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PFA 36 th Annual Meeting Penn State 10 th Annual Metal Casting Conference

PFA 36 th Annual Meeting Penn State 10 th Annual Metal Casting Conference. Technical Program Non-Contact Scanning for Foundry Dimensional Control. The Problem: Dimensional issues are a significant contributor to casting lead time and…………. Subsequent Action. Casting. Motivation.

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PFA 36 th Annual Meeting Penn State 10 th Annual Metal Casting Conference

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  1. PFA 36th Annual MeetingPenn State 10th Annual Metal Casting Conference Technical Program Non-Contact Scanning for Foundry Dimensional Control

  2. The Problem: Dimensional issues are a significant contributor to casting lead time and………… Subsequent Action Casting Motivation Action Motivation Week 0 2 7 8 9 10 11 13 16 17 18 19 23 Build production pattern Modify pattern Add chills Modify corebox Modify pattern Modify gating Modify pattern Modify pattern Modify pattern Modify core box Modify pattern flatness Modify gating Modify gating Modify pattern Modify gating Modify procedure Pattern pulled 1-2 3 4-5 6-7 8-20 21-132 135-190 191-235 235-250 250-255 256-280 281-288 289-290 291-292 293-327 328-334 335-342 DIM DIM QUAL QUAL DIM/QUAL QUAL DIM/QUAL DIM QUAL DIM DIM QUAL QUAL DES QUAL QUAL $$$ Transfer pattern Establish process controls First article casting evaluation NDE and testing approval Dimensional non-compliance Pattern change Chills added, corebox change New pattern built Pattern / heat treatment change Some castings rejected Machining adjusted Some castings rejected Some castings rejected QUAL DIM QUAL DIM QUAL/DIM QUAL/DIM DIM QUAL/DIM DIM DIM QUAL/DIM QUAL

  3. Opportunity: Non-contact scanning for casting dimensional management and control Introduction Bob Voigt, Penn State Non-Contact Dimensional Inspection of Metalcastings & Foundry Patterns Trevor Murko, FARO Scanning & Touch Probe Inspection With Articulated Arm Systems Jay Batema, Hexagon Metrology Final Perspectives Bob Voigt, Penn State

  4. Current Users include…..

  5. ScanningSystems 100 mm 115mm 143mm 33 mm 82mm • Up to 7000points / line • Up to 30 lines / second • 4,000,000 points / second Field of View

  6. Key:User-friendly software to manipulate the point cloud and quickly generate useful dimensional information in both traditional and visual formats

  7. Primary Use: Casting inspection & first article conformance validation

  8. Pattern Scanning • Compare to Casting Drawing • Determine Wear Properties • Create solidification model from actual pattern • Validate shrink rules

  9. Reverse Engineering Surfacing (IGES, STEP) PointCloud Meshing (STL)

  10. Point Cloud to CAM Casting can be scanned and compared to finished drawing. From here, CAM instructions can be created and sent to machines for finishing of part.

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