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Accuracy of the New Method of Alignment of Workpiece Using Structural-Light 3D Scanner

Gessner Andrzej, Ptaszyński Wojciech, Adam Waldemar

Advances in Science and Technology. Research Journal

2022

Vol. 16, no 1

1--14

This paper presents a new method of aligning workpieces for machining by means of optical measurements followed by the results of verification tests of this method. The overview of modern assessment methods of irregularly shaped blanks are discussed in this study, with particular emphasis on cast iron castings, as well as on problems related to their positioning and fixing for machining. A flowchart of the proposed method and its verification results in industrial conditions are also presented. The essence of the method is based on the comparison of two spatial models: a designed workpiece model and the actual model of a casting produced with a coordinate measuring technique. A series of six iron castings were tested. The obtained results indicate that the errors caused by locating amounted to a maximum of 2 mm (average 0.5 mm) and were three times lower than actual machining allowances. This points to the correctness of the developed method and the great potential for its industrial application. Additionally, a method for improving locating accuracy by modifying the shape of the retaining pin is presented.

Optimizing Body Machining Including Variable Casting Allowances

Gessner Andrzej

Management and Production Engineering Review

2021

Vol. 12, No. 2

65--74

The work contains the results of research conducted to optimize the machining of milling table castings. The possibility of reducing the total volume of machining allowances, reducing the wear of cutting tools, shortening machining time and eliminating idle machining passes was considered. The tests were carried out on two batches of castings supplied by two independent foundries. Casting geometry measurements were made using a structured light scanner. The analysis included machining with cemented carbide tools and tool ceramics at two machining centers: DMC200U and DMC270U. It has been shown that as a result of eliminating idle machining passes, it is possible to reduce machining time by 12% for the first and by 44% for the second casting supplier. The estimated annual savings for the production volume of 500 pcs of these castings can range from € 7388 to even € 23 346. The actual cost of cheaper casts was also calculated, taking into account the difference in machining cost resulting from larger machining allowances.