ABSTRACT:3D digitization of heritage artefacts, reverse engineering of industrial components or rapid prototyping-driven design are key topics today. Indeed, millions of archaeological finds all over the world need to be surveyed in 3D either to allow convenient investigations by researchers or because they are inaccessible to visitors and scientists or, unfortunately, because they are seriously endangered by wars and terrorist attacks. On the other hand, in case of industrial and design components there is often the need of deformation analyses or physical replicas starting from reality-based 3D digitisations. The paper is aligned with these needs and presents the realization of the ORION (arduinO Raspberry pI rOtating table for image based 3D recostructioN) prototype system, with its hardware and software components, providing critical insights about its modular design. ORION is an image-based 3D reconstruction system based on automated photogrammetric acquisitions and processing. The system is being developed under a collaborative educational project between FBK Trento, the University of Trento and internship programs with high school in the Trentino province (Italy).
Purpose
This paper aims to decrease the cost of repairing operations, of the damaged mechanical components, by enabling the strong automation of the process and the reduction of manual labor. The main purpose of the hybrid repair process is to restore the original shape of the mechanical parts, by adding and removing material according to the mismatch between the damaged object and the virtual model, to restore its geometrical properties.
Design/methodology/approach
The DUOADD software tool translates the information collected from a 3D scanner into a digital computer aided design solid model, which can be manipulated through Siemens NX computer aided manufacturing (CAM), to obtain the tool paths, for the Direct Laser Deposition (DLD) technology. DUOADD uses octrees to effectively analyze the damaged region of the mechanical part and then to discretize the volume to be added to export CAM-compatible information as a 3D model, for additive operations.
Findings
DUOADD is the missing link between two valuable existing technologies, 3D scan and CAM for additive manufacturing, which can now be connected together, to perform automatic repairing.
Research limitations/implications
A trade-off between resolution and computational effort needs to be achieved.
Practical implications
DUOADD output is a STEP file, transferred to the CAM software to create the additive and the milling tool paths. The maximum deviation was 40 micrometers, as compared with the original solid model.
Originality/value
The paper presents a new procedure and new software tools (DUOADD), for the automation of damaged objects restoration process. DUOADD software provides suitable data for using a 5-axis computer numerical control (CNC) milling machine equipped with a DLD tool.
In this paper, the refurbishing of worn-out brake discs by coating with powder via direct energy deposition (DED) is evaluated. A medium carbon steel powder was used to coat cast-iron discs. Deposition of this steel was carried out directly on the disc surface or, alternatively, after a previous deposition of a buffer layer made of stainless steel. It was seen that the use of a buffer layer ensured a good coating adhesion, despite the formation of cast microstructures at the interfaces between the disc and the two different coatings (buffer and outer layer). Coated discs were tested against two different Cu-free commercial friction materials to evaluate their tribological properties. Very similar friction coefficients, specific wear rates, and total emissions were measured for both friction materials sliding against the coated disc. These tribological data are slightly higher with respect to those obtained in the case of an uncoated disc, suggesting that improvement of the top coating composition and surface finishing is necessary in order to achieve better performances.
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