Next Generation Inspection System (NGIS III)

– 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


NGIS III Objectives

Perform on-machine inspection and repairof turbine engine blades and impellers.


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


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


NGIS III Objectives


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


NGIS III Objectives


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).


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



Z

Y

X

Z

3 Linear and 2 Rotary Axes (plus Rotary Tool Changer)

B

C



X

ScanningProbe andSpindle

Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis


NGIS III Scanning Probe and Spindle

Spindle

ContactScanningProbe

Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis



X BladeFixture

Blade and Impeller Fixtures are mounted on the C (Rotary) Axis


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”


PartGeometry


DesignFixture



Probe To Verify


Ship


Part Machining

Part Probing

5-Axis Cell

Create SurfaceModel


Repair)



Scan Data From A Welded Impeller


Detail of Scan Data From Welded Impeller


Scan Data From A Welded Blade

Weld Areas


PartGeometry


DesignFixture



Probe To Verify


Ship


Part Machining

Part Probing

5-Axis Cell

Create SurfaceModel


Repair)



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


PartGeometry


DesignFixture



Part Probing

5-Axis Cell

Probe To Verify


Ship


Part Machining

Create SurfaceModel


Repair)



NC Tool Path For Blade Machining

Tool Path


PartGeometry


DesignFixture



Part Probing

5-Axis Cell

Probe To Verify


Ship


Part Machining

Create SurfaceModel


Repair)



Machining the Weld Bead

NGIS III Tool Evaluation Study at MRI

Helical Burr Tool


PartGeometry


DesignFixture



Part Probing

5-Axis Cell

Probe To Verify


Ship


Part Machining

Create SurfaceModel


Repair)



PartGeometry


DesignFixture



Part Probing

5-Axis Cell

Probe To Verify


Ship


Part Machining

Create SurfaceModel


Repair)



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


• 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


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


Dr. Kam Lau


Tel: 301-330-8100Fax: 301-990-8648

Website: www.apisensor.com

Industry Participant Contacts


Mr. Neal Kearney


Tel: 818-717-5666

Website: www.deltatau.com



Mr. Tony Gable


Tel: 440-205-9195

Website: www.delcam.com



Mr. Tom Charron


Tel: 408-232-5300Fax: 408-519-5766

Website: www.rapidform.com



Mr. Larry Maggiano


Tel: 626-961-9661 X4508Cell: 630-215-6920

Website: www.mitutoyo.com


Documents

Next Generation Inspection System (NGIS III)