Three-dimensional image-based approach for imperfect structures surface modeling

Great attention has been given, in the scientific literature, to the effect of initial imperfections on the structural behavior of experimental samples under compression loads. Geometrical reconstruction of the as-built surface is therefore required to allow accurate numerical modeling. High-precision systems for inverse engineering are expensive, and most of the times geometrical imperfections are rather complex to be described without high computational efforts. In this paper, an image-based approach to model the surface of imperfect structures using open-source software and a common digital camera is presented. The proposed approach aims to generate high-quality surfaces from real imperfect structures, by employing the surface-from-motion and multi-view stereo techniques. A controlled frame capture is introduced to decrease both the computational effort and number of repeated correspondences. The surface fit is then computed by meshing the dense cloud of points and adjusting several surface regions describing the samples' profiles. The procedure is illustrated by using two damaged tubular member samples reconstructed by the proposed approach. Then, resulted geometries are verified by comparing measures from a three-dimensional high-precision laser scanner and a common mechanical procedure. Finally, a comparison of three-dimensional mappings of a ship panel with proposed approach and commercial photogrammetry software is performed. Verification results refer to the possibility of prototyping geometry surfaces from real imperfect samples by using inexpensive hardware and public domain software tools with acceptable level of accuracy.