Quality control in metal forming processes

Metal Forming

Quality Control In Metal Forming Processes

ZEISS´s optical 3D measuring systems are used in stamping, bending, drawing, pressing, and forming process chains to guarantee consistent quality assurance: They are used to determine material properties. They help to optimize the design and the simulation of parts and tools. They speed up tool try-out and first article inspection. Optical 3D measuring systems also ensure efficient production control and assembly analysis in series.

Material properties

Material properties

The knowledge of material properties of a sheet metal material provides a secure basis for adequate component design, for developing a functioning tool with good effective surfaces and for realistic simulation.

Realistic material properties are a prerequisite for reliable simulation and optimization of product variants, tool layout and forming processes.

The ARAMIS system helps to determine these material properties.



3D digitization helps to quickly generate and efficiently use CAD data.

Actual 3D coordinates enable reverse engineering of models, parts and tools. For that, the 3D geometry of these objects is fully scanned and then transferred into CAD data via surface reconstruction.

The inspection of parts can be carried out efficiently. During design, the CAD data is directly provided with inspection features. As soon as a part is produced, it can be inspected immediately.

Optical measuring systems provide fully automated full-field deviations between the complete actual 3D coordinates and the CAD data.

Reverse engineering of models, parts and tools

Full-field geometry acquisition with ATOS enables the surface reconstruction and adaption of model, part and tool geometries in existing CAD software packages.

Inspection planning on CAD models

The inspection of parts can already be planned during design. It is possible to provide the CAD data with inspection features. The ATOS software uses this data for an inspection at the push of a button.



Products and manufacturing processes are designed and optimized with numerical simulation methods. The results of these simulations are supposed to be as informative as possible.

An important factor for the simulation of metal forming processes are the material properties of the metal used. The material properties influence the deformation behavior of the part and therefore the accuracy of the simulation calculation.

With the ARGUS system, it is possible to check and optimize forming simulations based on experimental measurements.



Industrial 3D measurement technology helps to address many important challenges concerning the manufacturing and the use of tools in metal forming.

Certain tasks in toolmaking can be significantly accelerated with optical measuring systems. In tool try-out, tools can be quickly assessed to check if they work properly. In tool maintenance, 3D metrology is useful for increasing the service life of tools. If a tool is broken, it can be quickly repaired using measurement technology.

ATOS and ARAMIS systems digitize the tool and the try-out parts and create precise values for tool corrections.

Fast and safe milling of tools

A forming tool produced from a cast blank can be milled faster if the blank is digitized with the ATOS system. Based on this data, the runtime of the CNC machine can be reduced up to 50%.

Fast tool try-out

During tool try-out, it has to be checked whether the try-out parts meet the design requirements. With the ATOS system, it is possible to fully scan and analyze parts.

Tool correction based on optical measuring data

Tool try-out aims to iteratively produce a finished tool as fast as possible so that correct parts can be produced. Precise values for tool corrections can be obtained if the tool and try-out parts are digitized with the ATOS system.

Archiving of released tools

The tool deviates from the design data if it is modified manually during the tool try-out phase. With the help of the ATOS system, CAD data can be updated via a surface reconstruction.

Copy milling based on 3D measuring data

When broken tools need to be replaced or mirrored tool variants are needed, new tools can be directly milled based on STL data without a prior surface reconstruction. For that, the respective tool can be digitized fast and uncomplicated with the ATOS system.

Proactive wear measurement

Wearing tools produce parts with faulty geometries. With the ATOS system, tools can be regularly checked to detect critical tool wear at an early stage and to carry out maintenance in time.

Targeted and fast tool repair

In tool repair, material often has to be welded on and tools have to be iteratively reworked until they have their correct shape again. The ATOS system helps to quickly locate and repair the worn areas on the tool.

Faster production restart after tool change

A single stamping press is often used to produce different parts. In order to do that, the tool on the press has to be exchanged. With the ATOS system, it is ensured that the produced parts have the correct geometry after exchanging a tool.

Optimization of machine parameters

If the tool parameters that control the tool press are not optimally adjusted, they can cause a bad quality of the produced parts. The ARAMIS system helps to identify improper movements of the press during forming.

Fast identification of material defects caused by forming

The possibility of critical material defects caused by forming has to be eliminated in tool try-out. Visible material defects can be quickly detected with the ARGUS system, so that the tool can be reworked.

First article inspection

First article inspection

First article inspection is a test to examine whether the produced part meets the defined requirements under the conditions of series production.

For this purpose, a complete inspection of the measurement plan is carried out, form and position tolerances are measured and full-field deviations of the produced part are compared to its CAD model.

The ATOS system allows for a full-field first article inspection in 3D.

Series inspection

Series inspection

Industrial 3D measurement technology makes it possible to automate series inspection and to monitor the production process.

In quality assurance, optical measuring systems are used to check parts during series production. Such measuring systems enable high throughput and high reproducibility of measurements.

They allow for trend analyses to guarantee the process reliability of production. This involves monitoring whether and to what extent the production process is changing.

ATOS systems combined with an ATOS ScanBox enable a high throughput of inspected parts in series production.

Quality assurance in series production

The quality assurance in series production aims to monitor the production process and to reduce scrap. With the ATOS ScanBox, inspection processes can be automated and standardized.

Monitoring of production processes

In series production, the process reliability of the production has to be ensured by continuous monitoring. With the ATOS system, it can be monitored whether and how the production deviates over time.

Assembly analysis

Assembly analysis

In assembly, the individual parts are analyzed and put together into assemblies. During this process, the produced parts are checked to assess how well they fit together, how well they can be joined and how a single actual part behaves in relation to the nominal model (CAD).

Usually, very complex physical fixtures are used for analyses during assembly.

Thanks to the ATOS system, these fixtures are no longer necessary and the assembly can be checked virtually.

Assembly by virtualization

In assembly, physical fixtures are used to check how well different parts fit together for an installation or how well a single part matches the CAD model. With the ATOS system, the assembly analysis can be completely virtualized.

Virtual check of subassembly

In the assembly analysis, a joints master jig is used to check if the single parts can be joined to a subassembly. The joints master jig becomes unnecessary when using the ATOS system because the analyses are carried out virtually.

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