On-machine Inspection of Geometric Quality for Metallic W-ring Formed Profile

doi:10.3901/JME.2024.20.035

Abstract

Abstract: Metallic sealing ring is a static sealing structure part widely used in aero-engine, and its profile forming accuracy is the key to the sealing performance, which is of great significance in reducing engine internal flow losses and improving engine thrust-to-weight ratio. Currently, the formed quality of metallic sealing ring mainly uses final destructive sampling inspection, and the lack of geometric quality inspection method in the forming process prevents timdy finding its forming defects. To address the above problems, an on-machine inspection research of geometric quality for metallic W-ring formed profile is carried out. A multi-level registration and distance thresholds based irregular section profile measurement point cloud preprocessing method is proposed, to solve the problem of serious outliers, missing and noise in the measurement point cloud. In order to realize the accurate extraction of complex geometric feature parameters, a minimum area bounding rectangle based profile geometric feature parameters extraction method, a medial axis based wall thickness extraction method, and a curvature and pre-location based circular feature parameters extraction method are proposed. Based on the dual laser scanners, an on-machine measurement system is built, and integrate the above methods, the hardware and software module are developed. Finally, the experimental results demonstrate the advantage of the method. Compared with the traditional destructive inspection results, the average relative error of 1.350% for the profile geometric feature parameters, 3.219% for the wall thickness and 1.372% for the circular feature parameters.

Key words: metallic sealing ring, geometry quality, on-machine inspection, point cloud preprocessing, feature extraction

CLC Number:

TG806

PEI Haonan, DU Sizhe, LUO Ming. On-machine Inspection of Geometric Quality for Metallic W-ring Formed Profile[J]. Journal of Mechanical Engineering, 2024, 60(20): 35-50.

References

[1] CHEN Xi，WANG Yun. Analysis of fatigue life in high temperature of W pattern sealing rings used in aircraft engine[J]. Applied Mechanics & Materials，2014，496-500：571-574.
[2] 沈虹，郑天慧，陈玉洁. 航空发动机封严技术的进展[J]. 燃气涡轮试验与研究，2011(4)：51-55. SHEN Hong，ZHENG Tianhui，CHEN Yujie. Improvement of aero-engine sealing technology[J]. Gas Turbine Experiment and Research，2011(4)：51-55.
[3] SHAO Guangda，LI Hongwei，ZHANG Xin，et al. External-internal composite spinning technology for forming thin-walled Ω-sectioned ring of superalloy[J]. Journal of Materials Processing Technology，2020，291(2)：117004.
[4] 蔺小军，吴刚，单秀峰，等. 基于叶片截面线CMM测量数据的ICP配准改进算法[J]. 机械工程学报，2020，56(2)：1-8. LIN Xiaojun，WU Gang，SHAN Xiufeng，et al. An improved ICP registration algorithm based on CMM measurement data of blade section line[J]. Journal of Mechanical Engineering，2020，56(2)：1-8.
[5] 蔺小军，单晨伟，王增强，等. 航空发动机叶片型面三坐标测量机测量技术[J]. 计算机集成制造系统，2012，18(1)：125-131. LIN Xiaojun，SHAN Chengwei，WANG Zengqing，et al. Measurement techniques of coordinate measuring machine for blade surface of aero-engine[J]. Computer Integrated Manufacturing Systems，2012，18(1)：125-131.
[6] XIE Luofeng，ZHU Yangyang，YIN Ming，et al. Self-feature-based point cloud registration method with a novel convolutional siamese point net for optical measurement of blade profile[J]. Mechanical Systems and Signal Processing，2022，178：109243
[7] 丁少闻，张小虎，于起峰，等. 非接触式三维重建测量方法综述[J]. 激光与光电子学进展，2017，54(7)：27-41. DING Shaowen，ZHANG Xiaohu，YU Qifeng，et al. Overview of non-contact 3dreconstruction measurement methods[J]. Laser & Optoelectronics Progress，2017，54(7)：27-41.
[8] 李文龙，李中伟，毛金城. iPoint3D曲面检测软件开发与工程应用综述[J]. 机械工程学报，2020，56(7)：127-150. LI Wenlong，LI Zhongwei，MAO Jincheng. The development and application review of iPoint3D software for surface inspection[J]. Journal of Mechanical Engineering，2020，56(7)：127-150.
[9] WANG Zhongqi，YIN Ming，QU Dengying，et al. Optical measurement method for blade profiles based on blade self-features[J]. IEEE Transactions on Industrial Electronics，2022，69(2)：2067-2076.
[10] 何雨镐，谢福贵，刘辛军，等. 大型构件机器人原位加工中的测量方案概述[J]. 机械工程学报，2022，58(14)：1-14. HE Yuhao，XIE Fugui，LIU Xinjun，et al. Review on measurement schemes for robotic machining of large components in-situ[J]. Journal of Mechanical Engineering，2022，58(14)：1-14.
[11] LI Wenlong，WU An ，LI Zicheng，et al. A new calibration method between an optical sensor and a rotating platform in turbine blade inspection[J]. Measurement Science and Technology，2017，28(3)：035009.
[12] ZHANG Pan，KAI Zhong，LI Zhongwei，et al. High dynamic range 3D measurement based on structured light: a review[J]. Journal of Advanced Manufacturing Science and Technology，2021，1(2)：2021004.
[13] 石循磊，杜坤鹏，张继文，等. 基于线激光扫描的飞机表面锪窝孔参数提取方法[J]. 机械工程学报，2020，56(8)：148-154. SHI Xunlei，DU Kunpeng，ZHANG Jiwen，et al. Method for extracting hole parameters of aircraft surface based on linear laser scanning[J]. Journal of Mechanical Engineering，2020，56(8)：148-154.
[14] 李中伟，张攀，钟凯，等. AutoScan系列复杂零件自动化三维测量装备开发与应用[J]. 航空学报，2021，42(10)：119-136. LI Zhongwei，ZHANG Pan，ZHONG Kai，et al. Development and application of autoscan series automated 3d measuring equipment for complex parts[J]. Acta Aeronautica et Astronautica Sinica，2021，42(10)：119-136.
[15] 张丽艳，夷宏明，刘胜兰. 在机测量激光测头位姿的线性标定[J]. 光学精密工程，2016，24(4)：681-689. ZHANG Liyan，YI Hongming，LIU Shenglan. Linear calibration for on-machine measurement of laser probe pose[J]. Optics and Precision Engineering，2016，24(4)：681-689.
[16] KOU Meng，WANG Gang，LI Wenlong，et al. Calibration of the laser displacement sensor and integration of on-site scanned points[J]. Measurement Science and Technology，2020，31(12)：125104.
[17] NISHIKAWA S，OHNO K，MORI M，et al. Non-contact type on-machine measurement system for turbine blade[J]. Procedia CIRP，2014，24：1-6.
[18] 李文龙，李中伟，毛金城，等. 核主泵复杂零件机器人在位自动光学检测系统开发[J]. 机械工程学报，2020，56(13)：179-191. LI Wenlong，LI Zhongwei，MAO Jincheng，et al. The development of onsite-automatic-optical inspection system with robot for complex parts of nuclear main pump[J]. Journal of Mechanical Engineering，2020，56(13)：179-191.
[19] 李文龙，谢核，尹周平，等. 机器人加工几何误差建模研究：Ⅰ空间运动链与误差传递[J]. 机械工程学报，2021，57(7)：154-168. LI Wenlong，XIE He，YIN Zhouping，et al. The research of geometric error modeling of robotic machining: I spatial motion chain and error transmission[J]. Journal of Mechanical Engineering，2021，57(7)：154-168.
[20] 李文龙，谢核，尹周平，等. 机器人加工几何误差建模研究：Ⅱ参数辨识与位姿优化[J]. 机械工程学报，2021，57(7)：169-184. LI Wenlong，XIE He，YIN Zhouping，et al. The research of geometric error modeling of robotic machining: II parameter identification and pose optimization[J]. Journal of Mechanical Engineering，2021，57(7)：169-184.
[21] 李文龙，王刚，田亚明，等. 在机测量技术与工程应用研究进展[J]. 航空制造技术，2022，65(5)：14-35. LI Wenlong，WANG Gang，TIAN Yaming，et al. Research progress of on-machine measurement technology and its engineering applications[J]. Aeronautical Manufacturing Technology，2022，65(5)：14-35.
[22] RAKOTOSAONA M，LA B V，GUERRERO P，et al. POINTCLEANNET：Learning to denoise and remove outliers from dense point clouds[J]. Computer Graphics Forum，2020，39(1)：185-203.
[23] FLEISHMAN S，DRORI I，COHEN-OR D. Bilateral mesh denoising[J]. ACM Transactions on Graphics，2003，22(3)：950-953.
[24] DIGNE J，FRANCHIS C D. The bilateral filter for point clouds[J]. Image Processing On Line，2017，7：278-287.
[25] ALEXA M，BEHR J，COHEN-OR D，et al. Computing and rendering point set surfaces[J]. IEEE Transactions on Visualization & Computer Graphics，2003，9(1)：3-15.
[26] FLEISHMAN S，COHEN-OR D，SILVA C. Robust moving least-squares fitting with sharp features[J]. ACM Transactions on Graphics，2005，24(3)：544-552.
[27] KOLLURI R K. Provably good moving least squares[J]. ACM Transactions on Algorithms，2008，4(2)：18-25.
[28] SCHALL O，BELYAEV A，SEIDEL H P. Adaptive feature-preserving non-local denoising of static and time-varying range data[J]. Computer-Aided Design，2008，40(6)：701-707.
[29] JENKE P，WAND M，BOKELOH M，et al. Bayesian point cloud reconstruction[J]. Computer Graphics Forum，2006，25(3)：379-388.
[30] TAUBIN G. A signal processing approach to fair surface design[C]// The 22nd Annual Conference on Computer Graphics and Interactive Techniques(SIGGRAPH95). New York: ACM Press，1995：351-358.
[31] PAULY M，GROSS M. Spectral processing of point-sampled geometry[J]. Computer Graphics，2001，35(4)：379-386.
[32] CLARENZ U，RUMPF M，TELEA A. Fairing of point based surfaces[C]// Computer Graphics International，2004. Proceedings. IEEE Computer Society，2004.
[33] LOZES F，ELMOATAZ A，LEZORAY O. Partial difference operators on weighted graphs for image processing on surfaces and point clouds[J]. IEEE Transactions on Image Processing A Publication of the IEEE Signal Processing Society，2014，23(9)：3896-909.
[34] XIAO Chun. Multi-level partition of unity algebraic point set surfaces[J]. Journal of Computer Science and Technology，2011，26(2)：229-238.
[35] GU Xiaoying，LIU Yongshan，WU Qiong. A filtering algorithm for scattered point cloud based on curvature features classification[J]. Journal of Information and Computational Science，2015，12(2)：525-532.
[36] YAN Jieqiong，ZHOU Laishui，WANG Jun，et al. Structural feature-preserving point cloud denoising method for aero-engine profile[J]. International Journal of Aerospace Engineering，2022：95655062.
[37] MALI RA，GUPTA T，RAMKUMAR J. A comprehensive review of free-form surface milling– Advances over a decade. Journal of Manufacturing Processes，2021，62：132-167.
[38] 程云勇，张定华，卜昆，等. 涡轮叶片形状检测中的模型配准控制点集选取[J]. 机械工程学报，2009，45(11)：240-246. CHEN Yunyong，ZHANG Dinghua，BU Kun，et al. Model registration control point set selection for turbine blade shape inspection[J]. Journal of Mechanical Engineering，2009，45(11)：240-246.
[39] 张定华，程云勇，卜昆，等. 考虑弯扭变形的叶片模型配准方法[J]. 航空学报，2009，30(12)：2449-2455. ZHANG Dinghua，CHEN Yunyong，BU Kun，et al. Reliable alignment method for blade shape analysis considering its blend and twist deformation. Acta Aeronautica et Astronautica Sinica，2009，30(12)：2449-2455.
[40] 龚正国，程云勇，张定华，等. 基于光学扫描测量数据的叶片型面偏差分析研究[J]. 现代制造工程，2009(12)：97-100，132. GONG Zhengguo，CHEN Yunyong，ZHANG Dinghua，et al. Blade airfoil deviation inspection based on optical scanning data[J]. Modern Manufacturing Engineering，2009(12)：97-100，132.
[41] 敬石开，程云勇，张定华，等. 一种区域公差约束的叶片模型配准方法[J]. 计算机集成制造系统，2010，16(4)：883-886. JING Shikai，CHEN Yunyong，ZHANG Dinghua，et al. Tolerance zone constrained alignment method for turbine blade model[J]. Computer Integrated Manufacturing Systems，2010，16(4)：883-886.
[42] LI Taifeng，PAN Quanke，GAO Liang，et al. Differential evolution algorithm-based range image registration for free-form surface parts quality inspection[J]. Swarm & Evolutionary Computation，2017，36：106-123.
[43] 伍川辉，廖家，熊仕勇，等. 基于激光传感器的槽型轨轮廓匹配方法[J]. 浙江大学学报，2021，55(9)：1607-1614，1624. WU Chuanhui，LIAO Jia，XIONG Shiyong，et al. Contour matching method of groove track based on laser sensor[J]. Journal of Zhejiang University，2021，55(9)：1607-1614，1624.
[44] 程云勇，张定华，卜昆，等. 基于工业CT测量数据的空心涡轮叶片三维壁厚分析[J]. 机械强度，2009，31(5)：791-796. CHENG Yunyong，ZHANG Dinghua，BU Kun，et al. Hollow turbine blade 3d wall-thickness analysis based on its ICT measurement data[J]. Journal of Mechanical Strength，2009，31(5)：791-796.
[45] GADELMAWLA E. Computer vision algorithms for measurement and inspection of spur gears[J]. Measurement，2011，44(9)：1669-1678.
[46] LI Wenlong，ZHOU Liping，YAN Sijie. A case study of blade inspection based on optical scanning method[J]. International Journal of Production Research，2015，53(7-8)：2165-2178.
[47] PENG Gaoliang，ZHANG Zhujun，LI Weiquan. Computer vision algorithm for measurement and inspection of O-rings[J]. Measurement，2016，94：828-836.
[48] CHENG Yuqi，LI Wenlong，JIANG Cheng，et al. A novel cooling hole inspection method for turbine blade using 3D reconstruction of stereo vision[J]. Measurement Science and Technology，2022，33(1)：015018.
[49] 刘占，张俊，尹佳，等. 基于机器视觉的立铣刀几何与状态参数在机检测[J]. 航空学报，2022，43(7)：502-510. LIU Zhan，ZHANG Jun，YIN Jia，et al. On-machine detection of geometric and state parameters of end mills based on machine vision[J]. Acta Aeronautica et Astronautica Sinica，2022，43(7)：502-510.
[50] MICHEL A A，FRANK P F，TERRY M P. An algorithmic overview of surface registration techniques for medical imaging[J]. Medical Image Analysis，2000，4(3)：201-217.
[51] MYRONENKO A，SONG X. Point set registration: coherent point drift[J]. IEEE Transactions on Pattern Analysis & Machine Intelligence，2010，32(12)：2262-2275.
[52] DEMPSTER A P，LAIRD N M，RUBIN D B. Maximum likelihood from incomplete data via the EM algorithm[J]. Journal of the Royal Statistical Society. Series B (Methodological)，1977，39(1)：1-22.
[53] O'ROURKE J. Finding minimal enclosing boxes[J]. International Journal of Parallel Programming，1985，14(3)：183-199.
[54] ANDREW A M. Another efficient algorithm for convex hulls in two dimensions[J]. Information Processing Letters，1979，9(5)：216-219.
[55] TOUSSAINT G T. Solving geometric problems with the rotating calipers[C]// Proc. of IEEE Mediterranean Electrotechnical Conf. Piscataway，NJ：IEEE，1983：1-10.
[56] BIASOTTI S，ATTALI D，BOISSINNAT J D，et al. Skeletal structures[M]. Heidelberg：Springer，2008.
[57] ZHAO W. Shape and medial axis approximation from samples[D]. Ohio：The Ohio State University，2003.
[58] Al-SHARADQAH A，CHERNOV N. Error analysis for circle fitting algorithms[J]. Electronic Journal of Statistics，2009，3：886-911.