Inspection of freeform surfaces considering uncertainties in measurement, localization and surface reconstruction

Abstract

Inspection of a manufactured freeform surface can be conducted by building its surface model and comparing this manufactured surface model with the ideal design surface model and its tolerance requirement. The manufactured freeform surface model is usually achieved by obtaining measurement points on the manufactured surface, transforming these measurement points from the measurement coordinate system to the design coordinate system through localization, and reconstructing the surface model using the localized measurement points. In this research, a method was developed to estimate the locations and their variances of any selected points on the reconstructed freeform surface considering different sources of uncertainties in measurement, localization and surface reconstruction processes. In this method, first locations and variances of the localized measurement points are calculated considering uncertainties of the measurement points and uncertainties introduced in the localization processes. Then locations and variances of points on the reconstructed freeform surface are obtained considering uncertainties of the localized measurement points and uncertainties introduced in the freeform surface reconstruction process. Two case studies were developed to demonstrate how these three different uncertainty sources influence the quality of the reconstructed freeform curve and freeform surface in inspection.