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Next Generation Inspection System (NGIS III)

Next Generation Inspection System (NGIS III). April 19, 2005 Jeffrey A. Calkins Manufacturing Resources Inc. (MRI). NGIS III Project Team. NCMS Program Manager: Bill Waddell Technology Partners End User: NADEP Cherry Point, NC Other Industry and Government Participants

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Next Generation Inspection System (NGIS III)

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  1. Next Generation Inspection System (NGIS III) April 19, 2005 Jeffrey A. Calkins Manufacturing Resources Inc. (MRI)

  2. NGIS III Project Team • NCMS Program Manager: Bill Waddell • Technology Partners • End User: NADEP Cherry Point, NC • Other Industry and Government Participants • Solar Turbines • Philadelphia Naval Foundry and Propeller Center • NIST – Commercial Technologies for Maintenance Activities

  3. NGIS III Objectives • Perform on-machine inspection and repair • of turbine engine blades and impellers. – Commercial Technologies for Maintenance Activities

  4. NGIS III Objectives • Perform on-machine inspection and repair • of turbine engine blades and impellers. • Dramatically reduce the amount of hand blending of airfoil surfaces • under repair. Achieve “near net shape” blend on airfoil surfaces. Weld Areas – Commercial Technologies for Maintenance Activities

  5. NGIS III Objectives • Perform on-machine inspection and repair • of turbine engine blades and impellers • Dramatically reduce the amount of hand blending of airfoil surfaces under repair. • Achieve “near net shape” blend on airfoil surfaces • Reduce blending labor by 60% • Eliminate rework • Prevent scrap loss – Commercial Technologies for Maintenance Activities

  6. NGIS III Objectives • Perform on-machine inspection and repair • of turbine engine blades and impellers • Dramatically reduce the amount of hand blending of airfoil surfaces under repair: • Achieve “near net shape” blend on airfoil surfaces • Reduce blending labor by 60% • Eliminate rework • Prevent scrap loss Provide NADEP Cherry Point with a viable tool that can be also be adopted by other Depots and Industry users – Commercial Technologies for Maintenance Activities

  7. NGIS III Objectives • Perform on-machine inspection and repair • of turbine engine blades and impellers • Dramatically reduce the amount of hand blending of airfoil surfaces under repair: • Achieve “near net shape” blend on airfoil surfaces • Reduce blending labor by 60% • Eliminate rework • Prevent scrap loss (“killed” parts) Provide NADEP Cherry Point with a viable tool that can also be adopted by other Depots and Industry users Lay groundwork for additional future capabilities (e.g integrate material deposition process within the cell to eliminate welding). – Commercial Technologies for Maintenance Activities

  8. NGIS III 5-Axis Cell X Key Subsystems and Technology Providers • 5-axis machine and fixtures (MRI) • Open architecture control (Delta Tau) • Scanning algorithm and hardware (API, Mitutoyo) • Surfacing and machine program generation software (RapidForm, Delcam) – Commercial Technologies for Maintenance Activities

  9. NGIS III 5-Axis Cell Z Z X B Y C • 3 Linear and 2 Rotary Axes (plus Rotary Tool Changer) – Commercial Technologies for Maintenance Activities

  10. NGIS III 5-Axis Cell Scanning Probe and Spindle X Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis – Commercial Technologies for Maintenance Activities

  11. NGIS III Scanning Probe and Spindle Contact Scanning Probe Spindle Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis – Commercial Technologies for Maintenance Activities

  12. NGIS III 5-Axis Cell Blade Fixture X Blade and Impeller Fixtures are mounted on the C (Rotary) Axis – Commercial Technologies for Maintenance Activities

  13. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  14. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  15. Scan Data From A Welded Impeller – Commercial Technologies for Maintenance Activities

  16. Detail of Scan Data From Welded Impeller – Commercial Technologies for Maintenance Activities

  17. Scan Data From A Welded Blade Weld Areas – Commercial Technologies for Maintenance Activities

  18. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  19. Creating Blade Surface Model • Triangulate the set of points from scan data to convert it to a polygon mesh • Use volumetric polygon offset to account for the probe tip radius • Clean up the polygon mesh using RapidForm’s “polygon healing” toolset Scan Processing Suite – Commercial Technologies for Maintenance Activities

  20. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  21. NC Tool Path For Blade Machining Tool Path – Commercial Technologies for Maintenance Activities

  22. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  23. Machining the Weld Bead Helical Burr Tool NGIS III Tool Evaluation Study at MRI – Commercial Technologies for Maintenance Activities

  24. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  25. NGIS III Process Overview Part Geometry Master or Model Part Adaptive Part Probing Create Surface Model Part Set-Up (once per P/N) NC Tool Path Generation (Unique to Part Undergoing Repair) Design Fixture Part Probing 5-Axis Cell Part Machining Machine to Nominal + .005” Final Bench and Inspection Probe To Verify Ship – Commercial Technologies for Maintenance Activities

  26. NGIS III Project Status (April, 2005) • Major Project ElementStatus • 5-Axis Machine Complete • Open-Architecture Control Integration Complete • Blade and Impeller Fixtures Complete • Tooling Evaluation Complete • Probe & Scanning Software 1. API is continuing scanning algorithm development • with the original “on-machine” approach • 2. Mitutoyo is developing a “stand-alone” scanning • capability as another path to a technical solution • Machining Programs “Proof-of-concept” demonstration completed • User Interface and Process To be completed upon successful demonstration of • Automation scanning capability – Commercial Technologies for Maintenance Activities

  27. Alternative Scanning Approach Mitutoyo is providing equipment and technical support to develop an alternative to the project’s original scanning approach Evaluation work is under way with blade samples provided in March, 2005 Key Elements • Crysta-Apex CMM • MP-100 Scanning Probe • MCOSMOS Software – Commercial Technologies for Maintenance Activities

  28. Industry Participant Contacts Mr. Jeff Calkins E-mail: JCalkins@manufacturing-resources.com Tel: 440-786-3390 X103 Cell: 440-537-0311 Fax: 440-786-9107 Website: www.manufacturing-resources.com – Commercial Technologies for Maintenance Activities

  29. Industry Participant Contacts Dr. Kam Lau E-mail: kam.lau@apisensor.com Tel: 301-330-8100 Fax: 301-990-8648 Website: www.apisensor.com – Commercial Technologies for Maintenance Activities

  30. Industry Participant Contacts Mr. Neal Kearney E-mail: nkearney@deltatau.com Tel: 818-717-5666 Website: www.deltatau.com – Commercial Technologies for Maintenance Activities

  31. Industry Participant Contacts Mr. Tony Gable E-mail: TonyG@gt-tech.net Tel: 440-205-9195 Website: www.delcam.com – Commercial Technologies for Maintenance Activities

  32. Industry Participant Contacts Mr. Tom Charron E-mail: tomc@inustech.com Tel: 408-232-5300 Fax: 408-519-5766 Website: www.rapidform.com – Commercial Technologies for Maintenance Activities

  33. Industry Participant Contacts Mr. Larry Maggiano E-mail: Larry.Maggiano@mitutoyo.com Tel: 626-961-9661 X4508 Cell: 630-215-6920 Website: www.mitutoyo.com – Commercial Technologies for Maintenance Activities

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