Keywords: optical measurement, photogrammetry, accuracy evaluation, casting, marking out, machining allowance minimization.

This paper demonstrates an accurate assessment method for machine tool body casting utilizing an optical scanner and a reference design for the machine tool body. The process allows for the assessment of the casting shape accuracy, as well as determining whether the size of the allowances of all work surfaces is sufficient for appropriate machining, corresponding to the construction design. The method described enables dispensing with the arduous manual operation i.e. marking out. While marking out might take several working shifts for prototype casting, geometry scanning spans merely from several minutes to several hours, depending on the cast complexity and the available equipment.

The aim of the study in this paper is to introduce a new technological premise dispensing with manual marking out as well as allowing fast verification of cast shape and minimization of machining allowances. The proposed assessment method, while evaluating the geometric shape of the investigated cast as correct, enabled detection of a concomitant deficiency i.e. insufficient cleansing of the founding core cylinder surface, thus preventing tool damage during subsequent cut-machining. The results obtained contribute considerably to cast quality improvement. Additionally, a reduction of machining allowance mass of 11% was achieved for the investigated cast, relative to the values assumed extrinsically, according to the technological design.

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