An integrated vision control system for the evaluation of the shape-dimensional accuracy and quality of valve forgings used in motor truck engines

• Published in: Measurement : journal of the International Measurement Confederation Vol. 210; p. 112541
• Main Authors: Hawryluk, Marek, Gronostajski, Zbigniew, Jabłoński, Paweł, Janik, Marta, Suliga, Maciej
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 31-03-2023
• Subjects: Precision hot die forging; Shape-dimensional accuracy; Valve forging; Vison measurement system; Precision hot die forging; Shape-dimensional accuracy; Vison measurement system; Valve forging
• ISSN: 0263-2241; 1873-412X
• DOI: 10.1016/j.measurement.2023.112541

[Display omitted]
•A proposal of a useful measurement method for three key geometric features of valve forging.•The accuracy and reliability of system is not critically influenced by negative effect of industrial environment.•Development of an integrated vision control system for precision forgings verified in industrial conditions.•Versatility and the ability to expand with the measurement of subsequent geometric features.
The study refers to a system of vision control concerning the dimension and shape accuracy as well as quality of valve forgings assigned for motor truck engines produced in a two-operation process of forging in closed dies. The performed investigations included a complex review of the solutions regarding various methods of measuring the selected geometrical features or other parameters for different forged elements – forgings during the production process. The conducted literature analysis has showed that, due to the hard operation conditions of the forging processes, measurements of this type are very difficult and the elaborated measurement methods are often dedicated to specific forgings and forging processes. On this basis, a proprietary measuring method was developed based on an adapted industrial laser profilometer installed on a proprietary measurement station, making it possible to conduct measurements under industrial conditions, owing to the application of the elaborated construction enabling automatic collection and manipulation of the scanned forgings directly on the production line. The built system makes it possible to measure the 2 key geometrical characteristics of an exhaustion valve forging: feature A – the diameter of the outer valve head, feature B - the calotte's depth, as well as, additionally, feature C – the surface quality in the form of detection of the most frequent defect: radial scratches (cavities) on the upper surface of the disc-like forging. In the first place, measurements under laboratorial conditions were made, which were then repeated under industrial production conditions in order to determine the influence of operating conditions (like: vibrations, temperature, etc.). Next, a final verification of the constructed system was carried out for forgings measured under strictly industrial conditions (measurement of forgings collected directly from the process). The obtained results of the elaborated measurement method showed high accuracy of the proposed solution, as, compared to the results under laboratorial conditions vs. industry, the error in the case of the 2200th forging, for feature A, equalled 0.35 mm, and for feature B (for 2200th and 100th forging), it was about 0.02 mm. Further studies will focus on be the possibility of measuring the profile of the disc's transition into the leg as well as detection of defects on the forging's leg in the form of longitudinal scratches.