proposed to predict various process parameters for maximum productivity (without affecting product quality) during WEDM of Indian RAFM steel. The process parameters of WEDM considered for this study are: pulse current (I), pulse-on time (T _on), pulse-off time (T _off) and wire tension (WT).While, cutting speed (CS) and surface roughness (SR) were considered as machining performance parameters. Mathematical models relating the process and response parameters had been developed by linear regression analysis and standard deviation method was used to convert this multi objective into single objective by unifying the responses. The model was then implemented in firefly algorithm in order to optimize the process parameters. The computational results depict that the proposed method is well capable of giving optimal results in WEDM process and is fairly superior to the two most popular evolutionary algorithms (particle swarm optimization algorithm and differential evolution algorithm) available in the literature.

     

Design of high speed gate driver employing IZO TFTs

This paper presents a new bi-side gate driver integrated by indium-zinc-oxide thin film transistors (IZO TFTs). Our optimized operate method can achieve high speed performance by employing a lower duty ratio (25%) CK2 with its pulse located in the middle of the pulse of CK2L to fully use the bootstrapped high voltage of node Q. In addition, the size of devices is optimized by calculation and simulation, and the function of the proposed gate driver is predicted by the circuit simulation. Furthermore, the proposed gate driver with 20 stages is fabricated by the IZO TFTs process. It is shown that a 2.6 μs width pulse with good noise-suppressed characteristic can be successfully output at the condition of R_load = 6 kΩ and C_load = 150 pF. The power consumption of the proposed gate driver with 20 stages is measured as 1 mW. Hence, the proposed gate driver may be applied to the display of 4K resolution (4096 × 2160) at a frame rate of 120 Hz. Moreover, there is a good stability for the proposed gate driver under 48 h operation.     

FPGA implementation of reversible watermarking in digital images using reversible contrast mapping

Reversible contrast mapping (RCM) and its various modified versions are used extensively in reversible watermarking (RW) to embed secret information into the digital contents. RCM based RW accomplishes a simple integer transform applied on pair of pixels and their least significant bits (LSB) are used for data embedding. It is perfectly invertible even if the LSBs of the transformed pixels are lost during data embedding. RCM offers high embedding rate at relatively low visual distortion (embedding distortion). Moreover, low computation cost and ease of hardware realization make it attractive for real-time implementation. To this aim, this paper proposes a field programmable gate array (FPGA) based very large scale integration (VLSI) architecture of RCM-RW algorithm for digital images that can serve the purpose of media authentication in real-time environment. Two architectures, one for block size (8 × 8) and the other one for (32 × 32) block are developed. The proposed architecture allows a 6-stage pipelining technique to speed up the circuit operation. For a cover image of block size (32 × 32), the proposed architecture requires 9881 slices, 9347 slice flip-flops, 11291 number 4-input LUTs, 3 BRAMs and a data rate of 1.0395 Mbps at an operating frequency as high as 98.76 MHz.     

Design of embedded TCAM based longest prefix match search engine

The content addressable memory (CAM) based solutions are very useful in network applications due to its high speed parallel search mechanism. This paper presents a novel Ternary CAM (TCAM) based NAND Pseudo CMOS–Longest Prefix Match (NPC–LPM) search engine. The proposed system provides a simple hardware based solution using novel 11T TCAM cell structures and NPC word line technique, for network routers. The experiments were performed on 256 × 128 NPC–LPM system under 0.13 μm technology. The simulation result shows that the proposed design provides low power dissipation of 5.78 mW and high search speed of 315 MSearches/s under 1.3 V supply voltage. The presented NPC–LPM system meets the speed requirement of Optical Carrier (OC) 3072 with line-rate of 160 Gb/s in Ethernet networking and IPv6 protocol. The experimental results also show that the proposed system improves power-performance by 65%.     

Determination of optimal parameters for bilateral filter in brain MR image denoising

Noise elimination is an important pre-processing step in magnetic resonance (MR) images for clinical purposes. In the present study, as an edge-preserving method, bilateral filter (BF) was used for Rician noise removal in MR images. The choice of BF parameters affects the performance of denoising. Therefore, as a novel approach, the parameters of BF were optimized using genetic algorithm (GA). First, the Rician noise with different variances (σ = 10, 20, 30) was added to simulated T1-weighted brain MR images. To find the optimum filter parameters, GA was applied to the noisy images in searching regions of window size [3 × 3, 5 × 5, 7 × 7, 11 × 11, and 21 × 21], spatial sigma [0.1–10] and intensity sigma [1–60]. The peak signal-to-noise ratio (PSNR) was adjusted as fitness value for optimization.After determination of optimal parameters, we investigated the results of proposed BF parameters with both the simulated and clinical MR images. In order to understand the importance of parameter selection in BF, we compared the results of denoising with proposed parameters and other previously used BFs using the quality metrics such as mean squared error (MSE), PSNR, signal-to-noise ratio (SNR) and structural similarity index metric (SSIM). The quality of the denoised images with the proposed parameters was validated using both visual inspection and quantitative metrics. The experimental results showed that the BF with parameters proposed by us showed a better performance than BF with other previously proposed parameters in both the preservation of edges and removal of different level of Rician noise from MR images. It can be concluded that the performance of BF for denoising is highly dependent on optimal parameter selection.     

An optimum feature extraction method based on Wavelet–Radon Transform and Dynamic Neural Network for pavement distress classification

Quantification of pavement crack data is one of the most important criteria in determining optimum pavement maintenance strategies. Recently, multi-resolution analysis such as wavelet decompositions provides very good multi-resolution analytical tools for different scales of pavement analysis and distresses classification. This paper present an automatic diagnosis system for detecting and classification pavement crack distress based on Wavelet–Radon Transform (WR) and Dynamic Neural Network (DNN) threshold selection. The algorithm of the proposed system consists of a combination of feature extraction using WR and classification using the neural network technique. The proposed WR + DNN system performance is compared with static neural network (SNN). In test stage; proposed method was applied to the pavement images database to evaluate the system performance. The correct classification rate (CCR) of proposed system is over 99%. This research demonstrated that the WR + DNN method can be used efficiently for fast automatic pavement distress detection and classification. The details of the image processing technique and the characteristic of system are also described in this paper.     

High resolution ambulatory holter ECG events detection-delineation via modified multi-lead wavelet-based features analysis: Detection and quantification of heart rate turbulence

The presented study describes a false-alarm probability-FAP bounded solution for detecting and quantifying Heart Rate Turbulence (HRT) major parameters including heart rate (HR) acceleration/deceleration, turbulence jump, compensatory pause value and HR recovery rate. To this end, first, high resolution multi-lead holter electrocardiogram (ECG) signal is appropriately pre-processed via Discrete Wavelet Transform (DWT) and then, a fixed sample size sliding window is moved on the pre-processed trend. In each slid, the area under the excerpted segment is multiplied by its curve-length to generate the Area Curve Length (ACL) metric to be used as the ECG events detection-delineation decision statistic (DS). The ECG events detection-delineation algorithm was applied to various existing databases and as a result, the average values of sensitivity and positive predictivity Se = 99.95% and P+ = 99.92% were obtained for the detection of QRS complexes, with the average maximum delineation error of 7.4 msec, 4.2 msec and 8.3 msec for P-wave, QRS complex and T-wave, respectively. Because the heart-rate time series might include fast fluctuations which don’t follow a premature ventricular contraction (PVC) causing high-level false alarm probability (false positive detections) of HRT detection, based on the binary two-dimensional Neyman-Pearson radius test (which is a FAP-bounded classifier), a new method for discrimination of PVCs from other beats using the geometrical-based features is proposed. The statistical performance of the proposed HRT detection-quantification algorithm was obtained as Se = 99.94% and P+ = 99.85% showing marginal improvement for the detection-quantification of this phenomenon. In summary, marginal performance improvement of ECG events detection-delineation process, high performance PVC detection and isolation from noisy holter data and reliable robustness against holter strong noise and artifacts can be mentioned as important merits and capabilities of the proposed HRT detection algorithm.     

A reversible data hiding scheme based on the Sudoku technique

Data hiding, also known as information hiding, plays an important role in information security for various purposes. Reversible data hiding is a technique that allows distortion-free recovery of both the cover image and the secret information. In this paper, we propose a new, reversible data hiding scheme that is based on the Sudoku technique and can achieve higher embedding capacity. The proposed scheme allows embedding more secret bits into a pair of pixels while guaranteeing the good quality of the stego-image. The experimental results showed that the proposed scheme obtained higher embedding capacity than some other previous schemes. In addition, our proposed scheme maintained the good visual quality of the stego-image (i.e., PSNR > 46 dB), which outperforms some existing schemes.     

Early-stage atherosclerosis detection using deep learning over carotid ultrasound images

This paper proposes a computer-aided diagnosis tool for the early detection of atherosclerosis. This pathology is responsible for major cardiovascular diseases, which are the main cause of death worldwide. Among preventive measures, the intima-media thickness (IMT) of the common carotid artery stands out as early indicator of atherosclerosis and cardiovascular risk. In particular, IMT is evaluated by means of ultrasound scans. Usually, during the radiological examination, the specialist detects the optimal measurement area, identifies the layers of the arterial wall and manually marks pairs of points on the image to estimate the thickness of the artery. Therefore, this manual procedure entails subjectivity and variability in the IMT evaluation. Instead, this article suggests a fully automatic segmentation technique for ultrasound images of the common carotid artery. The proposed methodology is based on machine learning and artificial neural networks for the recognition of IMT intensity patterns in the images. For this purpose, a deep learning strategy has been developed to obtain abstract and efficient data representations by means of auto-encoders with multiple hidden layers. In particular, the considered deep architecture has been designed under the concept of extreme learning machine (ELM). The correct identification of the arterial layers is achieved in a totally user-independent and repeatable manner, which not only improves the IMT measurement in daily clinical practice but also facilitates the clinical research. A database consisting of 67 ultrasound images has been used in the validation of the suggested system, in which the resulting automatic contours for each image have been compared with the average of four manual segmentations performed by two different observers (ground-truth). Specifically, the IMT measured by the proposed algorithm is 0.625 ± 0.167 mm (mean ± standard deviation), whereas the corresponding ground-truth value is 0.619 ± 0.176 mm. Thus, our method shows a difference between automatic and manual measures of only 5.79 ± 34.42 μm. Furthermore, different quantitative evaluations reported in this paper indicate that this procedure outperforms other methods presented in the literature.     

Design,fabrication, and testing of MEMS solid propellant thruster array chip on glass wafer

This paper presents the internal ballistic design, fabrication procedure, and performance evaluation of a micro-electro mechanical systems (MEMS) solid propellant thruster array chip. The internal ballistic design was carried out to predict the performance of the thruster. Two different ignition models were used. The numerical results gave a maximum thrust of 3840 mN, and a total impulse of 0.42 mNs at the local ignition model. A photosensitive glass wafer only was used as the bare material for the thruster. The stability of the micro-igniter was improved by using a glass membrane with a thickness of tens of microns. The average thickness of the membrane was 35 μm. The proposed micro-igniter had a level of power consumption appropriate to ignite the solid propellant. The thermal, electrical, and mechanical characteristics of the fabricated micro-igniter were measured. The solid propellant was loaded into the propellant chamber without resort to a special technique due to the high structural stability of the glass membrane. An MEMS solid propellant thruster (MSPT) array was fabricated through anisotropic etching of photosensitive glass. An ignition control system was developed to control the ignition sequence. Ignition and combustion tests of the fully assembly MEMS thruster were performed successfully. The minimum ignition delay was 27.5 ms with an ignition energy of 19.3 mJ. The average of the measured maximum thrust and total impulse were 3619 mN and 0.381 mNs, respectively.     

A fault detection scheme based on minimum identified uncertainty bounds violation for broken rotor bars in induction motors

In this paper, a novel method for broken bars fault detection in the case of three-phase induction motors and under different payloads will be presented and experimentally evaluated. In the presented approach, the cases of a partially or full broken rotor bars are being also considered, caused by: (a) drilling 4 mm and 8 mm out of the 17 mm thickness of the same rotor bar and (b) fully drilled (17 mm) one, two and three broken bars. The proposed fault detection method is based on the Set Membership Identification (SMI) technique and a novel proposed minimum boundary violation fault detection scheme, applied on the identified motor's parameters. The system identification procedure is being carried out on the simplified equivalent model of the induction motor, during the steady-state operation (non-fault case), while at the same time the proposed scheme is able to calculate on-line the corresponding safety bounds for the identified variables, based on a priori knowledge of the measuring corrupting noise (worst case encountered). The efficiency, the robustness and the overall performance of the established fault detection scheme is being extensively evaluated in multiple experimental studies and under various time instances of faults and load conditions.