Table of Contents
- How can a casting be reworked to meet tolerances?
- How can the rework process be streamlined?
- What do operators need to ensure accurate modifications?
- With Creaform 3D scanners and the VIRTEK laser projector, operators achieve precise rework through easy guidance
High-value parts like castings are critical components produced through advanced manufacturing processes. Made from specialized materials like high-strength alloys, these complex, large-scale parts must meet stringent tolerances. Their critical role in systems like aerospace engines or large industrial pumps, combined with rigorous quality standards and testing requirements, contributes to their high production and replacement costs. As a result, when a casting falls outside tolerances, it is not simply discarded but meticulously reworked to meet specifications.
How can a casting be reworked to meet tolerances?
Reworking a casting to bring it within tolerances involves identifying deviations with precise measurements, followed by removing excess material via machining or grinding, or adding material through welding or metal spraying, or even mechanical correction.
Most of the time, operators use manual markers to transfer dimensions and adjustment points from the inspection report onto the casting surface.
However, these markers are prone to human error, resulting in less precise markings, especially on complex geometries like castings. They are also time-consuming, require significant operator skill, and offer lower repeatability since marks can fade or smudge.
How can the rework process be streamlined?
Without proper guidance, the rework process can become labor-intensive, require multiple iterations, and depend overly on operator expertise. To overcome these challenges, operators can leverage technology to make precise adjustments more efficiently and confidently.
Laser projection systems provide a major advantage over manual markers by displaying deviations directly on the casting surface. This not only reduces preparation time but also minimizes reliance on individual expertise and standardizes the rework process.
What do operators need to ensure accurate modifications?
To add or remove material according to the customer requirements and ensure the part is within the specified tolerance, operators need tools that can quickly capture the casting's dimensions and compare them to the CAD model. They also require a process that provides highly precise, consistent, and repeatable markings aligned with CAD or inspection data.
By combining accurate measurement tools with a well-aligned projection system, operators can make instant updates or refinements, ensuring reliable and efficient rework.
The Laser Projection Add-on allows the combination of two state-of-the-art technologies: Creaform 3D scanners + VIRTEK laser projector
1. Simplicity
Creaform proposes a unique and simple SCAN-ANALYZE-PROJECT solution.
- Scan the casting with a Creaform 3D scanner, such as the MetraSCAN 3D or the HandySCAN 3D|MAX Series. Then, create or import an inspection program.
- Analyze part conformity and deviations by comparing the scan data to a reference or CAD model.
- Project the non-conformities extracted from Inspection directly onto the casting with the VIRTEK laser projector.
2. Accuracy
Casting manufacturers need to rely on accurate inspection instruments capable of meeting submillimetre tolerances, as even small deviations can significantly impact the functionality and performance of castings. Metrology-grade solutions, such as Creaform 3D scanners and the VIRTEK laser projector, ensure castings meet strict quality standards, minimizing the time and effort for rework, as well as ensuring higher quality.
3. Speed
Because castings are made of intricate geometries and critical features, manufacturers also need quick measuring devices capable of inspecting these large and complex parts in their entirety, down to the smallest details. This Creaform/Virtek solution is optimized to scan and project on large parts of up to 15 m, directly on the shop floor and in any lighting conditions.
Traditional inspection methods can be slow and may not capture all the fine details, leading to the risk of missed defects or dimensional errors. High-speed inspection tools, such as Creaform 3D scanners, enable quick, comprehensive measurements across the entire casting, ensuring even the smallest deviations are detected and corrected early. This speeds up production, minimizes the risk of costly production delays, reduces scrap and costly problems in the manufacturing of high-value casting.
With Creaform 3D scanners and the VIRTEK laser projector, operators achieve precise rework through easy guidance
Creaform’s unique and simple SCAN-ANALYZE-PROJECT solution provides operators with easy-to-follow guidance for precise, efficient, and consistent casting rework.
1. Direct, Easy-to-follow Guidance
Direct and easy guidance simplifies the rework process by clearly indicating areas that require adjustment, reducing reliance on guesswork and manual interpretation. This not only accelerates the rework process but also reduces human error by minimizing dependence on operator skills and expertise.
2. Significant Time Saving
3D scanning rapidly captures 100% of the casting’s geometry in minutes, while laser projection directly displays deviations onto the casting, eliminating manual transfer and reducing setup time. This combination provides instant feedback and minimizes the need for rework cycles, significantly accelerating the manufacturing process.
3. Superior Quality and Compliance with Strict Tolerances
3D scanners measure the casting’s complete dimensions with micrometer-level accuracy, ensuring no deviations are missed, while laser projection delivers consistent and precise markings directly onto the parts. These two technologies combined improve the quality of the final casting, ensuring compliance with strict tolerances and quality standards.
