Measuring hand-pouring motion in casting process using augmented reality marker tracking

Abstract

Elucidations of workers’ pouring motions and the resultant inflow behavior of molten alloy into the mold are important because the inflow behavior is well known to affect casting quality. Nevertheless, few reports in the relevant literature describe studies of inflow behavior effects on casting quality because of difficulty in measuring the worker’s pouring motion. Therefore, this study was conducted to examine worker’s pouring motions in the actual casting field and to describe the relation between the motion and casting defects. For that, an augmented reality (AR) marker-tracking method was used to conduct contactless measurements of the pouring motion. Validation of the method revealed that the error was less than 0.9° during roll motion from 0° to 90°. Subsequently, measurements of worker’s pouring motions were conducted during actual aluminum alloy casting. Results demonstrated that the method enabled the continuous acquisition of the translation (x, y, and z) and rotation (roll, pitch, and yaw) of the crucible during pouring with a usual pouring device and crucible. Finally, the AR marker-tracking method was capable of revealing the difference of the worker’s pouring motions corresponding to the occurrence or non-occurrence of a misrun defect during the gravity die casting. The obtained results demonstrated that the AR marker-tracking method can be used to measure the worker’s pouring motion. It can reveal relations between its motion and the casting defect.