An automated reverse engineering process is developed that uses a structured light optical measurement system to collect dense point cloud geometry representations. The modeling process is automated through integration of software for point cloud processing, reverse engineering, solid model creation, grid generation, and structural solution. Process uncertainties are quantified on a calibration block and demonstrated on an academic transonic integrally bladed rotor. These uncertainties are propagated through physics-based models to assess impacts on predicted modal and mistuned forced response. Process details are discussed and recommendations made on reducing uncertainty. Reverse engineered parts averaged a deviation of 0.0002 in. (5 μm) which did not significantly impact low and midrange frequency responses. High frequency modes were found to be sensitive to these uncertainties demonstrating the need for future refinement of reverse engineering processes.
Uncertainties of an Automated Optical 3D Geometry Measurement, Modeling, and Analysis Process for Mistuned Integrally Bladed Rotor Reverse Engineering
Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received June 19, 2013; final manuscript received July 9, 2013; published online September 6, 2013. Editor: David Wisler.
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Kaszynski, A. A., Beck, J. A., and Brown, J. M. (September 6, 2013). "Uncertainties of an Automated Optical 3D Geometry Measurement, Modeling, and Analysis Process for Mistuned Integrally Bladed Rotor Reverse Engineering." ASME. J. Eng. Gas Turbines Power. October 2013; 135(10): 102504. https://doi.org/10.1115/1.4025000
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