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

Automatic post-processing for tolerance inspection of digitized parts made by injection moulding

This paper presents the advancements of an automatic segmentation procedure based on the concept of Hierarchical Space Partitioning. It is aimed at tolerance inspection of electromechanical parts produced by injection moulding and acquired by laser scanning. After a general overview of the procedure, its application for recognising cylindrical surfaces is presented and discussed through a specific industrial test case

Finite element model set-up of colorectal tissue for analyzing surgical scenarios

Finite Element Analysis (FEA) has gained an extensive application in the medical field, such as soft tissues simulations. In particular, colorectal simulations can be used to understand the interaction with the surrounding tissues, or with instruments used in surgical procedures. Although several works have been introduced considering small displacements, as a result of the forces exerted on adjacent tissues, FEA applied to colorectal surgical scenarios is still a challenge. Therefore, this work aims to provide a sensitivity analysis on three geometric models, taking in mind different bioengineering tasks. In this way, a set of simulations has been performed using three mechanical models named Linear Elastic, Hyper-Elastic with a Mooney-Rivlin material model, and Hyper-Elastic with a YEOH material model

Computer aided inspection procedures to support smart manufacturing of injection moulded components

This work presents Reverse Engineering and Computer Aided technologies to improve the inspection of injection moulded electro-mechanical parts. Through a strong integration and automation of these methods, tolerance analysis, acquisition tool-path optimization and data management are performed. The core of the procedure concerns the automation of the data measure originally developed through voxel-based segmentation. This paper discusses the overall framework and its integration made according to Smart Manufacturing requirements. The experimental set-up, now in operative conditions at ABB SACE, is composed of a laser scanner installed on a CMM machine able to measure components with lengths in the range of 5÷250 mm, (b) a tool path optimization procedure and (c) a data management both developed as CAD-based applications

A generative design method for cultural heritage applications: design of supporting structures for artefacts

This paper presents a Generative Design Method (GDM) for highly customised Cultural Heritage applications concerning the exhibition and conservation of pottery. As a fundamental requirement, archaeological finds must be preserved in their structural integrity. Additionally, when present, the exposition supports must be aesthetically pleasant meaning that they must be non-invasive in the field of view of the observer. Furthermore, each artefact presents a unique geometry, hence its supporting structure must be designed accordingly. The proposed GDM considers these requirements, adopting a synergy of CAD, CAE, and optimisation tools. It is developed through two phases. The first phase, P1, concerns with the structural integrity of the fragment. In this phase, a Parametric Modelling approach is chosen for its ease of use both in the Finite Element Analysis evaluations of artefacts and in the design and optimisations of feasible supporting structures. The output of the phase P1 is the optimised configuration of the functional elements of the support ('Ci') which are the interface region between the support itself and the fragment of pottery. They represent the input of the second phase, P2, that aims to generate lightweight concepts for the complete supporting structure considering the optimal 'Ci' configuration. During this phase, an aesthetics criterion (related to the minimisation of the support's visibility) is also considered to achieve non-invasive supporting structures. Doing so, the GDM provides informed decisions in the early stages of the design activities with a simulation driven approach oriented to manufacturing. In this way, users are able to focus on design requirements since the concept's variants are generated by means of an optimised configuration of standardised components ('Ci') and obstacle geometries

robust die compensation in sheet metal design through the integration of dual response surface and shape function optimization

In sheet metal forming, springback represents a major drawback increasing die set-up problems, especially for ultra-high strength steels. Finite Element Analysis is a well-established method to simulate the process during design, and multicriteria optimizations, for example, via surrogate models, are investigated in order to develop integrated design. Since to take into account also springback compensation die design may involve a large number of geometric variables, this paper presents a robust design formulation, based on the adoption of the shape function optimization, to describe springback in terms of weights directly associated to global shape variations of the die shape. Doing so, multicriteria optimization, which involves also die compensation, can be set up in a more intuitive approach, as requested in the preliminary steps of die design. After the introduction of the industrial problem, the mathematical formulation of the shape function optimization is presented together with its novel extension to Robust Design, which is based on the Dual Response Surface. Through a test case derived from the head part of a B-pillar, stamped from a Dual Phase sheet 1.5 mm thick, this novel extension investigates the effect of 6% variation from nominal values of initial yield stress and thickness. Results demonstrate the feasibility of the procedure, underlying that an optimal compensation may not be optimal in terms of process robustness

Bird’s eye view on lattice structures. Design issues and applications for best practices in mechanical design

Lattice structures for engineering applications are patterns of unit cells designed to make a larger functional structure. Research on lattice structures ranges in many fields, from mechanical characterization and cell and pattern designs in respect of their applications, to the manufacturing process and its final shape control. From the manufacturing point of view, some kinds of lattice structures can be infeasible when approached with traditional manufacturing methods. It may offer an inevitable limitation of their adoption. However, advancements in Additive Manufacturing (AM) have solved this manufacturing issue to a great extent, allowing to obtain major complexity of the cells that can be achieved. The topology, shape of the unit cell, and the characteristics of its replication pattern allow us to obtain many kinds of structures in respect of the different engineering requirements and manufacturing constraints. Nevertheless, the necessity of new or dedicated CADCAE approaches arises to manage the domains of multiscale modeling. These are some of the advantages and disadvantages that may arise while approaching the design of a component using lattice structures. The aim of this paper is to provide an overview that integrates the most recent applications of lattice structures with their related design and manufacturing issues so that, from a practical design point of view, any state-of-the-art improvements may be established in respect of the related field of applications. In this article, engineers and researchers may find a practical summary of the capabilities and processes of lattice structures that are currently available from a design and development point of view

Lightweight horse saddletree through reverse engineering and lattice structure design

Additive Manufacturing (AM) is currently making the relevance of lattice structure solutions increasing, allowing the achievement of high performance/mass ratio, where performance stands for energy absorption, stiffness, and/or insulation. This paper undertakes lattice structure for lightweight design of a horse saddletree. Saddletree is the backbone of a horse saddle, and it is composed of different components. In particular, the spring steel reinforcements inside the saddletree make it the heaviest part of the horse saddle, involving also multiple processes of manufacturing and manual assemblies. This paper aims to lightweight an existing saddletree with a Voronoi lattice solution, reducing several manual assemblies. From the methodological point of view, the lightweight design has been based on a multiscale approach, carried out via nTopology (static FEA on the original bulk design, implicit geometrical lattice generation from FEA result maps and Boolean operation among lattice results and bulk design implicit model). The original bulk design has been digitally acquired and modeled through Reverse Engineering techniques, so that a specific customized solution may be improved. A final weight reduction of 76.5% is achieved, providing an example of how topological optimization techniques coupled with AM (in particular Powder Bed Fusion technology) may reduce assembly efforts

Development of a multifunctional panel for aerospace use through SLM additive manufacturing

Lattice materials can overcome the need of light and stiff structures in the aerospace industry. The wing leading edge is one of the most critical parts for both on-board subsystem and structure features: it must withstand to the aerodynamic loads and bird-strike, integrating also the anti-ice system functions. Nowadays, this part is made by different components bonded together such as external skin, internal passageways, and feeding tubes. In the present work, a single-piece multifunctional panel made by additive manufacturing will be developed. Optimal design and manufacturing are discussed according to technological constraints, aeronautical performances and sustainability

Digital design of medical replicas via desktop systems: shape evaluation of colon parts

In this paper, we aim at providing results concerning the application of desktop systems for rapid prototyping of medical replicas that involve complex shapes, as, for example, folds of a colon. Medical replicas may assist preoperative planning or tutoring in surgery to better understand the interaction among pathology and organs. Major goals of the paper concern with guiding the digital design workflow of the replicas and understanding their final performance, according to the requirements asked by the medics (shape accuracy, capability of seeing both inner and outer details, and support and possible interfacing with other organs). In particular, after the analysis of these requirements, we apply digital design for colon replicas, adopting two desktop systems. ,e experimental results confirm that the proposed preprocessing strategy is able to conduct to the manufacturing of colon replicas divided in self-supporting segments, minimizing the supports during printing. ,is allows also to reach an acceptable level of final quality, according to the request of having a 3D presurgery overview of the problems. ,ese replicas are compared through reverse engineering acquisitions made by a structured-light system, to assess the achieved shape and dimensional accuracy. Final results demonstrate that low-cost desktop systems, coupled with proper strategy of preprocessing, may have shape deviation in the range of ±1 mm, good for physical manipulations during medical diagnosis and explanation