In 2018, ArcTron 3D was commissioned by a leading aluminium processing company to document a roll that had burst into many parts during the production process.
In order to get to the root of the problem, the manufacturer commissioned the ArcTron 3D company for high-precision 3D recording of the burst individual parts. In addition to various technical analyses by materials scientists and various production process experts, the 3D documentation was carried out by ArcTron using high-resolution 3D technologies.
The project started with an initial documentation and appraisal of the fragments, especially the fracture edges at the manufacturer’s factory. The documentation survey was carried out using high-resolution, mobile structural light surveying technology with an accuracy requirement in the 1/10 mm range.
During the post processing the 3D modelling of the individual fragments, the complex “3D puzzle” task of positioning the individual fragments was carried out, digitally reassembling the roll with its individual parts. In the context of this task, among other software packages our in-house software aspect3D was used. It enabled not only the composition of the 3D model in the individual parts, but also the crack documentation of the fragments in high detail accuracy.
In the summary of all the non-destructive tests, including the additional extensive ones, the cause of the bursting of the roll was likely to be a “not easily recognisable modification of the plant operator to enable a faster roll change”. The exact analysis finally revealed a crack at an inaccessible point as the reason for the incident. Based on these results, more than 60 other rolls were finally tested. The same cause of the problem could be seen and eliminated in three further cases, so the manufacturer was able to avoid high follow-up costs.