In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection

Publikation: Beitrag in Buch/Bericht/Sammelwerk/KonferenzbandAufsatz in KonferenzbandForschungPeer-Review

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OriginalspracheEnglisch
Titel des SammelwerksAchievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022
Herausgeber/-innenGabriela Vincze, Frédéric Barlat
Seiten1211-1220
Seitenumfang10
PublikationsstatusVeröffentlicht - 2022
Veranstaltung25th International Conference on Material Forming, ESAFORM 2022 - Braga, Portugal
Dauer: 27 Apr. 202229 Apr. 2022

Publikationsreihe

NameKey Engineering Materials
Band926 KEM
ISSN (Print)1013-9826
ISSN (elektronisch)1662-9795

Abstract

According to the current state of the art, wear conditions of forging dies are assessed visually in the dismantled state, as there is no measuring procedure available for inline wear measurement of hot forging dies. This paper introduces a handling concept for automated loading and in-situ tool inspection for a hot forging process. An industrial robot with a quick-change system mounted on its endeffector is utilized to integrate both, a high-temperature gripper and an endoscopic 3D-measurement sensor. By adapting the measuring method of fringe projection to an endoscopic design, the measuring system can be navigated into the difficult-to-access geometry of the forge and take high-precision 3D-measurements of the forging die. The ambient air heated by the forming process creates an inhomogeneous refractive index field around the measuring system and the hot die, which deflects the light during the measurement and deteriorates the overall accuracy of the reconstructed point cloud. This can lead to strong deviations in the reconstructed point clouds and the functional geometries calculated from them. Using a compressed air actuator, the measuring system can be protected from the heat effects of the measuring object, as well as from dirt. Furthermore, the effect of the inhomogeneous refractive index field can be significantly reduced. With this approach the in-situ wear measurement at highly stressed regions using the example of the mandrel radius and the flash radius will be demonstrated. These functional elements are of particular interest, as the thermal stress is high and large material flow takes place. For the wear determination, the functional elements of the tool are examined in detail by fitting geometrical features into the reconstructed point clouds and determining the deviations from a reference geometry. In addition, the measurement data is validated with the aid of a commercially available state-of-the-art measurement system.

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In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection. / Middendorf, Philipp; Rothgänger, Marcel; Peddinghaus, Julius et al.
Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022. Hrsg. / Gabriela Vincze; Frédéric Barlat. 2022. S. 1211-1220 (Key Engineering Materials; Band 926 KEM).

Publikation: Beitrag in Buch/Bericht/Sammelwerk/KonferenzbandAufsatz in KonferenzbandForschungPeer-Review

Middendorf, P, Rothgänger, M, Peddinghaus, J, Brunotte, K, Uhe, J, Behrens, BA, Quentin, L, Kästner, M & Reithmeier, E 2022, In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection. in G Vincze & F Barlat (Hrsg.), Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022. Key Engineering Materials, Bd. 926 KEM, S. 1211-1220, 25th International Conference on Material Forming, ESAFORM 2022, Braga, Portugal, 27 Apr. 2022. https://doi.org/10.4028/p-k81788
Middendorf, P., Rothgänger, M., Peddinghaus, J., Brunotte, K., Uhe, J., Behrens, B. A., Quentin, L., Kästner, M., & Reithmeier, E. (2022). In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection. In G. Vincze, & F. Barlat (Hrsg.), Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022 (S. 1211-1220). (Key Engineering Materials; Band 926 KEM). https://doi.org/10.4028/p-k81788
Middendorf P, Rothgänger M, Peddinghaus J, Brunotte K, Uhe J, Behrens BA et al. In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection. in Vincze G, Barlat F, Hrsg., Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022. 2022. S. 1211-1220. (Key Engineering Materials). Epub 2022 Jul 22. doi: 10.4028/p-k81788
Middendorf, Philipp ; Rothgänger, Marcel ; Peddinghaus, Julius et al. / In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection. Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022. Hrsg. / Gabriela Vincze ; Frédéric Barlat. 2022. S. 1211-1220 (Key Engineering Materials).
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T1 - In-Situ Wear Measurement of Hot Forging Dies Using Robot Aided Endoscopic Fringe Projection

AU - Middendorf, Philipp

AU - Rothgänger, Marcel

AU - Peddinghaus, Julius

AU - Brunotte, Kai

AU - Uhe, Johanna

AU - Behrens, Bernd Arno

AU - Quentin, Lorenz

AU - Kästner, Markus

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PY - 2022

Y1 - 2022

N2 - According to the current state of the art, wear conditions of forging dies are assessed visually in the dismantled state, as there is no measuring procedure available for inline wear measurement of hot forging dies. This paper introduces a handling concept for automated loading and in-situ tool inspection for a hot forging process. An industrial robot with a quick-change system mounted on its endeffector is utilized to integrate both, a high-temperature gripper and an endoscopic 3D-measurement sensor. By adapting the measuring method of fringe projection to an endoscopic design, the measuring system can be navigated into the difficult-to-access geometry of the forge and take high-precision 3D-measurements of the forging die. The ambient air heated by the forming process creates an inhomogeneous refractive index field around the measuring system and the hot die, which deflects the light during the measurement and deteriorates the overall accuracy of the reconstructed point cloud. This can lead to strong deviations in the reconstructed point clouds and the functional geometries calculated from them. Using a compressed air actuator, the measuring system can be protected from the heat effects of the measuring object, as well as from dirt. Furthermore, the effect of the inhomogeneous refractive index field can be significantly reduced. With this approach the in-situ wear measurement at highly stressed regions using the example of the mandrel radius and the flash radius will be demonstrated. These functional elements are of particular interest, as the thermal stress is high and large material flow takes place. For the wear determination, the functional elements of the tool are examined in detail by fitting geometrical features into the reconstructed point clouds and determining the deviations from a reference geometry. In addition, the measurement data is validated with the aid of a commercially available state-of-the-art measurement system.

AB - According to the current state of the art, wear conditions of forging dies are assessed visually in the dismantled state, as there is no measuring procedure available for inline wear measurement of hot forging dies. This paper introduces a handling concept for automated loading and in-situ tool inspection for a hot forging process. An industrial robot with a quick-change system mounted on its endeffector is utilized to integrate both, a high-temperature gripper and an endoscopic 3D-measurement sensor. By adapting the measuring method of fringe projection to an endoscopic design, the measuring system can be navigated into the difficult-to-access geometry of the forge and take high-precision 3D-measurements of the forging die. The ambient air heated by the forming process creates an inhomogeneous refractive index field around the measuring system and the hot die, which deflects the light during the measurement and deteriorates the overall accuracy of the reconstructed point cloud. This can lead to strong deviations in the reconstructed point clouds and the functional geometries calculated from them. Using a compressed air actuator, the measuring system can be protected from the heat effects of the measuring object, as well as from dirt. Furthermore, the effect of the inhomogeneous refractive index field can be significantly reduced. With this approach the in-situ wear measurement at highly stressed regions using the example of the mandrel radius and the flash radius will be demonstrated. These functional elements are of particular interest, as the thermal stress is high and large material flow takes place. For the wear determination, the functional elements of the tool are examined in detail by fitting geometrical features into the reconstructed point clouds and determining the deviations from a reference geometry. In addition, the measurement data is validated with the aid of a commercially available state-of-the-art measurement system.

KW - Endoscopic Inspection

KW - Fringe Projection

KW - Hot Forging Dies

KW - Wear Monitoring

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DO - 10.4028/p-k81788

M3 - Conference contribution

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T3 - Key Engineering Materials

SP - 1211

EP - 1220

BT - Achievements and Trends in Material Forming- Peer-reviewed extended papers selected from the 25th International Conference on Material Forming, ESAFORM 2022

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ER -

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