Method of Assessment of Casting Accuracy and Minimization of Machining Allowances

The publication demonstrates an accuracy assessment method for machine tool body casting utilizing an optical scanner and a reference design of the machine tool body. The process allows assessing 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 described method allows dispensing with the arduous manual operation - marking out. Marking out, depending on the size and complexity, might take several working shifts for prototype casting. In case of large and elaborate casts, as those of machine tool bodies, marking out is often restricted only to the first cast of the desired body produced in a given casting mold. Such course of action is based on an assumption that casting is reproducible; hence, no need to assess each and every individual cast. While this approach saves time, it often results in late detection of casting errors (allowance shifts or insufficiencies) during the actual machining process. That, in turn, results in considerable losses due to the disruption of the work process and often demands cast repair. The aim of the hereby presented study is to introduce a new technological premise dispensing with manual marking out as well as allowing fast verification of the cast shapes.