Digital image correlation for sensing kinematic fields in manufacturing processes: a review

PurposeThe purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.Design/methodology/approachNo methodology was used because the paper is a review article.Findingsno fundings.Originality/valueHerein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

Failure analysis and fatigue life prediction of high-speed rail clips based on DIC technique

With the development of rail transportation, the fatigue failure of rail clips has become an issue, which affects the operational safety of trains. In this study, reasons for the fatigue failure of rail clips were investigated to improve their service life. A digital image correlation (DIC) technique was conducted to obtain strain fields, vibration modes, and natural frequencies of a rail clip. The strain and displacement of a rail clip under dynamic cyclic loading were also obtained. A fastener system refinement model was developed to analyze the static, dynamic, and modal responses of the clip. The experimental tests and modal simulation results were mutually verified. The fatigue life was analyzed based on the verified FE model. The results revealed that the maximum strain and minimum fatigue life occur at the heel of the clip, in good agreement with the actual fracture position. As the amplitude and frequency of dynamic cyclic load increased, the fatigue life of the clip decreased sharply. Moreover, the normal wheel–rail force accompanied by high-frequency rail corrugations accelerated crack initiation and reduced the fatigue life. The findings of this study provide guidance for improving the service life of rail clips.

Strain Monitoring of an Aluminium Joint with an Optical System

The stresses distribution can be easily determined in the cross-section of the elements but in a joint, the distribution of stresses is more complicated. Its complexity is also increased if stiffeners are added to the joint and if the connecting bolts are not positioned in a regular configuration. An aluminium cantilever with a two bolts connection is experimentally tested to determine the real capacity. Stiffeners reduce the stress intensity in the connection, but they are prone to instability problems if they are subjected to compression. In order to determine the real stress development in the stiffeners, the Digital Image Correlation (DIC) technique was used. This technique determines the strains in the loaded parts which then can be equivalated to the stress distribution. The paper presents the stress development in the compressed stiffeners of an aluminium joint considering also improvement solution for increasing the bending capacity by reducing the instability parameters.

Analysis for Shear Behavior of SRC Deep Beams Based on Tests, Digital Image Correlation Technique, and Finite Elemental Simulation

Seven steel-reinforced concrete (SRC) deep beams were tested to investigate the shear performance, including peak loads, failure modes, mid-span deflections, and cracking patterns. The parameters include the shear span-to-depth ratio and the dimensions of the steel skeleton. The digital image correlation (DIC) technique was utilized for real-time recording of the in-plane strain and deformation. The experiment results show that the failure modes of specimens could be concluded as two forms: diagonal compression failure and shear failure. The DIC technique was proved to be efficient for tracking the development of crack patterns and recording the failure modes. The corresponding numerical analyses based on experiments were carried out and demonstrated to be a reliable method to simulate the shear response. Furthermore, the most significant parameters and their interactions were identified by finite element models parameter analysis. The steel skeleton height and shear span-to-depth ratio were the main parameters affecting shear capacity. A design formula based on the strength superposition method was presented. The calculated results were basically in agreement with the test results, where the mean and coefficient of variation were 1.04 and 0.09, respectively.

DIGITAL IMAGE CORRELATION IN ASSESSING STRUCTURED-LIGHT 3D SCANNER’S GANTRY STABILITY: PERFORMING DAVID’S (MICHELANGELO) HIGH-ACCURACY 3D SURVEY

The paper presents results from applying Digital Image Correlation (DIC) technique to determine deformations and verify stability on a gantry during surveying operations on the Michelangelo’s David at the Galleria dell’Accademia di Firenze museum in Florence. An advanced hi-resolution Structured-light 3D scanner has been used to create a hi-detailed digital twin of the masterpiece. Considering the high scanner sensitivity, a contactless, remote and passive monitoring system of the gantry stability has been chosen to guarantee maximum freedom of movement around the David and avoid any interference during scanning operations. Due to the remarkable elevation of the statue, which reaches almost 7 meters on his pedestal, and considering the cramped operating area around the statue, an ad-hoc gantry has been designed and deployed. The sophisticated scanner’s technique and the extreme hi-resolution required for the survey needed firm gantry stability during scanning operations from one side. The complex geometries and the considerable extension of the statue surface impose extended flexibility and a nimble elevation platform from the other side. Thanks to the DIC technique the gantry stability has been constantly monitored with an accuracy of 0.03 ÷ 0,04 pixels, optimising scanning scheduling and, consequently, operations efficiency. A comparison of scans with post-processed deformation patterns allowed to optimise the scanning schedule, minimising downtime, and maintaining the needed platform stability threshold for effective scanning.

Realisation and testing of novel fully articulated bird-inspired flapping wings for efficient and agile UAVs

Large birds have evolved an effective wing anatomy and mechanics, enabling airborne mastery of manoeuvres and endurance. For these very reasons, they are difficult to replicate and study. The aim of the present work is to achieve active wing articulations to mimic natural bird flapping towards efficient and agile Unmanned Aerial Vehicles (UAVs). The proposed design, bio-mimicking the black-headed gull, Larus ridibundus, has three active and independent servo-controlled wing joints at the shoulder, elbow and wrist to achieve complex controls. The construction of the wing is realised through a polymeric skin and carbon fibre–epoxy composite spars and ribs. The wing movements (flapping, span reduction and twisting) envelopes of the full-scale robotic gull (Robogull) are examined using the Digital Image Correlation (DIC) technique and laser displacement sensing. Its aerodynamic performance was evaluated in a wind tunnel at various flapping parameters, wind speeds and angles of attack. It is observed that a flapping amplitude of 45 $^\circ$ is more favourable than 90 $^\circ$ for generating higher lift and thrust, while also depending on the presence of span reduction, twist and wind speed. The model performs better at a flying velocity of 4m/s as compared with 8m/s. Both lift and thrust are high at a higher flapping frequency of 2.5Hz. Combined variation of the flapping frequency and stroke ratio should be considered for better aerodynamic performance. The combination of a lower stroke ratio of 0.5 with a flapping frequency of 2.5Hz generates higher lift and thrust than other combinations. Span reduction and wing twist notably and independently enhance lift and thrust, respectively. An increase in the angle-of-attack increases lift but decreases thrust. The model can also generate a significant rolling moment when set at a bank angle of 20 $^\circ$ and operated with independently controlled flapping amplitudes for the wings (45 $^\circ$ for the left wing and 90 $^\circ$ for the right wing). Based on the optimal values for the flapping amplitude (45 $^\circ$ ), flapping frequency (2.5Hz) and flying velocity (4m/s), the Strouhal number (St) of the Robogull model is 0.24, lying in the optimal range ( $0.2 < \mathrm{St} < 0.4$ ) for natural flyers and swimmers.