AluCast opts for Faro arm

Martin Haynes, quality and technical director at Wednesbury-based AluCast, an aluminium foundry, recently began a search for an accurate yet speedy metrology solution that would keep pace with increased production volumes.

Recently tasked with casting a range of urgently required prototype parts for an important customer, AluCast completed all of the relevant casting processes in record time. Having been told that the parts were now ready except for the required dimensional inspection process, which would take another day, the customer suggested it would visit AluCast’s facility and perform on-site inspection with its own Faro ScanArm.
Impressed by the speed of set-up and the Faro ScanArm’s ability to quickly scan each of the components and gather all of the required data, Haynes was convinced that it was the answer to AluCast’s dimensional inspection needs.
“As well as being impressed by the dimensional accuracy achieved and the clear presentation of the captured data, we were astonished at the equipment’s speed of operation,” he says. “In fact, we estimated that the inspection results our customer achieved in just one hour, would have taken us over eight hours with our existing equipment. In addition to the performance of the ScanArm, we received excellent reports from our customer related to the levels of support and service they receive from Faro UK.
Following a demonstration, AluCast duly invested in a Faro ScanArm HD.
“Our ScanArm HD has delivered on all of the promises made by the staff at Faro UK in terms of simplicity, accuracy and speed of use,” says Haynes. “As well as the inspection processes for which we purchased the Faro ScanArm, each day we are finding new uses for it.”
For further information www.faro.com

Mitutoyo CMM aids Artemis quality

Loanhead-based Artemis Intelligent Power, a specialist in digitally controlled hydraulic pumps, recently searched for an advanced CMM that could deliver the company’s required levels of precision and feedback. After considering several CMMs from alternative manufacturers, a Mitutoyo Strato-Apex 7106 was purchased and installed.

Fergus McIntyre of Artemis Intelligent Power says: “Not only did the Strato-Apex 7106 have the XYZ capacity [700 x 1000 x 600 mm] that would accommodate the range of components we manufacture, it provided the high-accuracy capabilities that would enable the inspection of our parts, many of which have challenging dimensional specifications.
“It helped our decision that the Strato-Apex CMM was easy to operate and that Mitutoyo UK have an excellent reputation for customer service,” he adds. “Soon after the machine’s installation and operator training, our staff quickly mastered the CMM’s controls and software.
“Given our projected increase in production and the large volumes of parts that will need accurate inspection, not only will the Mitutoyo CMM help take care of current R&D and goods-inward inspection needs, but its operating speed should help it remain ‘future-proof’ and able to handle increased output from our new production unit.
“To ensure that we fully exploit our Strat-Apex CMM’s CNC capabilities and fast operating speed, we will continuously add to our already written library of component inspection programs. This will enable us to load from a single part, up to a large batch of components, on to the CMM’s bed, recall the relevant program and instigate a rapid, fully automated inspection routine.”
For further information www.mitutoyo.co.uk

Adaptive manufacturing with metrology feedback

To perform the complex mathematical calculations required for metrology-based, real-time adaptive control of CNC machining processes, powerful CMM software needs to be directly integrated within the manufacturing system.

CappsNC, from Applied Automation Software, an adaptation of CappsDMIS CMM software, has been developed to program any machining centre so that it can perform advanced measurement, metrology and GD&T calculations using the standard DMIS language. Offline programming, with automatic collision avoidance and five-axis toolpath generation, allows the programming of all machine configurations, including multi-axis mill-turn machines.
A CAM style programming environment with realistic machine tool virtual model, simulation capabilities, automatic path generation with collision avoidance, and complete geometrical fitting and tolerancing functionality, are embedded within the CappsNC programming environment. Multi-view graphics with an intuitive UI programming environment make it simple to create measuring programs for any machine tool configurations.
CappsNC also connects with a comprehensive library of machine tool controllers, providing a real-time direct interface: a G-code program is generated from the DMIS measuring program. CappsNC graphics displays live 3D simulation of the measurement process with calculations performed as soon as measured data is collected. The calculated metrology characteristics, such as best-fitting the data set to a CAD model, are integral to ‘on-the-fly’ decision making. These are written back to the machine tool CNC as a part of the adaptive control cycle.
AAS says that CappsNC is an independent measuring probe brand that uses its own generated macros and can work with existing installed machine tool probes.
For further information www.aat3d.com

PC-DMIS 2018 R2 available from Hexagon

Hexagon’s Manufacturing Intelligence division recently launched PC-DMIS 2018 R2, the latest edition of its measurement software.

PC-DMIS 2018 R2 introduces a new reporting workflow, making it easier than ever to create customised reports with simple drag and drop functionality and an intuitive slideshow-style interface. A new QuickPath tool expands on existing QuickFeature functionality to simplify feature creation with a safe path. PC-DMIS 2018 R2 also introduces the ability to add run charts from qs-STAT into the PC-DMIS report.
Improved probe utility allows users to mark favourite tip configurations, create required tip angles by simply clicking on CAD, and buy replacements with shopping cart tools; a new e-Store is coming soon to hexagonmi.com. Improvements in the use of lasers, specifically for path creation and offline programming, also feature in the latest release.
“PC-DMIS 2018 R2 continues the recent trend towards maximising productivity in the three major metrology tasks: creation, execution and collaboration,” states Ken Woodbine, product line manager for Metrology Software at Hexagon Manufacturing Intelligence. “Creating measurement routines is even simpler and more intuitive with the addition of both QuickPath for adding motion in ‘walk up and measure’ applications, and the offline path visualisation and simulation for laser probes. Execution is also streamlined with improvements to our ‘Inspect’ module, making it easier to control access to routines, and for operators to search and find routines and reports.
“Collaboration is the ‘why’ of metrology, and PC-DMIS continues to work seamlessly with even more measurement devices and sensors,” he continues. “In addition, the introduction of Q-DAS run chart integration and ‘Shopshot’ offers a fuller picture of production processes.”
For further information www.hexagonmi.com

Optical µCMM takes centre stage

Alicona’s recently introduced Optical µCMM was displayed at the recent Advanced Engineering exhibition in Birmingham, UK.

The µCMM is said to be the only purely optical micro-coordinate 3D measuring system available, providing high levels of accuracy not available on multi-sensor machines. Users benefit from all the advantages of tactile co-ordinate measuring technology, but with optical surface measurement to measure dimensions, position, shape and surface finish of components using just one optical sensor.
When supplied with GD&T software, µCMM offers the high geometric measurement of a number of 3D features in relation to each other, which provides the ability to measure small surface features with sub-micron accuracy in a short time. In addition to geometric position, users are able to measure surface finish in the same cycle, thus providing improved productivity.
The range of measurable surfaces includes all common industrial materials and composites, such as plastic, PCD, CFRP, ceramics, chrome, silicon and so on, including matt and polished components. Simple automated operation is implemented by single-button solutions built into a specially designed handheld remote controller. Air-bearing axles with linear drives enable wear-free use and high-precision, rapid measurement, says Alicona.
Options include the motorised Real3D Rotation Unit, which turns the three-axis system into a five-axis system and enables users to measure components from several directions, including round parts.
The automation of measurement operations is facilitated by the Automation Manager interface. Thus, µCMM offers the fully automatic measurement and evaluation of surface roughness parameters and GD&T features. The measurement result is therefore completely operator-independent.
For further information www.alicona.com