Laser Scanning Based Object Detection to Realize Digital Blank Shadows for Autonomous Process Planning in Machining

The automated process chain of an unmanned production system is a distinct challenge in the technical state of the art. In particular, accurate and fast raw-part recognition is a current problem in small-batch production. This publication proposes a method for automatic optical raw-part detection to generate a digital blank shadow, which is applied for adapted CAD/CAM (computer-aided design/computer-aided manufacturing) planning. Thereby, a laser-triangulation sensor is integrated into the machine tool. For an automatic raw-part detection and a workpiece origin definition, a dedicated algorithm for creating a digital blank shadow is introduced. The algorithm generates adaptive scan paths, merges laser lines and machine axis data, filters interference signals, and identifies part edges and surfaces according to a point cloud. Furthermore, a dedicated software system is introduced to investigate the created approach. This method is integrated into a CAD/CAM system, with customized software libraries for communication with the CNC (computer numerical control) machine. The results of this study show that the applied method can identify the positions, dimensions, and shapes of different raw parts autonomously, with deviations less than 1 mm, in 2.5 min. Moreover, the measurement and process data can be transferred without errors to different hardware and software systems. It was found that the proposed approach can be applied for rough raw-part detection, and in combination with a touch probe for accurate detection

ACCURACY ANALYSIS OF THE CURVED PROFILE MEASUREMENT WITH CMM: A CASE STUDY

In the paper, analysis of the curved profile measurement accuracy is described. Since there was no CAD model or other reference profile for the measured detail, the first step was to generate the reference contour of the cam using the technical drawing and tolerance requirements. The test campaign consisted of three experiments aimed at determining the effect of scanning velocity on the results of form deviation δ measurement, evaluation of deviation δ measurement uncertainty and the measurement repeatability. The scanning time was checked, too. The obtained results demonstrated feasibility of the chosen CMM and measurement strategy. It was found also that the measurement uncertainty did not depend on the scanning sampling step from 0.05 to 0.2 mm, and the true measurement time was for 30-40% longer than that expected from the nominal scanning velocity

Manufacturing Metrology

Metrology is the science of measurement, which can be divided into three overlapping activities: (1) the definition of units of measurement, (2) the realization of units of measurement, and (3) the traceability of measurement units. Manufacturing metrology originally implicates the measurement of components and inputs for a manufacturing process to assure they are within specification requirements. It can also be extended to indicate the performance measurement of manufacturing equipment. This Special Issue covers papers revealing novel measurement methodologies and instrumentations for manufacturing metrology from the conventional industry to the frontier of the advanced hi-tech industry. Twenty-five papers are included in this Special Issue. These published papers can be categorized into four main groups, as follows: Length measurement: covering new designs, from micro/nanogap measurement with laser triangulation sensors and laser interferometers to very-long-distance, newly developed mode-locked femtosecond lasers. Surface profile and form measurements: covering technologies with new confocal sensors and imagine sensors: in situ and on-machine measurements. Angle measurements: these include a new 2D precision level design, a review of angle measurement with mode-locked femtosecond lasers, and multi-axis machine tool squareness measurement. Other laboratory systems: these include a water cooling temperature control system and a computer-aided inspection framework for CMM performance evaluation

Development of an electrochemical micromachining (μECM) machine

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University London.Electrochemical machining (ECM) and especially electrochemical micromachining (μECM) became an attractive area of research due to the fact that this process does not create any defective layer after machining and that there is a growing demand for better surface integrity on different micro applications such as microfluidics systems and stressfree drilled holes in the automotive and aerospace sectors. Electrochemical machining is considered as a non-conventional machining process based on the phenomenon of electrolysis. This process requires maintaining a small gap - the interelectrode gap (IEG) - between the anode (workpiece) and the cathode (tool-electrode) in order to achieve acceptable machining results (i.e. accuracy, high aspect ratio with appropriate material removal rate and efficiency). This work presents the design of a next generation μECM machine for the automotive, aerospace, medical and metrology sectors. It has 3 axes of motion (X, Y and Z) and a spindle allowing the tool-electrode to rotate during machining. The linear slides for each axis use air bearings with linear DC brushless motors and 2nmresolution encoders for ultra-precise motion. The control system is based on the Power PMAC motion controller from Delta Tau. The electrolyte tank is located at the rear of the machine and allows the electrolyte to be changed quickly. A pulse power supply unit (PSU) and a special control algorithm have been implemented. The pulse power supply provides not only ultra-short pulses (50ns), but also plus and minus biases as well as a polarity switching functionality. It fulfils the requirements of tool preparation with reversed ECM on the machine. Moreover, the PSU is equipped with an ultrafast over current protection which prevents the tool-electrode from being damaged in case of short-circuits. Two different process control algorithms were made: one is fuzzy logic based and the other is adapting the feed rate according to the position and time at which short-circuits were detected. The developed machine is capable of drilling micro holes in hard-to-machine materials but also machine micro-styli and micro-needles for the metrology (micro CMM) and medical sectors. This work also presents drilling trials performed with the machine with an orbiting tool. Machining experiments were also carried out using electrolytes made of a combination of HCl and NaNO aqueous solutions. The developed machine was used to fabricate micro tools out of 170μm WC-Co alloy shafts via micro electrochemical turning and drill deep holes via μECM in disks made of 18NiCr6 alloy. Results suggest that this process can be used for industrial applications for hard-to-machine materials. The author also suggests that the developed machine can be used to manufacture micro-probes and micro-tools for metrology and micro-manufacturing purposes.Brunel University European Commissio

3D Geometrical Inspection of Complex Geometry Parts Using a Novel Laser Triangulation Sensor and a Robot

This article discusses different non contact 3D measuring strategies and presents a model for measuring complex geometry parts, manipulated through a robot arm, using a novel vision system consisting of a laser triangulation sensor and a motorized linear stage. First, the geometric model incorporating an automatic simple module for long term stability improvement will be outlined in the article. The new method used in the automatic module allows the sensor set up, including the motorized linear stage, for the scanning avoiding external measurement devices. In the measurement model the robot is just a positioning of parts with high repeatability. Its position and orientation data are not used for the measurement and therefore it is not directly “coupled” as an active component in the model. The function of the robot is to present the various surfaces of the workpiece along the measurement range of the vision system, which is responsible for the measurement. Thus, the whole system is not affected by the robot own errors following a trajectory, except those due to the lack of static repeatability. For the indirect link between the vision system and the robot, the original model developed needs only one first piece measuring as a “zero” or master piece, known by its accurate measurement using, for example, a Coordinate Measurement Machine. The strategy proposed presents a different approach to traditional laser triangulation systems on board the robot in order to improve the measurement accuracy, and several important cues for self-recalibration are explored using only a master piece. Experimental results are also presented to demonstrate the technique and the final 3D measurement accuracy

Selected Papers from the 5th International Electronic Conference on Sensors and Applications

This Special Issue comprises selected papers from the proceedings of the 5th International Electronic Conference on Sensors and Applications, held on 15–30 November 2018, on sciforum.net, an online platform for hosting scholarly e-conferences and discussion groups. In this 5th edition of the electronic conference, contributors were invited to provide papers and presentations from the field of sensors and applications at large, resulting in a wide variety of excellent submissions and topic areas. Papers which attracted the most interest on the web or that provided a particularly innovative contribution were selected for publication in this collection. These peer-reviewed papers are published with the aim of rapid and wide dissemination of research results, developments, and applications. We hope this conference series will grow rapidly in the future and become recognized as a new way and venue by which to (electronically) present new developments related to the field of sensors and their applications

Optimization of Cutting Parameters for Pocket Milling on the Skin Plate in Al and Al-Li Materials

RÉSUMÉ L'objectif de cette étude est d'optimiser des paramètres de coupes pour l’usinage de poche sur une plaque mince en alliage d’aluminium et en alliage d’aluminium-lithium. Ces plaques minces sont utilisées dans l’industrie aéronautique pour fabriquer le fuselage d’un avion. Présentement, ces poches sur les plaques minces sont fabriquées par usinage chimique. Cette méthode chimique est dite nocive pour l’environnement. La méthode chimique pourrait être remplacée par une méthode mécanique comme l’usinage. En plus, les paramètres de coupes seront optimisés pour l’alliage d’aluminium-lithium. L’effet des paramètres de coupes a été étudié par des expériences utilisant la méthode de Taguchi. L’analyse de rapport signal sur bruit (Signal to Noise ratio) a été menée sur les données recueillies pour illustrer la significativité des facteurs des plans d’expériences et de leur contribution. La rugosité de la surface sur les pièces a été aussi étudiée et des paramètres optimaux ont été définis. Des vérifications ont été accomplies et la poche sur la plaque a été usinée à la satisfaction des exigences de l'ingénierie de l'industrie.----------ABSTRACT In the present work the pocket machining (milling) of the thin skin components made of aluminium and aluminium-lithium (Al-Li) alloys is studied. These milled components are known as principle parts of commercial airplanes. They have significant impacts on the airplane body weight and fuel consumption. Chemical milling is the main method used for pockets machining on these components. However, this method is not considered as an environmentally friendly operation due to severe contamination problems. To remedy these difficulties, this study intends to replace the chemical milling by an alternative machining method capable to do pocket machining. To that end, pocket milling was selected as machining method. Furthermore, in order to reduce the weight of airplane, an alternative material such as Al-Li alloys is proposed to replace the aluminum alloys. In the first phase of this study, a comprehensive literature review was conducted on milling and pocket milling of aluminum and aluminum-lithium alloys. The sample parts required for cutting operations were prepared in accordance with in specified dimensional geometries of the real parts used in industry. A milling fixture was then designed and manufactured in order to perform machining operations on the sample parts. The experimental tests were planned according to the Taguchi method design of experiment. The cutting parameters studied included: RPM, chip thickness (feed rate), depth of cut and lubricant. The one way and profile contouring milling operations were selected as machining strategies. A process failure mode and effect analysis (FMEA) was executed to determine the main failure modes during pocket milling operations and the surface roughness was used as performance criteria. The experimental results were analyzed using Signal to Noise ratio (S/N) strategy though Taguchi method. According to the experimental results, the optimal setting levels of cutting parameters are RPM (10000 rev/min), chip thickness (0.0508 mm), depth of cut (0.45 mm) and lubricant (MQL, 40 ml/min). Finally, the experimental verification tests were performed. According to the literature, a similar machining specification can be applied for conventional aluminium alloys and the Al-Li alloys. Consequently, in order to reduce the experimental cost and time, the optimum setting levels of process parameters proposed in this work could be applied in the machining of Al-Li work pieces