Many high-precision workpieces such as aircraft parts and casting molds are expensive. They need to be replaced after being worn down during use. In addition to replacement, repairing these high-value workpieces is a way to prolong the service life of the workpieces and save the maintenance cost of the enterprise. Using laser additive manufacturing technology to deposit metal powder on the worn parts can reshape the missing geometric shapes in the parts and realize the rapid repair of these high-value workpieces, thereby effectively extending their service life and reducing maintenance and repair costs for enterprises. Usually before the additive manufacturing repair of the workpiece, inspection and pre-processing are required to remove oil, residue, oxide layer or defective areas to ensure that the workpiece is repairable. In the process of formulating processing and repairing strategies, it is necessary to obtain accurate data of damaged workpieces. In this process, high-precision three-dimensional scanning and inspection technologies are indispensable. In this issue, the application case of high-precision 3D visual inspection solutions in additive manufacturing workpiece repair, and you will learn how high-precision inspection solutions help laser additive manufacturing technology to achieve accurate and rapid repair of high-value workpieces.
The OKIO 5M industrial-grade 3D scanner in the high-precision 3D vision inspection solution.
© Tianyuan 3D under Shining 3D
Accurately obtain and process data
Impact defect repair case
The high-precision 3D visual inspection program independently developed by Tianyuan 3D, a subsidiary of Shining 3D, includes a high-precision 3D scanner and the self-developed EINSENSE Q 3D digital inspection software. The University of Missouri laboratory has carried out a series of research in the field of laser additive manufacturing repair. One of the studies is to repair the impact defects of H13 molds by additive manufacturing.In the preparation stage for restoration, Tianyuan 3D’s high-precision blue-ray 3D scanning equipment OKIO 5M was used to process the scanned data of the workpiece, and combined3D scanningAnd reverse engineering, and finally realize the additive manufacturing repair of the mold.
// Damaged parts
Through observation, it can be found that the damaged part of the workpiece shown in the above figure has a complex shape, including a vertical surface and a narrow side in addition to the cone. The University of Missouri laboratory processed a certain amount of cladding damage in the workpiece to prepare the required geometry for additive manufacturing repair.
// Use scan to reconstruct damaged parts
Use the high-precision blue-ray 3D scanner OKIO 5M to place the workpiece on the platform or turntable to perform3D scanning.
The picture shows the STL model of the damaged H13 mold workpiece established using the scan data of OKIO 5M. The damaged shape is clearly identifiable. This is a prerequisite for planning a repair path.
The next steps include obtaining the target geometric shape, and generating the damaged workpiece based on the obtained geometric shape for pre-processing path, and completing the pre-processing.
Cracked blade repair case
// Get the damage of the blade
The cracks of the blade shown in the figure above are clearly visible on the front and back, and the shape is a curved surface groove. In this application case, the purpose of using high-precision three-dimensional scanning for inspection is to calculate the optimal machine-added repair plan.
// Use 3D scan data for modeling
The scan data is modeled, and the shape and location of the damaged part of the blade are clearly displayed in the model. Use professional inspection software for analysis, you can also plan the resection path and repair the workpiece. The blue line is the notch area on the workpiece, and the purple part is the optimal cutting path.
//Complete the pre-processed damaged blade
The damaged area of the blade has been machined according to the planned path and can be used for the next step of additive manufacturing repair.
Worn workpiece repair case
Workpiece scanning
When repairing some small-sized industrial parts, the researchers fixed the OKIO 5M on a tripod, used a robotic arm to grab the workpiece, and rotated it at multiple angles to obtain a complete 3D data model.
OKIO 5M adopts advanced blue light raster scanning technology to meet the needs of high-precision industrial three-dimensional inspection, and quickly obtain high-precision data of the workpiece.
//Extract wear part data
The 3D data of the standard workpiece and the worn workpiece are subjected to Boolean operation in the software to extract the 3D data of the worn part.
A watertight model (STL) is generated from the point cloud data of the wear part obtained by the Boolean operation.
// Repair path planning and direct repair
Based on the worn part model data obtained by scanning and post-processing, the repair path is generated through software calculation.
Repair by additive manufacturing technology, and then CNC machining, the worn workpiece is repaired.
Cracked die repair application
//Common repair ideas
In the damaged die shown in the figure above, the cracked and damaged locations generally need to be processed to accurately remove the material in the damaged location before the additive manufacturing repair is performed.In the process of defining the cut part, it is also necessary3D scanningTechnical participation. The figure shows the damaged model and its data modeling.
//Confirmation of tool path
Detect the shape and specific location of the scratches on the workpiece to determine the amount of resection and the boundary of the resection. Load it into the processing system, confirm the tool path, and generate the NC code at the same time. The blue part in the picture is the tool path, marking the part that needs to be cut.
The above restoration cases all use a three-dimensional scanner to obtain accurate data of the workpiece. This lays the foundation for subsequent workpiece repair planning, pre-processing, and final additive manufacturing repair.
Researchers from the University of Missouri laboratory successfully used the Tianyuan 3D high-precision 3D scanner OKIO 5M to reconstruct the wear part model and avoid human error. According to the repair path, the laser additive manufacturing technology successfully repairs the workpiece quickly, restores its mechanical properties, extends the service life, and eliminates the time-consuming work flow of manual repair such as welding and processing.
(Editor in charge: admin)
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