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– Commercial Technologies for Maintenance Activities
Next Generation Inspection System (NGIS III)Next Generation Inspection System (NGIS III)
April 19, 2005
Jeffrey A. CalkinsManufacturing Resources Inc. (MRI)
2 – Commercial Technologies for Maintenance Activities
NGIS III Project Team
NCMS Program Manager: Bill Waddell
Technology Partners
End User: NADEP Cherry Point, NC
Other Industry and Government Participants
Solar TurbinesPhiladelphia Naval Foundry and Propeller CenterNIST
MANUFACTURINGRESOURCES, INC
Advanced Technology for Manufacturing
3 – Commercial Technologies for Maintenance Activities
NGIS III Objectives
Perform on-machine inspection and repairof turbine engine blades and impellers.
4 – Commercial Technologies for Maintenance Activities
NGIS III Objectives
Perform on-machine inspection and repairof turbine engine blades and impellers.
Dramatically reduce the amount of hand blending of airfoil surfacesunder repair. Achieve “near net shape” blend on airfoil surfaces.
Weld Areas
5 – Commercial Technologies for Maintenance Activities
NGIS III Objectives
Perform on-machine inspection and repairof turbine engine blades and impellers
Dramatically reduce the amount of hand blending of airfoil surfaces under repair.
• Achieve “near net shape” blend on airfoil surfaces• Reduce blending labor by 60% • Eliminate rework • Prevent scrap loss
6 – Commercial Technologies for Maintenance Activities
NGIS III Objectives
Perform on-machine inspection and repairof turbine engine blades and impellers
Dramatically reduce the amount of hand blending of airfoil surfaces under repair:
• Achieve “near net shape” blend on airfoil surfaces• Reduce blending labor by 60%• Eliminate rework • Prevent scrap loss
Provide NADEP Cherry Point with a viable tool that can be also beadopted by other Depots and Industry users
7 – Commercial Technologies for Maintenance Activities
NGIS III Objectives
Perform on-machine inspection and repairof turbine engine blades and impellers
Dramatically reduce the amount of hand blending of airfoil surfaces under repair:
• Achieve “near net shape” blend on airfoil surfaces• Reduce blending labor by 60%• Eliminate rework • Prevent scrap loss (“killed” parts)
Provide NADEP Cherry Point with a viable tool that can also beadopted by other Depots and Industry users
Lay groundwork for additional future capabilities (e.g integrate materialdeposition process within the cell to eliminate welding).
8 – Commercial Technologies for Maintenance Activities
NGIS III 5-Axis Cell
X
• 5-axis machine and fixtures (MRI)• Open architecture control (Delta Tau)• Scanning algorithm and hardware (API, Mitutoyo)• Surfacing and machine program generation software (RapidForm, Delcam)
Key Subsystems and Technology Providers
9 – Commercial Technologies for Maintenance Activities
NGIS III 5-Axis Cell
Z
Y
X
Z
3 Linear and 2 Rotary Axes (plus Rotary Tool Changer)
B
C
10 – Commercial Technologies for Maintenance Activities
NGIS III 5-Axis Cell
X
ScanningProbe andSpindle
Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis
11 – Commercial Technologies for Maintenance Activities
NGIS III Scanning Probe and Spindle
Spindle
ContactScanningProbe
Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis
12 – Commercial Technologies for Maintenance Activities
NGIS III 5-Axis Cell
X BladeFixture
Blade and Impeller Fixtures are mounted on the C (Rotary) Axis
13 – Commercial Technologies for Maintenance Activities
Part Set-Up(once per P/N)
NGIS III Process Overview
AdaptivePart Probing
Part Probing
5-Axis Cell
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
DesignFixture
PartGeometry
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
14 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Part Probing
5-Axis Cell
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
15 – Commercial Technologies for Maintenance Activities
Scan Data From A Welded Impeller
16 – Commercial Technologies for Maintenance Activities
Detail of Scan Data From Welded Impeller
17 – Commercial Technologies for Maintenance Activities
Scan Data From A Welded Blade
Weld Areas
18 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Part Probing
5-Axis Cell
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
19 – Commercial Technologies for Maintenance Activities
Creating Blade Surface Model
1. Triangulate the set of points from scan data to convert it to a polygon mesh
2. Use volumetric polygon offset to account for the probe tip radius
3. Clean up the polygon mesh using RapidForm’s “polygon healing” toolset
Scan Processing Suite
20 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Part Probing
5-Axis Cell
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
21 – Commercial Technologies for Maintenance Activities
NC Tool Path For Blade Machining
Tool Path
22 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Part Probing
5-Axis Cell
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
23 – Commercial Technologies for Maintenance Activities
Machining the Weld Bead
NGIS III Tool Evaluation Study at MRI
Helical Burr Tool
24 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Part Probing
5-Axis Cell
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
25 – Commercial Technologies for Maintenance Activities
PartGeometry
Part Set-Up(once per P/N)
DesignFixture
NGIS III Process Overview
AdaptivePart Probing
Part Probing
5-Axis Cell
Probe To Verify
Final Benchand Inspection
Ship
Master or Model Part
Part Machining
Create SurfaceModel
NC Tool Path Generation(Unique to Part Undergoing
Repair)
Machine toNominal + .005”
26 – Commercial Technologies for Maintenance Activities
NGIS III Project Status (April, 2005)
Major Project Element Status
• 5-Axis Machine Complete
• Open-Architecture Control Integration Complete
• Blade and Impeller Fixtures Complete
• Tooling Evaluation Complete
• Probe & Scanning Software 1. API is continuing scanning algorithm development with the original “on-machine” approach
2. Mitutoyo is developing a “stand-alone” scanning
capability as another path to a technical solution
• Machining Programs “Proof-of-concept” demonstration completed
• User Interface and Process To be completed upon successful demonstration of Automation scanning capability
27 – Commercial Technologies for Maintenance Activities
• Crysta-Apex CMM• MP-100 Scanning Probe• MCOSMOS Software
Alternative Scanning Approach
Mitutoyo is providing equipment and technical support to develop analternative to the project’s original scanning approach
Evaluation work is under way with blade samples provided in March, 2005
Key Elements
28 – Commercial Technologies for Maintenance Activities
Industry Participant ContactsMANUFACTURINGRESOURCES, INC
Advanced Technology for Manufacturing
Mr. Jeff Calkins
E-mail: [email protected]
Tel: 440-786-3390 X103Cell: 440-537-0311Fax: 440-786-9107
Website: www.manufacturing-resources.com
29 – Commercial Technologies for Maintenance Activities
Dr. Kam Lau
E-mail: [email protected]
Tel: 301-330-8100Fax: 301-990-8648
Website: www.apisensor.com
Industry Participant Contacts
30 – Commercial Technologies for Maintenance Activities
Mr. Neal Kearney
E-mail: [email protected]
Tel: 818-717-5666
Website: www.deltatau.com
Industry Participant Contacts
31 – Commercial Technologies for Maintenance Activities
Mr. Tony Gable
E-mail: [email protected]
Tel: 440-205-9195
Website: www.delcam.com
Industry Participant Contacts
32 – Commercial Technologies for Maintenance Activities
Mr. Tom Charron
E-mail: [email protected]
Tel: 408-232-5300Fax: 408-519-5766
Website: www.rapidform.com
Industry Participant Contacts
33 – Commercial Technologies for Maintenance Activities
Mr. Larry Maggiano
E-mail: [email protected]
Tel: 626-961-9661 X4508Cell: 630-215-6920
Website: www.mitutoyo.com
Industry Participant Contacts