Real-Time Titanium Rod Diameter Measurement System

In high-precision titanium forging operations, monitoring the outer diameter of titanium rods is crucial for quality assurance, process control, and downstream compatibility. To address this, a specialized real-time diameter measurement system is deployed to ensure that every rod meets dimensional specifications during hot forging.

System Components

The diameter measurement system comprises two main subsystems:

• Mechanical Caliper Assembly:
  Engineered for high-temperature environments, the caliper is installed directly at the forging press outlet to capture accurate measurements as the titanium rod exits the machine.

• Control and Feedback System:
  Includes a programmable control cabinet, an industrial-grade computer (IPC), high-resolution display monitor, and an audio-visual alarm unit. When integrated into a smart production line, the system can transmit data to a centralized quality control platform for real-time analysis and decision-making.

To cope with the extreme temperatures of forged titanium, auxiliary components such as a high-pressure centrifugal fan and air filtration system are added to blow filtered air into the caliper, keeping internal electronics cool and stable throughout the process.

Measurement Workflow

As the titanium rod rotates and is continuously extracted from the forging machine, the caliper engages in non-contact or contact-assisted measurement of the rod’s outer diameter. If the measured value deviates from the pre-defined tolerance, the sound-light alarm is triggered to alert technicians immediately—ensuring rapid correction and reduced defect risk.

Probe Configuration Based on Diameter

The system is designed to accommodate a range of rod diameters:

• Rods ≤ 50 mm:
  A single-probe setup is used to measure from the center. This configuration is compact, efficient, and sufficient for small to medium-sized rods.

• Rods > 50 mm:
  A dual-probe system with adjustable spacing is employed. As the diameter of the rod decreases during forging, the probe distance is automatically or manually adjusted to maintain optimal accuracy.

This modular sensor design ensures flexibility across different product lines and forging conditions.

Extended Capabilities

To enhance quality monitoring, the system can be optionally equipped with a straightness detection module, enabling:

• In-line measurement of rod linearity

• Simultaneous capture of diameter and shape deviations

• Data integration for statistical process control (SPC)

With its high measurement precision and real-time feedback capability, the system supports automated decision-making and reduces reliance on manual inspection. It also contributes to minimizing material waste and rework rates.

Application Value

This titanium rod diameter measurement system is widely used in:

• Aerospace forging lines requiring strict dimensional accuracy

• Medical-grade titanium rod production with high surface finish and tolerance demands

• Precision component manufacturing where rod uniformity impacts CNC machining and downstream fitting

By ensuring continuous, precise monitoring and flexible sensor configuration, this system significantly improves titanium forging reliability, productivity, and quality control.