Real-time dimensional measurement of metal parts during the hot forging process

Project aim

The research aim is to add more intelligence (forging 4.0) to the forging process so that real-time data can be achieved at high temperatures. Real-time reliable data can help in the decision-making process to achieve better part quality.

Project background

Large forging is a key part of the manufacturing of high-value metal parts for the aerospace and steel industries. It is difficult to do the precise dimensional measurements of hot parts during large forging. Contact measurement tools such as calipers and scales are often used for dimensional measurement of hot parts in forging workshops. However, the high temperature of metal parts (700’C-1200’C), difficult working conditions, and large measurement errors make it difficult to achieve the forged part within the given tolerances.

Non-contact measurement techniques such as laser scanning, photogrammetry, and machine vision have been used recently for dimensional measurement of hot parts during the forging process but non-contact methods have some limitations. Laser scanning and photogrammetry are time-consuming methods as it takes time to process the data captured during hot forging. Machine vision methods have very poor anti-interface ability. The current challenge is to add more intelligence (forging4.0) to the forging process so that real-time data can be achieved at high temperatures. Real-time reliable data can help in the decision process to achieve better part quality.