innovations CASTING
Casting Achieves Optimal Fit via 3-D Scanning
W
hen Vigor Fab, a Seattle-based division of Vigor Industrial, re- ceived a contract
from the Washington State Department of Transportation to build a series of 144-car ferries, the shipbuilder had to locate a metalcasting facility that could deliver large castings with tight toler- ances. Vigor wanted to cast a skeg, a long, thin extension on the underside of the ferry that supports the propeller. Vigor Fab approached Bradken Inc.,
Kansas City, Mo., to cast the part at its nearby Tacoma, Wash., facility. While casting the large-section components, both customer and supplier benefi tted from Bradken’s recently installed 3-D scanning technology. Bradken’s ATOS Triple Scan System from Capture 3D Inc., Costa Mesa, Calif., helped accurately scan and inspect the large castings in less than eight hours, while also meeting the necessary tolerance requirements. Based on the principles of triangula-
tion, the ATOS Triple Scan measured the object’s surface geometry by integrat- ing three sensors into a single system. A fringe pattern is projected onto the object, and as the pattern rapidly shifts dur- ing each scan, two cameras capture the displacement and calculate the coordi-
The skeg required supplier-purchaser collaboration to meet tight tolerances.
nate measurements. After each scan, the software then aligns each measurement to build an accurate 3-D representation of the object for dimensional analysis. “T e 3-D scanning became very im-
portant for mating the hull piece with the cast part,” said Paul Shafer, senior buyer-new construction, Vigor Fab. “It was very accurate in telling us where the casting was standing proud, where it was recessed, how it moved and how we had to accommodate those issues.”
During heat treatment, the cast-
ing would experience slight changes in shape, meaning adjustments had to be made. Bradken’s team, along with Vigor Fab engineers, were able to ensure the castings met required tolerances. “It gave the necessary tools to our
engineering and quality assurance de- partments to fi ne tune our boat for the product we got,” Shafer said. “We could train our mind’s eye to see the scanning results so we could fi gure out our solu- tion and make it work for the boat.” Without the quick results from
Bradken’s scanning technology, Vigor Fab would have had to resort to less scientifi c methods of troubleshooting. “All we would have been able to do is
stick it up against the boat and then fi gure out what to do,” Shafer said. “It would have been a much more diffi cult process.” Since the implementation of Capture
Seattle’s Vigor Fab built the 144-car ferry, and the casting came from Bradken’s Tacoma plant.
3D’s metrology solutions, Bradken has continued to optimize use of the technol- ogy on a diverse range of castings and fabricated assembly projects. Bradken’s Tacoma facility is committed to continu- ous process improvement through the adoption of technology and investment in its employees. T rough use of the 3-D scanning technology, Bradken has advanced its manufacturing processes to meet evolving customer demands.
Jul/Aug 2014 | METAL CASTING DESIGN & PURCHASING | 49
Image courtesy the Washington State DOT
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