Calibration of robotic drilling systems with a moving rail

AbstractIndustrial robots are widely used in aircraft assembly systems such as robotic drilling systems. It is necessary to expand a robot’s working range with a moving rail. A method for improving the position accuracy of an automated assembly system with an industrial robot mounted on a moving rail is proposed. A multi-station method is used to control the robot in this study. The robot only works at stations which are certain positions defined on the moving rail. The calibration of the robot system is composed by the calibration of the robot and the calibration of the stations. The calibration of the robot is based on error similarity and inverse distance weighted interpolation. The calibration of the stations is based on a magnetic strip and a magnetic sensor. Validation tests were performed in this study, which showed that the accuracy of the robot system gained significant improvement using the proposed method. The absolute position errors were reduced by about 85% to less than 0.3mm compared with the maximum nearly 2mm before calibration

Single-Tooth Modeling for 3D Dental Model

An integrated single-tooth modeling scheme is proposed for the 3D dental model acquired by optical digitizers. The cores of the modeling scheme are fusion regions extraction, single tooth shape restoration, and single tooth separation. According to the “valley” shape-like characters of the fusion regions between two adjoining teeth, the regions of the 3D dental model are analyzed and classified based on the minimum curvatures of the surface. The single tooth shape is restored according to the bioinformation along the hole boundary, which is generated after the fusion region being removed. By using the extracted boundary from the blending regions between the teeth and soft tissues as reference, the teeth can be separated from the 3D dental model one by one correctly. Experimental results show that the proposed method can achieve satisfying modeling results with high-degree approximation of the real tooth and meet the requirements of clinical oral medicine

From crack-prone to crack-free: Eliminating cracks in additively manufactured Ti-48Al-2Cr-2Nb alloy by adjusting phase composition

At present, it remains a challenge to additively manufacture Ti-48Al-2Cr-2Nb (TiAl4822) alloy by laser powder bed fusion (LPBF) technology because of the severe cracking in the building process. In this work, it was found that cracks in LPBFed TiAl4822 alloy were more likely to occur in the region near the interfaces between α2 and B2 phases, and the underlying mechanism was addressed. This leads to a strategy to reduce or eliminate these cracks via reducing the phase interfaces between α2 and B2 phases by adjusting its phase composition. Through the design of LPBF process parameters, the purpose of adjusting phase composition of LPBFed TiAl4822 alloy in a wide range (from nearly α2 single-phase, to α2 + B2 + γ, and then to nearly B2 single-phase) was realized. As expected, with the reduction of the interfaces between α2 and B2 phases, the cracking behavior has been significantly alleviated. The exciting result was that the crack-free sample could be achieved in the LPBFed TiAl4822 alloy with nearly α2 single-phase structure. Its compressive strength was measured to be 1460.7 MPa comparable to that of its casting counterpart. The present work makes it possible to additively manufacture crack-free TiAl4822 alloy by tuning phase composition

Comparison of Mechanical Properties and Energy Absorption of Sheet-Based and Strut-Based Gyroid Cellular Structures with Graded Densities

Bio-inspired functionally graded cellular materials (FGCM) have improved performance in energy absorption compared with a uniform cellular material (UCM). In this work, sheet-based and strut-based gyroid cellular structures with graded densities are designed and manufactured by stereo-lithography (SLA). For comparison, uniform structures are also designed and manufactured, and the graded structures are generated with different gradients. The mechanical behaviors of these structures under compressive loads are investigated. Furthermore, the anisotropy and effective elastic modulus of sheet-based and strut-based unit gyroid cellular structures are estimated by a numerical homogenization method. On the one hand, it is found from the numerical results that the sheet-based gyroid tends to be isotropic, and the elastic modulus of sheet-based gyroid is larger than the strut-based gyroid at the same volume fraction. On the other hand, the graded cellular structure has novel deformation and mechanical behavior. The uniform structure exhibits overall deformation and collapse behavior, whereas the graded cellular structure shows layer-by-layer deformation and collapse behavior. Furthermore, the uniform sheet-based gyroid is not only stiffer but also better in energy absorption capacity than the uniform strut-based gyroid structure. Moreover, the graded cellular structures have better energy absorption capacity than the uniform structures. These significant findings indicate that sheet-based gyroid cellular structure with graded densities have potential applications in various industrial applications, such as in crashworthiness

Structural and Mechanical Characteristics of Cu50Zr43Al7 Bulk Metallic Glass Fabricated by Selective Laser Melting

In this work, the structural and mechanical characteristics of Cu50Zr43Al7 bulk metallic glass (BMG) fabricated by selective laser melting (SLM) are studied and the impacts from the SLM process are clarified. Cu50Zr43Al7 alloy specimens were manufactured by the SLM method from corresponding gas-atomized amorphous powders. The as-built specimens were examined in terms of phase structure, morphologies, thermal properties and mechanical behavior. The x-ray diffraction and differential scanning calorimetry results showed that structural relaxation and partial crystallization co-exist in the as-fabricated Cu50Zr43Al7 glassy samples. The nano- and micro- hardness and the elastic modulus of the SLM-fabricated Cu50Zr43Al7 BMG were higher than CuZrAl ternary BMGs with similar compositions prepared by conventional mold casting, which can be attributed to the structural relaxation in the former sample. However, the macro compressive strength of the SLM-fabricated Cu50Zr43Al7 BMG was only 1044 MPa mainly due to its porosity. This work suggests that the SLM process induced changes in structural and mechanical properties are significant and cannot be neglected in the fabrication of BMGs

High-Accuracy and Low-Cost Attitude Measurement Unit of the CubeSat

This paper proposes high-accuracy and reliable attitude measurement methods exclusive for CubeSat with restrictions of low cost, limited space, and low power consumption. The attitude measurement unit is equipped with Commercial Off-The-Shelf (COTS) components including Micro-Electro-Mechanical System (MEMS) gyro and two simultaneously operating star trackers (STR) to enhance the measurement accuracy. The Multiplicative Extended Kalman Filter (MEKF) is used to estimate the attitude of CubeSat, and four kinds of attitude estimation layouts are put forward according to the idea of weighted average of two quaternions from two STR and different architectures of information fusion. Using the proposed methods, the attitude measurement unit can continuously provide accurate and reliable attitude knowledge for attitude control unit when the CubeSat is running in orbit. Numerical simulation is performed to verify the effectiveness of the proposed methods, and it offers a reference for CubeSat developers from the perspective of engineering application