Casting process verification

The process of making cast prototypes comprises several stages:

• Making 2D drawing and designing in every detail the mould- and core-making technology,
• Making 3D drawing in one of the 3D graphic editors,
• Technology verification on one of the available simulation programs, e.g. MAGMAsoft, and modelling – whenever possible - the mechanical properties of the examined casting,
• Making prototype using one of the available rapid prototyping techniques,
• Making casting. Sometimes it is necessary to make a die from e.g. silicone rubber, and use it next for the manufacture of wax patterns.

At all and each of these stages, the manufactured products may change their dimensions due to the effect of rheology, shrinkage, and man’s interference. This is why it is necessary to check the dimensions of the ready prototype and compare them with the drawing made previously, which in this case serves as a reference standard. One of the best techniques used for this purpose is that of Renishaw Machine Checking Gauge.

The device “takes” measuring points and enables making a 3D drawing of the workpiece. The measuring arm operation is backed up by a scanning 3D head, thus extending considerably the range of the prototype measuring techniques. In both cases the dimensions of the cast prototype are compared with the starting 2D/3D drawing. The presentation is of a graphic character, which extends further the range of the workpiece verification.

Owing to the use of special computer software, it is possible to numerically trace the differences at any selected spot on the surface of the examined workpiece.

It is worth noting that the available equipment is applicable not only in the verification of cast metal prototypes, but also in the verification of prototypes made from other materials, like powders, organic resins, wax compositions, silicone rubber, plastics, etc.