Casting

If the CAD model of a part has been provided with inspection features already during design, the 3D measurement planning and inspection can be performed in a drawing-free process directly on the PMI data set. Furthermore, the full-field geometry acquired by the non-contact ATOS system allows refeeding and adapting component and tool geometries into existing CAD data if a tool correction is necessary (advanced CAD modeling). The obtained 3D measuring data also serves for the creation of design data in the field of reverse engineering.

Simulations serve to compute and visualize the mold filling, sprue, holding pressure, temperature control and filling time of the cast part. The purpose is to prevent errors and to optimize the use of materials, the cycle time and the machine size by predicting the process parameters and material behavior using the ARAMIS system during materials testing. The real component geometry can be measured with the ATOS system and numerically compared to simulated data in order to optimize and validate the simulation model.

3D digitization saves time and costs during toolmaking and maintenance. Controlling the individual manufacturing steps at an early stage during CNC machining of pressure die-cast tools and electrodes, wax patterns and ceramic core dies as well as sand core boxes via comparison of nominal and actual data reduces iteration loops, especially for multiple cavities. In try-out, the ATOS system offers 3D data to target the area for tool correction.

The systematic shape and dimension control of wax and foam patterns, wax assemblies, pattern plates and equipment ensures and accelerates the subsequent process steps in mold production and casting processes. By controlling the milling results at an early stage with the ATOS system, possible errors in pattern plates and pattern equipment can be identified and eliminated.

Measurements of molds and cores, for example made of sand or ceramics, ensure the process quality. The measuring data of molds and cores from the ATOS system enables virtual assembly analysis of mold halves and cores, which serves for the inspection of parting surfaces regarding offset, fitting and form fit of mold halves and core clearance. In investment casting, the wall thickness of the ceramic mold can be inspected to estimate its quality and the formation of burrs.

The first article inspection can be carried out based on the CAD model or PMI data set and CMM inspection with features such as GD&T. The full-field 3D inspection performed with the ATOS systems leave no area of the component unchecked. In quality control during series production, automated, production-related and mobile measuring cells, such as ScanBox, reduce scrap and rework time. Parts do not have to be transported to remote measuring rooms.

With its back projection function, the ATOS 3D sensor projects features such as isolines and punch marks straight from the software onto the real part. As a result, the conventional marking of heavy cast blanks is no longer needed. Efficient part alignment for CNC machining can be achieved. In addition, 3D measuring data provides the basis for adaptive manufacturing processes like adaptive machining.