Reverse engineering of metal mold for cover of a jerrycan

Modern 3D scanners are able to solve a wide range of tasks of reverse engineering. They are used to capture the geometry of the samples, obtained by molding, stamping, or mechanical machining. They can be used to obtain high-precision data on the dimensions of the object.

There are widespread cases when the tool would be adopted only after several attempts. This is because the final product turns out with some technological deviations from mathematical values, despite computer-aided design and advanced technology.

Range Vision PRO is able to detect the slightest deviation from production norms in the early stages, which minimizes costs and time to complete the tasks. They significantly reduce the development time of engineering to meet all production quality standards by quick and accurate collection of data on the geometry of the primary samples.

The following use case will help to demonstrate the high efficiency of the 3D scanners RangeVision PRO in achieving high-precision results of reverse engineering in the shortest possible time.

The customer consulted the branch of RangeVision in Nizhny Novgorod, Russia. The task was to scan the geometry of the foundry tool — cover of a jerrycan. A final objective of the customer was to use the results of digitization for production of the duplicate of the form on a CNC to the nearest 0.1 mm from the provided sample

The timing of the order was compressed since the form was temporarily removed from the production. The snap was a steel multi-section construction made with high precision, however, some places were much worn and even destroyed. The task was complicated by the presence of small elements in the design of the form - narrow grooves and small steps. In addition, some parts of the form were deformed.

The mold was disassembled into three parts to accomplish this task. Each part was cleaned and digitized with RangeVision PRO 2M 3D scanner.

The locations of the main working surfaces were fixed in each part of the mold concerning underlying surfaces while scanning.

The scanning of working surfaces was produced with software program “RangeVision ScanCenter” with an accuracy 0.05 mm. Markers were applied directly on the object to simplify the alignment of scans.

Collected 3D data was analyzed by the designer in order to exclude all deformations and wear elements present in the original model.

The damaged parts were reconstructed with the help of 3D modeling, and the resulting mathematical model allowed to produce this form again to replace worn-out elements.

The task took 5 working days: digitization took 16 hours or 2 working days, post-processing lasted for 24 hours in total or 3 working days. The achieving of the main aim became possible with the help of 3D scanners RangeVision PRO: the form was removed from the production only for 2 days which was the best option for the customer. It would last approximately 3 times longer to do this task with the help of coordinate measuring machine. Capturing the geometry would be less accurate as well.