Application of 3D scanning and computer simulation techniques to assess the shape accuracy of welded components

Abstract

While traditional measurement methods prove to be insufficient when facing more complex shapes and intricate challenges, increasingly efficient solutions are emerging in their place. 3D scanners in particular exhibit versatility. They clearly represent a useful tool in many fields with diverse requirements; thus, it is advisable to explore further areas of their potential applications, e.g., in quality control or reverse engineering. During our research, measurements were carried out on 40 welded elements using a caliper and on 11 other elements using the HandySCAN 700 Elite device by Creaform. The research was conducted at different stages of production, between subsequent operations. In addition, in the absence of interoperative nominal dimensions, a welding process simulation was performed in the Simufact Welding software. The simulation results were compared with actual deformations measured using a 3D scanner. The research enabled identification of the causes of excessive deformations and provided the basis for comparing the caliper with a modern laser device. A particular advantage of the scanner was demonstrated for complex issues requiring high flexibility and precise documentation of full geometry. The caliper proved to be more efficient only for quick execution of single, simple measurements at specific places. Incorporating the simulation in the Simufact Welding software into the analysis, allowed for a more precise validation of the planned technology. This solution presents a promising alternative to nominal models, particularly valuable when measurements are conducted between subsequent operations. Further research in this area is also recommended to enhance proposed methodology.