ct in dimensional metrology , engineering and - ku leuven
TRANSCRIPT
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CT in Dimensional Metrology ,
Engineering and Manufacture
CT in Production Quality Control - Leuven, June 4, 2013
Prof. Dr. Ir. Jean-Pierre KRUTH
Katholieke Universiteit Leuven (K.U.Leuven)Mechanical Engineering Dept.
Division PMA (Production engineering, Machine design & Automation)
Belgium
http://www.mech.kuleuven.be/pma/
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Evolution in 3D measuring devices
2005
CT scanner for dimensional metrology
X-ray CT Metrology for Engineering and Manufacture
1970
1980
Common 3D dimensional metrology equipment
CT scanner for material investigations
Medical CT scanner
Cartesian 3D-CMM Articulated measuring arm
Tactile probe Laser probe
CT-based equipment
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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.)
X-ray CT Metrology for Engineering and Manufacture
– 2K injection molding, plastic connectors with metal inserts
200 mm
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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
MedicalIndustrial
X-ray CT Metrology for Engineering and Manufacture
X-ray source X-ray detectorObject
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Difference between medical and industrial CT
Courtesy Metris
(Nikon Metrology)
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
X-ray CT Metrology for Engineering and Manufacture
1D line detector 2D flat panel detectorCourtesy GE-Phoenix
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Workflow in dimensional CT measurement
CT scan
Data Processing
3D Reconstruction
(CT Pro)
Object
2D X-ray images
3D grey voxel model
X-ray CT Metrology for Engineering and Manufacture
Data Analysis
Dimensional measurement
(VolumeGraphics)
Thresholding
Edge detection
(VolumeGraphics)
Surface modelDimensions
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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 10-1-10-2 (1..5%)
- Dimensional metrology: CMM 10-5-10-6 (laserinterferometry 10-7-10-8)
X-ray CT Metrology for Engineering and Manufacture
X-ray image with Nanotech™ transmission target Electron microscopy image of test pattern
5µm
1µm1µm
Outer bar width = 5 µmInner bar width = 1 µmThickness 1 µm goldImage at 80kV
5µm
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Projections taken from 4 orientations Reconstruction by backward projection
Principle of CT reconstruction: multimaterial
X-ray CT Metrology for Engineering and Manufacture
(Grey scale: grey →→→→ red →→→→ blue →→→→ purple)
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• Source current
• Source voltage
• Target material (spectrum)
• Beam filter(material & thickness)
• Number of poses
• Exposure time
Adjustable parameters in CT registration
Same spectrum – Higher intensity
1000µA
500µA
50
X-ray CT Metrology for Engineering and Manufacture
• Exposure time
• Averaging images
• Edge detection (thresholding)
• Beam hardening and other algorithms
• Part orientation (w.r.t. slantness)
• Etc.
Larger spectrum – Higher intensity
50 100
50
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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
X-ray CT Metrology for Engineering and Manufacture
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• Maximum penetration at 420 keV:� 70 mm Fe
� 200 mm Al
Maximum allowable material penetration
• Avoid thick parts
X-ray CT Metrology for Engineering and Manufacture
• 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
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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
X-ray CT Metrology for Engineering and Manufacture
– 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
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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
X-ray CT Metrology for Engineering and Manufacture
– 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
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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®)
Engineering and reverse engineering: case 1
}(Materialise Mimics®)
X-ray CT Metrology for Engineering and Manufacture
Data: courtesy of BRP-Rotax GmbH & Co. KG.
Processing: courtesy of Materialise N.V., Belgium
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• Slices through the 3D reconstructed CT model
• All internal structures are revealed
• Material differentiation based on density– Aluminium
– Steel inserts
Engineering and reverse engineering: case 1
Data: courtesy of BRP-Rotax GmbH & Co. KG.
Processing: courtesy of Materialise N.V., Belgium
X-ray CT Metrology for Engineering and Manufacture
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Image processing using Mimics® software of Materialise
Engineering and reverse engineering: case 1
X-ray CT Metrology for Engineering and Manufacture
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Extraction of water jacket from cylinder headOperations done on STL faceted model (STL mesh)
Engineering and reverse engineering: case 1
X-ray CT Metrology for Engineering and Manufacture
Courtesy of Materialise N.V., Belgium
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Re-meshing the water jacket
• Original skew triangle mesh is transformed in an equilateral triangle mesh, optimized for CFD analysis
Engineering and reverse engineering: case 1
X-ray CT Metrology for Engineering and Manufacture
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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
Engineering and reverse engineering: case 1
X-ray CT Metrology for Engineering and ManufactureData Courtesy of BRP-Rotax GmbH & Co. KG.
Courtesy of Materialise N.V., Belgium
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Results of CFD*calculationsand temperature profile
Engineering and reverse engineering: case 1
X-ray CT Metrology for Engineering and Manufacture
profilecomputed in Star-CD®
Courtesy of Materialise N.V. and Star-CD
* Computational Fluid Dynamics
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Case 2: Design and manufacturing of scaffold structures
Medical scaffolds = porous implants for bone regenerationPurpose: 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.
Engineering and reverse engineering: case 2
X-ray CT Metrology for Engineering and Manufacture
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• Design of regular porous structure for Ti scaffold
Engineering and reverse engineering: case 2
X-ray CT Metrology for Engineering and Manufacture
Unit cell Design Ti6Al4V scaffold
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• CT measurement of pore and beam size– Proved reproducibility of additive manufacturing
process
Engineering and reverse engineering: case 2
Micro-CT imaging
0% strain 5% compression
X-ray CT Metrology for Engineering and Manufacture
scaffold (n=5) PO 1.00
Average beam size (µm) 187 ± 5
Average pore size (µm) 620.55 ± 2.91
Global porosity (%) 81.05 ± 0.51
Interconnectivity (%) 100
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Engineering and reverse engineering: case 2
– using CT with in-situ loading bench
• Analysis of strength and failure mechanism
X-ray CT Metrology for Engineering and Manufacture
Development: G. Kerckhofs, K.U.Leuven-MTM
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Engineering and reverse engineering: case 2
– using CT with in-situ loading bench
• Analysis of strength and failure mechanism
X-ray CT Metrology for Engineering and Manufacture
Pores: 0.8 1.2 mm
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• 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)
Engineering and reverse engineering: case 2
Strain (-)
Stress (MPa)
X-ray CT Metrology for Engineering and Manufacture
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• 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
Engineering and reverse engineering: case 2
CT measured strains FEM predicted strains
X-ray CT Metrology for Engineering and Manufacture
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Overview of presentation
• Applications of CT technology in engineering
Internal shapes/geometries and (multi-material) assemblies
– Design
• Engineering and reverse engineering
• Mechanisms and assemblies
X-ray CT Metrology for Engineering and Manufacture
– 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
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Mechanism and assembly: watches
X-ray CT Metrology for Engineering and Manufacture
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Monitoring operation of mechanism
Mechanism and assembly: watches
X-ray CT Metrology for Engineering and Manufacture
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Mechanism and assembly: gear box
X-ray CT Metrology for Engineering and Manufacture
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Assembly (mechanic + electronic): camera
Complex assembly of mechanical, optical and electronic components (PCB, leads, wires, soldering spots,…)
X-ray CT Metrology for Engineering and Manufacture32
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Overview of presentation
• Applications of CT technology in engineering
Internal shapes/geometries and (multi-material) assemblies
– Design
• Engineering and reverse engineering
• Mechanisms and assemblies
X-ray CT Metrology for Engineering and Manufacture
– 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
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Additive manufacturing: SLS/SLM example
laser
Polymer
Metal (Steel)
X-ray CT Metrology for Engineering and Manufacture
Composite (Cermet-HM)
Metal (Ti)
Ceramic (Al2O3)
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Inlet duct in stainless steel (ILT)
Injection mould with conformal cooling (KUL-DNI)
Dimensional metrology: Examples of AM parts
Collimator for space device with cooling (CSL)
X-ray CT Metrology for Engineering and Manufacture
Air ducts in nylon (Boeing)
Part with conformal cooling channels(LayerWise-KUL)
Heat exchanger for satellite (Verhaert/QinetiQ Space)
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Dimensional metrology: AM cases - parts with holes
CT measurement of AM/SLM steel part with conformal cooling
X-ray CT Metrology for Engineering and Manufacture
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)
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• 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
Dimensional metrology: AM cases – nozzle with cooling
X-ray CT Metrology for Engineering and Manufacture
cooling channels
Real geometry
(Cut model)
Results of
CT-scan
Comparison with
CAD model
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3D CT reconstruction
Dimensional metrology: Case 2 – Diesel injector
Diesel injectorCourtesy Metris N.V., Belgium
X-ray CT Metrology for Engineering and Manufacture38
2D X-ray image
Injector 3D CT reconstruction
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Feature extraction and measurement (e.g. diameter and position of holes)
Cut through inlet holes of injector
Dimensional metrology: Case 2 – Diesel injector
Diesel injector
X-ray CT Metrology for Engineering and Manufacture39
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CAD Compare: Soll vs. Ist values
Dimensional metrology: Case 2 – Diesel injector
Diesel injector
X-ray CT Metrology for Engineering and Manufacture40
Error / mm
External geometry
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CAD Compare: Soll vs. Ist values
Error / mm
Internal geometry
Diesel injector
Dimensional metrology: Case 2 – Diesel injector
X-ray CT Metrology for Engineering and Manufacture41
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Dimensional metrology: Case 3 – Audi inlet fan
Audi Inlet Fan – CT model
X-ray CT Metrology for Engineering and Manufacture
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Audi Inlet Fan – CAD compare (Soll vs. Ist)
Dimensional metrology: Case 3 – Audi inlet fan
X-ray CT Metrology for Engineering and Manufacture
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Dimensional metrology: Case 3 – Audi inlet fan
CAD compare (Soll vs. Ist) Wall thickness
Dimensional Quality Control
X-ray CT Metrology for Engineering and Manufacture
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Dimensional metrology: Case 3 – Audi inlet fan
Simultanuous• Material• DimensionalQuality Control
X-ray CT Metrology for Engineering and Manufacture
Air inclusionsSize deviations
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“The heart of the car, if it stops the car stops”
Honda Hydraulic manifold
Dimensional metrology: Case 4 – Honda Hydraulic manifold
X-ray CT Metrology for Engineering and Manufacture
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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External geometry Internal geometry : cut
Honda Hydraulic manifold
Dimensional metrology: Case 4 – Honda Hydraulic manifold
X-ray CT Metrology for Engineering and Manufacture
CT model CT modelCAD compare CAD compare
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Dimensional metrology: Case 4 – Honda Hydraulic manifold
X-ray CT Metrology for Engineering and Manufacture
Measured (external)dimensions
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Dimensional metrology: Case 4 – Honda Hydraulic manifold
X-ray CT Metrology for Engineering and Manufacture
Measured (internal) dimensions
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Dimensional metrology: Case 5 – Metal screws
X-ray CT Metrology for Engineering and Manufacture
Part 1 Part 2Material: Steel (42CrMo4 or 1.72) Material: Aluminum (EN AW-7075)Dimensions: ~ Ø12 x 30 mm Dimensions: ~ Ø32 x 24 mmMeasurement time: 6 min. (720 projections)
Measurement time: 6 min. (720 projections)
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Dimensional metrology: Case 5 – Metal screws
X-ray CT Metrology for Engineering and Manufacture
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Dimensional metrology: Case 5 – Metal screws
Measure cylinder
Measure plane
X-ray CT Metrology for Engineering and Manufacture
Measure pitch
Measure angle
Measure length
Measure cylinder
Measure plane
Measure distance plane-plane
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Dimensional metrology: Case 5 – Metal screws
X-ray CT Metrology for Engineering and Manufacture
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Overview of presentation
• Applications of CT technology in engineering
Internal shapes/geometries and (multi-material) assemblies
– Design
• Engineering and reverse engineering
• Mechanisms and assemblies
X-ray CT Metrology for Engineering and Manufacture
– 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
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Dimensional measurement of assemblies
• CT-scanning of assembled components:the only way to measure components in the assembled state
X-ray CT Metrology for Engineering and Manufacture
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Overview of presentation
• Applications of CT technology in engineering
Internal shapes/geometries and (multi-material) assemblies
– Design
• Engineering and reverse engineering
• Mechanisms and assemblies
X-ray CT Metrology for Engineering and Manufacture
– 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
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Dimensional quality control
Material quality control
Dimensional & material QC: Case 1 – Car inlet fan
X-ray CT Metrology for Engineering and Manufacture
Porosity
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Dimensional & material QC: Case 2 – Turbine blade
Measuring:
• Dimensions
– Wall thickness
– Cooling holes
• Material quality
– Pores
– Corrosion
X-ray CT Metrology for Engineering and Manufacture
2D CT-scan3D: volumeCourtesy Metris N.V., Belgium
(Nikon Metrology N.V.)
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Special blade inspection system with 450kV
Dimensional & material QC: Case 2 – Turbine blade
X-ray CT Metrology for Engineering and Manufacture
RED – outside tolerance
system with 450kV
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Scatter Free Radiography (method)
Method:
Turbine blade scanned through a collimated fan
beam to produce scatter free 2D image.
2D flat panel detector
X-ray CT Metrology for Engineering and Manufacture
Side View
1D linear detector
Source & spot(450 kV micofocus)
Collimating plates
Part moving up
Reconstruction progressing downward
Flat fan beam
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Automatic measurement (data display)
X-ray CT Metrology for Engineering and Manufacture
Automatic wall / webthickness measurement
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Automatic measurement (results database)
X-ray CT Metrology for Engineering and Manufacture
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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)
X-ray CT Metrology for Engineering and Manufacture
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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
X-ray CT Metrology for Engineering and Manufacture
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Wall thickness measurementusing Volume Graphics software
3D plot
CT parameters:
• Voltage: 65 to 75 kV
• Current: 350 & 470 µA
• Magnification: ±200
• Filter: No
Dimensional & material QC: Case 3 – Sandwich panel
2D plot
X-ray CT Metrology for Engineering and Manufacture
Section plane
Section
Weld spot
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• Wall thickness analysis (Software: Volume Graphics)
Dimensional & material QC: Case 3 – Sandwich panel
X-ray CT Metrology for Engineering and Manufacture
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Minimal/Maximal wall thickness
Dimensional & material QC: Case 3 – Sandwich panel
Wall thickness analysis using Volume Graphics Software®
X-ray CT Metrology for Engineering and Manufacture
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• Weld analysis: density plot
Dimensional & material QC: Case 3 – Sandwich panel
Weld spot
X-ray CT Metrology for Engineering and Manufacture
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• Weld analysis in logitudinal direction
Density plot (material QC) Thickness plot (dimensional QC)
Dimensional & material QC: Case 3 – Sandwich panel
X-ray CT Metrology for Engineering and Manufacture
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Dimensional & material QC: Multimaterial/Assemblies
Case 4: Light bulbs
Production Quality Control:• Positioning electrodes
• Glass welds
• Assembly
• Materials defects
X-ray CT Metrology for Engineering and Manufacture
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Dimensional & material QC: Multimaterial/Assemblies
Case 4: Light bulbs
Production Quality Control:• Positioning electrodes
• Glass welds
• Assembly
• Materials defects
X-ray CT Metrology for Engineering and Manufacture
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Dimensional & material QC: Multimaterial/Assemblies
Case 4: Light bulbs
Production Quality Control:• Positioning electrodes
• Glass welds
• Assembly
• Materials defects
Assembly
X-ray CT Metrology for Engineering and Manufacture
Weld control
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Dimensional & material QC: Multimaterial/Assemblies
Case 4: Light bulbs
Production Quality Control:• Positioning electrodes
• Glass welds
• Assembly
• Materials defects
X-ray CT Metrology for Engineering and Manufacture
Weld control
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Thank you for your attention
X-ray CT Metrology for Engineering and Manufacture74
Courtesy Metris N.V., Belgium
(Nikon Metrology N.V.)