Computer-integrated dimensional inspection of manufactured parts with sculptured surfaces using CAD and coordinate measuring machine

The objective of this project is to investigate procedures for using the CAD/CAM system and the Coordinate Measuring Machine (CMM) for the dimensional measurement of manufactured parts with sculptured surfaces. Traditionally when sculptured surfaces have to be measured, section profiles are made for checking the dimensional quality of the surfaces. This is, however, very time consuming and inaccurate. It also requires special fixtures to locate and hold the part so that the designed profiles can be checked. In this project, a 3-D approach is utilized based on the integration of CAD and CMM for precision measurement of complex surfaces. The 2D section profiles and the special fixtures which were required for inspecting sculptured surfaces are eliminated as a result of several new algorithms developed in this research.;The CAD model based localization algorithm is developed to determine the part location and orientation prior to CMM inspection. Three geometric algorithms are also presented in this research for inspection point and probing vector generation. The concept of an attribute based inspection module is proposed for rational inspection planning. Finally, a comparative analysis is conducted to validate the best dimensional quality of the manufactured part. The resulting methodology may be applied for inspection of parts having complex surfaces such as turbine blades, car body panels, aerospace structural parts, and other net shape products.