– Commercial Technologies for Maintenance Activities

Next Generation Inspection System (NGIS III)Next Generation Inspection System (NGIS III)

April 19, 2005

Jeffrey A. CalkinsManufacturing Resources Inc. (MRI)

2 – Commercial Technologies for Maintenance Activities

NGIS III Project Team

NCMS Program Manager: Bill Waddell

Technology Partners

End User: NADEP Cherry Point, NC

Other Industry and Government Participants

Solar TurbinesPhiladelphia Naval Foundry and Propeller CenterNIST

MANUFACTURINGRESOURCES, INC

Advanced Technology for Manufacturing

3 – Commercial Technologies for Maintenance Activities

NGIS III Objectives

Perform on-machine inspection and repairof turbine engine blades and impellers.

4 – Commercial Technologies for Maintenance Activities

NGIS III Objectives

Perform on-machine inspection and repairof turbine engine blades and impellers.

Dramatically reduce the amount of hand blending of airfoil surfacesunder repair. Achieve “near net shape” blend on airfoil surfaces.

Weld Areas

5 – Commercial Technologies for Maintenance Activities

NGIS III Objectives

Perform on-machine inspection and repairof 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

6 – Commercial Technologies for Maintenance Activities

NGIS III Objectives

Perform on-machine inspection and repairof 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 beadopted by other Depots and Industry users

7 – Commercial Technologies for Maintenance Activities

NGIS III Objectives

Perform on-machine inspection and repairof 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 beadopted by other Depots and Industry users

Lay groundwork for additional future capabilities (e.g integrate materialdeposition process within the cell to eliminate welding).

8 – Commercial Technologies for Maintenance Activities

NGIS III 5-Axis Cell

X

• 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)

Key Subsystems and Technology Providers

9 – Commercial Technologies for Maintenance Activities

NGIS III 5-Axis Cell

Z

Y

X

Z

3 Linear and 2 Rotary Axes (plus Rotary Tool Changer)

B

C

10 – Commercial Technologies for Maintenance Activities

NGIS III 5-Axis Cell

X

ScanningProbe andSpindle

Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis

11 – Commercial Technologies for Maintenance Activities

NGIS III Scanning Probe and Spindle

Spindle

ContactScanningProbe

Scanning Probe and Spindle are Mounted Concentrically on the B (Rotary) Axis

12 – Commercial Technologies for Maintenance Activities

NGIS III 5-Axis Cell

X BladeFixture

Blade and Impeller Fixtures are mounted on the C (Rotary) Axis

13 – Commercial Technologies for Maintenance Activities

Part Set-Up(once per P/N)

NGIS III Process Overview

AdaptivePart Probing

Part Probing

5-Axis Cell

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

DesignFixture

PartGeometry

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

14 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Part Probing

5-Axis Cell

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

15 – Commercial Technologies for Maintenance Activities

Scan Data From A Welded Impeller

16 – Commercial Technologies for Maintenance Activities

Detail of Scan Data From Welded Impeller

17 – Commercial Technologies for Maintenance Activities

Scan Data From A Welded Blade

Weld Areas

18 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Part Probing

5-Axis Cell

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

19 – Commercial Technologies for Maintenance Activities

Creating Blade Surface Model

1. Triangulate the set of points from scan data to convert it to a polygon mesh

2. Use volumetric polygon offset to account for the probe tip radius

3. Clean up the polygon mesh using RapidForm’s “polygon healing” toolset

Scan Processing Suite

20 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Part Probing

5-Axis Cell

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

21 – Commercial Technologies for Maintenance Activities

NC Tool Path For Blade Machining

Tool Path

22 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Part Probing

5-Axis Cell

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

23 – Commercial Technologies for Maintenance Activities

Machining the Weld Bead

NGIS III Tool Evaluation Study at MRI

Helical Burr Tool

24 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Part Probing

5-Axis Cell

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

25 – Commercial Technologies for Maintenance Activities

PartGeometry

Part Set-Up(once per P/N)

DesignFixture

NGIS III Process Overview

AdaptivePart Probing

Part Probing

5-Axis Cell

Probe To Verify

Final Benchand Inspection

Ship

Master or Model Part

Part Machining

Create SurfaceModel

NC Tool Path Generation(Unique to Part Undergoing

Repair)

Machine toNominal + .005”

26 – Commercial Technologies for Maintenance Activities

NGIS III Project Status (April, 2005)

Major Project Element Status

• 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

27 – Commercial Technologies for Maintenance Activities

• Crysta-Apex CMM• MP-100 Scanning Probe• MCOSMOS Software

Alternative Scanning Approach

Mitutoyo is providing equipment and technical support to develop analternative to the project’s original scanning approach

Evaluation work is under way with blade samples provided in March, 2005

Key Elements

28 – Commercial Technologies for Maintenance Activities

Industry Participant ContactsMANUFACTURINGRESOURCES, INC

Advanced Technology for Manufacturing

Mr. Jeff Calkins

E-mail: JCalkins@manufacturing-resources.com

Tel: 440-786-3390 X103Cell: 440-537-0311Fax: 440-786-9107

Website: www.manufacturing-resources.com

29 – Commercial Technologies for Maintenance Activities

Dr. Kam Lau

E-mail: kam.lau@apisensor.com

Tel: 301-330-8100Fax: 301-990-8648

Website: www.apisensor.com

Industry Participant Contacts

30 – Commercial Technologies for Maintenance Activities

Mr. Neal Kearney

E-mail: nkearney@deltatau.com

Tel: 818-717-5666

Website: www.deltatau.com

Industry Participant Contacts

31 – Commercial Technologies for Maintenance Activities

Mr. Tony Gable

E-mail: TonyG@gt-tech.net

Tel: 440-205-9195

Website: www.delcam.com

Industry Participant Contacts

32 – Commercial Technologies for Maintenance Activities

Mr. Tom Charron

E-mail: tomc@inustech.com

Tel: 408-232-5300Fax: 408-519-5766

Website: www.rapidform.com

Industry Participant Contacts

33 – Commercial Technologies for Maintenance Activities

Mr. Larry Maggiano

E-mail: Larry.Maggiano@mitutoyo.com

Tel: 626-961-9661 X4508Cell: 630-215-6920

Website: www.mitutoyo.com

Industry Participant Contacts