Analyses of stone surfaces by optical methods

Ornamental stone products are generally used for decorative cladding. A major quality parameter is their aesthetical appearance, which directly impacts their commercial value. The surface quality of stone products depends on the presence of defects both due to the unpredictability of natural materials and to the actual manufacturing process. This work starts reviewing the literature about optical methods for stone surface inspection. A classification is then proposed focusing on their industrial applicability in order to provide a guideline for future investigations. Three innovative systems are proposed and described in details: a vision system, an optical profilometer and a reflectometer for the inspection of polished, bush-hammered, sand-blasted, flame-finished, waterjet processed, and laser engraved surfaces

Three-Dimensional Shape Measurements of Specular Objects Using Phase-Measuring Deflectometry

The fast development in the fields of integrated circuits, photovoltaics, the automobile industry, advanced manufacturing, and astronomy have led to the importance and necessity of quickly and accurately obtaining three-dimensional (3D) shape data of specular surfaces for quality control and function evaluation. Owing to the advantages of a large dynamic range, non-contact operation, full-field and fast acquisition, high accuracy, and automatic data processing, phase-measuring deflectometry (PMD, also called fringe reflection profilometry) has been widely studied and applied in many fields. Phase information coded in the reflected fringe patterns relates to the local slope and height of the measured specular objects. The 3D shape is obtained by integrating the local gradient data or directly calculating the depth data from the phase information. We present a review of the relevant techniques regarding classical PMD. The improved PMD technique is then used to measure specular objects having discontinuous and/or isolated surfaces. Some influential factors on the measured results are presented. The challenges and future research directions are discussed to further advance PMD techniques. Finally, the application fields of PMD are briefly introduce

Manufacturability analysis for non-feature-based objects

This dissertation presents a general methodology for evaluating key manufacturability indicators using an approach that does not require feature recognition, or feature-based design input. The contributions involve methods for computing three manufacturability indicators that can be applied in a hierarchical manner. The analysis begins with the computation of visibility, which determines the potential manufacturability of a part using material removal processes such as CNC machining. This manufacturability indicator is purely based on accessibility, without considering the actual machine setup and tooling. Then, the analysis becomes more specific by analyzing the complexity in setup planning for the part; i.e. how the part geometry can be oriented to a cutting tool in an accessible manner. This indicator establishes if the part geometry is accessible about an axis of rotation, namely, whether it can be manufactured on a 4th-axis indexed machining system. The third indicator is geometric machinability, which is computed for each machining operation to indicate the actual manufacturability when employing a cutting tool with specific shape and size. The three manufacturability indicators presented in this dissertation are usable as steps in a process; however they can be executed alone or hierarchically in order to render manufacturability information. At the end of this dissertation, a Multi-Layered Visibility Map is proposed, which would serve as a re-design mechanism that can guide a part design toward increased manufacturability

Investigation and development of an advanced virtual coordinate measuring machine

This thesis was submitted for the degree of Doctor of Philosophy and was awarded by Brunel UniversityDimensional measurement plays a critical role in product development and quality control. With the continuously increasing demand for tighter tolerances and more complex workpiece shapes in the industry, dimensional metrology often becomes the bottleneck of taking the quality and performance of manufacturing to the next level. As one kind of the most useful and powerful measuring instruments, coordinate measuring machines (CMMs) are widely employed in manufacturing industries. Since the accuracy and efficiency of a CMM have a vital impact on the product quality, productivity and manufacturing cost, the evaluation and improvement of CMM performance have always been important research topics since the invention of CMM. A novel Advanced Virtual Coordinate Measuring Machine (AVCMM) is proposed against such a background. The proposed AVCMM is a software package that provides an integrated virtual environment, in which user can plan inspection strategy for a given task, carry out virtual measurement, and evaluate the uncertainty associated with the measurement result, all without the need of using a physical machine. The obtained estimate of uncertainty can serve as a rapid feedback for user to optimize the inspection plan in the AVCMM before actual measurement, or as an evaluation of the result of a performed measurement. Without involving a physical CMM in the inspection planning or evaluation of uncertainty, the AVCMM can greatly reduce the time and cost needed for such processes. Furthermore, as the package offers vivid 3D visual representation of the virtual environment and supports operations similar to a physical CMM, it does not only allow the user to easily plan and optimise the inspection strategy, but also provide a cost-effective, risk-free solution for training CMM operators. A modular, multitier architecture has been adopted to develop the AVCMM system, which incorporates a number of functional components covering CMM and workpiece modelling, error simulation, inspection simulation, feature calculation, uncertainty evaluation and 3D representation. A new engine for detecting collision/contact has been developed and utilized, which is suitable for the virtual environment of simulated CMM inspections. A novel approach has been established to calculate errors required for the error simulation, where the data are obtained from FEA simulations in addition to conventional experimental method. Monte Carlo method has been adopted for uncertainty evaluation and has been implemented with multiple options available to meet different requirements. A prototype of the proposed AVCMM system has been developed in this research. Its validity, usability and performance have been verified and evaluated through a set of experiments. The principles for utilising the AVCMM in practical use have also been established and demonstrated. The results have indicated that the proposed AVCMM system has great potentials to improve the functionalities and overall performance of CMMs.ORSAS and the School of Engineering and Design of Brunel University

Adaptive, High-Resolution Ultrasound Phased Array Imaging for use in the Inspection of Laser Brazed Joints in the Automotive Sector

The inspection of welded and brazed joints has been performed in several industries using ultrasonic phased array. In the automotive sector, many of the current standards for brazed joint inspection do not apply due to the high variations in surface geometry and limited accessibility to the inspection region. As the automotive industry looks to integrate laser brazing into the production process, the need to determine the size and geometry of the joint, as well as the presence of any defects, is desirable to ensure product quality and reduce costs. Currently, the use of destructive techniques, such as cross-sectioning, is employed in the inspection process, with the ultimate desire being the shift to non-destructive methods. With this in mind, ultrasonic techniques have been investigated as a possible testing method. Ultrasound techniques have evolved over the decades, starting from a single element and eventually moving to phased array techniques. Recently, the investigation of the full matrix capture method has become popular in the field of ultrasound imaging. This technique, which separates the data acquisition process from the image formation process poses a viable solution to the inspection of laser brazed joints due to the ability to compensate for varying surfaces in post-processing.In this work, we make use of this technique, deriving the image formation process as an inverse problem for an arbitrary set of ultrasonic emitters and receivers. From this, the image formation process becomes equivalent to solving the inhomogeneous Helmholtz equation. By approximating the solutions to such an equation using the ray series expansion, an estimation of the solutions can be found in a time-efficient manner. When these solutions are found, the inverse process can be rewritten as a weighted, time-delayed summation of the acquired ultrasonic data. In current work, further approximations to this image formation process are often made; however, in the inspection of the laser braze process, these approximations are found to degrade image quality in a number of cases. In this work, we propose our second order corrections as a viable solution to increase the limit under which ultrasound imaging can currently occur. This is accomplished through the design of an ultrasonic array transducer and the manufacturing of a series of simulated defects, with the final assessment being performed on real joints.These techniques were found to improve imaging in a select set of samples when the radius of curvature dropped below 2 mm. In these cases, the use of the amplitude weighting was found to drastically improve system resolution, allowing for the determination of joint size, geometry and the presence of defects

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