Asahi Transnational

    
 
2020-10-29

[3DSCAN] Handheld Non-Contact 3D Scanner Implementation Case Study: Forging Plant in Thailand

3D Scan Case Study Forging Plant

 

Recently non-contact 3D measurement systems (3D scanners) have become more useful because of their wide variety, improved functions and accuracy as well as the improved performance of PC. For this reason, 3D scanners like a small handheld 3D scanner, whose usage have been limited in the manufacturing industry in the past, are now being fully utilized in the department such as Quality Control. This time, we had an opportunity to hear from customers in the forging industry in Thailand who had investigated a small and convenient handy 3D scanner at a relatively early stage, then implemented it. So I would like to introduce the story.

 

About Yanagawa Techno Forge (Thailand) Co.,LTD. (YTT)

In 1989, Hammer forging was started at Pathumthani factory.
Later, press forging and heat treatment machines for the crankshaft of motorcycles were implemented into the factory.
In 1997, merged into Yanagawa group, accomplished an expansion and started dealing with the U.S. by exporting valve rocker arms and wheel hubs for automobiles.
In 2006, the company name was changed to the current name “Yanagawa Techno Forge (Thailand) Co., Ltd.” and produce critical parts which require strength like automobile engine parts by hot forging as a “Forging Professional Group”.

 

Work of Forging Die Department

The forging is a manufacturing method in which metal is heated to a high temperature and beaten to form it. I think it’s easy to understand if you imagine making a sword or a blacksmith. Among them, YTT manufactures by a method called hammer forging, in which pressure is applied by hitting. Due to the manufacturing method of forging, the die life is short, and it is only about 5000 times, which is about 1/10 to 1/20 of the metal casting industry. Therefore, the frequency of mold repairs is high, and YTT repairs dozens of molds every month which means that the molds are replaced almost every day. This is an industry with a high load on the mold department. Of course, if the quality of the mold shape is not good, it will be impossible to make a good product.

 

Business with Us

Before YTT implemented the 3D scanner, we had occasionally been requested for 3D scanning, 3D inspection and 3D modeling when necessary. One day, when we created a 3D mold model from the 3D scanning data and assembled the upper and lower dies in the software, there was a problem that they inevitably deviated by about 1 mm. Since a deviation of 1 mm in the mold is a major issue, we carefully recheck the created 3D model, but the cause cannot be identified. We suspected that the origin of the coordinates might have shifted during the 3D scan, therefore we honestly talked to the customer without hiding the problem because we would like the customer to let us try the 3D scanning again. Customer said “the model is fine”. If a hammer forging die has an eccentric geometry, the impact of hitting will generate the moment which causes the upper die to shift, so we learned that the die is designed in advance to that extent.

 

Implemented Non-Contact 3D Measurement Systems (3D Scanner)

The first unit in 2015
YTT has decided to implement a 3D inspection as one of the quality controls when dealing with a major Japanese motorcycle manufacturer. The manufacturer was also a user of our non-contact 3D measurement systems. We usually propose 3D scanners to customers by comprehensively considering the equipment used by the customer’s customer, required tolerances, and product shape. At that time we picked two types of 3D measurement systems and brought them in to demonstrate the scanners. One of them, the small hand-held handheld 3D scanner, is convenient to carry and allows customers to measure at any location without having to move the mold. The accuracy was sufficient, so YTT liked it and decided to use that 3D scanner. It is light-weighted, easy to use and requires almost no preparation before the measurement, so YTT staff have been actively using it since its implementation which was the best aspect to select the 3D scanner according to the manager said. In fact, it is very convenient to check the shape in three dimensions which allows to measure the starting point, intersection, angle, etc., that was impossible before 3D scanning. In addition, inspections such as narrow shapes and R shapes that were difficult with other measurement tools now become possible. Needless to say, it was also useful in that the manual correction of the forging die was converted into data by 3D scanning and reflected in the 3D model, and the repair history was saved.

 

The second unit in 2020
At the start of production of new products, there was a need for further 3D shape evaluation because there were shapes that could not be measured with the existing 3D measuring machine (CMM). Since the convenience of handy 3D scanners had already penetrated in the organization, the one of the same manufacturer was purchased as the second unit. This new 3D scanner is the latest model, with more advanced scanning speeds and resolutions that surprised users. With more software features, it took 30 minutes, which used to take a day to include 3D scanning and the post process of data correction.

 

Time Saving Effect with a New 3D Scanner
· The new scanner saves time because it does not require spraying even on glossy surfaces (15 minutes → 0 minutes)
· Automatic surface generation saves time (3 hours → 20 minutes)
· Time reduction by automatic filling holes (2 hours → 10 minutes)
· Time reduction with finalizing function (30 minutes → 5 minutes)
· Time reduction by increasing commands

 

It’s hard for users to make time available when it comes to a whole day, but the shorter time makes it even more useful. Therefore, although the 3D scanner was convenient to carry around originally, now, for the most of time, YTT have the 3D scanner available in one workplace in the measurement room, so that people from various departments can come and use it when needed.

 

About Asahi Transnational Company Limited

Established in 2009, providing various engineering products and services which utilizes 3D data for mainly manufacturing industries in Thailand. The most of 3D engineering products are with the latest technologies, which can sometimes dramatically change a customer’s business process. We believe that our job is to free our customers especially engineers from low-productivity jobs, and to support their effort and courage to take on new challenges.

 


 

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