3-D SCANNING GAINING VALUE
FROM
One case study shows how 3-D scanning can trim lead times by quickly developing tooling for and ensuring dimensional accuracy of complex castings.
A GLENN MCQUARTER, BAY CAST, BAY CITY, MICHIGAN
casting buyer needed a large, curved component as a part of a new project, but the design’s size (1,200 lbs.) and curved shape presented specifi c challenges that severely limited the available methods of manu- facturing. Not only that, the turn-around time for the project was relatively short. T e customer approached Bay Cast Inc., Bay
City, Mich., which specializes in heavy-sectioned castings and large-format machining services. T is specifi c project highlighted how casting
buyers can realize the value of 3-D scanning as a way of ensuring the accuracy of fi rst article castings and minimizing tooling work. A customer needed 16 large castings in a 1030 steel alloy, including 10 large elbows (1,200-lb. cast- ings with a maximum envelope size of 132 x 58 x 15 in. and a maximum wall thickness of 1.44 in.) and six small elbows (500-lb. castings with a maximum envelope size of 93 x 42 x 8 in. and maximum wall thickness of 1.12 in.). 3-D scanning involves the use of a three-dimensional data acquisition device to
acquire X, Y and Z coordinates (or points) from the surface of a physical object. T e conglomeration of these points, known as a point cloud, then can be used to create a 3-D mesh and, eventually, a solid model in various CAD formats. T ese models then can be used in inspection, analysis, rapid manufacturing and reverse engineering ef- forts. T is case study examines one 3-D scanning method of the many used in various industries today in tackling a specifi c challenge associated with a 2014 project. T e customer initially pursued casting these parts, which were part of a new
project, because of the diffi cult design. T e only other viable method for production required rolling and shaping approximately 18 individuals pieces and then welding them together. Casting this component as a single part had the potential to lower costs and reduce lead times, as long as they could be cast to the desired shape.
Capabilities & Concerns Timing on this particular project was critical because these castings were part
of larger fabrication assemblies. Figure 1 shows the elbow piece in its fi nal applica- 30 | METAL CASTING DESIGN & PURCHASING | Sept/Oct 2015
Fig. 1. The component is a critical curved edge in a larger fabrication.
tion. Bay Cast’s engineering depart- ment, with a minimum amount of ex- perience with these castings’ geometry at the time, had these major concerns about casting this particular project: 1. Will parts with this much surface area and so little weight encounter a restraint to contraction on the large open sides?
2. Can the length of the longest overall dimension be held to a
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