Invention Journal of Research Technology in Engineering & Management (IJRTEM) ISSN: 2455-3689 www.Ijrtem. com Volume 3 Issue 6 ǁ September-October 2019 ǁ PP 43-49
Industrial Computed Tomography as an excellent tool for wall thickness investigation comparing CAD model and the real part made by EN AC-42100 aluminum Monika Barciewicz 1
(Laboratory of Coordinate Metrology, Faculty of Mechanical Engineering, Cracow University of Technology, Poland
ABSTRACT: This paper presents how industrial computed tomography can be used in the automotive world to quality control of aluminum alloys parts. For engineers in Research and Development Center working on the design and manufacturing process, it is essential to produce a real part with quality following customer requirements. The whole process takes time. New car parts are developed usually three to five years. Project Teams involved in designing process, production and logistic work parallel. Each team has to cooperate to create a car with all compatible systems. There are many repetitive steps in each project stage. The work as Mechanical/CAD Engineer is focused on designing CAD model, calculations, stack-ups, simulations analysis and the tests on real parts. All these activities are repeated until the final part will be produced. But even when serial parts are producing the changes come up and the whole re-designing process starts again. As mentioned, it is crucial to catch all internal and external defects. In this case was made initial sample test before design validation. The CT scan of the outlet tank (real part) was overlapped with its CAD model to compare wall thickness. The product is made by EN AC-42100 aluminum.
KEYWORDS: CAD model, cast aluminum part, industrial computed tomography, initial sample test, quality control
I.
INTRODUCTION
As Original Equipment Manufacturer (OEM) product development is a complicated process. Usually, it takes three to five years. Engineers working in Research and Development Centers has to first calculate and design mockup of the product. During the design development of each car system, the packaging and some customer requirements are changing. The Project Team consists of people working simultaneously on all calculations, 3d modelling, analysis stack-ups, simulations, tests and quality control of both - products and their forms necessary to manufacture. The mockup develops to prototype and this is the most important and intensive stage. At each development process stage, quality control is crucial to catch all internal and external defects. This is particularly important concerning cast components. Focusing on the prototype stage of the outlet tank, industrial CT helps to catch all problems with wall thickness and improve the design of the 3D CAD model and manufacturing process. As a cooling system part made by aluminum alloy, the outlet tank must meet the strict requirements needed for all performances. Computed tomography as a non-destructive testing method is an excellent tool for controlling and improving both the manufacturing process (casting) and the 3D modelling of tested components. More about technical aspects and application of CT in the automotive industry find in my previous work reference [1] and [2]. In this case was made initial sample test before Design Validation. Always before project stage - Design Validation, the first serial manufactured part must be checked before design approval. The initial sample test report (ISTR) is a documented evidence about the series-production readiness - the repeatability of your module inconsistent quality. For this purpose, a predefined quantity from the produced batch is used for the initial sampling. "Initial sample" refers to products which are manufactured for the first time under standard and realistic conditions. Any further production and product release of such a product has to take place under constant conditions, based on the initial sample [3]. The initial test purpose was the scan of outlet tank wall to compare wall thickness with the attached 3D model and approve calculated real weight of the sample.
II.
CASE STUDY - RESEARCH DATA OF INITIAL SAMPLE TEST
The 3D CAD model of the outlet tank was designed in Catia V5. Designing process was based on casting parts designing principles, company experience in designing of thermal systems’ parts, customer requirements and norms, and designer’s experience. The model fits to its cooling module and the car environment. All technical parameters meet automotive customer requirements of exchanger’s performance. The sample was produced by the casting process. Is made by EN AC-42100 aluminum. The initial sample test - quality control was done using CT scanning of the first produced outlet tank.
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