The Practical Verification of the Material Loss Detection Method for Cylindrical Shape Parts

Abstract

The Material Loss Detection Method for Cylindrical Shape parts (MLDMCS) was presented in the previous article. The verification of the method was executed on two different samples, manufactured from different materials and with different geometries. The main goal of research was to set the diameter tolerance for a detection process. The first sample was examined nine times with a modification of one parameter diameter tolerance. The results interpretation gives a possibility to check the proper set of data for future cylindrical shape examinations according to accuracy class of manufacturing. Preparation of the first sample was done in order to check: centricity of compared models, uniform material los detection mechanical friction worn, various distribution and shape of material loss, various depth of material loss. Second sample was prepared in order to check correct detection of material loss in case when element have a feature (like key slot), that is in a part but simultaneously it exist according to design. The main target is to recognize with the algorithm: what is, what is not and properly classify material loss. Furthermore second examination sample was damaged in a border area of the mentioned feature. The presented verification proves that is possible to apply the proposed MLDMCS in industry to support overhaul process of technical means. The important part of examination preparation is a set of a technological base that is used to fit together sample model (from 3D scanning) and the design pattern model (from CAD design). The main result is a material loss digital presentation, 3D and 2D simplified distribution. Groups of material loss can be assigned to specific areas in order to prepare refurbishing process turning surface layer before laser cladding is applied. The distribution map (2D and 3D) fully corresponds to material loss distribution on samples. Time of element examination with MLDMCS is strictly related to accuracy in angle division and axial division in distribution of singular volume. The verification proves that the 3rd generation of refurbishing process operation preparation is possible to put in to practice. However it has to be prepared with proper methods and equipment. The method should be applied especially in situation when an element is: refurbished in series, elements that are refurbished have similar design, elements characterizes with same accuracy class of manufacturing and similar diameters, but with various designs.