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<p>This paper focuses on the development of required hardware and software for automatic single-point strain analysis in sheet metal forming through image processing. The software was developed in python with a user-friendly GUI. The handheld USB microscope has been modified with side lighting for capturing the image. An image database has been created to validate the proposed system by capturing the filled and unfilled ellipses of different dimensions. These ellipses are printed on Steel, Aluminium, and Copper Sheets by screen-printing technique. The software can detect edges automatically and evaluate the strains with 100% efficiency, irrespective of the sheet material. The maximum absolute percentage error in the strain values were found to be 1.507, 1.009, and 0.945 for copper, steel, and aluminium respectively with average error less than 2%. The proposed system has also been tested on actual formed component. For this, the sheets are printed with open and filled circular grids of 3&#xa0;mm diameter and deformed into a hemispherical dome. The deformed circles are captured and strain values are evaluated successfully with the proposed strain measurement system. The proposed approach demonstrates a viable technique to compute the sheet metal surface strain with sufficiently high accuracy and less human interference compared to traditional manual methods such as using Mylar tape, toolmaker microscope, and travelling microscope.</p>

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Automatic edge detection of screen printed elliptical grids captured by modified USB microscope for single point strain analysis

  • 期刊论文

  • 发表日期：

    2025年1月17日

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  • Pankaj Wankhede,
  • Nara Guru Narayanaswamy,
  • Kurra Suresh,
  • Amrita Priyadarshini

摘要

This paper focuses on the development of required hardware and software for automatic single-point strain analysis in sheet metal forming through image processing. The software was developed in python with a user-friendly GUI. The handheld USB microscope has been modified with side lighting for capturing the image. An image database has been created to validate the proposed system by capturing the filled and unfilled ellipses of different dimensions. These ellipses are printed on Steel, Aluminium, and Copper Sheets by screen-printing technique. The software can detect edges automatically and evaluate the strains with 100% efficiency, irrespective of the sheet material. The maximum absolute percentage error in the strain values were found to be 1.507, 1.009, and 0.945 for copper, steel, and aluminium respectively with average error less than 2%. The proposed system has also been tested on actual formed component. For this, the sheets are printed with open and filled circular grids of 3 mm diameter and deformed into a hemispherical dome. The deformed circles are captured and strain values are evaluated successfully with the proposed strain measurement system. The proposed approach demonstrates a viable technique to compute the sheet metal surface strain with sufficiently high accuracy and less human interference compared to traditional manual methods such as using Mylar tape, toolmaker microscope, and travelling microscope.