High Geometric Quality Research Articles

ЭКСПЕРИМЕНТАЛЬНЫЕ ИССЛЕДОВАНИЯ КОМБИНИРОВАННОГО ПРОЦЕССА ЭЛЕКТРОХИМИКОМЕХАНИЧЕСКОГО ПОЛИРОВАНИЯ

This article presents the results of experimental studies of the electrochemical mechanical polishing process, which combines anodic dissolution, possessing high localizing properties, with the dynamic effects of abrasive grains. The essence of the combined process is described, when, under the influence of operating voltage, a continuous electrochemical dissolution of the treated surface occurs with the formation of oxide films on it, followed by their removal together with the treated metal by means of abrasive grains quasi-fixed in the polishing pad. The description and conditions of the conducted experiments are given. The influence of the weight content of the abrasive in the composition of the electrolyte-abrasive mixture on the removal of metal and the roughness of the treated surface is shown. The impact on the course of the combined process of the frequency of rotation of the polishing pad and the pressure of the workpiece on it is noted. At optimal values of the studied parameters, electrochemical-mechanical polishing makes it possible to ensure high geometric quality of the treated surface and high process productivity.

A simulation-based approach for assessment of injection moulded part quality made of recycled olefins

To produce plastic parts of high geometrical quality and dimensional stability through injection moulding process there are several key variables that must be considered. These include processing parameters such as packing time, cooling time, packing pressure, melt temperature, mould temperature and the intrinsic melt flow characteristics of polymeric materials used to produce the part. The challenge of producing high quality part is further compounded if the input polymer material is of reclaimed waste streams with inherent inconsistency in their nature. In this work, significant number of simulation-based studies are conducted using Autodesk Moldflow software to delineate the contributing issues pertinent to the part quality and achieve topological optimization by reducing critical parameters of shrinkage and warpage while ensuring overall cycle time viable for industrial production rates. Key simulation variables were obtained through experimental characterization of flow and thermal properties of the recycled olefin plastics. Different gate locations were simulated, and the best gate locations were selected for a two-gate system. These gates were provided with gate valve controllers for controlling the polymer flow to create cascaded injection moulding scenarios. Such scenarios were iterated with the objective of reducing the pressure required for cavity filling and thereby reducing the clamp force required. Optimized melt and mold temperatures of 245 °C, 20 °C were used for all the simulations performed. The result obtained from the most optimized simulation showed an average cycle time of 10.42 secs, volumetric shrinkage of 5.08%, warpage of 1.05 mm and clamp force of 79.81 tonne would be required to produce a part of 200 mm*100 mm*1.5 mm dimensions. Following a cascaded injection setup, it was shown that the clamp force could be reduced by 60.57%.

Research of adapted tool Design in Cold Forging of gears

In the drive and transmission technology, gears rank among the most frequently used machine elements in modern automotive and mechanical engineering. Gears are conventionally produced by cutting processes, as high geometrical quality standards are hereby ensured. With regard to economic and ecological aspects, cold forging represents a promising alternative for producing highly-loadable gears. An extrusion process for manufacturing spur and helical gears is the so-called “Samanta”-process. Compared to standard extrusion processes, an additional ejector system is avoidable. Thus, in particular for helical gears, the gear quality is not affected by the ejection operation. Furthermore, the process chain during the component production cycle is shortened which leads to a more efficient production. The achievable gear accuracy as well as insufficient tool life are major challenges while establishing the “Samanta”-process in industry. To enable an industrial application, deeper process understanding along with knowledge about the influences on the process results is required. In this context, the aim of this research work is to numerically investigate influences of tool-sided approaches within cold forging of spur and helical gears by the “Samanta”-process. Based on experimental results, FE-Models for both gearing types will be validated. Using the numerical models, the impact of geometrical adaptions in the forming zone of the applied dies on the resulting component and process properties will be investigated. These findings are intended to derive an effects matrix and respective practical recommendations regarding a further improvement of the process results within cold forging of gears by the “Samanta” principle. Furthermore, the identified findings are principally transferable to conventionally forward extrusion process for producing gears. The results reveal that the influence of the adapted gear areas of the tools is purposefully usable. As a consequence, the resulting component and process properties can be positively influenced for both types of gearing. The verification of the numerical findings in experimental forming tests promises great potential for applying the “Samanta”-process in industry.

Parameters determination and sensor correction method based on virtual CMOS with distortion for the GaoFen6 WFV camera

The GaoFen6 (GF6) satellite is an optical remote sensing satellite in China’s GaoFen series that combines the imaging abilities of high resolution and wide field of view (WFV). The WFV camera, equipped on the GF6, can obtain an image 800 km in width and with a resolution of 16 m, which represents the highest level of observation swath width among similar satellites in the world. Guaranteeing the high geometric quality of the imagery obtained by the WFV camera for subsequent remote sensing applications is a prominent problem that must be solved. This paper presents the key geometry processing method for the WFV camera, in which the parameters relative determination method based on two selected reference bands and the sensor correction based on virtual collinear complementary metal oxide semiconductor (CMOS) with distortion are proposed. To overcome the challenge of matching the tie points between different bands with large radiation differences, two bands—rather than traditional one band—were chosen as the reference bands for the WFV camera to perform the parameters relative determination. The geometric influence of the virtual CMOS is fully analyzed in the along- and across-track directions. Then, the virtual CMOS with a real calibrated distortion was designed; based on this design, a sensor correction was applied to stitch the whole image generated by single images in each band. This experiment verified the effectiveness of the proposed parameters relative determination and sensor correction methods in improving the internal relative accuracy and the registration accuracy; moreover, the mosaicking accuracy is also guaranteed.

Implicit 3D Modeling of Ore Body from Geological Boreholes Data Using Hermite Radial Basis Functions

Modeling ore body in 3D is the basis of digital intelligent mining. However, most existing three-dimensional mining software uses the contour approach that requires too much man–machine interaction and difficult partial updating. Moreover, accounting for uncertainty and low geometric quality picking is very difficult in the direct contour approach. Therefore, an implicit modeling approach to automatically build the three-dimensional model for ore body by means of spatial interpolation directly based on the geological borehole data with Hermite radial basis function (HRBF) algorithm as the core is proposed. Furthermore, in order to solve the problems of weak continuity of models due to the long-distance original boreholes as well as the boundary-point normal solution error, the densification of original borehole data with the virtual borehole as well as the calculation of point-cloud normal direction based on the adjacent hole-drilling method is proposed. The verification of two mine engineering projects and comparison with the explicit modeling results show that this approach could realize the automatic building of three-dimensional models for the ore body with high geometric quality, timely update and accurate results.

GEOMETRIC QUALITY ASSESSMENT OF LIDAR DATA BASED ON SWATH OVERLAP

This paper provides guidelines on quantifying the relative horizontal and vertical errors observed between conjugate features in the overlapping regions of lidar data. The quantification of these errors is important because their presence quantifies the geometric quality of the data. A data set can be said to have good geometric quality if measurements of identical features, regardless of their position or orientation, yield identical results. Good geometric quality indicates that the data are produced using sensor models that are working as they are mathematically designed, and data acquisition processes are not introducing any unforeseen distortion in the data. High geometric quality also leads to high geolocation accuracy of the data when the data acquisition process includes coupling the sensor with geopositioning systems. Current specifications (e.g. Heidemann 2014) do not provide adequate means to quantitatively measure these errors, even though they are required to be reported. Current accuracy measurement and reporting practices followed in the industry and as recommended by data specification documents also potentially underestimate the inter-swath errors, including the presence of systematic errors in lidar data. Hence they pose a risk to the user in terms of data acceptance (i.e. a higher potential for Type II error indicating risk of accepting potentially unsuitable data). For example, if the overlap area is too small or if the sampled locations are close to the center of overlap, or if the errors are sampled in flat regions when there are residual pitch errors in the data, the resultant Root Mean Square Differences (RMSD) can still be small. To avoid this, the following are suggested to be used as criteria for defining the inter-swath quality of data: <br><br> a) Median Discrepancy Angle <br><br> b) Mean and RMSD of Horizontal Errors using DQM measured on sloping surfaces <br><br> c) RMSD for sampled locations from flat areas (defined as areas with less than 5 degrees of slope) <br><br> It is suggested that 4000-5000 points are uniformly sampled in the overlapping regions of the point cloud, and depending on the surface roughness, to measure the discrepancy between swaths. Care must be taken to sample only areas of single return points only. Point-to-Plane distance based data quality measures are determined for each sample point. These measurements are used to determine the above mentioned parameters. This paper details the measurements and analysis of measurements required to determine these metrics, i.e. Discrepancy Angle, Mean and RMSD of errors in flat regions and horizontal errors obtained using measurements extracted from sloping regions (slope greater than 10 degrees). The research is a result of an ad-hoc joint working group of the US Geological Survey and the American Society for Photogrammetry and Remote Sensing (ASPRS) Airborne Lidar Committee.

GEOMETRIC QUALITY ASSESSMENT OF LIDAR DATA BASED ON SWATH OVERLAP

Abstract. This paper provides guidelines on quantifying the relative horizontal and vertical errors observed between conjugate features in the overlapping regions of lidar data. The quantification of these errors is important because their presence quantifies the geometric quality of the data. A data set can be said to have good geometric quality if measurements of identical features, regardless of their position or orientation, yield identical results. Good geometric quality indicates that the data are produced using sensor models that are working as they are mathematically designed, and data acquisition processes are not introducing any unforeseen distortion in the data. High geometric quality also leads to high geolocation accuracy of the data when the data acquisition process includes coupling the sensor with geopositioning systems. Current specifications (e.g. Heidemann 2014) do not provide adequate means to quantitatively measure these errors, even though they are required to be reported. Current accuracy measurement and reporting practices followed in the industry and as recommended by data specification documents also potentially underestimate the inter-swath errors, including the presence of systematic errors in lidar data. Hence they pose a risk to the user in terms of data acceptance (i.e. a higher potential for Type II error indicating risk of accepting potentially unsuitable data). For example, if the overlap area is too small or if the sampled locations are close to the center of overlap, or if the errors are sampled in flat regions when there are residual pitch errors in the data, the resultant Root Mean Square Differences (RMSD) can still be small. To avoid this, the following are suggested to be used as criteria for defining the inter-swath quality of data: a) Median Discrepancy Angle b) Mean and RMSD of Horizontal Errors using DQM measured on sloping surfaces c) RMSD for sampled locations from flat areas (defined as areas with less than 5 degrees of slope) It is suggested that 4000-5000 points are uniformly sampled in the overlapping regions of the point cloud, and depending on the surface roughness, to measure the discrepancy between swaths. Care must be taken to sample only areas of single return points only. Point-to-Plane distance based data quality measures are determined for each sample point. These measurements are used to determine the above mentioned parameters. This paper details the measurements and analysis of measurements required to determine these metrics, i.e. Discrepancy Angle, Mean and RMSD of errors in flat regions and horizontal errors obtained using measurements extracted from sloping regions (slope greater than 10 degrees). The research is a result of an ad-hoc joint working group of the US Geological Survey and the American Society for Photogrammetry and Remote Sensing (ASPRS) Airborne Lidar Committee.

Calibration of a catadioptric omnidirectional vision system with conic mirror

Omnidirectional vision systems that enable 360° imaging have been widely used in several research areas, including close-range photogrammetry, which allows the accurate 3D measurement of objects. To achieve accurate results in Photogrammetric applications, it is necessary to model and calibrate these systems. The major contribution of this paper relates to the rigorous geometric modeling and calibration of a catadioptric, omnidirectional vision system that is composed of a wide-angle lens camera and a conic mirror. The indirect orientation of the omnidirectional images can also be estimated using this rigorous mathematical model. When calibrating the system, which is composed of a wide-angle camera and a conic mirror, misalignment of the conical mirror axis with respect to the camera’s optical axis is a critical problem that must be considered in mathematical models. The interior calibration technique developed in this paper encompasses the following steps: wide-angle camera calibration; conic mirror modeling; and estimation of the transformation parameters between the camera and conic mirror reference systems. The main advantage of the developed technique is that it does not require accurate physical alignment between the camera and conic mirror axis. The exterior orientation is based on the properties of the conic mirror reflection. Experiments were conducted with images collected from a calibration field, and the results verified that the catadioptric omnidirectional system allows for the generation of ground coordinates with high geometric quality, provided that rigorous photogrammetric processes are applied.

Hexahedral mesh re-parameterization from aligned base-complex

Recently, generating a high quality all-hex mesh of a given volume has gained much attention. However, little, if any, effort has been put into the optimization of the hex-mesh structure, which is equally important to the local element quality of a hex-mesh that may influence the performance and accuracy of subsequent computations. In this paper, we present a first and complete pipeline to optimize the global structure of a hex-mesh. Specifically, we first extract the base-complex of a hex-mesh and study the misalignments among its singularities by adapting the previously introduced hexahedral sheets to the base-complex. Second, we identify the valid removal base-complex sheets from the base-complex that contain misaligned singularities. We then propose an effective algorithm to remove these valid removal sheets in order. Finally, we present a structure-aware optimization strategy to improve the geometric quality of the resulting hex-mesh after fixing the misalignments. Our experimental results demonstrate that our pipeline can significantly reduce the number of components of a variety of hex-meshes generated by state-of-the-art methods, while maintaining high geometric quality.

Characterisation of current and future GNSS performance in urban canyons using a high quality 3-D urban model of Melbourne, Australia

Global Navigation Satellite System (GNSS) is a critical space-borne geospatial infrastructure providing essential positioning supports to a range of location-sensitive applications. GNSS is currently dominated by the US Global Positioning System (GPS) constellation. The next generation GNSS is expected to offer more satellites, better positioning provision, and improved availability and continuity of navigation support. However, GNSS performance in 3-D urban environments is problematic because GNSS signals are either completely blocked or severely degraded by high-rising geographic features like buildings. The aim of this study is to gain an in-depth understanding of the changing spatial patterns of GNSS performance, measured by the number of visible satellites (NVS) and position dilution-of-precision (PDOP), in the urban canyons of Melbourne, Australia. The methodology used includes the following steps: (1) determination of the dynamic orbital positions of current and future GNSS satellites; (2) development of a 3-D urban model of high geometric quality for Melbourne Central Business District (CBD); (3) evaluation of GNSS performance for every specified location in the urban canyons; and (4) visualisation and characterisation of the dynamic spatial patterns of GNSS performances in the urban canyons. As expected, the study shows that the integration of the GPS and Galileo constellations results in higher availability and stronger geometry, leading to significant improvement of GNSS performance in urban canyons of Melbourne CBD. Some conclusions are drawn and further research currently undertaken is also outlined.

Triangulation of p-Order Parametric Surfaces

The generation of triangulations on p-order parametric surfaces is a fundamental first step to numerical solutions for multidomain problems involving complex geometries such as those encountered in biological fluid dynamics and other applications. In this study we develop a novel, computationally efficient method for generating triangulations in computational space, which, under parametric mapping, are of high geometric quality. Computational efficiency is maintained over parametric orders (p) through approximating the parametric surface by a grid of simplified vector functions. Unlike other length metric approximations, a maximum bound on the error introduced to the calculation of lengths by this approximation is defined to ensure the fidelity of the transformation. This technique is applied to three parametric functions which demonstrate its robustness in handling high mesh distortions, singularities, and high order surfaces. Further, three complex high-order biological finite element meshes are triangulated. High mesh quality and a linear relationship between triangle generation and CPU time is observed for each of these meshes.

Variation Simulation of Sheet Metal Assemblies Using the Method of Influence Coefficients With Contact Modeling

Sheet metal assembly is a common assembly process for several products such as automobiles and airplanes. Since all manufacturing processes are affected by variation, and products need to have a high geometric quality, geometry-related production problems must be analyzed during early design phases. This paper discusses two methods of performing this analysis. One way of performing the simulations relatively fast is to establish linear relationships between part deviation and assembly springback deviation by using the method of influence coefficient (MIC). However, this method does not consider contact between the parts. This means that the parts are allowed to penetrate each other which can affect the accuracy of the simulation result. This paper presents a simple contact modeling technique that can be implemented in to MIC to avoid penetrations. The contact modeling consists of a contact detection and a contact equilibrium search algorithm. When implemented, MIC still only requires two finite element analysis (FEA) calculations. This paper describes the steps in the contact algorithm and how it can be used in MIC, and finally the proposed contact modeling is verified by comparing the simulation result with commercial FEA software ABAQUS contact algorithm.

Inflight calibration of IRS-1C imaging geometry for data products

The Indian remote sensing satellite IRS-1C was launched in December 1995. Since June 1996 various data products have been operationally available from National Remote Sensing Agency in India. They are available through various international ground stations of EOSAT in other parts of the world. Knowledge of camera geometry as well as inter-camera alignment is critical to the operational generation of data products with high geometric quality. The imaging geometry is derived from measurements carried out on the spacecraft during the qualification stage. However, it was felt that there is a need to re-establish the IRS-1C imaging geometry from image data itself. This was successfully carried out during the initial phase of IRS-1C operations. Significant improvement in geometric quality of data products is achieved as a result of the procedures reported in this paper.

An Analysis of LANDSAT-4 Thematic Mapper Geometric Properties

Landsat-4 Thematic Mapper data of Washington, DC, Harrisburg, PA, and Salton Sea, CA were analyzed to determine geometric integrity and conformity of the data to known Earth surface geometry. Several tests were performed. Intraband correlation and interband registration were investigated. No problems were observed in the intraband analysis, and aside from indications of slight misregistration between bands of the primary versus bands of the secondary focal planes, interband registration was well within the specified tolerances. A substantial number of ground control points were found and used to check the images' conformity to the Space Oblique Mercator (SOM) projection of their respective areas. The means of the residual offsets, which included nonprocessing related measurement errors, were close to the one pixel level in the two scenes examined. The Harrisburg scene residual mean was 28.38 m (0.95 pixels) with a standard deviation of 19.82 m (0.66 pixels), while the mean and standard deviation for the Salton Sea scene were 40.46 (1.35 pixels) and 30.57 m (1.02 pixels), respectively. Overall, the data were judged to be a high geometric quality with errors close to those targeted by the TM sensor design specifications.