General application of rapid 3-D digitizing and tool path generation for complex shapes
A system for automatic tool path generation was developed at Sandia National Laboratories for finish machining operations. The system consists of a commercially available 5-axis milling machine controlled by Sandia developed software. This system was used to remove overspray on cast turbine blades. A laser-based, structured-light sensor, mounted on a tool holder, is used to collect 3D data points around the surface of the turbine blade. Using the digitized model of the blade, a tool path is generated which will drive a 0.375 inch grinding pin around the tip of the blade. A fuzzified digital filter was developed to properly eliminate false sensor readings caused by burrs, holes and overspray. The digital filter was found to successfully generate the correct tool path for a blade with intentionally scanned holes and defects. The fuzzified filter improved the computation efficiency by a factor of 25. For application to general parts, an adaptive scanning algorithm was developed and presented with simulation and experimental results. A right pyramid and an ellipsoid were scanned successfully with the adaptive algorithm in simulation studies. In actual experiments, a nose cone and a turbine blade were successfully scanned. A complex shaped turbine blade was successfully scanned and finished machined using these algorithms.
- Research Organization:
- Sandia National Labs., Albuquerque, NM (United States)
- Sponsoring Organization:
- USDOE, Washington, DC (United States)
- DOE Contract Number:
- AC04-94AL85000
- OSTI ID:
- 532613
- Report Number(s):
- SAND--97-2325; ON: DE98000068; BR: YN010000000
- Country of Publication:
- United States
- Language:
- English
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