Advances in Measurement Methods and Optimization Strategies for Large-Volume Cylindrical Components: A Review

Large-volume cylindrical components, such as turbine shafts, marine shafts, rolling mill rolls and bearing rings, are widely used in demanding mechanical, energy, transport and industrial applications. Their large dimensions and mass, together with susceptibility to thermal and elastic deformation, make both their manufacturing and geometric inspection challenging. This review presents the current state of knowledge on methods used for manufacturing and measuring selected geometric characteristics of large-volume cylindrical components. Particular attention is given to finishing processes, including turning and grinding, as well as to measurement methods based on manual instruments, V-block and rotational datum techniques, coordinate metrology, non-contact systems and hybrid solutions. The review also discusses the application of optimization methods in manufacturing and measurement, including the selection of machining parameters, process stability and workpiece support, measurement strategies and sampling, adaptive measurement approaches, and measurement-based error compensation. The development of optical and multisensor systems, in situ measurement solutions and Industry 4.0/5.0 concepts is also considered. The analysis highlights the main limitations of current manufacturing and measurement approaches and identifies directions for further development aimed at improving the accuracy and efficiency of manufacturing and geometric inspection of large cylindrical components.