Setting the Pace

ZEISS systems strengthen the competitiv­eness of TCG UNITECH


Automotive supplier TCG UNITECH went from being just one of many die casting companies to an industry leader in just a few years. To remain competitiv­e, the Managing Directors at the headquarte­rs in Kirchdorf, Austria decided to add a ZEISS computer tomograph to their existing system fleet comprising 16 ZEISS coordinate measuring machines and two ZEISS microscope­s.

Officer at TCG, explained to company management why the investment in a computer tomograph would pay off for the casting company. The engineer‘s calculatio­ns won out, and a ZEISS METROTOM 1500 has been in use right next to the production line at the Kirchdorf site since 2016. What is the greatest benefit of the system according to David Demmelmair, Head of Quality Management at TCG and Klaffenböc­k? “We can now determine whether the porosities detected are air pockets or shrinkage very quickly and, most importantl­y, reliably”, says Klaffenböc­k. Thanks to the ZEISS METROTOM 1500, TCG can now combine potential changes to the component directly with die casting process parameters and take targeted countermea­sures if there are errors. Yet process optimizati­on is not the only advantage of this CT scanner: now quality managers no longer have to perform additional measuremen­ts with other machines. “Instead of four quality-assurance inspection­s, we just measure once on the ZEISS METROTOM”, reports Klaffenböc­k. The particular locations on the components were ground down and then analyzed under a mi- CT scanner for reliable results Over two years ago, Rene Klaffenböc­k, Head of the Lab team and Environmen­tal

croscope, a process that took several hours under the best conditions. Meanwhile, other potentiall­y defective parts were still being produced. Klaffenböc­k knows that this is all a real time saver. And that is not all: with new orders, another advantage of the CT scanner has come into play. “For new parts or sampling, we now receive a complete, detailed image, and tool correction is fast and efficient with ZEISS Reverse Engineerin­g

software,” says Demmelmair. Moreover, customers have corroborat­ed the promising initial results at TCG. “This has sped up approval for batch production,” says Demmelmair. Finally, Demmelmair and Klaffenböc­k expect that computed tomography will save automotive suppliers both time and money. However, the introducti­on of the CT scanner has hardly made the company‘s coordinate measuring machines (CMMs) superfluou­s. “They are still an indispensa­ble part of the quality assurance process for machined, ready-to-install parts,” says Demmelmair. Ahead of the competitio­n Demmelmair and Klaffenböc­k are bringing their CT know-how to the CT Real research project headed by the Austrian Gießerei-Institut. One of the key project‘s focal points is on developing a standard for the reliable measuremen­t of die cast parts with a computer tomograph. Klaffenböc­k illustrate­s by just how much his company is leading the way in terms of expertise. Reducing the measuring times with the CT scanner is at the top of his to-do list. “This is a challenge we can only tackle with ZEISS’s assistance,” says Klaffenböc­k, who is as enthusiast­ic about the partnershi­p with the optics company as Demmelmair. All 16 coordinate measuring machines and the two microscope­s are ZEISS systems, as are the styli and the temperatur­e monitoring system, ZEISS TEMPAR. Bundling ZEISS expertise has resulted in outstandin­g synergies. Thus we can use the measuring programs written in CALYPSO for the

virtual inspection of the characteri­stics from the volume models created with the ZEISS METROTOM with only minimal adjustment­s.

One of the key project‘s focal points is on developing a standard for the reliable measuremen­t of die cast parts with a computer tomograph

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