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 Scanners a laser 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.

O que está alinhado para usinar

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.

Isso pode arruinar toda a peça de trabalho, como mostrado aqui:

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.

Isso pode garantir que os subsídios de usinagem sejam uniformes e suficientes, assim:

Alinhamento para irregularmente - em branco em branco

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.

Métodos tradicionais de alinhamento

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: Scanner 3D global de Ax

Para medir o elenco, seguimos estas etapas:

O engenheiro 3D digitalizou os dados completos de 3D do campo da fundição e alinhou as coordenadas de dados digitalizadas com o modelo CAD.

After the initial alignment, the engineer analyzed the machining allowance and adjusted the coordinates to make sure that the allowance was evenly distributed.

Comparou os dados digitalizados com o modelo CAD e gerou um relatório de comparação de desvio de cores.

Transferiu o sistema de coordenadas ajustadas para a máquina -ferramenta para usinagem.

Alinhamento para o eixo forjado em branco

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.

Solução: TrackScan+CMM portátil

Etapas de medição

Para medir o branco do eixo forjado, o engenheiro seguiu estas etapas:

Usado óptico tracking system Trackscan 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.

Os pontos identificados pelo CMM portátil também foram usados ​​como pontos de referência para o aperto.

Vantagens

A varredura 3D garante subsídio de usinagem suficiente

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.

Em seguida, você pode medir o subsídio em branco de forma abrangente e garantir que seja suficiente para usinar, evitar resíduos ou defeitos.

Posicione a referência de processamento com software profissional

Com o software profissional, você pode ajustar a distribuição de subsídios e localizar com rapidez e precisão a referência de processamento.

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.

Operar de forma estável e convenientemente no site -

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.

Gerar relatórios precisos e intuitivos em tempo real

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.