Three-dimensional shape and deformation measurement on complex structure parts

Stereo digital image correlation technique (stereo-DIC or 3D-DIC) has been widely used in three-dimensional (3D) shape and deformation measurement due to its high accuracy and flexibility. But it is a tough task for it to deal with complex structure components because of the severe perspective distortion in two views. This paper seeks to resolve this issue using a single-camera system based on DIC-assisted fringe projection profilometry (FPP). A pixel-wise and complete 3D geometry of complex structures can be reconstructed using the robust and efficient Gray-coded method based on a FPP system. And then, DIC is just used to perform the temporal matching and complete full-field pixel-to-pixel tracking. The in- and out-of-plane deformation are obtained at the same time by directly comparing the accurate and complete 3D data of each corresponding pixel. Speckle pattern design and fringe denoising methods are carefully compared and chosen to simultaneously guarantee the measuring accuracy of 3D shape and deformation. Experimental results demonstrate the proposed method is an effective means to achieve full-field 3D shape and deformation measurement on complex parts, such as honeycomb structure and braided composite tube, which are challenging and even impossible for the traditional stereo-DIC method.