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Content archived on 2024-04-19

3D CHARACTERIZATION OF DEFECTS IN MECHANICAL PARTS BY MULTI RADIOGRAPHY USING C.A.D. MODELS

Objective


The Project has shown that the concept of using the CAD Model of a component to create synthetic radiographs at a limited number of poses and, matching these images to the actual images of the component under test, is a very powerful technique for the detection of defects. This concept having been proven to b feasible will now require further optimisation to allow such a system to be used on a production basis. Advances in technology during the life of the Project will allow a pre-production model of the RADICAD System to meet the needs of end users in many industries.

The anticipated benefits of this technological advancement will be to allow high levels of non destructive testing on components to be applied in an automated or semi-automated manner. The requirement to acquire defect data with only a limited number of component positions will enable the technology to operate in the production process. The ability to project defects back into the CAD Model will assist in rapid prototyping of new castings and components. The anticipated cost of the Radicad System will be substantially lower than computer tomography technology. The prototype system is currently installed at Iveco, Turin, and has been fully tested and is available for demonstration.
The X-ray inspection of 3D industrial parts such as gear box housing or super plastic aeronautic parts is limited by many constraints. First, most of the time the parts cannot be inspected along each direction due to their thickness and the resulting X-ray attenuation prevents the use of tomography. Even when the acquisition is possible, the acquisition time required to perform a complete three-dimensional acquisition, reconstruction and volume control is not compatible with the number of parts to be inspected. However, for many industrial parts, the manufacturer is not interested in the inspection of complete parts, but wants to check for flaws in critical areas. It is proposed here to develop a complete automatic system which will correlate the information from multiple digital radiographs of the part in order to localise and characterise the flaws in the part CAD model. A gain of 5% on the time to market a new product and a 70% reduction on laboratory cost compared with the current non destructive and destructive analysis are expected by the end users. This system is not focused on only one application, it addresses the problem of localised defects when a CAD model of the part is known. Thus is intended to inspect a variety of materials from cast iron, to composites. Subsequent exploitations is envisaged which will ensure appropriate technology transfer to other industrial sectors such as micro-mechanics or even the biomedical field.

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Coordinator

OIS Engineering Ltd
EU contribution
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Address
Bessemer Way
NR31 0LX Great Yarmouth
United Kingdom

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