Casting mold conformity control based on molding analysis

Our partner, the Italian company INKAY TECHNOLOGY S.R.L., has completed a transmission case 3D scanning project for one of the automobile industry leaders.

The task was to assess the conformity of the cast case part received from the vendor to the initial CAD file and to decide on the necessity for casting mold modification if deviations are found.

The object scanned had a complex shape and many arbitrary shapes. Therefore, it was difficult to measure by conventional methods. The RangeVision Standard + 3D scanner was used to solve this problem.

The exterior of the case was scanned in the first stage. Markers were used to simplify the work: by distributing them wisely, the scanned object could be placed in any position in front of the scanner, and the scans were aligned automatically.

In the second stage, for scanning of the interior of the transmission case, the case was divided into two parts using a high-precision cutter. Each half was scanned separately.

All of the scanned parts were merged in the third stage. The groups of interior scans were aligned according to the exterior geometry of the same part that was scanned during the first stage, and the cut line did not impair the overall accuracy of the final STL model.

The final 3D model was compared directly to the initial CAD file used to prepare the casting mold.

A color map of the geometry deviations was developed. This comparison method is easy to see, and enables easy interpretation of the measurement results and use of them for casting mold modification or molding process optimization to achieve the required quality of the finished part. The accuracy of the conformity was verified by both points and sections.

As a result of the work, the casting mold was modified in accordance with the customer’s requirements, and production of parts compliant with all tolerances was launched.

Materials by RangeVision, courtesy INKAY Technology SRL.