Laser Deposition Cladding On-Line Inspection Using 3-D Scanner

Laser deposition directly deposits metal cladding to fabricate and repair components. In order to finish the fabrication or repair, 3-D shape of the deposition needs to be inspected, and thus it can be determined if it has sufficient cladding to fabricate a part after deposition process. In the present hybrid system in the Laser Aided Manufacturing Lab (LAMP) at the University of Missouri - Rolla, a CMM system is used to do the inspection. A CMM requires point-by-point contact, which is time consuming and difficult to plan for an irregular deposition geometry. Also, the CMM is a separate device, which requires removal of the part from the hybrid system, which can induce fixture errors. The 3-D scanner is a non-contact tool to measure the 3-D shape of laser deposition cladding which is fast and accurate. In this paper, A prototype non-contact 3-D scanner approach has been implemented to inspect the free-form and complex parts built by laser deposition. Registration of the measured model and 3-D CAD model allows the comparison between the two models. It enables us to determine if the deposition is sufficient before machining.Mechanical Engineerin

A Novel Approach for 3D Part Inspection Using Laser-plane Sensors

AbstractThe paper deals with the relevance of using laser-plane sensors in 3D part inspection. First, based on the evaluation of the measuring system capacities, a digitizing strategy permits to obtain a set of points with a sufficient quality as regards geometrical specifications. Despite the optimized strategy, the digitizing noise associated to the sensor alters data quality, and may affect the estimation of the surface defects (form deviation for instance is strongly affected by digitizing noise). An original filtering method is proposed to remove digitizing noise before the evaluation of the specifications

Zero-point fixture systems as a reconfiguration enabler in flexible manufacturing systems

ABSTRACT: Today's manufacturing systems need to be able to quickly adapt to customer demands, ranging from high volumes of mass production to high volumes of mass customization. Flexible Manufacturing Systems provide a high degree of flexibility to cope with these challenges. They consist of machine tools capable of executing a wide range of machining operations while the use of pallets to reference and block the parts allows the decoupling of the setup operations from the machining centers activity. This paper presents an ontology-based framework to support the design and management of flexible manufacturing systems, aimed at integrating the various involved activities including the pallet configuration and process planning, the management policies for short-term production planning and the pallet checking to verify the correct configuration of the physical pallet

Knowledge Capture in CMM Inspection Planning: Barriers and Challenges

Coordinate Measuring Machines (CMM) have been widely used as a means of evaluating product quality and controlling quality manufacturing processes. Many techniques have been developed to facilitate the generation of CMM measurement plans. However, there are major gaps in the understanding of planning such strategies. This significant lack of explicitly available knowledge on how experts prepare plans and carry out measurements slows down the planning process, leading to the repetitive reinvention of new plans while preventing the automation or even semi-automation of the process. The objectives of this paper are twofold: (i) to provide a review of the existing inspection planning systems and discuss the barriers and challenges, especially from the aspect of knowledge capture and formalization; and (ii) to propose and demonstrate a novel digital engineering mixed reality paradigm which has the potential to facilitate the rapid capture of implicit inspection knowledge and explicitly represent this in a formalized way. An outline and the results of the development of an early stage prototype - which will form the foundation of a more complex system to address the aforementioned technological challenges identified in the literature survey - will be given

A Comparison of Selected Algorithms of Form Deviation Calculation

The article concerns the verification of accuracy of selected algorithms of form deviation evaluation. The paper presents the results of experimental investigations concerning coordinate measurements of products composed of free-form surfaces, which are characterized by various degrees of geometric complexity. The experimental investigations were conducted with the use of the method of form deviation estimation which is based on the Lagrange interpolation of measured points and two additional algorithms available in the Calypso software, which cooperates with a coordinate measuring machine. Moreover, the experimental research was performed by using of the coordinate measuring machine ACCURA II equipped with the scanning probe VAST XT. Based on the analysis of gained results of coordinate measurements the method of form deviation calculation which uses the Lagrange interpolation of measured points in order to calculate an actual curve achieved better results than one of the analysed algorithms of the Calypso inspection software

An introduction of small-scale intelligent manufacturing system

Embargoed OA, manuscript version after 24 months from publishing date. Link to publishers version: http://doi.org/10.1109/SIMS.2016.7802896Manufacturing companies in Northern Peripheral and Arctic region are predominately small and medium-sized and face considerable challenges like geographical isolation and a lack of benefits offered by industrial clusters. For the ultimate goal of enhancing their competitiveness in a global market, it is imperative for companies to innovate or adopt innovations in order to quickly response to changes in market, meet customer demands, reduce time-to-market and lower cost. A novel concept for small-scale intelligent manufacturing systems (SIMS) is introduced, in which diverse methods and innovative technologies can be applied and integrated. This paper gives an introduction of SIMS, defines its design objectives, and summarizes major relevant tools, techniques and paradigms for the development of SIMS, to generate a facilitative environment for small and medium-scale manufacturing enterprises to embrace new and innovative technologies

Determination of Fatigue Life of Surface Propeller by Using Finite Element Analysis

Propeller design aims at achieving high propulsive efficiency at low levels of vibration and noise, usually with minimum cavitations. Achieving this aim is difficult with conventional propellers, as ships have become larger and faster propeller diameters have remained limited by draught and other factors. Surface piercing propeller offers an attractive alternative to high-speed crafts, which operate under limited draught. The performance of the vehicle depends upon the efficiency of the propeller. The geometric shape and its surface finish will decide the efficiency of the propeller. The material used is carbon UD and aluminum. The present project basically deals with the modeling, Analysis of the propeller using composite material of a marine vehicle having low draft. A propeller is complex 3D model geometry. CATIA modeling software is used for generating the blade model and tool path on the computer. Sectional data, pitch angle of the propeller are the inputs for the development of propeller model. Finite element analysis was carried out using ABAQUS. The propeller model developed in CATIA is converted in to IGES file and then imported to HYPERMESH for developing fine mesh of the model. As a part of the analysis static structural testing was conducted by varying material properties in pre-processing stage. Further fatigue analysis was performed to analyze the factor of safety. Based on the results obtained from both static analysis and dynamic analysis a better performing material is identified for the development of a propeller. The post processed results obtained from both analysis methods recommends carbon UD/ Epoxy for the fabrication of propeller

Digitization Methods of Grinding Pins for Technological Process Planning

The paper presents different techniques for digitizing grinding pins and discusses the use of digitalized pins and the results of measurements in technological process planning (TPP), focusing on the challenges of the digital era. It describes the potential of different measuring devices, taking into account the digitization of a real tool shape into virtual 2D and 3D models. The following methods for measuring grinding pins are presented in the study: contact and non-contact coordinate measurements – performed on coordinate measuring machines (CMM); optical measurements on microscopes (i.e. focus-variation technique); optical measurements using tool presetters; optical measurements with measuring arm; laser micrometer measurements; and laser triangulation sensor measurements. Moreover, the use of testers which are applied in contour measurements is analyzed. On the basis of the presented methods, taking into account their possibilities and limitations, we discuss how the obtained digital data can be used in the planning of technological processes.publishedVersio

On-line inspection and thermal properties comparison for laser deposition process

This thesis is focused on comparing the laser deposition cladding with intended design model and comparing the effect of laser deposition process on thermal properties with traditional welding process. It is research on two aspects of laser deposition cladding. The first part of the thesis is aimed at solving the geometric inspection of laser deposition cladding, and the second part is for comparing the thermal properties of laser deposition cladding to samples of conventional welding process --Introduction, page 1

Influence of boundary conditions on the prediction of springback and wrinkling in sheet metal forming

The high-strength steel sheets currently used in the automotive industry are prone to non-traditional behaviour during forming, being wrinkling and springback two of the most challenging geometrical predictions for numerical simulation. Thus, the finite element method requires accurate and reliable numerical models. This study presents the experimental and numerical analysis of a rail component with high tendency to develop wrinlding and 2D springback. Two different materials are used for the sheet blank, namely a mild steel (DC06) and a dual phase steel (DP600). The frictional behaviour between each metallic sheet and the forming tools is evaluated through the flat-die test, allowing the determination of a friction coefficient as a function of the normal pressure. The influence of the applied boundary conditions on the numerical results is evaluated by means of two distinct numerical models (full blank geometry and 1/4 of the blank with symmetry conditions). The results show that the wrinkling behaviour is strongly affected by the blanks material, as well as by the symmetry conditions defined in the numerical model. In fact, considering the full model of the blank, the numerical results are in better agreement with the experimental ones. However, the computational cost of the numerical simulation considering the full blank is substantially higher than using 1/4 of the blank.The authors gratefully acknowledge the financial support of the Portuguese Foundation for Science and Technology (FCT) under the projects with reference P2020-PTDC/EMS-TEC/0702/2014 (POCI-010145-FEDER-016779) and P2020-PTDC/EMS-TEC/6400/2014 (POCI01-0145-FEDER-016876) by UE/FEDER through the program COMPETE 2020. The first author is also grateful to the FCT for the Postdoctoral grant SFRH/BPD/101334/2014.info:eu-repo/semantics/publishedVersio