One-ton segments of an industrial crusher were digitized using 3D scanning to restore their geometry and prepare documentation for the manufacture of new parts. The work was carried out by specialists from the ODK Additive Technologies Center at the production site in Amursk.
Each segment of the crushing rolls weighs about a ton. The parts have a complex geometry with curved surfaces, holes, and internal cavities, so accurately restoring their shape using only conventional measurements is extremely difficult.
To obtain a digital model, specialists placed optical markers on the parts and sequentially scanned them from different angles. The result was further verified with control measurements and photography.
After data processing, specialists obtained a digital model of the parts and prepared a set of design documentation for the manufacture of the elements that needed to be replaced.
A separate challenge was the wear of the working surfaces. Since the actual shape of the parts after operation already differed from the original, CAT designers determined the nominal working profile and separated it from the deviations that appeared during operation.
The Additive Technologies Center notes that this approach allows restoring the geometry of complex parts even in the absence of original drawings. Reverse engineering technology is also used when working with elements of gas turbine and other engines, when a single preserved part remains as the original sample.