ATOS 3D-Coordinate Measurement Techniques in … 2 Optical 3D Coordinate Measuring Techniques in...

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GOM ATOS 3D-Coordinate Measurement Techniques in Foundry Process Chains 21 November 2014

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Page 2 Optical 3D Coordinate Measuring Techniques in Casting Processes GOM

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GOM – 3D Measurement Technology in Casting Processes Presentation overview

Patterns, forms, tools & dies

Inspection of cast parts

About the company

Functioning of optical 3D metrology



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GOM – Gesellschaft für Optische Messtechnik Company structure

GOM is a global industry partner for optical 3D measurement systems since more than 20 years

· Development, manufacturing and sales

· Over 200 employees

· More than 4,000 installations

· 7 GOM branch offices in Europe

· 45 dedicated partner offices worldwide

· Leading firms from the automotive and aviation industries as well as makers of consumer goods rely on metrology solutions from GOM



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GOM – Industrial 3D Metrology Measurement systems

· With comprehensive know-how in 3D coordinate metrology, material and component testing, inspection and analysis, digital image processing

· Material testing

· 3D shape and dimension inspection

· Dynamic component testing

ATOS Full-field

3D Digitizing

TRITOPCMM Mobile

Optical CMM

PONTOS Dynamic

3D Analysis

TRITOPDef Displacement Vector Analysis

ARAMIS Full-field 3D Strain Measurement

ARGUS Deformation Analysis in Metal Forming

GOM is a global industry partner for optical 3D measurement systems since more than 20 years



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GOM – Single-Source Provider Measurement systems, software solutions, technical service and support

Gravity die casting

Sand casting Pressure die casting

Investment casting

ATOS 3D Digitizer

Pattern & mold making



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ATOS 3D Metrology Deployment throughout the casting process chain

Cast parts Molding shop Core making shop

Design CAD

Simulation comparison Component warp

Model & tool construction

CNC processing

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ATOS 3D Digitizer: Full-field 3D Coordinate Measurement Technology

· Full-field data capture · Mobile · Large & small components · Manual and automatic · GOM Touch Probe: tactile and optical metrology



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ATOS 3D Digitizer Precise 3D coordinates with high-quality data

Optical 3D scanner for full-field 3D component measurement and inspection Precise 3D coordinates and high-quality data Any object size, surface characteristics and component complexity

3D surface measurements

· Injection molding and plastics industries

·Sheet metal forming industries

·Casting industry

· Tool and pattern making



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ATOS - Optical 3D Coordinate Measuring Machine Stereo camera system – industrial 3D metrology

Stereo camera technology

Flexibility Mobility

Robust

Blue Light technology

Triple scan



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ATOS - Optical 3D Coordinate Measuring Machine Function principle and measurement process

Fringe projection supplies precise 3D coordinates for each pixel

The result: a complete 3D point cloud (STL polygon mesh)

Approx. 2 seconds for each measurement Up to 8 million points per measurement field

Automatic transformation of individual measurements to a common coordinate system

Individual measurements are polygonized to eliminate overlapping areas

ATOS - Optical 3D Coordinate Measuring Machine Function



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Stereo Camera Setup Process security during operation

Security for every

measurement

Control DURING the

scanning process

Online monitoring of sensor and object movement

Prevention of measurement errors

Online monitoring of sensor calibration

Verifiable scanning accuracy

Online tracking of 3D sensor position

Flexible positioning of component or sensor

Supports various alignment strategies

Automatic transformation of single measurements

Secure

Precise

Flexible

Fast



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ATOS - Optical 3D Coordinate Measuring Machine 3D measurement data for following processes

· Export formats for following processes

STL mesh ASCI point cloud

IGES sections

IGES curves/contrast lines

IGES primitives



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Large Mobile

Small Stationary

ATOS - Optical 3D Coordinate Measuring Machine Flexible sensor concept: from small to large – stationary and mobile

Pin Plane Office Production

Modular design Easy adjustable



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Modular and Flexible Sensor Concept Mobile – Stationary - Automated

Automated Scanning Cell Stationary System Mobile Metrology

System

One Sensor Head | Modular Design | Easy Setup



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ATOS - Optical 3D Coordinate Measuring Machine Optically hidden surfaces

GOM Touch Probe GOM reference point system

CT data inspection with GOM software



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· ATOS sensor serves as tracker for the reference point group on the probe

· GOM Touch Probe

·Measurement on hidden/partly hidden surfaces

·Measurement of primitives

·Comparing measurements with CAD data

·Quick measurement of individual points

·Online alignment

ATOS - Optical 3D Coordinate Measuring Machine Optically tracked GOM Touch Probe



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ATOS - Optical 3D Coordinate Measuring Machine Optical and tactile in a one system

· ATOS Touch Probe combines full-field and tactile measurement

· Fast process, since all measurements are made with one system

·All evaluations (full-field and tactile) directly in the ATOS software



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ATOS Triple Scan Precise 3D measuring data for following processes

ATOS 3D coordinate metrology:

· High-quality 3D mesh

· High resolution for finest details

· Measurement of small radii

Reducible database for following processes:

· Precision-based

· Curvature-dependent

Data for following processes

Quality Control

CNC Processing

Reverse Engineering



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Step 1 Measurement

Step 3 Inspection report

Step 2 Inspection

3D Form and Dimension Analysis ATOS: Measurement process in three simple steps

Step 2 Alignment

Step 3 Evaluation

All 3D measurement data and inspection results in compact format for exchange and further analysis

Free GOM Inspect software Colleagues and customers

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GOM Inspect Professional 3D Inspection Software: Shape and dimension analysis of cast parts

Component warp

Sink marks

Shrinkage analysis

Material accumulation

Allowance analysis

3D shape & dimension control with CAD

2D analysis against drawing

Measurement of undercuts

First article inspection



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Shape and Dimension Analysis of Cast Components CAD import, measurement plan import, FTA import

· CAD data import with surface tolerances and FTA features

· Measurement plan import

· CATIA V4, CATIA V5, PRO/E,

Unigraphics, IGES, STEP, JT-

Open, Parasolid.

· CAD data import with tolerances & FTA · Measurement plan import · CAD interfaces included



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Shape and Dimension Analysis of Cast Components Flexible alignment of measurement data

· Flexible alignment of measurement data to CAD

· Different alignment options, RPS, 3-2-1, best fit,…

· Flexible alignment · Alignment independent from fixture · Optimization of contact/support points



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Shape and Dimension Analysis of Cast Components 3D shape and dimension control with CAD

· Full-field verification with CAD data

·Component warp

·Sink marks

·Shrinkage analysis

·Allowance check / machining allowances

· Clear and easy to understand · Problematic areas immediately locatable · Decisions can be taken fast



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Shape and Dimension Analysis of Cast Components 2D analysis: CAD - inspection sections

· 2D inspection sections

·2D section versus CAD data

·Overview of section positions

·Vector lines

·Deviation points

· Tolerance bands

· Detailed analysis · Overview of section positions · Deviation points



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Shape and Dimension Analysis of Cast Components 2D analysis: CAD - inspection sections

· 2D inspection sections

·2D section versus CAD data

·Overview of section positions

·Vector lines

·Deviation points

· Tolerance bands

· Deviations as vector lines · Visualization of tolerance bands · Tolerances from CAD or manual



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Shape and Dimension Analysis of Cast Components STL versus STL: component vs. component, component vs. simulation

· Comparison of components from different mold cavities in multiple cavity tools

· Comparison with boundary / reference samples

· Comparison after changes of casting parameters

· Simulation comparison

· Faster verification of casting parameters · Analysis of tool cavities · Component deformation vs.simulation



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Shape and Dimension Analysis of Cast Components Complete material thickness analysis

· Full-field material thickness analysis

·Sink marks

·Melt flow

·Material accumulation

· Verification of CAD data for demolding chamfers / draft angles

· Fast definition of critical areas · Check for demolding draft angles · Detection of material accumulation



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Shape and Dimension Analysis of Cast Components Geometric dimensioning and tolerancing (GD&T)

· Geometric dimensioning and tolerancing (GD&T)

·Quick and automatic data selection

· Transparent reference systems

·Clear visualization of tolerance zones

·Simple interpretation of results

· Full surface data base · Simple results interpretation · EN ISO 1101 and ASME Y 14.5



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Shape and Dimension Analysis of Cast Components Inspection against drawing / CMM inspection

· CMM inspection

· Positions

·Distance inspection

·Dimension inspection (scalar)

·Angle inspection

· CMM inspection possible at any points · Complete first article inspection report · Automatable



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· Primitives

·Best fit

·Cheby fit

·Manual input

· 2D dimensioning

· Positions

·Distances

·Angles

· Analysis is possible at any points · 3D or section-based · User-defined reports



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· Dimensions

·Virtual calipers

· Inside caliper gage

· Outside caliper gage

· Disc caliper gage

· Cutting caliper gage

· Analysis is possible at any points · 3D or section-based · User-defined point selection



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Shape and Dimension Analysis of Cast Components Optically inaccessible areas – optically tracked touch probe

· Analysis of hidden areas with touch probe

·Online point probing

·Comparison with CAD data

·Check of geometry elements

· Measurement of undercuts · Fast measurement of individual points · Fast check of primitives



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Shape and Dimension Analysis of Cast Components Inspection reports and reporting

· Exporting measurement data and inspection reports

· Tables

·Customizable inspection reports

· Free GOM Inspect software

· Table export · Customizable inspection reports · 3D results in GOM Inspect software



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Step 1 Measurement

Step 3 Inspection report

Step 2 Inspection

3D Shape and Dimension Analysis ATOS: Measurement process in three simple steps

Step 2 Alignment

Step 3 Evaluation

All 3D measurement data and inspection results in compact format for exchange and further analysis

Free GOM Inspect software Colleagues and customers



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· Advantages

· Fast, full-field measurement

·Complete data capture

·Mobile – moves toward the object

· Flexible – different object sizes

·No fixture for stable components needed

·Variable alignment

· Disadvantage

·Slow for small number of inspection features

3D Shape and Dimension Analysis Comparison: tactile – optical

· Advantages

·Established technique

·Quick, with small number of inspection features

· Disadvantages

·Slow on free-form surfaces

· Long running times, little data

·Component holders needed

·User-dependent alignment

Tactile methods Optical methods



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· Measurement of inspection features acc. to drawing

· Evaluation of the 3D point cloud

3D Shape and Dimension Analysis Conventional first article inspection vs transparent 3D analysis



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· Traditional component drawing with inspection features for tactile measurement

· Only functional dimensions are defined via geometric dimensioning & tolerancing

· For all other surfaces

·CAD dataset as master

· Profile tolerance

3D Shape and Dimension Analysis Simplifying drawings

Component dimensioning for tactile measurement technology

Component dimensioning for optical metrology



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Optical 3D Coordinate Measurement Technology Targeted tool corrections

First article inspection

High data density

Multiple alignment

Good visualization

Fast feedback

Minimum intervention in the tool

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Patterns, Electrodes, Dies and Tools

· Inspection of milling results

· Wear analysis

· Reverse engineering

· Tool optimization

· Tool modification

· Maintenance and archiving

· CNC milling on ATOS data



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Patterns, Electrodes, Dies and Tools Inspection of milling results, wear analysis

· Complete inspection of milling results

· Wear analysis

· Complete analysis for fast, effective tool optimization



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Models, Electrodes, Patterns and Tools Reverse engineering

· Data backup of functioning and optimized pattern plates and tools

· For maintenance and archiving

· Integration of current tool modifications in the CAD base

Reverse engineering



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· Components are measured in one common coordinate system

· Automatic transformation of all individual parts in assembly on the basis of reference points

· Analysis options prior to casting:

Max. allowance check prior to casting

Determination of core clearance

Max. material thickness analysis, 2D and 3D

Compensation for shrinkage through scaling (global or various in X,Y,Z direction)

Patterns, Electrodes, Dies and Tools Virtual assembly



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Patterns, Electrodes, Dies and Tools Virtual assembly

· Analysis options prior to casting:

· Virtual assembly of a casting mold with sand cores

Determination of core clearance and core positions prior to casting

Determination of max. material thickness in 2D and 3D prior to casting



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Patterns, Electrodes, Dies and Tools Fit of die/mold halves / virtual material thickness

· GOM reference point system

· Fit of die/mold halves and calipers

·Virtual material thickness

· Indirect material thickness analysis

· Testing die-spotting surfaces

· Fit of die/mold halves and sliders

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CNC-machining of casted blanks

· Measuring of the real shape

· Allowance control

· Alignment on CNC machine

· Verification of milling results



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Rapid Milling on ATOS data direct duplication of patterns and tool blanks

· Duplication of patterns and tools

· Direct milling on ATOS data without reverse engineering

· Hybrid data

·Mesh data can be integrated directly into surface models



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CNC-machining of casted blanks alignment – tool path calculation - control

· Time-saving digitising of the real shape of the blank due to large measuring volume

· Alignment of measured data to CAD data

· Allowance control of blank geometry to CAD

· Positioning of the measured blank on the CNC-machine and milling of the calculated tool paths

· Utitlisation of the scanned blank data for

·Optimising of milling strategies / Rough machining based on the real blank shape

· Identification of obstacles on the blank

· Prevention of tool collisions

· Reduction of machining times

· Verification of the milling result



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Rapid Milling – CNC-Fräsen auf ATOS Daten Ausrichtung – Aufmaßkontrolle - Fräsbahngenerierung

· CNC-machining of casted blanks

·Capturing the real shape

·Allowance Control

Good alignemnt on CNC machnine

· Tool path calculation on ATOS-data

No „Airmilling“

Reduction of machining times

· Real shape of casted blank through ATOS data

Realizing obstacle contours

Avoiding tool collision

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Summary



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ATOS Triple Scan Precise 3D measuring data for following processes

ATOS 3D coordinate metrology:

· High-quality 3D mesh

· High resolution for finest details

· Measurement of small radii

Reducible database for following processes:

· Precision-based

· Curvature-dependent

Data for following processes

Quality Control

CNC Processing

Reverse Engineering



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ATOS 3D Metrology Deployment throughout the casting process chain

Cast parts Molding shop Core making shop

Design CAD

Simulation comparison Component warp

Model & tool construction

CNC processing



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Integration in Industrial Processes –ATOS Solution Advantages

· Increasing integration in industrial development and production processes with major potential for:

Improving process reliability

Optimizing production processes

Reducing development times

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Thank you for your attention

[email protected]

www.gom.com

Date post:	27-Mar-2018
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ATOS 3D-Coordinate Measurement Techniques in … 2 Optical 3D Coordinate Measuring Techniques in...

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