case study

The Easy Approach To Complex Casting Inspection

How Blue Light Metrology 3D Scanning Upgrades The Digital Quality Control Workflow

21 Jan, 2022

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The Easy Approach To Complex Casting Inspection

Highly precise and reliable part inspection is crucial for product quality and reliability in the industrial and manufacturing sector. In the course of digitalization, metrology 3D scanning technology has proven an excellent tool, facilitating workflows while significantly shortening them at the same time. With the increasing affordability and invaluability of metrology 3D scanners, the gap between 3D scanning and other measuring technologies is closing. 

Despite efficient and high-quality metrology 3D scanners have become growingly accessible, the learning curve of the devices is usually high, the software complicated to operate and the effective capturing motion of the scanner a task the machinist first needs to get used to. This real customer case on inspecting casting parts unpacks how to precisely inspect industrial parts at ease.

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Image 1: Inspection Report

This inspection report boasts tons of information at each corner and every angle. Of course, a complex part as such requires detailed output of information in order to secure product stability and security. How can such a detailed report be obtained? Let´s embark on the journey of fast, efficient and hustle-free casting parts inspection.

High-quality Casting Parts for Demanding Applications

Many times, when a batch of castings dispatches the factory, customers require a detailed inspection report prior to processing the pieces in-house.

Image 2: Casting parts in the factory

In this particular case the product of interest has some very complex characteristics. The casting is irregular in shape and features several curved surfaces, presenting a challenge for manual measurement. The hurdles of applying a CMM for measurement in this case  are large work volume and the danger of damage of the device which can occur easily with a CMM. But most importantly, the inner cavity of the casting needs to be measured precisely as well. 

Considering all factors, using a non-contact high-precision 3D scanner to inspect the casting was the ideal solution.

3D Scanning & Inspection for Quality Control of Castings

H3 3D Data Acquisition of the Casting

Image 2: 3D data acquisition of the casting body
Image 3: Scan data of the casting acquired by FreeScan UE

In the first step of the process, the entire body of the casting was scanned to acquire the part´s external shape. As the casting was heavy and difficult to move, the 750g weighted FreeScan UE could give full play to its lightweight features, enabling the operator to move it around the part flexibly and scan from different angles to obtain the complete 3D data.

Scanning the Internal Cavity

Image 4: Cutting the castings
Image 5: Internal cavity scan data

In order to inspect the internal cavity of the casting, it is necessary to cut and slice the casting to be able to acquire the data of the part´s internal structure. Complete and error-free data can be obtained thanks to the capacity of the software enabling seamless stitching together of all the parts. 

Note:

Iron casting parts can be affected shrinkage due to temperature changes during the molding process. Especially in the internal cavity, poor control can lead to uneven wall thickness and affect product performance. This unpredictable variable can be avoided effectively by regularly conducting internal cavity inspection with a 3D scanner.

Casting Inspection

The data obtained is imported into Geomagic Control X for inspection. Using an inspection software in direct conjunction with the FreeScan UE enables the direct output of a set of required reports, in this case the machining allowance report, appearance and internal cavity report, as well as the dimensional report. A total of 46 points were measured and detailed results obtained.

Image 6: Inspection report
Image 7: Inspection report

Non-contact, high-precision, efficient measurement tools are the key to obtaining detailed and accurate inspection results. FreeScan UE can be operated flexibly in a wide range of environment settings, enabling large-format scanning and rapid access to complete high-quality 3D data of castings, providing strong support for the output of detailed inspection reports.

SHINING 3D developed the FreeScan UE to make highly precise 3D scanning data for reverse engineering and inspection accessible and easy to operate for businesses and individuals operating in industrial and factory environments. 

Do you want to learn more about 3D scanning and how our products come to application in the mold industry? You can read it in one of our latest episodes of Metrology Monday here.


21 Jan, 2022

More about SHINING 3D

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SHINING 3D is the global 3d digitiziting technology solution provider, empowering users across industries with devices aimed at their specific requirements for diversified applications, and making professinal and high quality 3d digitizing technology accessible for everyone.

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