We were asked by a client to undertake a quality control inspection of a 230kg industrial casting, used as the outer housing of an industrial filtration system.
The Inspection Challenge
We were asked by Simpson Patterns Ltd of Sheffield to undertake a quality control inspection of a large 230kg industrial casting, used as part of an industrial filtration system.We used our blue light 3D scanning system to perform the inspection and compare the results to the CAD model of the original design in order to assess production quality.
Detailed information was required on the general profile of the cast part as well as wall thicknesses at given locations in order to look for the possibility of “core shift” whilst the part was being cast. This was especially important as the end customer had previously had this problem with components cast by other companies.
The Inspection Methodology
Following the completion of scanning PES Performance engineers worked alongside our client in order to develop an inspection methodology bespoke both to the part and the client’s commercial requirements.
Repeatability and multiple part inspection was a key aspect of this inspection as the client intends to inspect multiple parts in order to validate the specified tolerances and dimensions on the casting.
The inspection itself consisted of several stages. A Pass/Fail model was initially used to show any areas of the part that fell outside the specified tolerance. Areas shown in green represent areas within tolerance, the red areas represent regions where the part is out of tolerance, which could be due to lack of thickness or too much of it.
The pass /fail model was then further developed to show any deviation in tolerance from area to area across the component. This information is shown in a 3D colour map. Cool colours indicate where the part is undersized, green areas where the part is very close to being identical to the CAD model and warmer colours represent where the part is slightly oversized. All measurements are based on the required tolerance for the part, applied to the original CAD model.
Utilising our inspection technology, we were able to analyse multiple versions of the same part using the same testing methodology. This functionality allows us to evaluate the repeatability of the manufacturing process for the given part. The information provided was then fed back to the end client for their evaluation.
The same technique can be used to re-evaluate a design and its given tolerances. Should too many parts be failing inspection it may be necessary to amend the component design. Likewise where parts are consistently well within tolerance it may be possible to tighten the tolerance on the parts to more accurate constraints.
Added value through inspection
We can inspect large or small castings, from a single part to 100s of parts, either at your premises or through our bureau service: Scanning Inspection Provides.
• Tractability on each component and archived data.
• Design for manufacture opportunities taken from the report of inspections trends.
• Optimisation of the manufacturing process.
• Identification of common trends leading to training and development for the team.
• Added advantage in securing ongoing work through a robust and bespoke inspection process.
• 100% confidence in the part when delivered.
• Cost benefit. Investing in a quality inspection processes can save time, money, via rejected parts, and risk.
If you would like to know any more information about Simpson Castings capabilities or have a specific project to discuss then please contact Mark Rixham here.