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Multi-view camera system for measurement of heavy forgings

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Abstract

Open-die forging is used to manufacture heavy durable parts such as shafts. In-process measurements are required for shape correction. The passive 3D measurement method is based on forging silhouettes in images and has demonstrated its advantages in this application. However, when using two cameras, only four tangents are available to determine the cross-section. In this paper, we propose a novel multi-camera multi-observation method for forging measurements; it increases the number of tangent lines used to determine the forging cross-section. The results suggest a decrease in measurement error proportional to the square root of the observation number. The six-observation precision is ± 0.5 mm in a measurement volume of 6 × 6 × 2 m for axis straightness and diameter measurements (95% confidence interval). However, many outliers remain in case of diameter measurement. In addition, the forging circularity can be measured. The proposed system shows good agreement with the laser scanning measurement method. Overall, the system has considerable potential for forging manufacturing applications.

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Acknowledgements

We thank the ZĎAS company for allowing the research team to conduct experiments in their factory. We would like to thank Editage (www.editage.com) for English language editing. Special thanks belong to the Institute of Geodesy, Faculty of Civil Engineering, Brno University of Technology, namely Ing. Tomáš Volařík, Ph.D., for the laser scanning measurement.

Funding

This research was funded by the Technology Agency of the Czech Republic (Project: TREND FW01010098) and the Faculty of Mechanical Engineering, Brno University of Technology (Internal Specific Projects: FSI-S-20–6296 and FSI-S-20–6187).

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Brno University of Technology, Technická 2896/2, 616 69, Brno, Czech Republic

    Jakub Hurník, Aneta Zatočilová, Tereza Konečná, Pavel Štarha & Daniel Koutný

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  1. Jakub Hurník
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  2. Aneta Zatočilová
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  3. Tereza Konečná
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  4. Pavel Štarha
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Contributions

Jakub Hurník was responsible for conceptualization, methodology, software, and writing of an original draft. Material preparation and data collection were performed by Aneta Zatočilová, Pavel Štarha, and Jakub Hurník. The analysis of the data was carried out by Jakub Hurník and Aneta Zatočilová. Aneta Zatočilová and Daniel Koutný were responsible for project administration and funding acquisition. Tereza Konečná was responsible for the formal analysis. Daniel Koutný was performing the supervision. All authors read and approved the final manuscript.

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Correspondence to Jakub Hurník.

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Hurník, J., Zatočilová, A., Konečná, T. et al. Multi-view camera system for measurement of heavy forgings. Int J Adv Manuf Technol 121, 7295–7310 (2022). https://doi.org/10.1007/s00170-022-09809-6

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