Development of a reconstruction quality metric for optical three-dimensional measurement systems in use for hot-state measurement object

Optical three-dimensional (3-D) geometry measurements are state of the art when it comes to contactless quality control and maintenance of the shape of technical components that exclude tactile measurements due to filigree or internal structures. Optical inspection methods are also characterized by a fast and high-resolution 3-D inspection of complex geometries. And due to their noncontact principle, they can carry out measurements in places that would otherwise not be accessible due to harsh environmental conditions or specimens such as hot forged parts. However, there are currently no methods to estimate the reconstruction quality for the optical 3-D geometry measurements of hot objects. The mainly used geometric measurement standards cannot be used for the characterization of hot measurements since the calibrated geometrical values are not transferable to high temperatures. For the development of such a metric, we present the fundamentals of the concepts and algorithms for an estimation of the reconstruction quality are presented and evaluated using a two-dimensional simulation model. The generated findings were applied to the 3-D geometry measurement of a hot object in a laboratory environment. The results are compared with general state-of-the-art reconstruction quality metrics

Simulation assisted process chain design for the manufacturing of bulk hybrid shafts with tailored properties

To manufacture semi-finished hybrid workpieces with tailored properties, a finite element simulation assisted process chain design was investigated. This includes the process steps of cross wedge rolling, hot geometry inspection, induction hardening, and fatigue testing. The process chain allows the utilisation of material combinations such as high-strength steels with low-cost and easy to process steels. Here, plasma transferred arc welding is applied to supply the process chain with hybrid specimen featuring different steel grades. An overview of the numerical approaches to consider the various physical phenomena in each of the process steps is presented. The properties of the component behaviour were investigated via the finite element method (FEM) and theoretical approaches. At first, the manufacturing of a hybrid workpiece featuring a near net shape geometry with improved mechanical properties due to recrystallising the weld was computed, using the example of a cross wedge rolling process. The rolling process was designed by means of FEM to determine suitable process parameters and to reduce experimental testing. An optical multi-scale geometry inspection of the hot workpiece is meant to be carried out after each manufacturing step to detect potential undesired forming or cooling-induced deformations. Due to the heat transfer from the hot component to the ambient medium, an optical measurement is affected by the developing inhomogeneous refractive index field in air. To gain a basic understanding of the refractive index field and induced light deflection effects, computations were conducted using heat transfer and ray tracing simulations. According to the proposed process route, a subsequent local heat treatment of the hybrid component is required to adapt the mechanical properties by a spray cooling assisted induction hardening. The heat treatment step was computed via a 2D FEM calculation. After finishing by machining, the hybrid material shafts are examined in fatigue tests under load conditions. To predict the component’s lifetime under rolling contact fatigue, a damage accumulation model was combined with an FE simulation. The resulting residual stress state after quenching and the geometry after the finishing process were used as input data for the fatigue life calculations

Automated tracking of the Florida manatee (Trichechus manatus)

The electronic, physical, biological and environmental factors involved in the automated remote tracking of the Florida manatee (Trichechus manatus) are identified. The current status of the manatee as an endangered species is provided. Brief descriptions of existing tracking and position locating systems are presented to identify the state of the art in these fields. An analysis of energy media is conducted to identify those with the highest probability of success for this application. Logistic questions such as the means of attachment and position of any equipment to be placed on the manatee are also investigated. Power sources and manateeborne electronics encapsulation techniques are studied and the results of a compter generated DF network analysis are summarized

Traceability of on-machine tool measurement: a review

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand

Surface deformation and elasticity studies in the Virgin Islands

The report consists of four sections. The first section describes tilt and leveling measurements on Anegada, the most northerly of the British Virgin Islands; the second section contains a discussion of sea-level measurements that were initiated in the region and which played a significant role in the development of a network of sea-level monitors now telemetered via satellite from the Alaskan Shumagin Islands. The third part of the report is a brief description of surface deformation measurements in Iceland using equipment and techniques developed by the subject grant. The final part of the report describes the predicted effects of block surface fragmentation in tectonic areas on the measurement of tilt and strain

Design of Experiment Analysis of an Electronics Package Lid Using Finite Element Analysis

A design of experiment analysis is reported on data from warpage simulations using finite element analysis of a lidded electronics package. Warpage in a lid of an optical electronics package can detrimentally affect the reliability of the package as well as its optical performance. The present study focuses on the variety of materials and designs of lids relevant to recent technologies in electronics packaging. The finite element analysis (FEA) formulation in this study accurately predicts deformation and warpage in the elastic region with optimal computational time achieved through a choice of boundary conditions and mesh sensitivity studies. The results from FEA are compared to analytical calculations made using the classical laminate plate theory (CLPT) as well as the modified Suhir’s theory. It is observed that FEA results are more accurate as they account for the performance of die attach/ underfill materials regardless of the small thickness of the layer. The FEA data are finally used to conduct a design of experiments (DOE) analysis to investigate the influence of 3 distinct designs and 6 material choices on warpage of a lid. The analysis indicates that there is no significant interaction between the two parameters expected to affect the warpage in the lid. Material properties of the lid are found to have a greater effect on the warpage of the lid as compared to variabilities introduced in lid designs in this study. The FEA simulations performed consider only material behavior within the elastic limit and, in some situations, plastic deformation may occur which is more permanent and as such requires a more comprehensive analysis in the plastic region to enhance the data set for DOE studies

Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing

Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot be tolerated. Developments in process control have allowed significant enhancement of AM techniques and marked improvements in surface roughness and material properties, along with a reduction in inter-build variation and the occurrence of embedded material discontinuities. As a result, the exploitation of AM processes continues to accelerate. Unlike established subtractive processes, where in-process monitoring is now commonplace, factory-ready AM processes have not yet incorporated monitoring technologies that allow discontinuities to be detected in process. Researchers have investigated new forms of instrumentation and adaptive approaches which, when integrated, will allow further enhancement to the assurance that can be offered when producing AM components. The state-of-the-art with respect to inspection methodologies compatible with AM processes is explored here. Their suitability for the inspection and identification of typical material discontinuities and failure modes is discussed with the intention of identifying new avenues for research and proposing approaches to integration into future generations of AM systems

Microstructure and Mechanical Properties of Ti-6Al-4V Produced by Selective Laser Sintering of Pre-alloyed Powders

The purpose of this research is to investigate the microstructure and mechanical properties of Ti6Al4V pre-alloyed powders producing by direct metal laser sintering technique. Through this research, the direct fabrication of Ti6Al4V metal parts by selective laser sintering machine has been carried out using EOS GmbH M270 equipment. Employing intricate thermo-mechanical interaction between the laser beam and the metallic powders, the machine consolidates predefined cross sections and binds the particles together to form solid parts which correspond to CAD data.The geometrical feasibility of the parts, including process accuracy were statistically analysed by simple benchmark studies. The intricate correlation between powder materials and process parameters were thoroughly investigated via fractography, metallography and standard physical testing.It was found that, SLS technologies are capable of directly producing near to full density metal parts with good mechanical properties.Ti6Al4V produced by laser sintering has very fine α+ microstructure. This fine and stable microstructure demonstrated a high yield stress and UTS with low elongation at break. The fracture surface has a dimple features typical of a ductile structure. Dimensional analyses were performed on the customised benchmark showing process accuracy below 50 m. Designated heat treatments modified the microstructure which influences the mechanical behaviour of the parts

Development of a laser based surface profilometer using the principle of optical triangulation

The metrology industry is constantly looking for new ways to accurately and quickly inspect and digitise surface topographies including the calculation o f surface roughness parameters and generating point clouds (a collection o f 3-dimensional points which describe a surface or surfaces) for modelling or reverse engineering purposes. Many types o f profllometer systems currently exist and the past decade has seen the rise in popularity o f optical based systems, however most optical profilometers are expensive to purchase and to maintain. The development o f optical profilometers can also be exceptionally complex depending on the type o f system and its fragility may not make it suitable for m ost workshop or factory floor applications. This project covers the development of a profllometer using the principle of optical triangulation. The developed system has a scanning table area of 200 by 120 millimetres and a vertical measurement range of five millimetres. The position o f the laser sensor above the target surface also has an adjustable range of 15 millimetres. A control program was developed to automatically scan user selected part and surface areas. This new system was characterised in terms of dimensional accuracy. The maximum cosine error of the system was measured at 0.07°. Dynamic accuracy of the system was measured at 2fim in the Z-axis (height) and at approximately 10|a.m in the X and Y axes. Good dimensional correlation between scanned parts (coins, screws, washers, and fibre optic lens moulds) were achieved. Testing of the system will be also discussed, including the limitations of the profllometer and possible improvements to the system

Automatic tolerance inspection through Reverse Engineering: a segmentation technique for plastic injection moulded parts

This work studies segmentations procedures to recognise features in a Reverse Engineering (RE) application that is oriented to computer-aided tolerance inspection of injection moulding die set-up, necessary to manufacture electromechanical components. It will discuss all steps of the procedures, from the initial acquisition to the final measure data management, but specific original developments will be focused on the RE post-processing method, that should solve the problem related to the automation of the surface recognition and then of the inspection process. As it will be explained in the first two Chapters, automation of the inspection process pertains, eminently, to feature recognition after the segmentation process. This work presents a voxel-based approach with the aim of reducing the computation efforts related to tessellation and curvature analysis, with or without filtering. In fact, a voxel structure approximates the shape through parallelepipeds that include small sub-set of points. In this sense, it represents a filter, since the number of voxels is less than the total number of points, but also a local approximation of the surface, if proper fitting models are applied. Through sensitivity analysis and industrial applications, limits and perspectives of the proposed algorithms are discussed and validated in terms of accuracy and save of time. Validation case-studies are taken from real applications made in ABB Sace S.p.A., that promoted this research. Plastic injection moulding of electromechanical components has a time-consuming die set-up. It is due to the necessity of providing dies with many cavities, which during the cooling phase may present different stamping conditions, thus defects that include lengths outside their dimensional tolerance, and geometrical errors. To increase the industrial efficiency, the automation of the inspection is not only due to the automatic recognition of features but also to a computer-aided inspection protocol (path planning and inspection data management). For this reason, also these steps will be faced, as the natural framework of the thesis research activity. The work structure concerns with six chapters. In Chapter 1, an introduction to the whole procedure is presented, focusing on reasons and utilities of the application of RE techniques in industrial engineering. Chapter 2 analyses acquisition issues and methods that are related to our application, describing: (a) selected hardware; (b) adopted strategy related to the cloud of point acquisition. In Chapter 3, the proposed RE post-processing is described together with a state of art about data segmentation and surface reconstruction. Chapter 4 discusses the proposed algorithms through sensitivity studies concerning thresholds and parameters utilised in segmentation phase and surface reconstruction. Chapter 5 explains briefly the inspection workflow, PDM requirements and solution, together with a preliminary assessing of measures and their reliability. These three chapters (3, 4 and 5) report final sections, called “Discussion”, in which specific considerations are given. Finally, Chapter 6 gives examples of the proposed segmentation technique in the framework of the industrial applications, through specific case studies