Abstract
Fringe projection profilometry in combination with other optical measuring technologies has established itself over the last decades as an essential complement to conventional, tactile measuring devices. The non-contact, holistic reconstruction of complex geometries within fractions of a second in conjunction with the lightweight and transportable sensor design open up many fields of application in production metrology. Furthermore, triangulation-based measuring principles feature good scalability, which has led to 3D scanners for various scale ranges. Innovative and modern production processes, such as sheet-bulk metal forming, thus, utilize fringe projection profilometry in many respects to monitor the process, quantify possible wear and improve production technology. Therefore, it is essential to identify the appropriate 3D scanner for each application and to properly evaluate the acquired data. Through precise knowledge of the measurement volume and the relative uncertainty with respect to the specimen and scanner position, adapted measurement strategies and integrated production concepts can be realized. Although there are extensive industrial standards and guidelines for the quantification of sensor performance, evaluation and tolerancing is mainly global and can, therefore, neither provide assistance in the correct, application-specific positioning and alignment of the sensor nor reflect the local characteristics within the measuring volume. Therefore, this article compares fringe projection systems across various scale ranges by positioning and scanning a calibrated sphere in a high resolution grid.
Highlights
The demand for new resource-saving production methods drives the development of new technologies [1]
The scalability of fringe projection profilometry in particular enables this measurement technology to be used in a wide range of applications in production metrology and quality assurance
A wide variety of commercial sensors have positioned themselves on the market in recent years, which are of particular importance for highly innovative manufacturing technologies, such as sheet-bulk metal forming
Summary
The demand for new resource-saving production methods drives the development of new technologies [1]. As an example of such a process, a stage sequence for the production of a component with internal and external gearing is shown in Figure 1 [5]. In this process, a cup is first deep-drawn from a 4 mm wide round blank. The semi-finished material used is a low-alloy steel DC04 (St14) with material number 1.0338 in a nominal sheet thickness of 2 mm which is supplied by Salzgitter Flachstahl GmbH (Salzgitter, Germany) This material has a purely ferritic microstructure and is often used in the cold-rolled condition for the forming of inner and outer car body components, and for elements in the household appliance industry. An internal gearing is ironed and calibrated This process serves to explore and extend the limits of the technology SBMF. Achievable geometrical, topographical, and mechanical properties for the production of process component 1 were studied and analyzed in detail by
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