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Wednesday, September 30, 2009Day 2: Software & Analysis8:00 a.m. - 8:45 a.m. Check-in/Registration & Continental Breakfast8:45 a.m. - 9:00 a.m. Welcome9:00 a.m. - 9:40 a.m. Non-contact Honeycomb InspectionTim Shinbara Jr., Northrop GrummanHoneycomb core has become more prevalent within aerospace manufacturing as weight continues to be minimized without impact to structural integrity. As honeycomb core increases its presence within the air vehicle that are demanding higher contoured machining requirements with subsequent inspection. Current probing processes used during honeycomb core inspections create potentials for deforming the core, increasing the time of inspections and compensating for tip diameter (reducing the accuracy). Leveraging advances in optical systems may allow for a non-contact core inspection solution. In cooperation with Twin Coast Metrology and Verisurf, Northrop Grumman intends to present a comparative analysis of inspecting machined, contoured honeycomb core with a touch probe against Twin Coast Metrology's advanced optical system solution. 9:40 a.m. - 9:50 a.m. Break9:50 a.m. - 10:30 a.m. 21st Century Math Engine Identifies the Real Problem: The Cost of Currently Unreliable Data Analysis TechniquesMichael Garvey, M-7 Technologies and Ingobert Schmadel, Inora TechnologiesThe biggest obstacle to cutting cost and optimizing manufacturing processes in the 21st century is inadequate computer intelligence! A state of the art aircraft still carries too much shimming material, because of poor manufacturing accuracy. This paper will address two major issues and present a holistic, state of the art computer intelligence solution to the problem. Using computer intelligence that is capable of automatic and accurate Unexpected Deviation Detection (UDD) handling will lead to datum invariant, repeatable and consistent results, as a 21st century manufacturer would expect. 10:30 a.m. - 10:40 a.m. Break10:40 a.m. - 11:30 a.m. Dense 3D Scan Point Cloud Processing Software ReviewMichael Raphael, Direct DimensionsWith the advent of higher powered 3D scanners comes the challenge of dealing with the dense point cloud data sets. Direct Dimensions uses a wide variety of 3D scanning equipment to capture the as-built shape of existing objects. The common problem with all of these projects is the need to process the point cloud data. While applications fall generally into either reverse engineering and inspection, both directions present challenges for processing the large data sets efficiently, quickly, and properly. This presentation will focus on an overview of the software tools available commercially that address these problems with a comparison of the various workflows, strategies, and results that one can expect from the various solutions. 11:30 a.m. - 1:30 p.m. Lunch on Show Floor & Visit Exhibits1:30 p.m. - 2:10 p.m. A Process to Reduce Maintenance and Retro Fitting Design Time using Portable 3D ScanningChengChih Lin, Perceptron and Muhammad Ahmed, Eastern Michigan University3D digital scanning plays an essential role in numerous aspects of commercial and non-commercial airplane design and manufacturing. From digital archiving to retrofitting, advanced 3D scanning and CAD helps reduce maintenance time and improve core design. However, when the design process includes small parts or components which require precision and interactions/ assembly with other materials, raw scan data alone is not sufficient to ensure superior quality standards. In recent years, several portable 3D laser scanning solutions have been created to meet comprehensive design and manufacturing needs. These systems come with all hardware & software components needed to capture, store, and process 3D data. The user of this type of system ensure that point cloud data captured by the PCMM is efficiently processed, stored, and accessible by an organization's third party point cloud handling software. The application of this new technology ranges from installing new apparatus and gages on the dash panels, to rearranging and modifying the seating. With the capability to produce supplemental 3D surface data in aircraft coordinate systems, laser scanning solutions have shown to help stacking issues, sub-assemblies and custom corporate interiors designs for regional airliners, business aircraft and helicopters. Advancements in software algorithm development allow 3D scanning solutions to provide superior flexibility, accuracy, portability and usability compared to conventional technologies. This paper proposes the recommended process for complex retro fittings and modifications using latest 3D scanning solutions. 2:10 p.m. - 2:20 p.m. Break2:20 p.m. - 3:00 p.m. Cessna Caravan Case Study: Reverse EngineeringTom Kinnare & Ray Ryan, East Coast MetrologyIn an effort to increase the performance capabilities of the Cessna Caravan, engineers asked for assistance in the reconfiguration of the Cessna Caravan power plant. The project goal was to take the current configuration of the aircraft and replace the PT6 - 114A engine with a PT6-135A to provide increased horse power. This will improve climb rate, allow heavier payloads and increase the maximum altitude of the aircraft. The project began with the measurement and reverse engineering of major aircraft components from the firewall forward. The first was direct measurement of features. The second was measurement of point data on section planes to describe freeform shapes. Major frame components, cowlings, and mockups of the new nosebowl and inlet duct were measured. CAD models of the existing parts were then created from the direct feature data, or, in the case of ducts and cowlings, by lofting surfaces through the section data. Existing part and mockup models were then integrated into an assembly of the firewall forward, including a customer supplied model of the new engine. Design changes were made to the models of the mocked up inlet system and nosebowl to improve the fit. Further changes were made in response to comments by the engine manufacturer. SLA rapid prototypes of the parts were made and installed on an airframe. This showed the need for additional minor changes. The new ducts were to be made in carbon fiber. Working closely with the manufacturer, we adjusted the duct shapes for easier manufacturing. Sample sheet metal and machined part drawings and models were likewise sent to the prospective manufacturers for their comments. Part designs were adjusted in the CAD models to address their concerns. 3:00 p.m. - 3:10 p.m. Break3:10 p.m. - 3:50 p.m. 3D Scanning and Modeling Processes for Reverse Engineering Airplane OMLsMichael Raphael, Direct DimensionsThere are many reasons why firms need to model the exterior contour of existing aircraft OMLs (Outer Mold Lines). Most aircraft flying today were not designed in a modern 3D CAD program. Even with a current 3D digital design, the actual as-built contour deviates from the intended shape, at least at some level. A wide variety of 3D measurement technologies and modeling software tools have been used for nearly 15 years to accurately capture and model these shapes for many different applications and purposes. This presentation will focus on the evolution of 3D scanning methods and processes through many examples, with emphasis on practical application, costs, schedules, deliverables, etc. Having real-world customers who demand higher quality and lower price over time for this application, Direct Dimensions has continually searched for the best tools and methods for performing these projects. This experience and perspective will be freely shared with the audience in order to develop an appreciation for the selection of such tools for these projects. 3:50 p.m. - 4:00 p.m. Daily Wrap Up
If you have questions regarding a U.S. event contact service@sme.org or call 800.733.4763. For Canadian events contact canadasales@sme.org or call 888.322.7333. ![[Send More Info]](/images/gmninfo.gif)
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