Gom Applications In Aerospace Testing

GOM The Use of Optical Metrology in the Aerospace Industry September 2, 2014

2-Frame Setup / Frame 2 2-Frame Setup / Frame 1

3-Frame Setup / Frame 1 3-Frame Setup / Frame 2 3-Frame Setup / Frame 3



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The Use of Optical Metrology in the Aerospace Industry GOM

GOM – Industrial 3D Measuring Techniques Company Overview

· Development, manufacturing and sales

· Over 300 employees

· 7 GOM branch offices in Europe

· 45 dedicated partner offices worldwide

· More than 8,000 installations

· Measurement technology for companies from the automotive and aerospace industries as well as from the consumer goods sector

GOM is a global partner for optical 3D metrology with over 20 years' experience





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GOM Customers (Extract)

Automobile manufacturers · Audi D · Avtovaz RU · Bentley UK · BMW AT, D, UK · Chrysler USA · Daimler D · Fiat IT · Ford BE, D, UK, USA, BR · Freightliner USA · General Motors AU, AT, BR, USA · Honda CN, JP, USA · Hyundai KR · Isuzu JP · Jaguar UK · Kia KR · Land Rover UK · McLaren UK · Modenas MY · NAZA MY · Nissan JP, UK, USA · Opel D · Porsche D · PSA FR · Renault FR, ES, TR · Seat ES · Skoda CZ · Subaru JP · Suzuki CN · Tata Motors Limited IN · Toyota D, J, TR, USA, CA · Volkswagen CN, D, MX, PL · Volvo SE · Temsa TR

Automotive suppliers · Autopal CZ · Batz ES · Bertone IT · Bertrandt D · Bosch D, CH · Bridgestone JP · Carcoustics LI · DAAZ RU · Delphi JP · Faurecia D, FR · FES D · Goodyear USA · Hella Leuchtensysteme D · IAV D · Italdesign-Giugiaro IT · Kautex Textron D · Läpple D · LUK D · Magna CA, AT · Mahle D · Matador SK · Matrici ES · Metalbages ES · Michelin FR · Montupet FR · Nothelfer DE · OLHO Technik DE · Pierburg Kolbenschmidt AG, D · Pininfarina IT · Solvay BE · ThyssenKrupp D

Aerospace · Airbus D · Airforce Research Laboratories USA · Aselsan TR · Boeing USA · Cessna USA · Chrom Alloy USA, TH · DLR D · EADS D, FR · ELBAR SULZER NL · Eurocopter D · Federal Aviation Administration USA · FOI SE · Gorbynov Aviation Production RU · Honeywell IE, USA · Howmet UK, USA, JP · IMA Dresden DE · IMPO RU · Lockhead Martin USA · MTU D · NASA USA · Northrop Grumman Systems Corp. USA · ONERA FR · Pratt & Whitney USA, NO · RollsRoyce UK, USA · Saturn RU · Snecma Propulsion Solide FR · Solar Turbines USA · Triumph USA · Turbine Services USA · Vulcan Air IT · VZLÚ CZ





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Material manufacturers · ACTech DE · Alcan (Alusuisse) CH · Arcelor BE · BASF DE · Bayer DE · DuPont US · Hydro (VAW) DE · Salzgitter DE · Tata Steel IN · Thyssen Krupp DE · Thyssen Nirosta DE · Tokai Rubber Industries JP · Voest Alpine Stahl AT

Others · Alfa Laval SE · Bundeskriminalamt DE · Corning US · EXXON US · Hidrostal CH · Sea Ray Boats US

Consumer goods · 3B Scientific DE · Adidas DE, USA, KR + 13 suppliers · Apache Footwear DE · Asics JP · Balda CN · BenQ CN · Blaupunkt DE · Bosch DE, CH · Braun DE, CN · Ching Luh Shoes CN · Ecco DK · Embraco BR · FisherPrice USA · Fuji JP · Green Point CN, TW · Head Tyrolia AT · Hitachi Taga JP · Lego DK · LG Electronic KR · Luxottica IT · Mattel Tools MY · Microsoft USA · Nolato SE · Oakley US · Olympus JP · Playworks USA · Samsung, KR · Siemens DE, DK · SonyEricsson SE · Sony JP, USA · Sun Microsystems USA · VDO DE · Vertu UK · Villeroy+Boch LU, DE · Walt Disney USA

Research · BAM DE · EPFL Lausanne CH · ETH Zürich CH · Forschungszentrum Karlsruhe DE · Fraunhofer DE · GKSS Geestacht DE · Imperial College UK · Int. Automotive Research Centre, UK · Istanbul Technical University TR · IUC SE · Kaitech KR · KTH SE · KU Leuven BE · Laurence Livermore National Labs USA · Max Plank Institute DE · Nagasaki Industrial Research Center JP · Naval Research Lab USA · Nottingham University UK · PCC Leoben AT · Queen Mary College UK · RWTH Aachen DE · Sandia National Lab USA · Shenyang Aircraft Research Inst CN · TU Delft NL · TU Dresden DE · TU Eindhoven NL · TU Graz AT · TU München DE · Uni Padova IT · US Army Research Lab USA · Warwick University UK

GOM Customers (Extract)





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GOM – Industrial 3D Measuring Techniques Measurement systems

· Material Testing · 3D Coordinate Measurement · Component Testing

ATOS

ATOS ScanBox

TRITOP

ARAMIS

PONTOS

PONTOS

ARAMIS

TRITOP ARGUS

Viewing and evaluation software





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GOM – Industrial 3D Measuring Techniques Measurement systems

Full-field 3D Digitizing

ATOS

3D Shape and Dimension Inspection

Material Testing

Dynamic Component Testing

Full-field 3D Strain Measurement

ARAMIS

Deformation Analysis in Sheet Metal Forming

ARGUS

Mobile Optical CMM

TRITOP

Dynamic 3D Analysis

PONTOS

Measurement Systems Overview





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ATOS 3D Surface Measurement

· Static measurements of any 3D geometry / surface

· Full-field component measurement · Inspection / GD&T ·Quality control · Reverse engineering / design · Rapid manufacturing

· Evaluation in

· Injection molding und plastics industry · Sheet metal and forming industry · Casting industry · Tooling and molding

3D Digitizing





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· Complete 3D measuring machine in two light weight cases

· 100% mobile ·Minimal hardware efforts

· Non-contact

· No contact of the object during the measurement

· High accuracy

· No wear and tear elements · No decrease of the accuracy

· Easy handling

· Flexible measuring system · Independent of environmental influences (climate chamber, outdoor)

TRITOP Optical 3D Coordinate Measurement Machine

Optical CMM





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ARAMIS Material- and Component Testing

· 3D deformation measurement

· Determination of material properties · Component testing

· Flexibility for all applications · Standard applications, e.g. tensile tests, … · High temperature measurements · High speed measurements · Validation of FE simulation · Real-Time measurements

· Integration in existing testing environment · Tensile testing devices, load frames, … · Replacement for extensometers and strain gauges

3D Deformation Analysis





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PONTOS Dynamic Deformation Analysis

· Dynamic deformation analysis · Deformation (Torsion, bending, displacement, etc.)

· Velocity · Acceleration · Analysis of vibration

· Dynamic behavior of components, e.g.

· Deformation in wind tunnel · Drop tests · Crash tests · Structural vibrations

Dynamic Analysis of 3D Coordinates

Numerical Simulations





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Verification of Numerical Simulations

· Numerical simulations are today widely used in the development of aerospace components

Finite Element Simulation vs. ARAMIS Measurement





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· Optical metrology supports the setup, verification and optimization of numerical simulations





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· 3D shape measurements · Input geometry · Position and shape verification





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· 3D shape measurements · Input geometry · Position and shape verification

· 3D deformation measurements

· Material parameters · Boundary conditions · Verification of

· Position · Shape · Displacement / deformation · Strain





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· Application webinar „Verification of Numerical Simulations“

· https://support.gom.com/x/0gkwAQ

3D Digitizing Quality Control





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CNC Processing

Data for following processes

Quality Control

Rapid Manufacturing

Reverse Engineering

High-quality 3D mesh (STL) · High resolution for finest details · Measurement of small radii

Full-field 3D Coordinate Measurement Applications





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Full-field 3D Coordinate Measurement Control of Shape and Dimensions - Trend analysis

Production & wear monitoring · Determination of process capability · Identification of part and tool wear trends · Repair & maintenance





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Full-field 3D Coordinate Measurement 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

3D Digitizing Reverse Engineering





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Reverse Engineering Black Hawk Upgrade Program

· Black Hawk upgrade program of the Australian Army for electronics upgrades





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· Due to the age of helicopters the existing CAD models were too inaccurate to plan the integration of the new equipment





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· Due to the age of helicopters the existing CAD models were too inaccurate to plan the integration of the new equipment

· Objectives:

·Measure the external airframe and produce 3D scan data to within an accuracy of 0.1 mm

·Measure certain internal and external areas of interest to the same accuracy

· Produce an integrated set of data within the same coordinate frame work

·Model the aircraft using the scan data and produce an integrated 3D model for CAD analysis





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· Measurement of external airframe

· 3D coordinates evaluated with Photrogrammetry (TRITOP)





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· Measurement of external airframe

· 3D coordinates evaluated with Photrogrammetry (TRITOP)





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· Measurement of internal and external areas of interest

· Digitizing with the ATOS system using the external airframe measurement from TRITOP as reference





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· Coordinate frame work alignment and CAD model generation

Applications in Aerospace Testing





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Optical 3D Metrology In Aerospace Testing and Engineering

Image by courtesy of the NLR, Netherlands





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· Material Research






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· Elements / Structural Details







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· Sub-Components








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· Full Components

· Sub-Components




Material Testing Application Tensile Test





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Material Testing Tensile Test

· Material testing with ARAMIS

· Tensile tests

· Full-field strain evaluation





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· Tensile tests


· Stress-strain curves

· Engineering stress

· True stress





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· Tensile tests



· Young‘s modulus





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· Tensile tests




· Yield strength

· Tensile strength





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· Tensile tests




· Yield strength

· Tensile strength

· Poisson‘s ratio





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· Tensile tests




· Yield strength

· Tensile strength

· Poisson‘s ratio

· Metals: R-value and N-value





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Material Testing Applications in Material Testing


· Tensile tests

· Shear tests

· 3-point / 4-point bending tests

· Torsion tests

· Fatigue tests

·…





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Material Testing Applications in Material Testing


· Tensile tests

· Shear tests

· 3-point / 4-point bending tests

· Torsion tests

· Fatigue tests

·…

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

Element / Structural Details and Sub-Component Testing





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Element and Sub-Component Testing Verification of Numerical Simulations

· Element / structural details and sub-component testing

·Measurement of structural details

Images and results by courtesy of the NLR, Netherlands





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· Full field deformation analysis with ARAMIS






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· Full field deformation analysis with ARAMIS

· Verification of numerical simulations


Element / Structural Details and Sub-Component Testing Connections - Rivets





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Element and Sub-Component Testing Connections - Rivets


· 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





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· Time of rivet failure





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· Time of rivet failure

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

Element / Structural Details and Sub-Component Testing Shear Panel Testing





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Element and Sub-Component Testing Shear Panel Testing


·Measurement of sub-components

Images and results by courtesy of IMA Dresden





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






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· Shear panel testing demonstrator






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· Result from numerical simulation · Out-of-plane displacement (buckling)

Finite element simulation – Out-of-plane displacement






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· 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


Element / Structural Details and Sub-Component Testing Rotor Blade Bending Test





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Element and Sub-Component Testing Rotor Blade Bending Test

· Helicopter drone rotor blade

· Blade length: 1540 mm

· CFRP composite rotor





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· Objectives

· Verification of strain gauge positions derived from numerical simulation

Strain gauges





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· Objectives


· Verification of the numerical simulation

Strain gauges





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· Objectives


· Verification of the numerical simulation

· Replacing strain gauges with optical measuring system ARAMIS

Strain gauges





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· Blade length: 1540 mm ·CFRP composite rotor

Strain gauges





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· Full-field strain evaluation in Y-direction of coordinate system





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· Full-field strain evaluation in Y-direction of coordinate system

· Strain gauge are not positioned in maximum strain areas





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





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

· Non homogeneous strain distribution in root area of the rotor blade





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· Strain gauge positioned to measure in X-direction

· Comparison ARAMIS against strain gauges





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





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· Strain in X-direction





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· Non homogeneous local deformation behavior

· Strain gauge was positioned next to maximum strain area





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· Comparison of strain gauge measurements with ARAMIS point-wise results





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· Evaluation of principle strain (Major Strain)





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· Evaluation of principle strain (Minor Strain)





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· Comparison of results from numerical simulation and ARAMIS measurement





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· Why using ARAMIS?

· 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

3D Shape

Strain

Displacement

Component Testing Wind Tunnel Testing with Delta Wing Model





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Component Testing Deformation Measurement in Wind Tunnel

· Delta wing aircraft model

·Measurements at a speed of Mach 0.8 for the analysis of the wing deformation with different angles of attack towards the air flowing direction





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· The measurement is carried out in a wind tunnel, thus the optical measuring system is positioned in front of a windows recording images through the glass window





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· The measurement is carried out in a wind tunnel, thus the optical measuring system is positioned in front of a windows recording images through the glass window

· Point-wise evaluation of the wing tip deflection





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· Point group (component) definition over markers attached to hull and both wings 3D coordinates are calculated from the attached measurement markers





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· Coordinate system alignment · X-direction: Direction of air flow · Y-direction: Left to right wing · Z-direction: Hull in viewing direction

X

Y

Z





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· Coordinate system alignment · X-direction: Direction of air flow · Y-direction: Left to right wing · Z-direction: Hull in viewing direction

· To calculate only the wing tip deflection relatively to the hull a rigid body motion compensation is calculated using the 3D coordinates derived from the markers positioned on the hull





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· Deflection of the wing tips relatively to the hull





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· Deflection of the wing tips relatively to the hull

Component Testing Aerodynamic Testing of Sample Return Capsule in Wind Tunnel





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Component Testing Aerodynamics of Sample Return Capsule

· Devices to return rock or dust samples from space are so called sample return capsules





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· Return capsules are designed to protect a sample container, which is stored inside the capsule, from the extreme heat produced during the re-entry into the atmosphere





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· The return velocity of approximately 45000 km/h (13 km/s) must be drastically reduced before the capsule enters lower layers of the atmosphere to prevent overheating





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· A blunt geometry of the capsule is thus mandatory to produce enough resistance for velocity reduction in higher atmosphere layers





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· A blunt geometry of the capsule is thus mandatory to produce enough resistance for velocity reduction in higher atmosphere layers

· Blunt geometries are tending to be aerodynamically instable and are starting to swing, especially when decelerated to the speed of sound and below





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· The use of parachutes was not considered due to the complexity and costs of the capsule





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· To protect the sample container the capsule must not impact the ground with the top face and must stay within a specific angle from the trim position





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· To protect the sample container the capsule must not impact the ground with the top face and must stay within a specific angle from the trim position

· To evaluate the aerodynamic behavior different capsules were tested in the vertical wind tunnel at the DLR in Köln





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· Aerodynamic behavior of capsule in vertical wind tunnel at free fall conditions before impact





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· The possible rigid body motion of the used stereo camera sensor inside the wind tunnel is compensated using 3D measurement points from the nozzle (green points)





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· The possible rigid body motion of the used stereo camera sensor inside the wind tunnel is compensated using 3D measurement points from the nozzle (green points)

· The 3D coordinate system alignment is done with a coordinate alignment to the CAD data set of the nozzle

· Y-axis in flow direction

· For visualization purposes the CAD data set from the capsule is additionally imported into the measuring project





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· Capsule motion in 3D space





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· 6 degree of freedom analysis





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· Trajectory from capsule center point in the first 5 seconds of the test





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· Trajectory from capsule center point in the first 5 seconds of the test

· Displacement Y over displacement X

Vibration Measurement Ground Vibration Testing with Full Scale Aircraft





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Structural Vibration Analysis Ground Vibration Test on Aircraft

· Structural vibration analysis of an aircraft





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· Controlled excitation at nose and wing tip using a white noise within 5Hz – 35 Hz





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· Controlled excitation at nose and wing tip using a white noise within 5Hz – 35 Hz

· Objectives:

· Modal analysis of one wing

· Comparison with traditional accelerometer measurement system





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· Measurement preparation for the accelerometer measurement system





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·Mounting and wiring of individual accelerometers





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· Connecting amplifiers and data loggers





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· Connecting amplifiers and data loggers

· Calibration of each individual accelerometer





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· Measurement preparation for the optical point-wise measurement using PONTOS





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· Application of ultra light-weight self-adhesive measurement markers





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· Optical stereo camera sensor calibration and positioning





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· Coordinate system transformation for result evaluation





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· 3D coordinate measurement during the structural vibration test





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· 3D coordinate measurement during the structural vibration test

· Data export in Universal File Format (UFF) for further modal analysis in e.g. ME’Scope, LMS, Matlab, etc.





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· Modal evaluation of structural vibration test

· Amplitude frequency response curves for the evaluation in Z-direction with different excitation at nose and wing





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· Modal evaluation of structural vibration test

· Amplitude frequency response curves for the evaluation in Z-direction with different excitation at nose and wing

· Further evaluation and visualization is carried out using third party software packages





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· Comparison to accelerometer measurements

· Very good correlation of the optical measurement results to the accelerometer measurements





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· Comparison to accelerometer measurements

· Very good correlation of the optical measurement results to the accelerometer measurements

· Point N136 shows a larger deviation which occurred due to a not perfectly mounted accelerometer





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· Summary

· Fast test object preparation and system setup

· Fast calibration of the measurement system

· There is no need to calibrate each individual measurement point for each direction

· No influence on the test object from the measurement markers

· Useful extension to existing measuring setups

· Time and money saving for structural testing





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· Full Components

· Sub-Components




Thank you for your attention

[email protected] www.gom.com

Software

Gom Applications In Aerospace Testing