Staged Measurement Model and Method for Geometric Shape of Super Large Ring Forging Processes Based on Multi-source Information Fusion

doi:10.3969/j.issn.1004-132X.2025.11.033

China Mechanical Engineering ›› 2025, Vol. 36 ›› Issue (11): 2747-2756.DOI: 10.3969/j.issn.1004-132X.2025.11.033

Staged Measurement Model and Method for Geometric Shape of Super Large Ring Forging Processes Based on Multi-source Information Fusion

Xiaokai WANG¹^,²^,³(), Gefei ZHENG¹^,²^,³(), Kangwen HUANG¹^,²^,³, Ziqiang LIU¹^,²^,³, Xinghui HAN¹^,²^,³, Lin HUA¹^,²^,³

^1.Hubei Key Laboratory of Advanced Technology of Automobile Parts，Wuhan University of Technology，Wuhan，430070
^2.Hubei Collaborative Innovation Center of Automotive Components Technology，Wuhan University of Technology，Wuhan，430070
^3.Hubei Engineering Center of Material Green Precision Forming Technology and Equipment，Wuhan University of Technology，Wuhan，430070

Received:2025-01-09 Online:2025-11-25 Published:2025-12-09
Contact: Gefei ZHENG

基于多源信息融合的超大型环件轧制过程几何形状分阶段测量模型和方法

汪小凯¹^,²^,³(), 郑戈飞¹^,²^,³(), 黄康文¹^,²^,³, 刘子强¹^,²^,³, 韩星会¹^,²^,³, 华林¹^,²^,³

^1.武汉理工大学现代汽车零部件技术湖北省重点实验室, 武汉, 430070
^2.武汉理工大学汽车零部件技术湖北省协同创新中心, 武汉, 430070
^3.武汉理工大学材料绿色精密成形技术与装备湖北省工程中心, 武汉, 430070

通讯作者: 郑戈飞
作者简介:汪小凯，男，1982年生，教授、博士研究生导师。研究方向为运载装备智能制造及先进无损检测。E-mail：wxk0919@163.com
郑戈飞^*（通信作者），男，1998年生，博士研究生。研究方向为成形过程在位检测。E⁃mail：599902605@qq.com。
基金资助:
国家自然科学基金(52175362);国家自然科学基金(U2037204);教育部创新团队发展计划(IRT_17R83);高等学校学科创新引智计划(B17034)

Abstract

Abstract:

To enhance the geometric shape measurement accuracy in super-large ring rolling processes， a staged measurement method was proposed based on multi-source information fusion. This method utilized real-time data from three laser displacement sensors， combining with the characteristics of the rolling feed and rounding-sizing stage， to accurately measure the ring's diameter growth velocity， center offset， and roundness error in distinct phases. Theoretical models for the ring's diameter growth velocity and outer contour roundness errors were established， the formation mechanism of the diameter growth velocity and roundness error of ring were analyzed. By constructing a finite element simulation model of ϕ10 m super large ring rolling in ABAQUS software， the proposed multi-source fusion method was comparatively analyzed against industrial camera imaging and single-point laser measurement， which verified superior accuracy of the proposed method and the influences of the mandrel feed speed on the ring's geometric state were explored. Finally， the effectiveness of the proposed method was confirmed by scaled-down rolling experiments， with the outer contour fitting accuracy reaching as 91.7% in the final rolling stages.

Key words: super large ring, radial-axial rolling, center offset, roundness error, error separation

摘要：

为提高超大型环件轧制几何形状测量精度，提出一种基于多源信息融合的分阶段测量方法。该方法利用三个激光位移传感器实时数据，结合轧制进给和整圆定径阶段特性，分阶段精确测量环件直径增长速度、环心偏移及圆度误差。建立了环件理论直径增长速度模型和外轮廓圆度误差模型，分析了环件直径增长速度和圆度误差的形成机制。通过在ABAQUS软件中构建ϕ10 m超大型环件轧制有限元仿真模型，将所提多源融合方法与工业相机拍摄、单点激光测量进行对比分析，验证了所提方法具有更高的准确性，并探究了芯辊进给速度对环件几何状态的影响。最终，通过缩比轧制实验验证了所提方法的有效性，轧制末期环件外轮廓拟合精度达91.7%。

关键词: 超大型环件, 径轴向轧制, 环心偏移, 圆度误差, 误差分离

CLC Number:

TG335.11

Xiaokai WANG, Gefei ZHENG, Kangwen HUANG, Ziqiang LIU, Xinghui HAN, Lin HUA. Staged Measurement Model and Method for Geometric Shape of Super Large Ring Forging Processes Based on Multi-source Information Fusion[J]. China Mechanical Engineering, 2025, 36(11): 2747-2756.

汪小凯, 郑戈飞, 黄康文, 刘子强, 韩星会, 华林. 基于多源信息融合的超大型环件轧制过程几何形状分阶段测量模型和方法[J]. 中国机械工程, 2025, 36(11): 2747-2756.

Figures/Tables 16

Fig.1 Schematic diagram of metal flow during the rolling process

Fig.2 Evolution of roundness error during the rolling process

Fig.3 Measurement principle of the geometric shape of the ring component

Fig.4 Measurement of roundness error during the early stage of rolling

Fig.5 Virtual sensor measurement method simulation model

Fig.6 Single-point measurement method simulation model

Fig.7 Three-point measurement method simulation model

Fig.8 Comparison of ring offset measurement effects among different measurement methods

Fig.9 Comparison of outer diameter measurement effects among different measurement methods

Fig.10 Finite element simulation of rolling process

Fig.11 Comparison of circularity error measurement effects among different measurement methods

Fig.12 Influence of different mandrel feed speeds on the increase in diameter

Fig.13 Influences of different mandrel feed speeds on circularity error and ring center offset

Fig.14 Sensor layout in rolling experiment

Fig.15 Ring blank and the formed ring product

Fig.16 Circular contour measurement

References 12

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Staged Measurement Model and Method for Geometric Shape of Super Large Ring Forging Processes Based on Multi-source Information Fusion

基于多源信息融合的超大型环件轧制过程几何形状分阶段测量模型和方法

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