A system has been developed to measure the three-dimensional weld pool surface geometry in the gas metal arc welding (GMAW) process. It utilizes the specular nature of the weld pool surface by projecting a five-line laser pattern onto the surface and imaging its reflection. Specifically, the laser reflection is intercepted by an imaging plane and captured using a high speed camera. The reflected pattern is used to reconstruct the weld pool surface based on the law of reflection. Two reconstruction algorithms, referred to as center-points reconstruction and piece-wise weld pool surface reconstruction algorithm, are applied to sequentially reconstruct the weld pool height and three-dimensional surface geometry. Reconstructions has been conducted using simulated weld pool surface to provide a method to compare the reconstruction result with a known surface and evaluate the reconstruction accuracy. It is found that the proposed method is capable of reconstructing weld pool surface with acceptable accuracy. The height error of reconstructed center-points is less than 0.1 mm and the error of estimated weld pool boundary is less than 10%. Reconstruction results from images captured in welding experiments are also demonstrated.
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April 2013
Research-Article
Reconstruction of Three-Dimensional Gas Metal Arc Weld Pool Surface From Reflected Laser Pattern
YuMing Zhang
YuMing Zhang
1
e-mail: ymzhang@engr.uky.edu
Institute for Sustainable Manufacturing and Department of Electrical and
Computer Engineering,
Institute for Sustainable Manufacturing and Department of Electrical and
Computer Engineering,
University of Kentucky
,Lexington, KY 40506
1Corresponding author.
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YuMing Zhang
e-mail: ymzhang@engr.uky.edu
Institute for Sustainable Manufacturing and Department of Electrical and
Computer Engineering,
Institute for Sustainable Manufacturing and Department of Electrical and
Computer Engineering,
University of Kentucky
,Lexington, KY 40506
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received February 15, 2011; final manuscript received October 1, 2012; published online March 22, 2013. Assoc. Editor: Wei Li.
J. Manuf. Sci. Eng. Apr 2013, 135(2): 021002 (11 pages)
Published Online: March 22, 2013
Article history
Received:
February 15, 2011
Revision Received:
October 1, 2012
Citation
Ma, X., and Zhang, Y. (March 22, 2013). "Reconstruction of Three-Dimensional Gas Metal Arc Weld Pool Surface From Reflected Laser Pattern." ASME. J. Manuf. Sci. Eng. April 2013; 135(2): 021002. https://doi.org/10.1115/1.4023374
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