Thesis

Development of a dimensional measurement system for hot forged parts at elevated temperature

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Awarding institution
  • University of Strathclyde
Date of award
  • 2025
Thesis identifier
  • T17334
Person Identifier (Local)
  • 201756768
Qualification Level
Qualification Name
Department, School or Faculty
Abstract
  • Precision in-process dimensional measurement during high-temperature metal forming operations, such as hot forging, is key to guaranteeing product quality, enhancing material utilization, and ensuring process consistency. Conventional post-process measurement methods, including coordinate measuring machines (CMMs) and callipers, involve cooling prior to inspection, which causes delays, raises scrap rates, and reduces efficiency in flaw detection. Although next-generation optical systems such as GOM ATOS can achieve highaccuracy 3D scanning, they cannot be used for real-time in-process measurement in the harsh forging environment because of thermal expansion issues, glare, and material reflectivity. This warrants the development of a non-contact measuring system capable of providing accurate and reliable real-time dimensional measurement. This work reports the development and validation of a real-time non-contact dimension measurement system tailored to hot forging applications. It is based on optical metrology techniques and advanced image processing algorithms exploiting photogrammetry for the provision of high-precision measurements under high temperature conditions. The system was developed to work effectively within the temperature range of 900°C to 1200°C, with the desired measurement accuracy of ±1 mm at both the pixel and sub-pixel levels, thereby ensuring adherence to industrial tolerances for forged components. Experimental validation was carried out both in laboratory and hot forging environments to confirm the accuracy and reliability of the proposed system. The system's performance was also benchmarked against the commercial GOM ATOS optical scan system through the assessment of the key parameters of measurement error, repeatability, and robustness in mild steel workpiece length and diameter measurement. Statistical analysis, such as confidence interval analysis, error quantification, and comparative analysis, also guaranteed that the measurement errors were within ±1 mm for the majority of the length and diameter measurements of workpieces, with reproducible and consistent measurements. The results of this research have provided a worthy contribution through a low-cost and scalable solution for real-time dimensional measurement for high-temperature forgings.
Advisor / supervisor
  • Zante, Remi C.
  • Butler, David
Resource Type
DOI

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