Scanning and touch probing of large components and hot dies in a hostile environment

Wyman Gordon is a major supplier of forgings to both military and commercial aerospace manufacturers. Their need to generate critical high-accuracy measurement data in a hostile forging environment presented unique challenges. The requirements included the ability to measure large components up to 23 feet, measure hot dies, and a need for both discreet point probing and high-density point cloud acquisition. All of which takes place in a setting where thermal extremes and particulate contamination are guaranteed. In addition, there was a frequent need to reverse-engineer patterns and tooling that may be up to 50 years old.

Wyman Gordon decided to invest in our unique measuring solution consisting of a Breuckmann structured light scanner navigated by a Metronor DUO electro-optical large volume coordinate measurement system - the NaviScan3D. The NaviScan3D is portable, allowing the users to take the measurement system to the workpiece on the shop floor. The system can probe deep into hidden areas, and generates high-accuracy scans of large surfaces very quickly. This is especially important in the die shop where worn dies are repaired in a process which entails heating the die, welding new material onto the die, then machining the die.

Because of the high temperatures involved, a scanning solution that requires targets was simply not viable. A laser line scanner was also out of the question, because prolonged exposure to the intense heat would damage both the line scanner and the operator. Metronor and Breuckmann's unique solution overcomes all these obstacles since the stand-off distance of the NaviScan3D is large enough to position the scanner away from the effects of the hot die.

In the die repair process, dies are heated to around 450F before welding to minimize distortion. Traditionally, the die must cool before the process of machining the welded material can begin. However, several days can be lost if the machining process reveals that inadequate material was added during weld-up. The die must then be reheated, and the process repeated. The NaviScan system is used to scan the dies while still hot. The scan data is then compared to a CAD model of the die, and areas that still need material are identified through a color coded map. These areas are then welded up while the die is still hot, saving significant time.

Using the NaviSCAN3D in the shop is fast and easy. For most jobs it is a simple matter of rolling the system out to the area of the shop where the object is to be scanned, then setting up the Metronor DUO system as it would normally be used for single point measurement. At this point the Light pen can be used to establish the object coordinate axis system and inspect the part, or scanning can commence with or without a coordinate system in place. In either case, Metronor and Breuckmann provide flexibility, ease of use, and most importantly, savings in time and money.