CT in Dimensional Metrology, Engineering and Manufacture

Transcription

1 CT in Production Quality Control - Leuven, June 4, 2013 CT in Dimensional Metrology, Engineering and Manufacture Prof. Dr. Ir. Jean-Pierre KRUTH Katholieke Universiteit Leuven (K.U.Leuven) Mechanical Engineering Dept. Division PMA (Production engineering, Machine design & Automation) Belgium jean-pierre.kruth@mech.kuleuven.be

2 Evolution in 3D measuring devices CT scanner for dimensional metrology CT scanner for material investigations Cartesian 3D-CMM Articulated measuring arm 1970 Medical CT scanner CT-based equipment Tactile probe Laser probe Common 3D dimensional metrology equipment

3 Industrial demand for 3D CT measurement Part complexity increases as a result of more complex design, higher function integration and new production technologies: Hollow hydroformed camshafts or hollow constructed crankshafts (Dr. A. Sterning) Additive manufactured components (LayerWise Inc.) 200 mm 2K injection molding, plastic connectors with metal inserts

4 Difference between medical and industrial CT Medical Main differences of industrial CT: X-ray source and detector do not rotate Object rotates (patient does not) Rotational axis vertical rather than horizontal 2D flat panel detector or 1D linear detector Higher power (200 KeV, 450 KeV, 15 MeV) Should provide traceable measurements for dimensional quality control Industrial X-ray source Object X-ray detector

5 Difference between medical and industrial CT Main differences of industrial CT: X-ray source and detector do not rotate Object rotates (patient does not) Rotational axis vertical rather than horizontal 2D flat panel detector or 1D linear detector Higher power (200 KeV, 450 KeV, 15 MeV) Should provide traceable measurements for dimensional quality control Courtesy Metris (Nikon Metrology) 1D line detector 2D flat panel detector Courtesy GE-Phoenix

6 Workflow in dimensional CT measurement CT scan Data Processing 3D Reconstruction (CT Pro) 3D grey voxel model Object Data Analysis Dimensional measurement (VolumeGraphics) 2D X-ray images Thresholding Edge detection (VolumeGraphics) Dimensions Surface model

7 CT metrology: no resolution, but accuracy - Medical and material applications are satisfied with resolution - Dimensional metrology requires accuracy and traceability to the unit of length (the meter) Required accuracy: - Medical and material applications: none or (1..5%) - Dimensional metrology: CMM (laserinterferometry ) 1µm 1µm 5µm X-ray image with Nanotech transmission target 5µm Electron microscopy image of test pattern Outer bar width = 5 µm Inner bar width = 1 µm Thickness 1 µm gold Image at 80kV

8 Principle of CT reconstruction: multimaterial Projections taken from 4 orientations Reconstruction by backward projection (Grey scale: grey red blue purple)

9 Adjustable parameters in CT registration Source current Source voltage Target material (spectrum) Beam filter (material & thickness) Number of poses Exposure time Averaging images Edge detection (thresholding) Beam hardening and other algorithms Part orientation (w.r.t. slantness) Etc. Same spectrum Higher intensity 1000µA 500µA 50 Larger spectrum Higher intensity

10 Edge detection Where is the edge of the material or part? Problem: there is a gradual transition of gray values at the edge Solution: complex edge detection algorithms

11 Maximum allowable material penetration Maximum penetration at 420 kev: 70 mm Fe 200 mm Al Avoid thick parts Avoid slant parts giving total extinction along its long side giving over-expore along its short side Proper part orientation may resolve problem

12 Applications of CT in engineering & mfg. Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

13 Applications of CT in engineering & mfg. Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

14 Engineering and reverse engineering: case 1 Case 1: Reverse Engineering and CAE of cylinder head Scanning cylinder head on 10 MeV CT machine + 2D reconstruction 3D reconstruction + STL meshing Segmentation of different materials and internal structure Re-meshing for FEM and CFD (Computational Fluid Dynamics) CFD calculation (Star-CD ) (Re)design using STL-based CAD systems (Materialise 3-matic ) }(Materialise Mimics ) Data: courtesy of BRP-Rotax GmbH & Co. KG. Processing: courtesy of Materialise N.V., Belgium

15 Engineering and reverse engineering: case 1 Slices through the 3D reconstructed CT model All internal structures are revealed Material differentiation based on density Aluminium Steel inserts Data: courtesy of BRP-Rotax GmbH & Co. KG. Processing: courtesy of Materialise N.V., Belgium

16 Engineering and reverse engineering: case 1 Image processing using Mimics software of Materialise

17 Extraction of water jacket from cylinder head Operations done on STL faceted model (STL mesh)

18 Engineering and reverse engineering: case 1 Re-meshing the water jacket Original skew triangle mesh is transformed in an equilateral triangle mesh, optimized for CFD analysis

19 Engineering and reverse engineering: case 1 Thickness analysis and local mesh refining Wall thickness analysis: detect and visualize thin structures Local mesh refining in thin sections to ensure optimal results during CFD analysis Courtesy of Materialise N.V., Belgium Data Courtesy of BRP-Rotax GmbH & Co. KG.

20 Engineering and reverse engineering: case 1 Results of CFD* calculations and temperature profile computed in Star-CD * Computational Fluid Dynamics Courtesy of Materialise N.V. and Star-CD

21 Engineering and reverse engineering: case 2 Case 2: Design and manufacturing of scaffold structures Medical scaffolds = porous implants for bone regeneration Purpose: production of scaffolds with regular porous structures Manufacturing by additive manufacturing (SLS/SLM) from Ti powder Analysis of achievable pore and beam sizes by SLS/SLM (CT metrology) Analysis of strength and failure mechanism of scaffold (CT with in-situ loading) Own-made in-situ uniaxial loading bench in CT device.

22 Engineering and reverse engineering: case 2 Design of regular porous structure for Ti scaffold Unit cell Design Ti6Al4V scaffold

23 Engineering and reverse engineering: case 2 CT measurement of pore and beam size Proved reproducibility of additive manufacturing process Micro-CT imaging 0% strain 5% compression scaffold (n=5) PO 1.00 Average beam size (µm) 187 ± 5 Average pore size (µm) ± 2.91 Global porosity (%) ± 0.51 Interconnectivity (%) 100

24 Engineering and reverse engineering: case 2 Analysis of strength and failure mechanism using CT with in-situ loading bench Development: G. Kerckhofs, K.U.Leuven-MTM

25 Engineering and reverse engineering: case 2 Analysis of strength and failure mechanism using CT with in-situ loading bench Pores: mm

26 Engineering and reverse engineering: case 2 Testing and calculating strength (yield, UTS) and Young modulus (E) Comparison of deformed and un-deformed CT images to calculate strain Comparison/mapping to FEM calculation (validation) Stress (MPa) Strain (-)

27 Engineering and reverse engineering: case 2 Calculation of strength (yield, UTS) and Young modulus (E) Comparison of deformed and un-deformed CT images to calculate strain Comparision/mapping to FEM calculation CT measured strains FEM predicted strains

28 Overview of presentation Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

29 Mechanism and assembly: watches Courtesy Metris N.V., Belgium (Nikon Metrology N.V.)

30 Mechanism and assembly: watches Monitoring operation of mechanism Courtesy Metris N.V., Belgium (Nikon Metrology N.V.)

31 Mechanism and assembly: gear box Courtesy Metris N.V., Belgium (Nikon Metrology N.V.)

32 Assembly (mechanic + electronic): camera Complex assembly of mechanical, optical and electronic components (PCB, leads, wires, soldering spots, ) Courtesy Metris N.V., Belgium (Nikon Metrology N.V.) 32

33 Overview of presentation Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

34 Additive manufacturing: SLS/SLM example laser Polymer Metal (Steel) Ceramic (Al 2 O 3 ) Composite (Cermet-HM) Metal (Ti)

35 Dimensional metrology: Examples of AM parts Injection mould with conformal cooling (KUL-DNI) Inlet duct in stainless steel (ILT) Collimator for space device with cooling (CSL) Air ducts in nylon (Boeing) Heat exchanger for satellite (Verhaert/QinetiQ Space) Part with conformal cooling channels (LayerWise-KUL)

36 Dimensional metrology: AM cases - parts with holes CT measurement of AM/SLM steel part with conformal cooling CT measurement of AM/SLM parts (steel and aluminum) to check smallest possible hole diameter Block (80x8x8 mm) with holes (0.4mm to 4 mm)

37 Dimensional metrology: AM cases nozzle with cooling Non-destructive and contactless measurement Check of internal geometry of conformal cooling channels in nozzle CAD compare: comparision of actual dimensions with CAD model (Ist vs. Soll) CAD model of nozzle with conformal cooling channels Results of CT-scan Comparison with CAD model Real geometry (Cut model)

38 Dimensional metrology: Case 2 Diesel injector Diesel injector Courtesy Metris N.V., Belgium Injector 3D CT reconstruction 2D X-ray image 38

39 Dimensional metrology: Case 2 Diesel injector Diesel injector Cut through inlet holes of injector Feature extraction and measurement (e.g. diameter and position of holes) 39

40 Dimensional metrology: Case 2 Diesel injector Diesel injector CAD Compare: Soll vs. Ist values External geometry Error / mm 40

41 Dimensional metrology: Case 2 Diesel injector Diesel injector CAD Compare: Soll vs. Ist values Internal geometry Error / mm 41

42 Dimensional metrology: Case 3 Audi inlet fan Audi Inlet Fan CT model

43 Dimensional metrology: Case 3 Audi inlet fan Audi Inlet Fan CAD compare (Soll vs. Ist)

44 Dimensional metrology: Case 3 Audi inlet fan Dimensional Quality Control CAD compare (Soll vs. Ist) Wall thickness

45 Dimensional metrology: Case 3 Audi inlet fan Simultanuous Material Dimensional Quality Control Air inclusions Size deviations

46 Dimensional metrology: Case 4 Honda Hydraulic manifold Honda Hydraulic manifold The heart of the car, if it stops the car stops Courtesy Metris N.V., Belgium (Nikon Metrology N.V.)

47 Dimensional metrology: Case 4 Honda Hydraulic manifold Honda Hydraulic manifold External geometry Internal geometry : cut CT model CAD compare CT model CAD compare

48 Dimensional metrology: Case 4 Honda Hydraulic manifold Measured (external) dimensions

49 Dimensional metrology: Case 4 Honda Hydraulic manifold Measured (internal) dimensions

50 Dimensional metrology: Case 5 Metal screws Part 1 Part 2 Material: Steel (42CrMo4 or 1.72) Material: Aluminum (EN AW-7075) Dimensions: ~ Ø12 x 30 mm Dimensions: ~ Ø32 x 24 mm Measurement time: 6 min. (720 projections) Measurement time: 6 min. (720 projections)

51 Dimensional metrology: Case 5 Metal screws Courtesy Metris N.V., Belgium (Nikon Metrology N.V.)

52 Dimensional metrology: Case 5 Metal screws Measure cylinder Measure plane Measure pitch Measure distance plane-plane Measure cylinder Measure plane Measure angle Measure length

53 Dimensional metrology: Case 5 Metal screws

54 Overview of presentation Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

55 Dimensional measurement of assemblies CT-scanning of assembled components: the only way to measure components in the assembled state

56 Overview of presentation Applications of CT technology in engineering Internal shapes/geometries and (multi-material) assemblies Design Engineering and reverse engineering Mechanisms and assemblies Manufacturing Dimensional Metrology / Precision / Quality Control Additive Manufacturing (Rapid Prototyping & Manufacturing) Internal and external geometry Assemblies and multi-material components Accuracy, calibration and traceability Combined dimensional and material quality control

57 Dimensional & material QC: Case 1 Car inlet fan Dimensional quality control Material quality control Porosity

58 Dimensional & material QC: Case 2 Turbine blade Measuring: Dimensions Wall thickness Cooling holes Material quality Pores Corrosion Courtesy Metris N.V., Belgium (Nikon Metrology N.V.) 2D CT-scan 3D: volume

59 Dimensional & material QC: Case 2 Turbine blade Special blade inspection system with 450kV RED outside tolerance

60 Scatter Free Radiography (method) 2D flat panel detector Method: Turbine blade scanned through a collimated fan beam to produce scatter free 2D image. Part moving up Side View 1D linear detector Flat fan beam Source & spot (450 kv micofocus) Collimating plates Reconstruction progressing downward

61 Automatic measurement (data display) Automatic wall / web thickness measurement

62 Automatic measurement (results database)

63 Dimensional & material QC: Case 3 Sandwich panel Case 3: Lightweight sandwich panel Production Quality Control: Check wall thickness (Dimensional Quality Control) Check weld quality (Material Quality Control)

64 Dimensional & material QC: Case 3 Sandwich panel Case 3: Lightweight sandwich panel Continuous production method: Thermoforming flat polymer foil Folding to create honeycomb Welding folds and top + bottom foils

65 Dimensional & material QC: Case 3 Sandwich panel Wall thickness measurement using Volume Graphics software CT parameters: Voltage: 65 to 75 kv Current: 350 & 470 µa Magnification: ±200 Filter: No 3D plot 2D plot Section Section plane Weld spot

66 Dimensional & material QC: Case 3 Sandwich panel Wall thickness analysis (Software: Volume Graphics)

67 Dimensional & material QC: Case 3 Sandwich panel Minimal/Maximal wall thickness Wall thickness analysis using Volume Graphics Software

68 Dimensional & material QC: Case 3 Sandwich panel Weld analysis: density plot Weld spot

69 Dimensional & material QC: Case 3 Sandwich panel Weld analysis in logitudinal direction Density plot (material QC) Thickness plot (dimensional QC)

70 Dimensional & material QC: Multimaterial/Assemblies Case 4: Light bulbs Production Quality Control: Positioning electrodes Glass welds Assembly Materials defects

71 Dimensional & material QC: Multimaterial/Assemblies Case 4: Light bulbs Production Quality Control: Positioning electrodes Glass welds Assembly Materials defects

72 Dimensional & material QC: Multimaterial/Assemblies Case 4: Light bulbs Production Quality Control: Positioning electrodes Glass welds Assembly Materials defects Assembly Weld control

73 Dimensional & material QC: Multimaterial/Assemblies Case 4: Light bulbs Production Quality Control: Positioning electrodes Glass welds Assembly Materials defects Weld control

74 Thank you for your attention Courtesy Metris N.V., Belgium (Nikon Metrology N.V.) 74