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Post-Welding Measuring of a Forging Die

Successful process optimisation with naviSCAN 3D

Cutting edge portable and flexible 3D-digitising technology from Breuckmann combined with a Metronor optical tracking system enables Wyman Gordon to achieve significant cost reductions in their repair procedures.

 

Wyman Gordon, located in Worcester, MA, USA is a major supplier of forgings to manufacturers both in the civil and military aircraft industry. The naviSCAN 3D system of Breuckmann is used to verify the pre-production mould as well in the context of reverse engineering (shape verification) of used tooling.


In order to generate accurate data in a typically rough industrial environment, a number of challenges are to be addressed, including the size of the objects to be measured (up to 9 m), high temperatures of the tools, as well as the inherently rough conditions in an industrial forging workshop.

 

 

Digitisation Task and Challenges

  • Complete full-area surface measurement of the forging die with the objective of
    achieving highest level of accuracy and resolution
  • Temperature of the measuring object at 200°C
  • Non-contact measurement of very large measuring object (up to 9 m)
  • Data evaluation on site (while the measuring object is still hot)
  • Easy, flexible and quick solution
  • Rough industrial environment
  • High accuracy
  • Material: tooling steel
  • Surface (welding seam) is partially reflective
  • Size: ca. 3 m x 1.5 m

 

 

Result

The CAD file is imported into the Breuckmann Software OPTOCAT2007 as

reference data. The subsequent false colour comparison allows for the coloured visualisation of the discrepancies between target and actual data.

 

As a result, a few ‘negative, blue’ areas have been detected in the data set, indicating a lack of material welded to that particular spot of the object. This valuable information was given directly to the welders on site, enabling them to immediately carry out any necessary rectification.

 

Technical Specifications naviSCAN 3D

stereoSCAN 3D-HE

  • Operation principle: topometric multi area sensor
  • Diagonal measuring range: 400 mm
    (6 measuring areas can be configured optionally)
  • Accuracy: 25 μm
  • Camera resolution: two CCD 5.0 megapixel cameras (2448 x 2048 pixel)
  • Light source: 200 Watt Discharge lamp (High Power Projector)
  • Operation distance: 880 mm
  • Sensor weight: ca. 8 kg (including naviFRAME)
  • Acquisition time: < 1s
  • naviFRAME: 24 infrared LEDs
  • Digitisation software: OPTOCAT (Breuckmann GmbH)
  • Inspection software: OPTOCAT (Breuckmann GmbH)

  

Navigator Metronor Duo

  • Operation principle: optical tracking system
  • Measuring range: sensor distance: 1.5 - 10 m standard, optional up to 30 m
  • Accuracy: Given 6 m: 3D length accuracy +/- 0,030 mm*
  • Sensor (2 pcs): CCD cameras

 

[*Accuracy at given distance from the camera, calculated by measuring a 1 m long measuring stick lengthwise, transverse and upright at 1σ]

 

Probing unit (light pen):

 

  • Type: wireless, hand held, quick-change styli
  • Material: Carbon Fibre with embedded active targets
  • Styli: User configurable set of 5 pcs with titanium extensions / angles
  • Styli type: Ruby spheres (incl.), scribe tip (incl.), edge styli (opt.)
  • Hidden point accessibility: 600 mm
  • Net weight: 0.52 kg
 

 

 

 

Pictures

Measuring object: Forging die
Setup of digitisation process
Measuring with naviSCAN
Measuring process
Evaluation of data