Challenges in Temperature Measurement in Hot Forging Processes: Impact of Measurement Method Selection on Accuracy and Errors in the Context of Tool Life and Forging Quality.
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| Title: | Challenges in Temperature Measurement in Hot Forging Processes: Impact of Measurement Method Selection on Accuracy and Errors in the Context of Tool Life and Forging Quality. |
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| Authors: | Hawryluk, Marek1,2 (AUTHOR) marek.hawryluk@pwr.edu.pl, Dudkiewicz, Łukasz1,2,3 (AUTHOR), Krawczyk, Jakub1,3 (AUTHOR), Janik, Marta1 (AUTHOR), Lachowicz, Marzena1,2 (AUTHOR), Skwarski, Mateusz1,3 (AUTHOR) |
| Source: | Materials (1996-1944). Aug2025, Vol. 18 Issue 16, p3850. 21p. |
| Subjects: | Temperature measurements, Forging (Manufacturing process), Production engineering, Manufacturing processes, Metrology, Thermography, Measurement errors, Pyrometry |
| Abstract: | This study investigates the influence of temperature measurement accuracy on tool failure mechanisms in industrial hot forging processes. Challenges related to extreme operational conditions, including high temperatures, limited access to measurement surfaces, and optical interferences, significantly hinder reliable data acquisition. Thermal imaging, pyrometry, thermocouples, and finite element modeling were employed to characterize temperature distributions in forging tools and billets. Analysis of multi-stage forging of stainless steel valve forgings revealed significant discrepancies between induction heater settings and actual billet surface temperatures, measured by thermal imaging. This thermal non-uniformity led to localized underheating and insufficient dissolution of hard inclusions, confirmed by dilatometric tests, resulting in billet jamming and premature tool failure. In slender bolt-type forgings, excessive or improperly controlled billet temperatures increased adhesion between the forging and tool surface, causing process resistance, billet sticking, and accelerated tool degradation. Additional challenges were noted in tool preheating, where non-uniform heating and inaccurate temperature assessment compromised early tool performance. Measurement errors associated with thermal imaging, particularly due to thermal reflections in robotic gripper monitoring, led to overestimated temperatures and overheating of gripping elements, impairing forging manipulation accuracy. The results emphasize that effective temperature measurement management, including cross-validation of methods, is crucial for assessing tool condition, enhancing process reliability, and preventing premature failures in hot forging operations. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
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| Header | DbId: egs DbLabel: Engineering Source An: 187614983 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Challenges in Temperature Measurement in Hot Forging Processes: Impact of Measurement Method Selection on Accuracy and Errors in the Context of Tool Life and Forging Quality. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Hawryluk%2C+Marek%22">Hawryluk, Marek</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> marek.hawryluk@pwr.edu.pl</i><br /><searchLink fieldCode="AR" term="%22Dudkiewicz%2C+Łukasz%22">Dudkiewicz, Łukasz</searchLink><relatesTo>1,2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Krawczyk%2C+Jakub%22">Krawczyk, Jakub</searchLink><relatesTo>1,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Janik%2C+Marta%22">Janik, Marta</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Lachowicz%2C+Marzena%22">Lachowicz, Marzena</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Skwarski%2C+Mateusz%22">Skwarski, Mateusz</searchLink><relatesTo>1,3</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Aug2025, Vol. 18 Issue 16, p3850. 21p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Temperature+measurements%22">Temperature measurements</searchLink><br /><searchLink fieldCode="DE" term="%22Forging+%28Manufacturing+process%29%22">Forging (Manufacturing process)</searchLink><br /><searchLink fieldCode="DE" term="%22Production+engineering%22">Production engineering</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+processes%22">Manufacturing processes</searchLink><br /><searchLink fieldCode="DE" term="%22Metrology%22">Metrology</searchLink><br /><searchLink fieldCode="DE" term="%22Thermography%22">Thermography</searchLink><br /><searchLink fieldCode="DE" term="%22Measurement+errors%22">Measurement errors</searchLink><br /><searchLink fieldCode="DE" term="%22Pyrometry%22">Pyrometry</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: This study investigates the influence of temperature measurement accuracy on tool failure mechanisms in industrial hot forging processes. Challenges related to extreme operational conditions, including high temperatures, limited access to measurement surfaces, and optical interferences, significantly hinder reliable data acquisition. Thermal imaging, pyrometry, thermocouples, and finite element modeling were employed to characterize temperature distributions in forging tools and billets. Analysis of multi-stage forging of stainless steel valve forgings revealed significant discrepancies between induction heater settings and actual billet surface temperatures, measured by thermal imaging. This thermal non-uniformity led to localized underheating and insufficient dissolution of hard inclusions, confirmed by dilatometric tests, resulting in billet jamming and premature tool failure. In slender bolt-type forgings, excessive or improperly controlled billet temperatures increased adhesion between the forging and tool surface, causing process resistance, billet sticking, and accelerated tool degradation. Additional challenges were noted in tool preheating, where non-uniform heating and inaccurate temperature assessment compromised early tool performance. Measurement errors associated with thermal imaging, particularly due to thermal reflections in robotic gripper monitoring, led to overestimated temperatures and overheating of gripping elements, impairing forging manipulation accuracy. The results emphasize that effective temperature measurement management, including cross-validation of methods, is crucial for assessing tool condition, enhancing process reliability, and preventing premature failures in hot forging operations. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/ma18163850 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 21 StartPage: 3850 Subjects: – SubjectFull: Temperature measurements Type: general – SubjectFull: Forging (Manufacturing process) Type: general – SubjectFull: Production engineering Type: general – SubjectFull: Manufacturing processes Type: general – SubjectFull: Metrology Type: general – SubjectFull: Thermography Type: general – SubjectFull: Measurement errors Type: general – SubjectFull: Pyrometry Type: general Titles: – TitleFull: Challenges in Temperature Measurement in Hot Forging Processes: Impact of Measurement Method Selection on Accuracy and Errors in the Context of Tool Life and Forging Quality. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Hawryluk, Marek – PersonEntity: Name: NameFull: Dudkiewicz, Łukasz – PersonEntity: Name: NameFull: Krawczyk, Jakub – PersonEntity: Name: NameFull: Janik, Marta – PersonEntity: Name: NameFull: Lachowicz, Marzena – PersonEntity: Name: NameFull: Skwarski, Mateusz IsPartOfRelationships: – BibEntity: Dates: – D: 15 M: 08 Text: Aug2025 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 19961944 Numbering: – Type: volume Value: 18 – Type: issue Value: 16 Titles: – TitleFull: Materials (1996-1944) Type: main |
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