Open Die Forgings

In the open die forging sector, dimensional controls are usually carried out in manual way. The quality and accuracy of the measurements strictly depend on the operator’s skills and production downtime are required. Some measures, useful to optimize forging operations are very difficult to get, and some other measures are quite long or imprecise. Furthermore, the presence of hot material makes this task difficult and is an important risk for the operators safety.

For these reasons Forges are unable to get the most from this operation and to fully achieve their targets in terms of process optimization, costs reduction and safety improvement.

It is with this limitations in mind that Tecnogamma has designed 3D PORTAL, an innovative measurement solution for the automatic and remote 3D acquisition of large open-die forgings. Compared to traditional manual systems, a more safe, complete and accurate measurement is assured.

Operators are provided with a wide range of measures (punctual, linear and sections measures, 2D and 3D visualization, 2D and massive comparison) highlighting the pieces geometry and shape defects.

3D Portal

Automatic laser dimensional measurement during forging

3D PORTAL is an optical system, based on phase shift ranging, for the 3D survey and automatic dimensional check of hot or cold open die forgings according to use in the forging phase or in the finishing working process.

The system, thanks to its flexible configuration, can be employed for the dimensional measurement of a wide range of open-die forgings, both axial-symmetric and special pieces, even for high-duty applications, addressed to serve all the main forgings market places, such as naval, energy, oil and gas, nuclear, petrochemical, gears, plant and equipment, machinery.

3D PORTAL has been versioned in different configurations varying in the number of the measuring heads employed and in the mechanical structure – fixed or moving (the measuring units can be mounted on a lateral motorized guide or not) – in order to identify the system configuration that hand by hand better suites the producer’s requirements in terms of forge layout and geometry and shape of the pieces to be measured.
Moreover, in case of special shaped forgings, a portable scanner head can be added in order to increase the vision angle and reduce the shadow areas.
Visible vertical sliding laser to support manual length measurement as visible horizontal laser for alignment and straightness are available as optional modules.

TECHNICAL SPECIFICATIONS

Measured Parameters	› External diameters at any section › Part of internal diameters according to the piece shape › Length › Straightness › External ovalization (depending on the forgings shape) › Internal ovalization (e.g. shell, torus)Eccentricity
Additional Functionalities	› Comparison with IGES format drawings reference. › Color-scale visualization between acquired and nominal solids for automatic visualization of excess and lack of material
Data Storing	IGES format compatible with 3D CAD tools (e.g for production certification and availability of quality report for each measured piece and each production batch)
Temperature Range	Up to 1250° C
More info?	Use functions below "Request the Brochure" or "Ask the Expert"

LATEST PRESS RELEASE

April 29, 2012
Irish Railways choose RAMSYS Asset Management Tool by MERMEC Group »

January 25, 2012
MERMEC receives the prestigious Oscar of Photonics »

December 12, 2011
President Keynote Speech to Customers and Employees »

Read all