Summary
Plymouth Foundry Inc. (PFI) successfully manufactured new pattern equipment using advanced 3D scanning and modeling technology. The project involved transforming an old rough casting and print into a modern, precise 3D model, which was then used to create high-quality aluminum matchplates. This case study highlights the overall specifications, uses, and applications of the new pattern equipment, as well as the detailed manufacturing process and rigorous quality control steps undertaken by PFI.
Project Specifications
- Client Requirement:
- The client provided PFI with a rough casting and an outdated print, seeking the creation of new pattern equipment that met their critical dimensional specifications.
- Specifications:
- Pattern Equipment: 1 on 20 x 26 Aluminum Roberts Sinto Matchplate
- Material: Solid Aluminum Block
- Technology Used: Hexagon Absolute 7-Axis Arm 85/Blue Light Scanner, Polyworks Inspector and Modeler, Magma Soft
Uses and Applications
The new pattern equipment manufactured by PFI is essential in the production of high-quality cast components. This equipment is specifically designed to ensure precision and repeatability in the manufacturing process, making it invaluable for applications in industries such as automotive, aerospace, and heavy machinery.
Manufacturing Process
Initial Assessment and Scanning:
- PFI received the rough casting and old print from the client.
- The casting was scanned using PFI’s Hexagon Absolute 7-Axis Arm 85/Blue Light Scanner.
- The scanned data was processed using Polyworks Inspector and Modeler to create an accurate 3D model.
3D Modeling and Client Approval:
- The initial 3D model was modified to meet the critical dimensions required by the client.
- The modified 3D model was then submitted to the client for approval.
Pattern Creation:
- Upon client approval, the 3D model was sent to a pattern shop.
- A new 1 on 20 x 26 Aluminum Roberts Sinto Matchplate was machined from a solid aluminum block.
Gating and Riser System:
- PFI utilized their Polyworks Modeler (Magma Soft) software package to design the gating and riser system.
- This software allowed PFI to run solidification simulations to ensure the casting process would be flawless.
Quality Control Steps
PFI adheres to stringent quality control measures throughout the manufacturing process to ensure the final product meets the highest standards:
Dimensional Accuracy
Each stage of the process, from scanning to final machining, involved rigorous checks to ensure dimensional accuracy.
Simulation Validation
The gating and riser system design was validated through solidification simulation to preemptively address potential casting issues.
Material Integrity
The use of high-quality solid aluminum blocks and advanced machining techniques ensured the durability and reliability of the pattern equipment.
Conclusion
Plymouth Foundry’s expertise in advanced scanning, modeling, and machining technology allowed them to deliver precise and high-quality pattern equipment that meets the stringent requirements of their client. This project not only demonstrates PFI’s commitment to innovation and quality but also their capability to handle complex manufacturing challenges efficiently. The new pattern equipment is set to play a crucial role in the client’s production process, ensuring consistent and high-quality outputs.
Project Gallery
