Support Possibilities for 3D Scanning of Forging Tools with Deep and Slim Impressions for an Evaluation of Wear by Means of Replication Methods.

Marek Hawryluk,Jacek Ziemba,Zbigniew Gronostajski,Miłosz Lisowski,Marta Janik,Piotr Górski

doi:10.3390/ma13081881

Marek Hawryluk, Jacek Ziemba + Show 4 more

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https://doi.org/10.3390/ma13081881

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Abstract

This article discusses the problems related to the use of non-contact 3D scanning techniques and their support by means of replication methods for the analysis of the geometrical changes in deep tool impressions used for the forward extrusion of valve-type elements assigned for motor truck engines. The 3D scanning method, despite its unquestionable advantages, also has certain limitations, such as scanning the inner surfaces of deep cavities. This is caused by the fact that the larger the angle between the reflected laser light and the normal direction to the measured surface, the larger the area covered for the analysis, yet at the same time, the higher the measurement error. The authors performed an analysis of the geometrical loss of the tools as well as the corresponding replication masses, together with a discussion of the results related to minimization of the measuring errors. For the analyzed tool, the maximum angle during direct scanning was 40 degrees, which unfortunately does not enable an analysis of the entire pattern, while for larger angles, it is necessary to make the measurement by indirect scanning, i.e., by replicating the cavity imprint of the tool. Therefore, for a given geometry, the reflection angle should be determined individually.

Highlights

The coordinate measurement technique is at present commonly applied in e.g., the forging industry [1,2], for the measurement of both forged elements–forgings [3,4] as well as the tools shaping those products
The traditional measurement methods based on the classic measurement equipment, and modern non-contact measurement methods based on 3D scanning are applied [5,6,7]
(see Figure 5), we can see a simulation of the effect of a change in the filtering of the same measurement data through a determination of the maximal value of the angle between the normal direction and the reflected laser light during the 3D scanning of the new tool on the obtained measurement area

Summary

Introduction

The coordinate measurement technique is at present commonly applied in e.g., the forging industry [1,2], for the measurement of both forged elements–forgings [3,4] (with different degrees of geometry complexity) as well as the tools shaping those products. The traditional measurement methods based on the classic measurement equipment, and modern non-contact measurement methods based on 3D scanning are applied [5,6,7]. Such an approach has been demonstrated in the studies of Hawryluk and Ziemba [8,9] for the wear analysis of die inserts. It should, be pointed out that not all forging tools have a geometry which can be analyzed with the use of 3D scanning methods. In the case when, despite a relatively complicated inner geometry, it is Materials 2020, 13, 1881; doi:10.3390/ma13081881 www.mdpi.com/journal/materials

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