0
Research Papers

A Systematic Approach for Online Minimizing Volume Difference of Multiple Chambers in Machining Processes Based on High-Definition Metrology

[+] Author and Article Information
De-Lin Huang

State Key Lab of Mechanical System
and Vibration,
Shanghai Jiaotong University,
Shanghai 200240, China;
School of Mechanical Engineering,
Shanghai Jiaotong University,
Shanghai 200240, China
e-mail: cjwanan@sjtu.edu.cn

Shi-Chang Du

State Key Lab of Mechanical System
and Vibration,
Shanghai Jiaotong University,
Shanghai 200240, China;
School of Mechanical Engineering,
Shanghai Jiaotong University,
Shanghai 200240, China
e-mail: lovbin@sjtu.edu.cn

Gui-Long Li

School of Mechanical Engineering,
Shanghai Jiaotong University,
Shanghai 200240, China
e-mail: lgllg68629315@qq.com

Zhuo-Qi Wu

School of Mechanical Engineering,
Shanghai Jiaotong University,
Shanghai 200240, China
e-mail: zqwu@sjtu.edu.cn

1Corresponding author.

Manuscript received May 31, 2016; final manuscript received January 26, 2017; published online May 8, 2017. Assoc. Editor: Dragan Djurdjanovic.

J. Manuf. Sci. Eng 139(8), 081003 (May 08, 2017) (17 pages) Paper No: MANU-16-1306; doi: 10.1115/1.4035897 History: Received May 31, 2016; Revised January 26, 2017

The volume variation of multiple chambers of a workpiece is one of the most important factors that can directly influence the performance of the final product. This paper presents a novel systematic approach for online minimizing the volume difference of multiple chambers of a workpiece based on high-definition metrology (HDM). First, the datum of high-density points is transformed by a random sample consensus (RANSAC) algorithm due to its good robustness in fitting. Second, a procedure containing reconstruction of interior curved surfaces of chambers, boundary extraction, and projection is developed to calculate the accurate volumes of the multiple chambers. Third, a model for obtaining an optimized machining parameter for depth of chambers is explored to minimize the volume difference of any two ones of all the chambers. The model is formulated as a multi-objective optimization (MOO) problem, and a new procedure of multi-objective particle swarm optimization (MOPSO) algorithm is developed to solve this problem. Finally, a milling depth is output as the optimal milling parameter for controlling the volume variation of multiple chambers. The results of a case study show that the proposed approach can minimize the volume difference of four combustion chambers of a cylinder head and it can be well applied online in volume variation control of multiple chambers in machining processes.

Copyright © 2017 by ASME
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Fig. 1

A cylinder head with four combustion chambers and offline volume measurement: (a) cylinder head, (b) a combustion chamber, and (c) titration methods

Grahic Jump Location
Fig. 2

High-density points measured by new HDM technology: (a) point cloud of a cylinder head and (b) point cloud of a combustion chamber

Grahic Jump Location
Fig. 4

The framework of the proposed approach

Grahic Jump Location
Fig. 5

The structure of input data collected from a cylinder head: (a) point cloud collected from a cylinder head, (b) local distribution of the collected point cloud, and (c) the detailed form of the collected point cloud as input data

Grahic Jump Location
Fig. 6

The description of RANSAC algorithm

Grahic Jump Location
Fig. 7

An illustration of Gram–Schmidt transformation

Grahic Jump Location
Fig. 8

Area of missing points in the collected point cloud

Grahic Jump Location
Fig. 9

Large blank areas in the collected point cloud

Grahic Jump Location
Fig. 10

Interpolations needed in a row

Grahic Jump Location
Fig. 11

Schematic diagram of structured point cloud mesh generation: (a) sequential point cloud, (b) quadrilateral mesh, and (c) triangular mesh

Grahic Jump Location
Fig. 12

Direction indications of row and column

Grahic Jump Location
Fig. 13

An illustration of determining initial row and terminal row

Grahic Jump Location
Fig. 14

Segmentation of convex pentahedron

Grahic Jump Location
Fig. 15

Area calculation of triangle with three known vertex coordinates

Grahic Jump Location
Fig. 16

The cutaway picture of the chamber with milled part

Grahic Jump Location
Fig. 17

Calculation of the optimal milling parameter of a single combustion chamber

Grahic Jump Location
Fig. 18

Multi-objective PSO algorithm

Grahic Jump Location
Fig. 19

The procedure of MOPSO algorithm

Grahic Jump Location
Fig. 20

The diagram of Pareto front

Grahic Jump Location
Fig. 21

Cylinder head of B12 engine with four combustion chambers

Grahic Jump Location
Fig. 22

Online measurement equipment based on HDM system: (a) measurement component and (b) industrial personal computer

Grahic Jump Location
Fig. 23

The measurement process: (a) locate, (b) clamp, and (c) flip over

Grahic Jump Location
Fig. 24

Actual operation of the online measurement equipment: (a) online measurement and (b) an example of measurement

Grahic Jump Location
Fig. 25

Process of machining combustion chambers of cylinder head

Grahic Jump Location
Fig. 26

Point cloud before and after datum transformation: (a) point cloud measured by HDM and (b) point cloud transformed by RANSAC

Grahic Jump Location
Fig. 27

Point cloud before and after filtering: (a) point cloud before filtering and (b) point cloud after filtering

Grahic Jump Location
Fig. 28

Cylinder head combustion chamber surfaces after reconstruction: (a) reconstruction result of a combustion chamber and (b) local amplification of the reconstructed surface of combustion chambers

Grahic Jump Location
Fig. 29

Statistical averages of Z coordinates of each point cloud row

Grahic Jump Location
Fig. 30

Efficient point cloud boundary extraction

Grahic Jump Location
Fig. 31

Cylinder head combustion chamber boundary

Grahic Jump Location
Fig. 32

Maximum volume variation of combustion chambers of each cylinder head before and after milling

Grahic Jump Location
Fig. 33

Comparison of the DR of optimal strategy and nonoptimal strategy

Grahic Jump Location
Fig. 34

Comparison of the MVRR of optimal strategy and nonoptimal strategy

Grahic Jump Location
Fig. 37

Comparison of volume variation of combustion chambers of each cylinder head before and after milling: (a) comparison of first cylinder head, (b) comparison of second cylinder head, (c) comparison of third cylinder head, (d) comparison of fourth cylinder head, (e) comparison of fifth cylinder head, (f) comparison of sixth cylinder head, (g) comparison of seventh cylinder head, (h) comparison of eighth cylinder head, (i) comparison of ninth cylinder head, and (j) comparison of tenth cylinder head

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In