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Procedia CIRP 79 (2019) 343–348
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12th
12thCIRP
CIRPConference
Conferenceon
onIntelligent
IntelligentComputation
ComputationininManufacturing
ManufacturingEngineering,
Engineering,18-20
CIRPJuly 2018,
ICME '18
th
12 CIRP Conference on Intelligent Computation in Manufacturing
Gulf of Naples, Italy Engineering, CIRP ICME '18
Integration of28th reverse engineering
CIRP Design and
Conference, Mayultrasonic
2018, Nantes,non-contact
France testing
Integration for
procedures of reverse
quality engineering
assessment of and ultrasonic
CFRP non-contact
aeronautical testing
components
A new methodology
procedures fora,b,* to analyze
quality the functional
assessment of CFRP and physical architecture
aeronautical components of
Tiziana
existing Segreto for
products , Alberto Bottillo , Alessandra
an assembly
a,d
oriented Caggiano
a,b
, Massimo
product family Martorellic
identification
Tiziana Segretoa,b,*, Alberto Bottilloa,d, Alessandra Caggianoa,b, Massimo Martorellic
Fraunhofer Joint Laboratory of Excellence on Advanced Production Technology (Fh-J_LEAPT UniNaples), Naples, Italy
a

Dept.
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
of Laboratory
Industrial Engineering,
of ExcellenceUniversity of Naples Federico II, P.le Tecchio 80, 80125 Naples, Italy
b
Fraunhofer
a
Joint on Advanced Production Technology (Fh-J_LEAPT UniNaples), Naples, Italy
cb
Fraunhofer JL IDEAS
Dept. of Industrial - Dept. ofUniversity
Engineering, Industrial of
Engineering, University
Naples Federico of Tecchio
II, P.le Naples Federico
80, 80125II,Naples,
Naples,Italy
Italy
d
Dept.
ÉcoleofNationale
Chemical,
c Materials and Industrial Production Engineering, University of Naples Federico II, P.le Tecchio 80, 80125 Naples, Italy
Fraunhofer JL IDEAS
Supérieure d’Arts - Dept.Arts
et Métiers, of Industrial
et MétiersEngineering, University
ParisTech, LCFC of Naples
EA 4495, 4 RueFederico
AugustinII, Naples,Metz
Fresnel, Italy57078, France
d
Dept. of Chemical, Materials and Industrial Production Engineering, University of Naples Federico II, P.le Tecchio 80, 80125 Naples, Italy
* Corresponding author. Tel.: +39-081-7682371; fax: +39-081-7682362. E-mail address: tsegreto@unina.it
**Corresponding
Correspondingauthor.
author.Tel.:
Tel.:+33
+39-081-7682371; fax: +39-081-7682362.
3 87 37 54 30; E-mail E-mail address: tsegreto@unina.it
address: paul.stief@ensam.eu

Abstract
Abstract
Abstract
Nowadays, the quality assurance of aeronautical components is a very crucial issue. Diverse defects can be generated during composite material
Incomponents
Nowadays, manufacturing
the
today’s business quality such the
assurance
environment, as aeronautical
of voids, delamination,
trend towards componentscracks,
more product etc. The
is a very crucial
variety identification
and issue. Diverse
customization of these defects
defects requires
can beDue
is unbroken. generatedtheduring
to this use ofcomposite
different
development, the types of
material
need of
inspection
components
agile methods.
and reconfigurable In this
manufacturing paper,
such as
production two diverse
voids,
systems non-contact
delamination,
emerged inspection
cracks,
to cope withetc. techniques, i.e. aand
The identification
various products laser-based
of reverse requires
these defects
product families.engineering method
the and
To design and anproduction
use optimize
of differentultrasonic
types of
testing procedure,
inspection
systems as well as are
methods. integrated
toInchoose the to
this paper, provide
two
optimaldiversea complete
product quality
non-contact
matches, assessment
inspection
product of carbon
techniques,
analysis i.e.fibre
methods a are reinforced
laser-based polymer
needed. reverse
Indeed, components
engineering
most for applications
of themethod
known and in the
an ultrasonic
methods aim to
aeronautical
analyze field.orare
testing aprocedure,
product Aonecustom
productmade
integrated to software
provide
family acode
on the was developed
complete
physical quality in order
assessment
level. Different to
ofcreate
product carbon a fibre
userhowever,
families, interface
reinforcedallowing
differfor
polymer
may the visualization
components
largely for of
in terms andnumber
analysis
applications
the of
inand
the
the reverse
aeronautical engineering
field. A and
custom ultrasonic
made information
software code for
was the detection
developed in of geometrical
order to create and
a userinternal flaws
interface of the
allowing
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production component
for the under
visualizationinspection.
and analysis of
©
the2018 The
reverse Authors.
engineering Published
and by
ultrasonicElsevier B.V.
information for the detection of geometrical and internal flaws of the component
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster under inspection.
Peer-review
©
© 2018
these The
products
2019 under
in newresponsibility
Authors.
The Authors. byof
Publishedoriented
assembly
Published by the
Elsevier scientific
product
Elsevier committee
B.V.families
B.V. of the 12th CIRP
for the optimization Conference
of existing assemblyonlines
Intelligent Computation
and the creation in reconfigurable
of future Manufacturing
Engineering.
Peer-review
assembly
Peer-review under
systems. responsibility
under Based on Datum
responsibility of
Flow
of the the scientific
scientific committee
Chain,committee
the physical 12ththe
of
structure
of the of12the
CIRP
th CIRP Conference on Intelligent Computation in Manufacturing
products is
Conference onanalyzed.
IntelligentFunctional
Computationsubassemblies are identified,
in Manufacturing and
Engineering.
aEngineering.
functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
Keywords:between
similarity Non-contact testing;families
product Ultrasonicbynon-destructive inspection;
providing design Laser-based
support to both,reverse engineering;
production system Composite
plannersmaterials; Quality
and product control An illustrative
designers.
Keywords:
example ofNon-contact
a nail-clippertesting; Ultrasonic
is used non-destructive
to explain inspection;
the proposed Laser-based
methodology. Anreverse engineering;
industrial case studyComposite
on twomaterials; Quality control
product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
1. Introduction
Peer-review under responsibility of the scientific committee of the 28th CIRP inspected component2018.
Design Conference without taking into account the other NDI
1. Introduction inspected
inspections component
of the partwithout
[4-8]. taking into account the other NDI
One of the major advancements of the aircraft industry is the inspections
The integration of [4-8].
of the part different NDI results in a unique user
Keywords: Assembly; Design method; Family identification
One of theof
introduction major advancements
composite materials,of thein aircraft
particularindustry is the
of carbon The integration
interface of different
can significantly NDI the
improve results in a control
quality unique of usera
introduction of composite materials, in particular
fibre reinforced polymer (CFRP) materials, for the construction of carbon interface
component allowing for a complete evaluation of the possiblea
can significantly improve the quality control of
fibre
of lightreinforced
weight polymer
aircrafts (CFRP)
leading materials,
to a reductionfor theofconstruction
utilization component
defects allowing for a complete evaluation of the possible
[9-10].
of light
1.costs weight aircrafts leading to a
and the increase of structure effectiveness [1].
Introduction reduction of utilization of the
defects product
[9-10].
In this paper, range
twoand NDIcharacteristics
procedures, amanufactured
laser-based reverseand/or
costs
Due and tothe
theincrease of structureand
non-homogeneous effectiveness
anisotropic[1]. properties of assembled
In this in this
paper, system.
two NDI In this context,
procedures, the
a
engineering (RE) scanning method and an ultrasonic (UT) non- main challenge
laser-based reverse in
Due
composites to
Due to the the non-homogeneous
materials, and
a large number
fast development anisotropic
in the properties
of defects
domain (e.g. of
of modelling
engineering and(RE)analysis
scanning is now
method not only
and an to cope
ultrasonic
destructive inspection technique, are considered for the quality with
(UT) single
non-
composites materials,
delamination, cracks,
communication and anvoids, a large number
fibrestrend
ongoing fractures, of defects (e.g.
etc.) can occur
of digitization and products,
destructive
assessment a limited
inspection
of a CFRP product range are
technique,
aeronautical orcomponent.
existing
considered product
for thefamilies,
quality
delamination,
during
digitalization, cracks, voids,
composites
manufacturing fibres fractures,
manufacturing
enterprises etc.)
[2]. facing
are candamage
occur
The important but also
assessmentto beofable
a to
CFRP analyze and
aeronautical to compare
component.
The RE method was employed using a laser scanner system products to define
during composites
development
challenges in and
today’s manufacturing
propagation
marketinenvironments:
composite [2].components
The damage
could
a continuing new product
The RE families.
method was It can be
employed observed
using athat
laser
in order to acquire the external geometry, whereas the UT NDI classical
scanner existing
system
development
eventually
tendency towards and propagation
lead toreduction in composite
the failureofofproduct
the entire aircraft. timescould
components
development and product
in orderfamilies
procedure to was
acquirearethe
regrouped
utilized external
to detect ingeometry,
function
the of clients
whereas
internal material or structure
the features.
UT NDI
eventually lead to lifecycles.
In this product
shortened context, the failure In
of addition,
non-destructive theinspection
entirethere
aircraft.
(NDI) techniques
is an increasing However,
procedure assembly
was oriented
utilized to
of the CFRP aeronautical component. product
detect the families
internal are hardly
material to find.
structure
playInathis
demand ofcontext,
fundamental non-destructive
customization,role forbeing atinspection
the detection
the same (NDI)
of defects
time in techniques
during both
a global of On
The acquired RE and UT data are subjected to in
the the
CFRP product family
aeronautical level,
component.products differ mainly two
a pre-
play a fundamental
the manufacturing
competition role for the
phase and the
with competitors detection
all service
over the of defects
lifeworld. during
[3]. This trend, both main
processing phase in order to obtain data that are readable the
Thecharacteristics:
acquired RE (i) the
and number
UT data of components
are subjected and
to (ii)
a pre-
for
the
which manufacturing
Currently,
is inducing phase
many the and the
typesdevelopment service
of NDI methods life [3].
fromaremacro available in the
to micro type of components
processing phase in(e.g.
the implementation oforder
a newmechanical,
to user
obtain electrical,
data
interface. that are electronical).
readable for
Currently,
industrial
markets, fieldmany
results types
forinflaw of NDIlot
detection
diminished methods
and analysis,
sizes arebut
due available
to each in the
method
augmenting theClassical methodologies
Aimplementation
new custom of a new
made considering
user interface.
software mainly
code wassingle products
developed in
industrial field
is used varieties
product in separatefor flaw detection
laboratoriestothat
(high-volume and analysis, but
do not communicate
low-volume each method
production) with
[1]. or
LabVIEW© environment to realize the integration betweenthe
solitary,
A new already
custom existing
made product
software codefamilies
was analyze
developed in
the
is
each
To used
cope in
other. separate
with Each
thisNDI laboratories
laboratory
augmenting that
variety doasnot
provides itscommunicate
well NDI results
as to onwith
be able the
to product
LabVIEW© structure on a physical
environment level the
to realize (components
integrationlevel) which
between the
each other.
identify Each NDI
possible laboratory provides
optimization potentials its NDI
in theresults on the
existing causes difficulties regarding an efficient definition and
production
2212-8271 ©system,
2018 The it is important
Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison of different product families. Addressing this
Peer-review
2212-8271 ©under
2018responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the 12 CIRP Conference on Intelligent Computation in Manufacturing Engineering.
th

Peer-review under responsibility of the scientific committee of the 12th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
2212-8271©©2017
2212-8271 2019The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-reviewunder
Peer-review underresponsibility
responsibility
of of
thethe scientific
scientific committee
committee of the
of the 28th12th CIRP
CIRP Conference
Design on 2018.
Conference Intelligent Computation in Manufacturing Engineering.
10.1016/j.procir.2019.02.082
344 Tiziana Segreto et al. / Procedia CIRP 79 (2019) 343–348
T. Segreto et al. / Procedia CIRP 00 (2018) 000–000

improved RE and the UT data in a single user interface. In the surface and detect defects in a fast and effective manner [21,
implemented interface, the user can interactively visualize and 22]. Moreover, the UT NDI can be applied for the metrological
manipulate the 3D model generated by the RE laser-based characterization (e.g. thickness estimation) of a component.
method and at the same time inspect the internal material
structure of the CFRP component retrieving the corresponding 3.1. Laser-based RE system
UT information. Moreover, it is possible to inspect in more
details a presumable defect by directly selecting the The laser-based RE scanning system considered in this
corresponding area on the integrated model. paper is the VI 9i laser scanner by Konica Minolta (Fig. 2). It
offers different measurement ranges and performances
2. The aeronautical component (accuracy and precision) for three different interchangeable
lenses (tele, middle and wide) for the two selectable scan depth
The component considered for the inspection with the two distance as summarised in Table 1.
non-contact testing techniques is a carbon fibre reinforced In order to acquire the entire geometry of the aeronautical
polymer panel utilized in the aeronautical field consisting of CFRP component, the sample was positioned in two diverse
three sub-components (Fig. 1): positions: front and back side. The laser was placed at a scan
distance equal to 600 mm and a telephoto lens was utilized for
 the skin, that is the base panel with nominal dimensions the point cloud acquisition due to its high precision and
equal to 304.8 x 914.4 mm accuracy levels.
 two stringers with 5.7 x 914.8 mm nominal dimension. The surfaces of the CFRP aeronautical component were
acquired by performing 46 scans obtaining a highly dense point
Both the skin and the stringers are composed of CFRP cloud with over 12 million points.
prepreg plies made of CYCOM 977-2 epoxy matrix and Toray
T300 carbon fibres. In particular, the skin is a laminate
composed by 17 plies with the following symmetrical stacking
sequence [+45/90/02/-452/+45/0]s whereas the stringers are
constituted by laminates made of 11 plies symmetrically
disposed with the following fibres orientation [+45/90/0/-
45/0]s. On the top and bottom surfaces of each laminate, a thin
fibreglass ply is applied for corrosion protection.
(a) (b)
3. Non-contact testing systems
Fig.1. Geometrical model of the aeronautical CFRP component: (a) the skin
A reverse engineering system based on the use of a laser and (b) the stringer.
scanner and an ultrasonic non-destructive inspection technique
were utilized for the detection of the external geometry and the Table 1. The Konica Minolta laser scanner characteristics.
internal material structure of the CFRP component, Distance Tele Middle Wide
respectively. (mm) (mm) (mm) (mm)
RE procedures based on laser scanner are commonly Measurement 600 111x83x40 198×148×64 359×269×108
employed in the manufacturing sector for the acquisition of the range 1000 185×139×110 329×247×176 598×449×284
geometrical features of a component in order to obtain a 3D 600 ±0.008 ±0.016 ±0.032
digital model usable, e.g. for measurement and geometrical Precision
1000 ±0.024 ±0.048 ±0.096
inspection, product repair, remanufacturing, etc. [11-14]. 600 ±0.05 ±0.10 ±0.20
The functioning of a laser-based RE system is generally Accuracy
1000 ±0.10 ±0.20 ±0.40
based on the triangulation method: a laser stripe is projected
onto a surface and the reflected beam is detected by a camera
obtaining a point cloud of the external surfaces of the scanned
object [11]. The main advantages of this technique consist of
the high acquisition velocity and part integrity assurance (there
is no contact between the inspection probe and the part, thus
assuring its integrity) [15, 16].
On the other hand, ultrasonic non-destructive inspection is
the most utilized procedure in the industrial area for the quality
control of components capable of detecting surface, subsurface
and internal defects [17, 18]. This technique is based on the
measurement of the variations of the reflected and/or
transmitted UT energy generated by a piezoelectric transducer
[19, 20]. Based on the information carried out by the UT signal,
(a) (b)
diverse types of flaws (e.g. crack location, flaw size, fibre
orientation, etc.) could be achieved. The UT NDIs are capable Fig. 2. Laser-based RE system: (a) front and (b) back side position of the
to easily and rapidly inspect the part considering only one CFRP aeronautical component.
Tiziana Segreto et al. / Procedia CIRP 79 (2019) 343–348 345
T. Segreto et al. / Procedia CIRP 00 (2018) 000–000

3.2. UT NDI system 4.2. UT data pre-processing

The UT NDI system (Fig. 3) utilized for the acquisition of The volumetric UT file obtained during the UT scan
the internal material structure of the aeronautical CFRP procedure is constituted by the whole set of full digitized UT
component is developed at the Fraunhofer Joint Laboratory of waveforms for each material interrogation point.
Excellence on Advanced Production Technology, Naples, Italy For the UT data file pre-processing, a custom made
[20 - 22] and consists of: software (RoboTest© v.2.0, developed in LabVIEW©
environment) was utilized [23]. This software is capable to
 Oscillator/detector for the UT probe excitation and the provide single or multiple UT images of the internal structure
detection of the UT returning signals of the CFRP component under examination. The pre-
 Transmitter/receiver UT immersion probe processing phase starts with the selection of the typical UT
 Digital oscilloscope connected to the oscillator/detector and waveform represented with a diagram where the x axis
to PC corresponds to the time of flight expressed in seconds whereas
 6-axis robotic arm for the UT probe displacement the y axis corresponds to UT signal in Volt/div (Fig. 5).
 PC utilized for the UT waveform acquisition and processing
as well as the UT probe displacement control

A pulse-echo UT technique was utilized for the detection


of the entire UT waveform (full volume – FV) in the
propagation direction (z-direction) during x-y scanning of the
part surface [21]. The FV UT scan was executed in water using
an immersion UT probe with a frequency of 5 MHz and a
diameter of 4 mm covering an area of 100 mm x 300 mm with
a scan step equal to 1 mm. The UT data, obtained after the UT
scanning procedure, were stored in a volumetric file.

4. Pre-processing of the RE and UT data

The acquired RE point cloud and UT data were subjected to


a pre-processing phase in order to obtain data suitable for the
new software code development.

4.1. RE data pre-processing

As the output of the RE scanning process corresponds to Fig. 3. UT non-destructive inspection system [20].
multiple point clouds, the first step of the pre-processing phase
is a point set registration corresponding to the alignment of the
diverse acquired point clouds. Markers (red points in Figure 2)
were applied on the aeronautical CFRP component in order to
easily align the obtained multiple scans. After this step, a single
point cloud containing the x, y and z information of the part
surface was achieved.
This point cloud was then improved by using diverse tools:
deletion of the unnecessary points, point cloud filtering, noise
and overlap reduction aimed to reduce the high volume of the
(a)
obtained RE data.
The resulting pre-processed point cloud was used to
generate the STL file with a number of triangles over 2 million.
Generally, an STL file approximates a point cloud with
triangles defined by a perpendicular direction and three points
representing the vertices of the triangle in the 3D coordinate
system, obtaining the so-called “polygon mesh/polygonal
model/mesh”.
The obtained polygonal model of the CFRP component was
subjected to a repairing and optimization phase including
smoothing of the triangles, holes and gaps filling for the
reconstruction of the incomplete triangles, and polygon triangle (b)
reduction (Fig. 4).
Fig. 4. STL of the aeronautical CFRP component: view of (a) the stringers
and (b) the skin.
346 Tiziana Segreto et al. / Procedia CIRP 79 (2019) 343–348
T. Segreto et al. / Procedia CIRP 00 (2018) 000–000

equal sub-gates that will be utilized for the UT images


generation. The time axis represents the UT propagation in the
thickness direction of the CFRP component: in this way, each
sub-gate width describes the internal material structure of the
corresponding thickness portion of the CFRP component. In
Figure 5, three equal subdivisions of the UT signal are chosen
and the corresponding UT images are shown in Figure 6 where
Fig. 5. Typical UT waveform of the aeronautical CFRP component. each UT image (a, b, c) corresponds to 1/3 of sample thickness.

5. Integration of the UT and RE data

The integration between the UT and RE data was realized


through a new custom made software code development (Fig.
7) added to the previous described software “RoboTest©”.
Diverse steps are required for the software code
implementation and are summarized below:
(a)
1. STL file (obtained from the RE scanning procedure) origin
modification
2. STL 3D model import
3. Selection of the RE scanned point on the imported STL 3D
model and relative UT waveform reclaim from the UT data
file
4. UT image generation of the internal structure of the CFRP
component
(b) 5. Projecting and wrapping of the generated UT image on the
STL 3D model
6. Procedure iteration with the repetition of the steps 2, 3, 4
and 5.

5.1. STL file origin modification

In order to integrate the results obtained with the two diverse


non-contact testing systems, the RE and UT data need to have
(c)
the same origin in a unique 3D coordinate system. For this
Fig. 6. Three UT images of the material structure of the CFRP aeronautical reason, the origin of the STL file was translated and fixed into
component. Each UT image relates to 1/3 of the component nominal a corner of the CFRP aeronautical component and the x and y
thickness. axis were aligned to its two main borders following the same
alignment of the UT scan procedure. Therefore, a
By using a time gate subdivision (red lines), it is possible correspondence between the coordinates of the STL file and the
to divide the UT signal in a desired number (from 1 to 16) of coordinates of the UT scan points was established.

Fig. 7. STL 3D model import.


Tiziana Segreto et al. / Procedia CIRP 79 (2019) 343–348 347
T. Segreto et al. / Procedia CIRP 00 (2018) 000–000

5.2. STL import the aim to obtain the 3D digital model of the CFRP component.
The applied UT NDI procedure is based on a pulse-echo UT
The first task performed by the new software code is to scanning technique in water through the use of an immersion
import the STL file. A pop-up window opens asking the path UT probe. The UT data were utilized to inspect the internal
where the STL file is stored and in few seconds the 3D model structure of the CFRP component by visualizing the UT images
is shown in the appropriate window (Fig. 8). In this window, provided by the software.
an operator can visualize and manipulate the 3D model using
the interactive user interface.

5.3. RE point selection and UT waveform reclaim

By using a red marker, a user can choose and select a point


on the imported STL model and, considering its x and y
coordinates, retrieve the corresponding UT complete waveform
that will be plotted on a two-axis graph (Fig. 8).

5.4. UT image generation

As explained in sub-section 4.2, UT images can be


generated by a user selection of the time gates on the chosen
UT waveform.
Each pixel of the generated UT image has a grey tone value
proportional to the peak amplitude of the corresponding UT
waveform in that interrogation point. The overall grey tone Fig. 8. STL 3D model visualization.
scale ranges from 0 (black) to 255 (white), which are the
minimum and maximum limits of peak amplitude observed in
the set time-gate over all the scan points (Fig. 9) [21-22].

5.5. Integration of the RE and UT results

The integration of the RE and UT data is realized by


projecting and wrapping the generated UT image on the STL
model by matching the x and y coordinates of the scanned point
with the relative pixel of the UT image. Therefore, an
integrated 3D model is created containing both the 3D
geometrical representation (provided by the STL file) and the
UT information (Fig. 10).

5.6. Iteration of the integration procedure

The explained procedure can be reiterated selecting a new Fig. 9. UT image generation.
scan point on the STL model integrated with the previous
projected UT image (Fig. 10). This represents a huge advantage
for the user who can choose the new point directly by
visualizing the UT scan that allows to effectively highlight
possible component defects.

6. Conclusions

A new custom made software code was implemented for the


realization of a user interface operating for the complete quality
assessment of a CFRP aeronautical component.
Two diverse non-contact testing techniques, a laser-based
reverse engineering scanning method and an ultrasonic non-
destructive inspection technique, were considered for the
detection of the external geometry and the internal material
structure of the CFRP component, respectively.
The RE technique was based on the use of a laser scanner
employed for the acquisition of the geometrical features with Fig. 10. RE and UT integration interface.
348 Tiziana Segreto et al. / Procedia CIRP 79 (2019) 343–348
T. Segreto et al. / Procedia CIRP 00 (2018) 000–000

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2018;5/2:3690-3698.
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corresponding UT waveform. The UT information was used to assurance of lightweight material. Procedia CIRP 2017;66:259-264.
[10] Caggiano, A., Segreto, T., Teti, R., 2018, Cloud Manufacturing on-
generate UT images describing the internal structure of the demand services for holistic quality assurance of manufactured
CFRP component. components, Procedia CIRP 2017; 67: 144-149
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