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A vision-based method for dimensional in situ measurement of cooling holes in aero-engines during laser beam drilling process

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Abstract

Uncertainty dimensions of geometrical features in film cooling holes will inevitably affect the aerothermal behavior and mechanical characteristics of the engine. To realize the measurement of key parameters of film cooling holes, this article introduces a vision-based method for dimensional in situ measurement of the holes in aero-engines during the laser beam drilling process. In the measurement process, images of the holes can be acquired through the equipped camera in the laser drilling machine. Specifically, dual-tree complex wavelet transform is applied to eliminate the overwhelming interfering noise and preserves the necessary edge information; a local Gini index-based method is proposed to extract the edge information from the complex texture contained in the workpiece surface. Furthermore, the least square approach is employed for dimension measurement. Besides, a nickel-based wafer drilling experiment is presented on a femtosecond five-axis laser drilling machine. Compared with the off-line vision method, the experiment results indicate the calculated mean absolute errors of the diameter and the roundness of the proposed method are evaluated to be 0.00005 mm and 0.01113 mm respectively. This study, therefore, paves the way for in situ measurement of film cooling holes in aero-engines without any additional measuring instrument during the laser drilling process.

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Funding

This work was supported in part by the Laser Manufacturing and Additive Manufacturing Project of the National Key Research and Development Program of China (2018YFB1108000), in part by the Wenzhou Municipal Key Science and Research Program (ZG2019031), and in part by the Zhejiang Provincial Natural Science Foundation of China under Grant LQ21E050003.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Wenzhou University, Wenzhou, 325035, China

    Weifang Sun, Guang Ma & Fengping Li

  2. Wenzhou Academy of Special Equipment Science, Wenzhou, 325000, China

    Jiyan Yi

  3. Institute of Laser and Optoelectronics Intelligent Manufacturing, Wenzhou University, Wenzhou, 325000, China

    Guang Ma, Fengping Li & Chengji Lu

  4. Lyncwell Innovation Intelligent System (Zhejiang), Co. Ltd, Wenzhou, 325000, China

    Xiaogang Li

  5. Key Lab of Advanced Transducers and Intelligent Control System, Ministry of Education and Shanxi Province, College of Physics and Optoelectronics, Taiyuan University of Technology, Taiyuan, 030024, China

    Guang Feng

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  1. Weifang Sun
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Correspondence to Weifang Sun or Fengping Li.

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Sun, W., Yi, J., Ma, G. et al. A vision-based method for dimensional in situ measurement of cooling holes in aero-engines during laser beam drilling process. Int J Adv Manuf Technol 119, 3265–3277 (2022). https://doi.org/10.1007/s00170-021-08463-8

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  • DOI: https://doi.org/10.1007/s00170-021-08463-8

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