Application of the reverse 3D scanning method to evaluate the wear of forging tools divided on two selected areas

Gronostajski, Z.; Hawryluk, Marek; Kaszuba, M.; Widomski, Paweł; Ziemba, Jacek

doi:10.1007/s12239-017-0065-x

Cited by 17 publications

(9 citation statements)

References 19 publications

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“…Refs. [13,14] analyze the progressing wear of forging tools and forging defects by monitoring volume changes in the manufactured workpieces using 3D mesh reconstruction. In addition, the use of optical scanners allows the integration of numerical methods (such as Finite Element Analysis) in the dimensional inspection pipeline to quantify the thermal and structural damage of the forging tool [1,3].…”

Section: Off-line Dimensional Inspection In Warm-die Manufacturingmentioning

confidence: 99%

In-Line Dimensional Inspection of Warm-Die Forged Revolution Workpieces Using 3D Mesh Reconstruction

et al. 2019

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Industrial dimensional assessment presents instances in which early control is exerted among "warm" (approx. 600 • C) pieces. Early control saves resources, as defective processes are timely stopped and corrected. Existing literature is devoid of dimensional assessment on warm workpieces. In response to this absence, this manuscript presents the implementation and results of an optical system which performs in-line dimensional inspection of revolution warm workpieces singled out from the (forming) process. Our system can automatically measure, in less than 60 s, the circular runout of warm revolution workpieces. Such a delay would be 20 times longer if cool-downs were required. Off-line comparison of the runout of T-temperature workpieces (27 • C ≤ T ≤ 560 • C) shows a maximum difference of 0.1 mm with respect to standard CMM (Coordinate Measurement Machine) runout of cold workpieces (27 • C), for workpieces as long as 160 mm. Such a difference is acceptable for the forging process in which the system is deployed. The test results show no correlation between the temperature and the runout of the workpiece at such level of uncertainty. A prior-to-operation Analysis of Variance (ANOVA) test validates the repeatability and reproducibility (R&R) of our measurement system. In-line assessment of warm workpieces fills a gap in manufacturing processes where early detection of dimensional misfits compensates for the precision loss of the vision system. The integrated in-line system reduces the number of defective workpieces by 95%. matrix orientation in the forging process is crucial since a severe misalignment between the punch press and the forming matrix axes disables the posterior machining process, resulting in a scrapped part. The circular runout [4] of the forged revolution workpiece indicates the deviation between the punch orientation and the forming matrix axis.Standard tools for dimensional assessment of these workpieces rely on contact between the probe and the measured workpiece. Such is the case of Coordinate Measurement Machines (CMMs), which provide highly accurate measurements [5]. However, dimensional assessment with standard CMMs (and contact methods in general) is not convenient due to (1) the high temperatures directly affect (or even damage) the probe and, (2) long measurement times for the cooled-down workpieces. Consequently, a delay of nearly 20 min between the production of a single part and its dimensional assessment (including its cooling down, transportation to the metrology office and measuring times) arises. Such time delay translates into an uncertainty in the quality control process of approximately 400 potential defective workpieces (worst case scenario) for each measurement.This manuscript presents an optical (i.e., contact-avoiding) system for in-line dimensional assessment of warm forming of revolution workpieces. Our system can continuously measure the circular runout of the parts at around 600 • C in less than 60 s per part. Results from experiments conducted in this manuscript show ...

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Section: Off-line Dimensional Inspection In Warm-die Manufacturingmentioning

confidence: 99%

In-Line Dimensional Inspection of Warm-Die Forged Revolution Workpieces Using 3D Mesh Reconstruction

et al. 2019

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“…Figure 11 shows the image with die inserts divided into two selected specific areas (A and B), which on the basis of a preliminary analysis showed the presence of various destructive mechanisms. In addition, the analysis by 3D reverse scan showed that on the basis thereof much more rapid wear of the forging tools in the area A can be seen (a new tool cross is made in this area which acts as marker 42 ).…”

Section: Measurements and Control Of Forging Instrumentationmentioning

confidence: 99%

“…(a) The idea of scanning 3D-reverse scanning method—the division on selected areas and (b) the results of the tool wear analysis in selected areas, based on cyclically collected forgings 42 …”

Section: Measurements and Control Of Forging Instrumentationmentioning

confidence: 99%

A Review of Current and New Measurement Techniques Used in Hot Die Forging Processes

Hawryluk

Ziemba

Sadowski³

2017

Measurement and Control

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The work presents the possibilities of applying modern measuring techniques, classic and coordinate measuring techniques in the forging industry (various stages of technological sequence), with the use of various measuring tools, instruments and machines applied in workshop metrology. The work points to different aspects of measuring techniques used mainly for two groups of objects, emphasizing their important role in the context of safety (achieved forgings-products) and the significant measurement problems due to the extreme conditions in industrial hot forging processes. The first group comprises various measurements of forgings (control during and after forging and mechanical treatment). The second group includes measurements of the forging equipment involving a broadly understood quality control (geometrical characteristics, surface quality etc.), often combined with comprehensive control and durability analysis of forging tools. The work analyzes the possibility and validity of applying scanning techniques for direct control of the quality and change of the geometry of the tools in industrial forging processes, without the necessity of their disassembly, and also measurement systems of temperature, forces and displacement in forging processes.

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“…from a laboratory to a forging unit), for the purpose of rapid measurement and analysis of results, e.g. : heavy die, steel plate, etc., without the need to dismount tools and interrupt production in order to assess critical geometric features [11][12]18]. Thanks to their mobility and universality, measuring arms are also an alternative to coordinate measuring machines in applications permitting lower accuracy of measurement [21,31].…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

“…Thanks to their mobility and universality, measuring arms are also an alternative to coordinate measuring machines in applications permitting lower accuracy of measurement [21,31]. Publications concerning the application of scanning measuring techniques can be found in the available literature, mainly for final quality control of products [24, 29,], but increasingly often, also for control of forging tools and instrumentation [11][12][13]18]. It should be noted that the application of scanning techniques only allows for determination of geometric changes relative to the assumed nominal object, i.e.…”

Section: Wear Analysis Of Die Inserts In the Hot Forging Process Of Amentioning

confidence: 99%

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

Dworzak¹,

Hawryluk²,

Ziemba³

2017

Adv. Sci. Technol. Res. J.

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This article presents a wear analysis of die inserts used in the hot forging process of a forked forging (yoke), an element applied in steering systems of passenger vehicles. Studies involved the application of an original reverse scanning method intended for rapid and reliable wear analysis of forging tools (with complicated shape) affording easy assessment without the need to dismount tools from the forging unit. The developed method involves analysis of progressive wear of forging tools based on measurements (scanning) of forgings periodically collected from the process and constitutes a useful tool for measurement and testing. As the authors' earlier works have demonstrated, the proposed new approach to analysis of tool wear with the application of reverse 3D scanning has proven successful in multiple instances in the case of axially symmetrical objects. The presented results of studies indicate that it is possible to utilize the expanded method to analyze the lifetime of forging tools, including tools with complex geometry. Application of the reverse scanning method allows for continuous and practical monitoring of the condition of forging tools over the course of the forging process and should have a positive impact on improving production output and reducing production costs.

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Application of the reverse 3D scanning method to evaluate the wear of forging tools divided on two selected areas

Cited by 17 publications

References 19 publications

In-Line Dimensional Inspection of Warm-Die Forged Revolution Workpieces Using 3D Mesh Reconstruction

In-Line Dimensional Inspection of Warm-Die Forged Revolution Workpieces Using 3D Mesh Reconstruction

A Review of Current and New Measurement Techniques Used in Hot Die Forging Processes

Wear Analysis of Die Inserts in the Hot Forging Process of a Forked Type Forging Using Reverse Scanning Techniques

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