Ultrasonic on-machine scanning for thickness measurement of thin-walled parts: modeling and experiments

Lian, Meng; Li, Haibo; Zhang, Tongyu; Bo, Qile; Li, Te; Wang, Yongqing

doi:10.1007/s00170-019-04021-5

Cited by 18 publications

(9 citation statements)

References 18 publications

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“…Finally, a 200 MHz DAQ data acquisition card ADLINK PCIe-9852 was adopted to obtain the ultrasonic waveforms. The density and longitudinal velocity of the trailing arm were measured as ρ = 7836 kg/m 3 As shown in Figure 3b, twelve points are selected from the trailing arm for thickness measurement, and three experimental waveforms are collected at each point. Since ultrasonic has a strong directivity, the incident direction of the acoustic beam shall be in agreement with the direction of normal vector of the point when ultrasonic signals are acquired [18], thus, the kinematic equation [19] for the 5-DOF manipulator is established according to the Denavit-Hartenberg parameters [20] and the CAD model of the trailing arm.…”

Section: Thickness Matching Algorithmmentioning

confidence: 99%

“…Several methods can be adopted in thickness measurement [3], such as micrometer, eddy current, ultrasonic pulse-echo method [4], ultrasonic resonance method [5], etc. The micrometer measurement accuracy is high, but it cannot measure the wall thickness before destroying a trailing arm.…”

Section: Introductionmentioning

confidence: 99%

“…The micrometer measurement accuracy is high, but it cannot measure the wall thickness before destroying a trailing arm. Eddy current thickness gauge is mainly used for the thickness determination of the nonmagnetic coating upon the ferromagnetic material [3]. At present, commercial thickness gauges with the ultrasonic pulse-echo method have been widely used for thickness measurement [5,6].…”

Section: Introductionmentioning

confidence: 99%

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Measuring the Wall Thickness of a Trailing Arm Using Ultrasonic Measurement Model

Chen

Zhang³

et al. 2020

Coatings

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Trailing arms are widely used in the automobiles’ suspension system, and effective detection of their wall thickness is essential to ensure their mechanical properties and to evaluate the casting process. In this work, an ultrasonic measurement model (UMM) is firstly established with consideration of the curvature and thickness of the trailing arm, then the UMM is introduced to predict the theoretical ultrasonic waveforms with different hypothetical thicknesses of the trailing arm. Next, the experimental ultrasonic waveforms are collected and matched with the predicted theoretical waveforms by using the correlation matching algorithm. The hypothetical thickness with the best match is regarded as the wall thickness of the trailing arm. Finally, an automatic ultrasonic experiment was conducted on a trailing arm with a 5-degrees of freedom (DOF) manipulator, in which the ultrasonic beam can radiate into a trailing arm at normal incidence. The results are compared with those determined by the micrometer and microscope, showing that their relative errors are controlled within 0.08 mm, which reveals the effectiveness of the present method. The method can also work for wall thickness measurements of curved components with CAD models.

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Section: Thickness Matching Algorithmmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Measuring the Wall Thickness of a Trailing Arm Using Ultrasonic Measurement Model

Chen

Zhang³

et al. 2020

Coatings

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“…1 The flexible joint For thickness measurement and sub-micron size measurement methods, J. Zhao [5] developed a high-precision digital image correlation method for measuring the radial run-out of rotation by using a low-cost dial indicator and a portable USB digital microscope, and the accuracy can reach sub-micron level. M. Lian [6] proposed an ultrasonic automatic scanning technology for the thickness measurement of large narrow-walled parts. The position of the ultrasonic sensor can be adjusted adaptively according to the surface contour of the parts, and the measurement accuracy can be controlled within 0.04mm.…”

Section: Introductionmentioning

confidence: 99%

On-machine Measurement and Uncertainty Analysis for Semicircular Narrow Neck Thickness based on Ultra-precision Machine Tool

Jin¹,

Gao²,

Li³

et al. 2021

Preprint

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As flexible joint is a typical low-rigidity micro part, which have four narrow neck structures evenly distributed around its central axis, it is necessary to strictly control the dimensional accuracy of the narrow necks to improve the consistency of stiffness. However, the radius of the arc of the narrow necks is less than 2mm, and the thickness of thinnest part of the necks formed by two adjacent arcs is only tens of microns, which also has sub-micron accuracy requirement. These cross-scale dimensional characteristics and accuracy requirements give rise to extremely difficulty on the measuring process. In this paper, an on-machine measurement method for the semicircular narrow necks was presented and a measuring device was developed based on the comparative principle by making full use of the high linearity characteristic in the small measuring range of the sensor probes. Meanwhile, the on-machine measurement process based on ultra-precision machine tools was also introduced in details. The experiments results show that the uncertainty of the measurement method proposed is less than 0.2µm, and the repeatability is less than 0.1μm, which meet the measuring requirement of flexible joint. Furthermore, the effect of probe position, measurement force, environmental factor and the accuracy of the sensor on total measuring accuracy was analyzed, which could provide further evidences to improve the measuring accuracy. of micro-scale hybrid surface texture.

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“…uncertainty of temperature change is 0.577°C , so the measurement error uncertainty caused by the temperature is given by the Equation(5).According to 3.2, the measurement error uncertainty caused by the deformation of workpiece when temperature change is formulated as Equation(6). interval as 95%, the expanded uncertainty coefficient K=2, the total expanded uncertainty can be obtained as Equation(7…”

mentioning

confidence: 99%

On-machine measurement and error analysis for narrow neck thickness based on ultra-precision machine tool

Jin

Gao

et al. 2021

Preprint

View full text Add to dashboard Cite

As flexible joint is a typical low-rigidity micro part, which have four narrow neck structures evenly distributed around its central axis, it is necessary to strictly control the dimensional accuracy of the narrow necks to improve the consistency of stiffness. However, the radius of the arc of the narrow necks is less than 2mm , and the thickness of thinnest part of the necks formed by two adjacent arcs is only tens of microns, which also has sub-micron accuracy requirement. These cross-scale dimensional characteristics and accuracy requirements give rise to extremely difficulty on the measuring process. In this paper, an on-machine measurement method for the semicircular narrow necks was presented and a measuring device was developed based on the comparative principle by making full use of the high linearity characteristic in the small measuring range of the sensor probes. Meanwhile, the on-machine measurement process based on ultra-precision machine tools was also introduced in details. The experiments results show that the measurement error of the method proposed is less than 0.2 µm , and the repeatability is less than 0.1 μm , which meet the measuring requirement of flexible joint. Furthermore, the theoretical error and the uncertainty caused by probe position, measurement force, environmental factor and the accuracy of the sensor was analyzed, which could provide further evidences to improve the measuring accuracy of micro-scale hybrid surface texture.

show abstract

Ultrasonic on-machine scanning for thickness measurement of thin-walled parts: modeling and experiments

Cited by 18 publications

References 18 publications

Measuring the Wall Thickness of a Trailing Arm Using Ultrasonic Measurement Model

Measuring the Wall Thickness of a Trailing Arm Using Ultrasonic Measurement Model

On-machine Measurement and Uncertainty Analysis for Semicircular Narrow Neck Thickness based on Ultra-precision Machine Tool

On-machine measurement and error analysis for narrow neck thickness based on ultra-precision machine tool

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