Casting & Forging

Casting & Forging

Do you face the challenge of optimally aligning a cast or forged part for machining and spending excessive time using trial and error? Or later, finding that there’s insufficient stock? Even scrapping the part after wasted time on the CNC machine? We can help you eliminate these problems.
You can of course use Metronor for simple quality assurance but we offer a lot more. It’s a common task – finding the best orientation for your casting or forging before machining. The consequences of getting it wrong can be expensive when the CNC machine starts cutting through air. All of this is made worse as the parts get larger and have geometries that are more complex. The use of Metronor to eliminate these challenges represents a massive return of investment.

The benefits Metronor provides are not only relevant to those machining a delivered casting or forging – if you are the manufacturer of the parts, you can find the optimum orientation and mark the part before delivery to the customer. With this, you add substantial value to the product and set yourself ahead of your competitors.

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PERFECTLY ADJUSTING A PART DIRECTLY ON A CNC MACHINING BED

You start by using the CAD model of the finished machined part as a reference, then getting a rough alignment of the model to the casting or forging, and finally measuring the critical features of the part. These are usually the surfaces to be machined and are quite often difficult to reach – here Metronor’s unrivalled ability to perform deep-probing is essential.

Other advantages of Metronor are fast set-up of the cameras, no warm-up time, stress-free use of the Lightpen for a wide range of probing, no repositioning and subsequent loss of accuracy (leap-frogging – unlike with articulated acasting_forging_2rms and other systems), no stickers needed, no deep knowledge of photogrammetry required, etc.

Once the relevant surfaces have been measured, we use a specific algorithm called MMC (Maximum Material Compensation) to find the orientation of the part that provides the optimum stock distribution at the surfaces that have been measured. The image on the left shows a simple example of the effect of MMC. The resulting orientation is defined by a slight transformation to the coordinate system of the part to be machined in all 6 degrees of freedom. There are various ways of making use of this information to achieve the correct alignment on the CNC machine. It can be adjusted directly on a CNC machining bed, even whilst another part is being machined.

 

punch_probe_metronorPunch Probe

A unique way of marking the transformed coordinate system. Datum marks can be made on the part by simply locating a desired point and then creating a punch mark with our special probe (“virtual scribing”). A small device that brings great benefits. Also if you are a company creating castings or forgings, simply mark the optimal orientation before delivery. This provides full documentation and guarantees that the part can be successfully machined, avoiding shipping scrap and dissatisfied customers, and bringing competitive value to your business.

 


precision_positioning_kit_metronorPrecision Positioning Kit

A further useful tool at your disposal is the use of a pad instead of a Lightpen in order to easily adjust the part in all 6 degrees of freedom (6DOF). The Precision Positioning pad is a target that is simply mounted on the part so that it can be seen by the cameras and used with special software functions in Metronor’s PowerINSPECT to display the 3 angles (pitch, roll and yaw). The pad is another unique tool we provide so that you can get to that optimal alignment in the easiest and fastest way possible.

DUO System

The accuracy provided by a SOLO single-camera system is usually sufficient but in order to achieve the largest coverage of the part without having to move a camera, the optimal configuration often used is the 2-camera system DUO, using the so-called “switch-mode” capability of the DUO.
Additionally, options such as the Punch Probe, the Product Positioning Kit and various probe extensions are available. Read DUO specifications.

Metronor Portable CMMs for Casting

Source: Kristiansands Jernstøperi AS. Watch this video on Youtube.

 

 



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