Determining the Assumptions for the Selection of Measurement Methods for Products Manufactured with Incremental Methods

The article presents the method of determining the assumptions for the selection of measurement methods for products manufactured with the use of incremental processes. In the research area, an analysis of 3D printing methods was carried out in terms of the specificity of the additive process, the materials used, the possibility of process deformations, and the accuracy of technological machines. With regard to the measurement methods, the analysis covered the accuracy of the method, the speed of the measurements, the costs of the measurements and the applicability to additive manufactured products. As a result of the analysis, assumptions were made for the criteria for selecting measurement methods for incrementally manufactured objects. The accuracy of prototyping in incremental processes largely depends on the accuracy of their numerical models. Taking this into account, simulations and studies of program processing of data were also carried out, starting from the development of a 3D-CAD model, through the export of numerical models and the preparation of data for manufacturing and control-measurement processes

The Place of 3D Printing in the Manufacturing and Operational Process Based on the Industry 4.0 Structure

The article presents the place of 3D printing in the manufacturing and operational process. It analyzes selected incremental technologies in the product life cycle. It describes selected processes for testing the properties of materials used in 3D printing, including accelerated aging tests and simulation of operating conditions. Areas of application of 3D printing were defined, starting from design and prototype development through manufacturing of technological tools and finally finished products. Design criteria of additivelymanufactured elements in relation to the exploitation process are discussed. A methodology for the development of 3D-CAD models of manufactured elements, software processing of data and data storage format for manufacturing products and spare parts is presented. The assumptions of repair procedures based on the production of spare parts by means of 3D printing in relation to data circulation compatible with the idea of Industry 4.0 structure have been adopted

Tomographic and tension analysis of polypropylene reinforced with carbon fiber fabric by injection molding

The use of thermoplastic materials has had significant growth in recent years. However, with great mechanical requirements, thermoplastics have limitations to their use. To improve these restrictions, these materials are reinforced to obtain better properties. Polypropylene is one of the most versatile polymers and is used in almost all modern industries. Thus, the aim of this study is to create composite materials that offer performance for various industrial fields using carbon fiber fabric reinforcement, which is an inexpensive material widely used by the aerospace, automotive, and marine industries. The samples are produced by the over-injection molding of polypropylene. The investigation is focused on the impact of two critical control parameters in the injection molding process: temperature and pressure. Twelve experiments have therefore been considered, taking into account the combination of three factors: the presence or absence of carbon fiber fabric reinforcement, three levels of temperature (200 °C, 220 °C, and 240 °C), and two injection pressures (5000 kPa and 10,000 kPa). To evaluate the influence of these factors, three analyses were carried out: first, on the samples’ shrinkage using a portable metrology-grade 3D laser scanner; second, on the internal defects using computed tomography (CT); and third, on the mechanical properties with tensile tests. From the results obtained, it is observed that the mold shrinkage fell slightly when PP samples were reinforced with carbon fiber, with both materials (PP and carbon-fiber-reinforced PP) having linear behavior with temperature. It is also noticed that polypropylene behaves as a crystalline material when processed at higher temperatures and pressures. From tests on the mechanical properties, it is concluded that the mean yield strength of PP-CF for injection temperatures of 220 °C and 240 °C represents an increase of 43% compared to the non-reinforced material

Analysis of Surface Microgeometry Created by Electric Discharge Machining

The objective of this work is to study the geometric properties of surface topographies of hot-work tool steel created by electric discharge machining (EDM) using motif and multiscale analysis. The richness of these analyses is tested through calculating the strengths of the correlations between discharge energies and resulting surface characterization parameters, focusing on the most representative surface features—craters, and how they change with scale. Surfaces were created by EDM using estimated energies from 150 to 9468 µJ and measured by focus variation microscope. The measured topographies consist of overlapping microcraters, of which the geometry was characterized using three different analysis: conventional with ISO parameters, and motif and multiscale curvature tensor analysis. Motif analysis uses watershed segmentation which allows extraction and geometrically characterization of each crater. Curvature tensor analysis focuses on the characterization of principal curvatures and their function and their evolution with scale. Strong correlations (R2 > 0.9) were observed between craters height, diameter, area and curvature using linear and logarithmic regressions. Conventional areal parameter related to heights dispersion were found to correlate stronger using logarithmic regression. Geometric characterization of process-specific topographic formations is considered to be a natural and intuitive way of analyzing the complexity of studied surfaces. The presented approach allows extraction of information directly relating to the shape and size of topographic features of interest. In the tested conditions, the surface finish is mostly affected and potentially controlled by discharge energy at larger scales which is associated with sizes of fabricated craters

Problem of Non-Measured Points in Surface Texture Measurements

This work is focused on the issue of non-measured points – one of the most important problems in surface texture measurements using optical methods. The fundamental aim of this research is to analyse errors of surface texture measurements caused by the presence of non-measured points. This study is divided into two parts. In the first part, circles with non-measured points were artificially created on peak portions of measured surfaces. In the second part – the results of measurement by a Talysurf CCI Lite interferometer were analysed. A measurement area of 3.3 × 3.3 mm contained 1024 × 1024 points. The measurements were performed with different intensity of light. Changes of parameters regarding the analysed errors depended on a surface type. The following parameters are susceptible to errors: skewness Ssk, areal material ratio Smr, as well as the following feature parameters: Spd, Sda, Sdv, Sha and Shv. Inaccuracies of measurement in valley parts of two-process textures led usually to larger errors of parameter computations compared with deviations in peak portions

3D Parametric and Nonparametric Description of Surface Topography in Manufacturing Processes

Surface topography has a profound influence on the function of a surface [...

The use of 3d scanner for testing changes in shape of human limbs under the influence of external mechanical load

Three-dimensional scanning is used in many fields: medicine, architecture, industry, reverse engineering. The aim of the article was to analyze the changes in the shape of the limbs under the influence of a mechanical external load using the method of three-dimensional scanner uses white light technology. The paper presents a system of human movement, passive part - skeleton and active part - the muscles, and principles of their interaction, which results in a change of the position of the body. Furthermore, by using the 3D scan, the differences in appearance of the arm and leg depending on the size of the external load in different positions have been presented. The paper shows that with increasing load, which muscles must prevent, increases the volume of certain parts of the legs, while another parts of them will be reduced. Results of the research using three-dimensional scanner allow determining what impact on changing the legs shape has an external mechanical load

Multiscale Evaluation of Jaw Geometry Reproduction Obtained Via the Use of Selected Orthodontic Materials in Dental Implants and Orthodontics—In Vitro Case Study

In this paper, the multiscale analysis of the reproduction accuracy of jaw geometry obtained via the use of selected orthodontic materials is discussed. Impressions were made from two types of impression material. An accuracy assessment of the model geometry mapping was performed using noncontact systems, including a fringe projection optical 3D scanner, computed tomography, and a focus variation microscope. Measurements were made in three modes for comparison, as were the silicone and polyether impression materials. These modes were a jaw model and impression, an impression and plaster model, and plaster and jaw models. The research results are presented as colorful maps of deviations. Data analysis showed that deviations were the smallest in the case of silicone and that the best fit occurred between the silicone impression and the plaster model. The conducted research confirmed the validity of the assumptions considering the use of multiscale analysis for geometric analysis. The use of modern multiscale measurement methods allows for shorter and more efficient prosthetic operations. At present, these devices are expensive and complicated to use, but developments in technology should simplify the process, and prosthetic professionals should be aware of the possibilities described in the paper

The use of modern measurement techniques for designing pro ecological constructions

In the paper some possibilities of application modern length and angle metrology techniques to design constructions that support ecology were presented. The paper is based on a project where a lighter bus and train car seat was developed. Different options were presented including static and dynamic photogrammetry, computed tomography and thermography. Research related with dynamic behaviour of designed structures gave input to determine deformation of a seat and passengers sitting on it during communication accidents. Works connected to strength of construction elements made it possible to optimize its dimensions maintaining proper durability. Metrological actions taken in relation to production machines and equipment enabled to better recognize phenomena that take place during manufacturing process and to correct its parameters, what in turns also contributed to slim down the construction

The use of 3d scanner for testing changes in shape of human limbs under the influence of external mechanical load

Three-dimensional scanning is used in many fields: medicine, architecture, industry, reverse engineering. The aim of the article was to analyze the changes in the shape of the limbs under the influence of a mechanical external load using the method of three-dimensional scanner uses white light technology. The paper presents a system of human movement, passive part - skeleton and active part - the muscles, and principles of their interaction, which results in a change of the position of the body. Furthermore, by using the 3D scan, the differences in appearance of the arm and leg depending on the size of the external load in different positions have been presented. The paper shows that with increasing load, which muscles must prevent, increases the volume of certain parts of the legs, while another parts of them will be reduced. Results of the research using three-dimensional scanner allow determining what impact on changing the legs shape has an external mechanical load