The mechanical industry is constantly evolving, and so are the components that it produces. Nowadays, components come in various shapes and structures, which require high precision and accuracy.
A blank is a piece of material that is ready to be machined into a final product. Aligning the blank correctly on the machine tool is important for ensuring the accuracy and efficiency of the machining process. However, manual alignment and traditional ways can be time-consuming and prone to errors.
To avoid these errors and conduct the machining precisely, engineers need to make sure that the part is in the right place relative to the machine tool and cutting tool.
In this blog, we will show you how Scantech’s portable 3D レーザースキャナー can help you with it by identifying the position and orientation of the blank on the machine tool and correcting the tool path before machining.
We will introduce two cases of aligning, respectively irregularly-shaped blank and forged axle blank, and demonstrate the benefits of our 3D scanning technology.
機械加工のために何が調整されていますか
Alignment for machining is the process of adjusting the position of the blank relative to the machine tool and cutting tool to ensure the quality and accuracy of the machining.
For example, suppose we have a machine tool (black section), a blank (gray section), and a CAD machining model (orange section). Ideally, we want to align them vertically, like this:
However, in reality, many factors can affect the alignment, such as machining errors and surface roughness. If we do not adjust the position of the blank with the reference of the CAD model, we may end up with parts that don’t have sufficient machining allowances in some areas.
ここに示すように、これはワークピース全体を台無しにする可能性があります：
To avoid this problem, we need to measure and correct the position of the blank with the reference of the CAD model. Therefore, we can adjust the machining path accordingly.
これにより、加工手当が均一で十分であることを保証できます。
不規則な-形の空白のアライメント
The case involves an irregularly-shaped blank made of cast aluminum alloy. As it is hard to position reliable references, the position of the blank to the machining tool changes every time it is clamped, which affects the subsequent machining.
To solve this problem, we need to scan the geometry of the blank quickly and accurately, and also measure the coordinates of the blank and the machine tool to identify the position relationships.
Then, we can adjust the machining coordinates accordingly, to make sure that there is enough machining allowance on the whole surface of the product. Finally, we can locate the machining reference plane precisely, to guide the following machining steps.
従来のアライメント方法
The traditional method to align is manual marking. It requires multiple adjustments and depends on the worker’s experience, which is time-consuming, tedious, and inefficient.
It is hard to position irregular workpieces accurately, which requires many trials and tests. Therefore, it is hard to guarantee the quality of machining and easily leads to defective products.
Solution: AXグローバル3Dスキャナー
キャストを測定するために、これらの手順に従いました。
エンジニア3Dは、キャストの完全なフィールド3Dデータをスキャンし、スキャンされたデータ座標をCADモデルと整列させました。
最初のアライメントの後、エンジニアは機械加工手当を分析し、座標を調整して、手当が均等に分布していることを確認しました。
スキャンされたデータをCADモデルと比較し、色偏差比較レポートを生成しました。
加工のために調整された座標系を工作機械に転送しました。
鍛造車軸ブランクのアライメント
The case involves a large forged axle blank that needs to be machined. To make a precise shaft, the cutting tool touches the shaft blank while it rotates and cuts off some material. The customer needs to align for machining and find the rotating axis.
解決策：TrackScan+ポータブルCMM
測定手順
鍛造シャフトブランクを測定するために、エンジニアは次の手順に従いました。
使用された光学 tracking system トラックスカン to scan the whole forged shaft blank. Then, aligned the measured coordinate system of the blank with the machining CAD coordinate system. Fine-tuned the coordinates of the blank to make sure that the machining allowance was evenly distributed.
The engineer moved the Portable CMM around the part until its coordinates matched the center coordinates shown in the software. In this way, the engineer identified the center of two ends of the blank and found the rotating axis.
ポータブルCMMによって識別されるポイントは、クランプの基準点としても使用されました。
利点
3Dスキャンは、十分な加工手当を保証します
With a 3D scanner, you can quickly and easily get the full-size 3D data of various parts, without touching them. Even the edges and corners that are hard to reach can be captured completely.
その後、空白の手当を包括的に測定し、機械加工、廃棄物または欠陥を回避するのに十分であることを確認できます。
プロのソフトウェアで処理リファレンスを配置します
プロフェッショナルなソフトウェアを使用すると、手当の分布を調整し、処理リファレンスを迅速かつ正確に見つけることができます。
This will help you to machine the blank parts in the next step, without depending on manual experience. This way, you can lower the processing risk and boost the processing efficiency.
-サイトで安定して便利に動作します
The scanner is easy to operate by hand and can be taken to the workshop site. It can handle complex site conditions (such as vibration, temperature, humidity, light, etc.) and perform stably. It can capture the 3D data of various materials and objects effortlessly, saving you time and money.
正確で直感的なレポートをリアルタイムで生成します
You can compare the 3D data with the CAD model and get an automatic real-time deviation report. This will provide you with detailed and intuitive data support for determining the machining allowance and aligning the position in the following steps.
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