Optical Strain measurement for Aerospace Testing. From

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GOM

Rob Wood | 18th October 2018

Optical Strain measurement for Aerospace Testing. From coupon level to full air frame

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GOM is a Technology Company

Global industrial partner with over 20 years experience in the development and production of optical 3D metrology solutions

Hardware and Software

Material and component testing3D coordinate measurement

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Projected pattern Regular pattern Stochastic pattern Point markers

Know-how:

· Digital image processing

· 3D coordinate measurement techniques

· Quality control

· Material parameters

· Automation

GOM – Precise Industrial 3D Metrology

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Optical metrology from GOM provides:

∙ Fast measurement and results

∙ Clear visualization of measurement reports

∙ Flexibility for task, location and parts

∙ Mobile measurement solutions

∙ Process safety

GOM measuring systems are complementary or used as an alternative to:

∙ 3D coordinate measuring machines

∙ Gauges

∙ Accelerometers and displacement sensors

∙ Strain gauges

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Optical metrology has become a standard in the development and production of industrial products

Automotive industry Aerospace industry Research and universitiesConsumer goods industry

GOM measurement systems are used worldwide in industry, research institutions and universities

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GOM – Customers (Extract)

Over 14,000 system installations worldwide

Automotive

Audi, Avtovaz, Bentley, BMW, Chrysler, Daihatsu Motor, Daimler, Fiat, Ford, GM , Honda, Hyundai , Isuzu, Jaguar, Kia, Land Rover, McLaren, Modenas, NAZA, Nissan, Opel, Porsche, PSA, Renault, Seat, Skoda, Subaru, Suzuki, Tata Motors, Toyota, VW, Volvo, Temsa, …

Turbines

ABB Turbo systems , Alstom, Aviadvigatel, BTL, Chromalloy, Elbar Sulzer, E.ON, GorbynovAviation, Honeywell, Howmet, IMA Dresden, MTU, Pratt & Whitney, Rolls Royce, Salut, Saturn, Siemens PG, Snecma, Solar Turbines, Triumph, Turbine Services, …

Consumer Goods

Adidas, Asics, ASUS, Blaupunkt, Bosch, Braun, Ching Luh Shoes, Ecco, FisherPrice, Foxconn, Fuji, Gillette, Greenpoint, Hilti, Lego, LG Electronic Mattel, Microsoft, Motorola, Nautor, Nike, Nokia, Philips, Reebok , Samsung, SANYO, Siemens, Sony, Stihl, Villeroy+Boch, Walt Disney, …

Material Supplier

ACTech, Alfa Laval, Alcan (Alusuisse), Arcelor, , BASF, Bayer, Corning, DuPont, EXXON, Hydro (VAW), PierburgKolbenschmidt, Salzgitter, Shell, Tata Steel, ThyssenKrupp, Thyssen Nirosta, Tokai Rubber Industries, VoestAlpine Stahl, …

Automotive Suppliers

Automotive Lighting, Batz, Bertrandt, Bosch, Bombardier, Bridgestone, Carcoustics, DAAZ, Dräxlmaier, Faurecia, Georg Fischer, Gienanth, Goodyear, Hella, Johnson Controls, Kautex Textron, Michelin, Nothelfer, Pininfarina, Siemens, Thule, ThyssenKrupp, ZF Sachs, …

Aerospace

Airbus, Air Force Research Labs, Aselsan, Boeing, Cessna, ChromAlloy, DLR, DNV, EADS, Eurocopter, FAA, FOI, Goodrich, Gorbynov Aviation, Hansen Transmissions, Hydro, IMPO, JAXA, Lockheed Martin, NASA, NLR, Northrop Grumman, ONERA, Vulcan Air, VZLÚ, …

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GOM Headquarters

Founded in 1990

Private, owner managed company

Research and development, production and administration in Braunschweig, Germany

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GOM – The Owners

Dr. Konstantin Galanulis

Founder of GOM

Sales

Finance

Human Resources

Dr. Detlef Winter

Founder of GOM

Hardware Development

Automation

Production

Dirk Bergmann

Owner of GOM

Software Development

Support

Product Management

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GOM Metrology Network

60 sites worldwide

1,000 metrology specialists

GOM Group with 8 companies and branches

Continuous growth to over 500 employees in GOM Group

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Founded in 2002

∙ Subsidiary of GOM mbH

∙ Based in Coventry

Today: 20 employees

Sales and support of optical 3D measuring systems

∙ Hardware and Software

GOM UK

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ARGUSOpticalforming analysis

PONTOS Live3D motion analysis& component positioning

Measuring Systems for 3D Coordinate Measurement & 3D Testing

ATOSFull-field3D scanning

ARAMISOptical3D deformation analysis

TRITOPMobileoptical CMM

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ATOSFull-field 3D Scanning

Non-contact,

full-field 3D metrology

Complete component geometry

Precise 3D coordinates

Deviation to CAD

Shape and dimension analysis

Reporting

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ATOSFull-field 3D Scanning

Applications

Quality control

Reverse Engineering

Rapid prototyping

Manufacturing

Virtual assembly

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ATOS ScanBoxOptical 3D Measuring Machine

Automated full-field 3D metrology

Standardized robotic measurement cell

Fully automated 3D digitizing and inspection

For different component sizes and applications

4105 5108 5120 Serie 7 Serie 86130

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3D Metrology

Quality Control

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Production & wear monitoring

Determination of process capability

Identification of part and tool wear trends

Repair & maintenance

Trend Analysis for Quality Control

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Inspection of Airfoil Properties

Max. profile thickness, centroid, mean line,…

Twist analysis, leading & trailing edge points,…

Flow inlet & exit angle, chord line with stagger angle, …

and user defined inspection principles

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ARGUSOpticalforming analysis

PONTOS Live3D motion analysis& component positioning

Measuring Systems for 3D Coordinate Measurement & 3D Testing

ATOSFull-field3D scanning

ARAMISOptical3D deformation analysis

TRITOPMobileoptical CMM

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ARAMISOptical 3D Deformation Analysis

Full-field and point-based material and component testing

3D surface coordinates

3D displacement, velocity and acceleration

Surface strains

Strain rates

Buckling

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ARAMISOptical 3D Deformation Analysis

Applications

Determination of material properties (FLC)

Dynamic behaviour of components

Component analysis

Structural testing and vibrations

Verification of FE simulations

Real-time control of testing machines

Crash and impact tests

Durability and fatigue studies

NDT (Non Destructive Testing)

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UK ARAMIS users

Extract of UK ARAMIS users:

∙ BAE Systems, Brough

∙ Agusta Westland

∙ Airbus

∙ Rolls Royce

∙ Jaguar Land Rover, multiple systems and departments

∙ Tata Steel, Rotherham

∙ TWI, Cambridge

∙ Exova, Lancaster

∙ DSTL, Porton Down

∙ Depuy Synthes

∙ JCB

∙ Renault Sport F1

∙ Mercedes GP

∙ Imperial College London 3 x departments

∙ Cambridge University

∙ WMG, Warwick University

∙ Oxford University

∙ Loughborough University

∙ Brunel University

∙ National Composites Centre (NCC), Bristol

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Integrated and Unified Evaluation Workflow

Digital image correlation

∙ Area-based, full-field evaluation of applied stochastic patterns

3D motion analysis

∙ Point-wise evaluation of applied measurement markers

ARAMIS

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Integrated and Unified Evaluation Workflow

Digital image correlation


3D motion analysis


ARAMIS

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Principle of Optical 3D Measurement

Digital Image Correlation (DIC)

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Theoretical Basis

Measurement Methods

Global Strain Measurement

∙ Length Measurement

∙ One Strain Value for homogeneous Strain Distributions

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Theoretical Basis

Measurement Methods




Local Strain Measurement

∙ Strain Gauge

∙ One Strain Value for local Strain Distribution

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Theoretical Basis

Measurement Methods




Local Strain Measurement

∙ Strain Gauge

∙ One Strain Value for local Strain Distribution

ARAMIS Strain Measurement

∙ Global and Local Measurement

∙ 1 … 1.000.000 Measurement Points

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Preparation of specimen

∙ Stochastic or deterministic pattern

∙ Pattern follows the deformation of the test specimen under load or motion

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Image acquisition

∙ Reference image is recorded before the test starts to provide a reference for all displacement and strain calculations

∙ This reference image can be understood as a displacement and strain calibration

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Image acquisition

∙ Reference image

∙ Acquisition of images during the test

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Image acquisition

Image processing

∙ Pattern recognition using Digital Image Correlation

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Image acquisition

Image processing

3D coordinates

∙ Image coordinates based on facet centers

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Image acquisition

Image processing

3D coordinates

3D displacements and velocity

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Image acquisition

Image processing

3D coordinates

3D displacements and velocity

Strain tensor

∙ Major and Minor strain

∙ Strain in X, Y, Shear strain

∙ Thickness reduction

∙ Strain rates for all strain measures

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Point Components

Identification of reference point markers in all images

Calculation of 3D or 2D coordinates from identified reference point markers

Motion Analysis

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Overview

ApplicationsAerospace Testing

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Optical 3D Metrology

Aerospace Testing and Engineering

Full Components

Sub-Components

Elements / Structural Details

Material Properties

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Local Effects on Specimens Surface

Application Tensile Test

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Steel with distinct Yield Effect

Comparison local strain and extensometer measurement

Tensile Test

Local and global Strain

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Steel with distinct Yield Effect

Comparison local strain and extensometer measurement

Tensile Test

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Composite Material

CFRP Material – 45 deg layup

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Tensile Tests with ARAMIS

Full-field strain evaluation

Stress-strain curves

∙ Engineering stress

∙ True stress

Stress-Strain Curves

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Young‘s modulus


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Young‘s modulus

Yield strength

Tensile strength


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Young‘s modulus

Yield strength

Tensile strength

Poisson‘s ratio

Poisson’s Ratio

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Young‘s modulus

Yield strength

Tensile strength

Poisson‘s ratio

Metals: R-value and N-value

R-Value and N-Value for Metals

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Applications

Tensile tests

Shear tests

3-point / 4-point bending tests

Torsion tests

Fatigue tests

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Material Testing with ARAMIS

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Applications

Tensile tests

Shear tests

3-point / 4-point bending tests

Torsion tests

Fatigue tests

… and many more

For the determination of material parameters and the development of accurate material models

Material Testing with ARAMIS

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Full Components

Sub-Components


Material Properties

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Aerospace Structural Details Testing

Riveted Joint

Failure Analysis

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Riveted Joint Failure Analysis

Connections – Rivets

Element / Structural Details and Sub-Component Testing

∙ Evaluation of rivet connections

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∙ The evaluation of load over time shows that at 280s the load drops due to rivet failure

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∙ Major strain evaluation

∙ Time of rivet failure

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∙ Major strain evaluation

∙ Time of rivet failure

∙ Maximum strain directions visualized for the area of the three rivets on the top left

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Full Components

Sub-Components


Material Properties

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Aerospace Sub-Component Testing

Airframe Panel

Failure Analysis

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Shear Panel Testing


Measurement of Sub-Components

Testing of panels under shear load for the verification of numerical simulations

Airframe Panel Failure Analysis

Images and results by courtesy of IMA Dresden

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Shear Panel Testing




Shear panel testing demonstrator



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Shear Panel Testing





Result from numerical simulation

∙ Out-of-plane displacement (buckling)


Finite element simulation – Out-of-plane displacement


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Shear Panel Testing





Result from numerical simulation

∙ Out-of-plane displacement (buckling)

Full-field measurement results

∙ Out-of-plane displacement (buckling) aligned to CAD data set


Finite element simulation – Out-of-plane displacement

ARAMIS measurement result – Out-of-plane displacement Images and results by courtesy of IMA Dresden

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Aerospace Component Testing

Rotor Blade Bending Test

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Helicopter drone rotor blade

Blade length: 1540 mm

CFRP composite rotor

Measuring Object

Measuring object: helicopter drone rotor blade made of carbon fiber reinforced plastic

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Verification of strain gauge positions

Positioning derived from numerical simulation

Objectives

Strain gauges

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Verification of strain gauge positions

Positioning derived from numerical simulation

Verification of the numerical simulation

Replacing strain gauges with optical measuring system ARAMIS

Objectives

Strain gauges

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Verification of Numerical Simulations

Overview Finite Element Simulation

Input Geometry (Mesh)

Material Parameters

Boundary Conditions

Shape

Displacement

Strain

Position

FE Optimization

Meshing

FE Verification

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Full-field strain evaluation in X-direction of coordinate system

Reveals non homogeneous strain distribution in root area of the rotor blade

Full-field Strain Analysis

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Focused Strain Analysis Root Area

Further investigation focused on root area to provide a better local resolution of the measurement results

Measuring image of the root area of the rotor blade

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Non homogeneous local deformation behavior

Longitudinal strain (strain in x direction) distribution

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Non homogeneous local deformation behavior

Strain gauge was positioned next to maximum strain area

Longitudinal strain (strain in x direction) distribution

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Comparison of strain gauge measurements with ARAMIS point-wise results


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Evaluation of 1st principle strain (Major Strain)


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Evaluation of 2nd principle strain (Minor Strain)


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Verification of Numerical Simulation

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Replacement of strain gauges

∙ Time and cost saving

∙ With ARAMIS there is no need to know where to measure

Full-field verification of numerical simulations

ARAMIS delivers in addition to the strain values 3D coordinates (shape) and 3D displacements (3D motion) at the same time

Why Using ARAMIS?

3D Shape

Displacement

Strain

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Full Components

Sub-Components


Material Properties

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Large Scale Full Component Testing

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Large Scale Component Testing

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Winglet Testing

Fatigue and Life Cycle Testing Airbus supplier FACC

Airbus A350 XWB

Composite Materials

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Jet Engine Fan Blade Containment

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ARAMISBack Face 3D Full-Field Surface Displacement

· Frame rate: 35,000 Hz

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ARAMISBullet Impact in Kevlar Matt

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Summary

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Full components

Sub-components

Elements/structural details

Material research

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Free evaluation software

3D digital image correlation


3D motion analysis


Free 2D correlation and motion analysis software

What is GOM Correlate?

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GOM Correlate free 2D correlation

Applications of 2D digital image correlation

Material testing

∙ All kinds of in-plane material tests

∙ Tensile tests

∙ 3- and 4-point bending tests

∙ Shear tests

∙ …

Component testing

∙ Civil engineering

∙ Buildings

∙ Bridges

∙ Walls

∙ Large scale structures

…

GOM Correlate

Source: Google

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Video tutorials provide free training

6 episodes are available:

User Interface

Image Acquisition

2D Evaluation

3D Surface Components

3D Point Components

Reporting

∙ www.youtube.com/GOMMetrology

∙ support.gom.com Manuals & Tutorials GOM Correlate

GOM Correlate Video Tutorials

http://www.youtube.com/GOMMetrology

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Thank you for your attention.

[email protected]


Documents

Optical Strain measurement for Aerospace Testing. From