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Research Papers

Spiral Curve-Based Efficient Five-Axis Sweep Scanning of Barrel-Shaped Surfaces

[+] Author and Article Information
Pengcheng Hu

Huazhong University of Science
and Technology,
Wuhan 430070, China
e-mail: foxpcheng@gmail.com

Huicheng Zhou

School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430070, China
e-mail: zhouhuicheng@hust.edu.cn

Kai Tang

Department of Mechanical
and Aerospace Engineering,
Hong Kong University of Science
and Technology,
Kowloon 999077, Hong Kong
e-mail: mektang@ust.hk

Chenhan Lee

School of Mechanical Science and Engineering,
Huazhong University of Science
and Technology,
Wuhan 430070, China
e-mail: chenhanlee@hotmail.com

Jihong Chen

School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
Wuhan 430070, China
e-mail: jihong@hust.edu.cn

Jianzhong Yang

School of Mechanical Science and Engineering,
Huazhong University of Science
and Technology,
Wuhan 430070, China
e-mail: yangjz@hust.edu.cn

Lei Li

School of Mechanical Science and Engineering,
Huazhong University of Science
and Technology,
Wuhan 430070, China
e-mail: hpctju@163.com

1Corresponding author.

Manuscript received December 5, 2017; final manuscript received February 1, 2018; published online April 2, 2018. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 140(7), 071001 (Apr 02, 2018) (16 pages) Paper No: MANU-17-1760; doi: 10.1115/1.4039383 History: Received December 05, 2017; Revised February 01, 2018

Barrel-shaped surfaces are widely used in industries, e.g., blades, vases, and tabular parts. Because a part such as an aero-engine blade is typically quite large, the efficiency of its measurement becomes a critical issue. The recently emerged five-axis sweep scanning technology offers to be a powerful means to significantly increase the efficiency of measurement. However, currently it still mostly relies on humans to manually plan a five-axis sweep scanning path, and in most cases, the surface is simply divided into a number of smaller open patches for which the sweep scanning is then individually planned. We present an algorithm for automatically planning the five-axis sweep scanning for an arbitrary barrel-shaped surface in the form of either a compound, a trimmed, or a simple surface. The planning algorithm is novel in that no partitioning of the surface is needed and a single continuous five-axis sweep scanning path will be generated for the entire surface. By eliminating the nonsweeping time spent by the stylus due to its air-moves between multiple patches and also the time-costly approach-retraction operations required for each patch, the proposed algorithm is able to significantly reduce the total inspection time, sometimes more than 50%, as validated in our physical inspection experiments.

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Figures

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Fig. 1

Two exemplifying barrel-shaped surfaces: (a) a blade and (b) a vase

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Fig. 2

(a) Five-axis inspection machine, (b) continuous sweep scanning, and (c) point-by-point inspection

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Fig. 3

Five-axis sweep scanning path

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Fig. 4

Reparametrization of a blade surface

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Fig. 5

(a) Triangulation of a compound blade surface and (b) result of reparametrization

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Fig. 6

(a) Two set of line segments in the u−v square and (b) the dividing curve and guiding curve

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Fig. 7

Definition of stylus orientation and trajectory curve

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Fig. 8

Determination of the yaw angle of stylus orientation for a blade surface

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Fig. 9

(a) Ct with a constant tilt angle θ0=38 deg and (b) Ct after the optimization of stylus orientation

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Fig. 10

Sample points {c1,c2,…,cm} on Ct

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Fig. 11

Curvature of Ct before and after optimization

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Fig. 12

Search range of ci+1: (a) case 1 and (b) case 2

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Fig. 13

Binary searching of ti+1

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Fig. 14

(a) Nominal sweeping curves for the blade surface and (b) the final sweeping curves

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Fig. 15

Construction of Wt

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Fig. 16

(a) Triangulation of S1, (b) reparametrization result of S1, (c) triangulation of S2, and (d) reparametrization result of S2

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Fig. 17

(a) E(t), Gt, and C(t) of S1; (b) sweeping curves of S1—concave patch; and (c) sweeping curves of S1—the convex patch

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Fig. 18

(a) E(t), Gt, and C(t) of S2; (b) sweeping curves of S2—view 1; and (c) sweeping curves of S2—view 2

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Fig. 19

Contact angle of the sweep scanning path of S1

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Fig. 20

Contact angle of the sweep scanning path of S2

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Fig. 21

Sweep scanning paths of S1 by apexblade on (a) the concave patch and (b) the convex patch (only a partial Ct is shown)

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Fig. 22

Sweep scanning paths of S2 by modus (only a partial C(t) is shown)

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Fig. 23

Physical inspection photos of (a) S1 and (b) S2

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Fig. 24

Point clouds acquired with our sweep scanning paths on (a) S1 and (b) S2

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Fig. 25

Point clouds acquired with the commercial software apexblade and modus on (a) S1 and (b) S2

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Fig. 26

(a) Contact angle α and (b) nominal sweep curve Vi from the stylus orientation Ti

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