CPT International 04/2015

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SPECIAL Figure 3: The measurement data can be analyzed immediately and compared directly with the CAD data. Deviations to CAD are highlighted in color and problematic areas are easy to recognize, enabling specific improvements to be made to the manufacturing process argument against the use of the laser tracker, however, was that the results varied between operators. Faster inspection In the end, Bradken chose the ATOS Triple Scan from GOM, an optical 3-D fringe projection scanner equipped with measuring cameras with high resolution of up to 12 megapixels (Fig ure 2). Tests conducted in Tacoma demonstrated that, within eight hours, ATOS was able to deliver precise scans with the specified tolerances along with an extensive analysis of the complete domed casting. Other key criteria in Bradken’s decision included the flexible range of different measuring volumes and simple handling. Another plus offered by the ATOS Triple Scan is the Blue Light Technology (Figure 3). The narrow-band blue light of the projection unit allows the scanner to perform measurements independent of ambient lighting conditions and better scanning of shiny surfaces. ATOS Triple Scan is a 3-in-1 sensor system: It uses the right and left cameras individually in combination with the projector. This new method results in three individual sensors each with different viewing perspectives of the object, so that three views instead of one are captured during a single measurement. This means that the number of individual scans is significantly reduced, even when scanning complex parts. Scanning in deep pockets is a further advantage offered by this solution. Unlike conventional tactile coordinate measuring systems (which scan only individual points) or laser scanners (which analyze measurement data for specific sections), optical 3-D metrology systems such as ATOS capture the entire surface of the Bradken castings. This is done by applying the principles of triangulation: Using a projector, fringe patterns are projected onto the object to be measured and captured by two cameras. In this manner, millions of measuring points with precise details can be obtained in a few seconds by non-contact measurement. Using the information thus gathered, the ATOS software automatically determines the 3-D coordinates in the form of a high-resolution point cloud (ASCI/STL). The generated polygon mesh describes freeform surfaces and primitives which can, during shape and dimensional analysis, then be compared with the drawing or directly with the CAD data (Figure 4). Bradken’s engineers are thus able to instantly identify dimensional deviations in the on-screen color plot, thus providing substantial time savings for the Tacoma-based foundry. In addition to the ATOS Triple Scan, Bradken also uses the mobile Tritop photogrammetry system to improve the dimensional accuracy of large castings and assemblies such as turbine housings. To enable point-based coordinate measurement and deformation analysis, photographs of the component are taken from different angles. Having incorporated the GOM metrology systems into its inspection processes, Bradken is now able to measure large and complex components as well as mounted assemblies – capturing the complete object, meeting tight tolerances and working within appropriate time limits. As a result, the foundry’s investment has paid off faster than originally expected. Inspections no longer need to be outsourced, delivering additional cost savings. Less rework due to the combination of simulation and 3-D measurement Since the introduction of GOM metrology solutions, Bradken has managed to reduce rework significantly, and to optimize and accelerate its production processes overall. Large objects in particular, such as gas turbine housings, may experience severe deformation or distortion during the cooling process. In order to predict the resulting loads, Bradken uses the Magmasoft casting simulation software. In this context, it was important for Bradken to be able to relate the actual dimensional deviation to the calculated results. This was possible thanks to the measurement of the individual castings with the ATOS and Tritop systems. Based on the measuring results, the pattern was modified in such a way that the new casting could be manufactured with the correct dimensions right from the very start. The combination of simulation and 3-D measurement speeds up manufacturing processes because it enables the foundry to avoid time-consuming rework, this being otherwise necessary to achieve the requested tolerances. Without the ATOS and Tritop metrology systems it would not have been possible to check object surfaces and geometries during the search for the best solution. www.gom.com 50 Casting Plant & Technology 4/2015
K NEWS EUROGUSS Europe’s meeting place for the die-casting sector “Good luck” is the message from 12 to 14 January 2016 at Euroguss in Nuremberg, Germany. Once again, the international die-casting trade fair has a great deal to offer: the latest technology, processes and products on the exhibition stands presented by total of around 550 exhibitors, the “Forschung, die Wissen schaf(f)t” special show, (“Research for Knowledge”) the new “Oberflächentechnik” Pavilion (“Surface Technology”), specialist presentations and current trends and developments in the congress along with the award presentation ceremonies for the two aluminium and zinc die-casting competitions. The total of around 11,000 expected trade visitors are decision-makers from the automotive industry, machinery and equipment construction, the electronics industry, energy and medical technology sectors along with die-casting foundries. “Euroguss is continuing on its course of growth”, says a delighted Heike Slotta, Director Exhibitions, from NürnbergMesse. “Already in 2014, with 470 exhibitors, we registered a substantial increase of over 20 %. 2016 we are expecting around 550 exhibitors. This proves: the exhibition concept is absolutely spot on, the demand for die-casting products is continuing unbroken.” In order to offer all exhibitors sufficient space, the previous exhibition Halls 7 and 7A have now therefore been joined by Hall 6. Around half the Euroguss exhibitors are international. After Germany with a big gap, the list of the most important exhibiting countries from Europe is headed by Italy followed by Turkey, Austria, Switzerland, Spain, France and Slovenia. The exhibitors are die-cast foundries along with their suppliers, equipment suppliers and service-providers. At the fair they will be showing die-cast products, technology along with machinery, peripheral appliances, furnaces, molds, prototyping, metals, alloys as well as release agents and operating materials. Apart from this there is At the Euroguss trade fair in Nuremberg, Germany, in January 2016 around 550 exhibitors are expected, a clear increase to 2014 when 470 exhibitors attended the major die-casting event (Photos: NürnbergMesse) also a range of products covering the post-treatment of die-cast parts, quality assurance, control and drive technology along with software. Information on the exhibitors, pro ducts and hall layout plans is available on the Internet at www.euroguss.de/exhibitors-products. The Research for Knowledge special show has now already been held for the third time at the fair. In Hall 7, Stand 642, around 10 research institutes, universities and technical colleges will be providing an insight into their latest projects, presenting their services and research focal points, main research areas and also showing their range of training and further training options and opportunities. Among those participating: » Neue Materialien Fürth » Fraunhofer-Institut für Fertigungstechnik und Angewandte Materialforschung (IFAM, Fraunhofer Institute for Manufacturing Technology and Advanced Materials) » Lehrstuhl Werkstoffkunde und Technologie der Metalle (WTM, Chair of Metals Science and Technology) » Fraunhofer-Entwicklungszentrum Röntgentechnik (Fraunhofer Development Centre for X-Ray Technology) » Verein für praktische Gießereiforschung (Association of Practical Foundry Research) » Hochschule Aalen Gießereilabor (University of Aalen, Foundry Laboratory) » Universität Kassel Fachgebiet Gießereitechnik (University of Kassel, Faculty of Foundry Technology) The post-treatment and coating of functional and highly durable die-cast parts is a key theme for die-cast foundries. Corresponding machinery and process technology ensure a high-quality finish for die-cast product surfaces. Deburring, grinding, polishing, coating or finishing are the corresponding processing cycles. For the first time, a separate exhibition area and pavilion will be dedicated to this special topic. Here, suppliers in the areas light metals-processing and finishing will be presented. The specialist presentations delivered by the International German Die Casting Congress on all three days of the fair are very popular with the trade fair visitors. The forum, which is positioned at the heart of the fair action in Hall 6, provides a good opportunity to enter into an exchange with colleagues and experts on current sector themes and Casting Plant & Technology 4/2015 51
Page 1 and 2: www.giesserei-verlag.de December 20
Page 3 and 4: EDITORIAL K On the way to a smart f
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Page 45 and 46: Figure 1: voestalpine Nortrak casts
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Page 57 and 58: Abrasives 64 pages, English, German
Page 59 and 60: K IMPRINT PREVIEW / IMPRINT K Previ

CPT International 04/2015

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