Manufacturing Technology Journal - Latest articles

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Machining of M390 Microclean® and M398 Mircoclean® PM Steels – the Comparison of Cutting Forces and Surface Roughness

Jozef Majerík, Juraj Majerský, Henrieta Chochlíková, Igor Barényi, Jana Escherová, Mária Kubasáková

Manufacturing Technology 2023, 23(6):853-860 | DOI: 10.21062/mft.2023.096  

Article deals with comparison of cutting forces and surface roughness between materials produced by powder metallurgy M390 and M398 Microclean® from producer, company Böhler. Main interest is the analysis & comparison of the cutting forces and surface roughness after the processing by cutting in-serts with DNMG and WNMG geometry, radius 0.4 and 0.8 mm, after hard turning at the same pro-cess parameters for both materials and all types of cutting inserts. The comparative studies were car-ried out for cutting forces and surface roughness with the aiming to observe the difference between “old generation” M390 and “new generation”...

Utilization of Metal Forming Process Mathematical Modelling to Predict the Spring-back of the Dual-phase Steel Stamping

David Koreček, Pavel Solfronk, Jiří Sobotka

Manufacturing Technology 2023, 23(6):827-836 | DOI: 10.21062/mft.2023.095  

Nowadays, the digitalization of the production process is an indispensable part of the stampings production in the pre-series stage, but also as a subsequent support for series production. Automotive producers are under pressure to comply with the ever decreasing CO2 production standards for cars, which predicates the use of modern material types with an advantageous weight-to-strength ratio. This paper focuses on the use of mathematical modelling in a numerical simulation environment to predict the deformation process and subsequent material spring-back of dual-phase steel DP500. The material data and characteristics are used to define the material...

Wear Analysis of Indexable Inserts after Machining of Austenitic Steel 1.4404

Karel Sramhauser, Natasa Naprstkova, Iryna Hren, Frantisek Spalek, Tomas Vlach, Radim Kunes, Ondrej Tupy

Manufacturing Technology 2023, 23(6):917-926 | DOI: 10.21062/mft.2023.094  

This article deals with the comparison of the wear of indexable CNMG carbide inserts from two dif-ferent manufacturers when turning austenitic stainless steel 1.4404, which is not intended as the pri-mary material to be machined from the point of view of the tested inserts. The main goal was to demonstrate the different course of wear by testing inserts of the same type according to ISO 6987 showing the connection between the design and processing of the inserts in connection with the se-lected cutting parameters. The monitored type of wear was the main flank wear VBmax, depending on the length of the machining time. Optical and electron microscopes...

Hydrogen Embrittlement of 11SMn30 Free-cutting Steel

Lukáš Šikyňa, František Nový, Peter Palček, Petra Drímalová, Martin Slezák, Milan Uhríčik, Veronika Chvalníková

Manufacturing Technology 2023, 23(6):900-908 | DOI: 10.21062/mft.2023.092  

The main objective of the work was to describe the laboratory methods suitable for hydrogenation of free-cutting steels and to study the hydrogen embrittlement of 11SMn30 free-cutting steel. Hydrogenation and subsequent mechanical testing of hydrogenated steel is not common laboratory method as it requires precise and expensive equipment, is time consuming and dangerous as hydrogen is highly reactive and explosive. Currently, there are several theories of hydrogen embrittlement mechanisms of steels that describe the causes of material degradation by hydrogen. However, those theories are not universally valid; individual accounts have been developed...

Effect of PWHT of X6Cr-NiNbN 25-20 Steel on the Evolution of the Sigma Phase during Creep Exposure at 700 °C

Jakub Rehorek

Manufacturing Technology 2023, 23(6):893-899 | DOI: 10.21062/mft.2023.091  

Superheaters and reheaters made of heat–resistant austenitic steels are being replaced in existing fos-sil fuel power plants to operate at Advanced Ultra Super Critical (A-USC) parameters of steam. New-ly developed and used high nickel content austenitic steels, such as in X6Cr NiNbN 25-20, are pre-dicted to significantly suppress the precipitation of a hazardous σ-phase during long-term creep expo-sure. The σ-phase causes premature failure of the component during creep, which is usually support-ed by a local change in hardness in the case of welded assemblies. Experimental results show that PWHT significantly improved reduction of...

Structural and Mechanical Properties of CuZn30 Cartridge Brass in Real Production Conditions

Jan Luštinec, Miroslav Roško, Vladivoj Očenášek

Manufacturing Technology 2023, 23(6):846-852 | DOI: 10.21062/mft.2023.090  

The paper deals with the technology of production of deep-drawn plates from alpha brass CuZn30. Surface and hidden defects are often observed in these deep-drawn sheets. The research was aimed at reducing the occurrence of these defects and subsequently reducing scrap and increasing the quality of these metallurgical products with a tighter tolerance of the required structural and mechanical properties throughout the length and width of the sheets. The production technology was monitored from the preparation of the batch and casting parameters on the existing operating equipment, through the processing of the ingots by hot and cold rolling, to the...

3D printing of Copper by Electrochemical Deposition Method

Michal Mišurák, Jan Šerák, Dalibor Vojtěch

Manufacturing Technology 2023, 23(6):880-892 | DOI: 10.21062/mft.2023.089  

Additive manufacturing commonly also called 3D printing is a process which creates 3D structures according to digital 3D models by successive deposition of material layer by layer. Electrochemical 3D printing is a relatively new form of additive manufacturing, which creates metallic structures by electrochemical reduction of metallic ions from the electrolyte onto a conductive substrate. Advantages of this technology are ability to produce structures of several materials, without inert atmosphere, thermal stresses and without using laser optics. Theoretical part was focused on introduction to additive manufacturing and overview on its technologies,...

Influence of Draw-Beads Geometry on the Surface Quality of Zn-Mg Coating

Josef Bradáč, Jiří Sobotka

Manufacturing Technology 2023, 23(6):758-768 | DOI: 10.21062/mft.2023.088  

In terms of surface protection of outer car body parts, zinc coatings are currently highly used in automotive industry. Concretely, hot dip galvanized (HDG) sheets are used in most cases. However, other possible alternatives such as zinc-magnesium coatings (Zn-Mg), which are usually referred to as ZM coatings, are also more frequently applied. Thanks to magnesium, the corrosion resistance is significantly increased, which also positively influences the coating thickness. On the other hand, the presence of magnesium makes this coating harder and brittle, which significantly limits its use to produce complex car-body stampings. To prevent the stamped...

Effect of Plasma Nitriding and Sensitization on the Microstructure and Microhardness of AISI 304 Austenitic Steel

Martin Slezák, Milan Uhríčik, Peter Palček, Veronika Chvalníková, Petra Drímalová, Lukáš Šikyňa

Manufacturing Technology 2023, 23(6):909-916 | DOI: 10.21062/mft.2023.087  

This article deals with the influence of plasma nitriding and sensitization on the microstructure and microhardness of AISI 304 austenitic steel. The microstructure of AISI 304 austenitic steel in all states was observed on a Neophot 32 optical microscope. The initial structure consisted of polyhedral austenite grains of different sizes. The microstructure contained a large number of non-metallic MnS-based inclu-sions. After plasma nitriding, a continuous nitriding layer was formed under the steel surface, while the grain shape was preserved. After the processes of sensitization and plasma nitriding followed by sensiti-zation, carbides were excluded...

Evaluation of the Corrosion Resistance of the Al-Si-Cu-Mg Alloy with the Addition of Zirconium

Marek Matejka, Dana Bolibruchová, Daniel Kajánek

Manufacturing Technology 2023, 23(6):861-869 | DOI: 10.21062/mft.2023.085  

Aluminum alloys are one of the most used materials today, and therefore great emphasis is placed on their continuous development. Improving the ratio of strength and stiffness to weight, improving plasticity, casting properties or resistance to corrosion are examples of properties of aluminum alloys that are constantly being improved. This work focuses on the evaluation of the corrosion resistance of the Al-Si5Cu2Mg alloy with graded addition of zirconium (0.05; 0.10; 0.15; 0.20 wt.%). Corrosion re-sistance was evaluated based on immersion, exposure and potentiodynamic polarization tests. The addition of Zr to the AlSi5Cu2Mg alloy improved the thermodynamic...

An Investigation into Conventional Spinning Process Using Ball Shaped Rollers as Forming Tool

Ayman Ali Abd-Eltwab, Gamal I. Helal, Mohamed N. El-Sheikh, Essam Khalaf Saied, Ahmed M. Atia

Manufacturing Technology 2023, 23(6):788-800 | DOI: 10.21062/mft.2023.084  

Conventional spinning is one of the oldest processes used widely in manufacturing to obtain cup shape products. Conventional spinning is the technique that produce axisymmetric part or component over rotating mandrel with the help of rigid tool known as rollers. The shape of roller is very important parameter for the success of the spinning process. This paper datils about using ball shaped rollers as forming tool in conventional spinning process experimentally. The experimental work was carried out on the center lathe machine as forming machine, the spinning tool or spinning rollers was installed on a dynamometer replaced the tool post while the mandrel...

Experimental Investigation of Armour (Armox-Aramid-UHMWPE)

Jindřich Viliš, Roman Vítek, Jan Zouhar, Michal Stejskal, Vlastimil Neumann

Manufacturing Technology 2023, 23(6):935-948 | DOI: 10.21062/mft.2023.083  

In this study, the ballistic resistance of multi-layered composite armour is experimentally investigated. The composition of this armour consisted of armour steel Armox 500T, para-aramid fabric Twaron CT 747 and ultra-high molecular weight polyethylene Endumax Shield XF33. To compare the ballistic resistance, the ballistic resistance of the armour with the perforated steel Armox 500T was tested. The rifle cartridges 7.62 x 51 mm FMJ NATO M80 were used to test this resistance. The aim of this experiment was to compare the ballistic resistance of unperforated and perforated steel Armox 500T. As part of the experimental part, the chemical composition...

Machinability of UMCo50 Cobalt Superalloy

Oskar Zemčík, Karel Kouřil, Martin Slaný, Jan Zouhar, Josef Sedlák, Štěpán Kolomý

Manufacturing Technology 2023, 23(6):949-957 | DOI: 10.21062/mft.2023.082  

Testing of machinability of the UMCo50 superalloy was carried out within the project following the actual production of the semi-finished product by casting. Turning was chosen as the machining method to minimize the effect of an interrupted cut. Considering the machinability of a hard-to-machine alloy, the cutting material with the fine-grained WC-Co carbide with the TiN/TiAlN gradient PVD coating was selected. The progression of cutting forces, chip formation and tool wear were evaluated. Images of the material structure of the semi-finished product and the resulting chips were taken. From the measured values, graphs of the dependence of the chip...

Optimization of Threads Production on Thin – Walled Castings

Dana Stančeková, Jozef Mrázik, Anna Rudawska, Miroslava Ťavodová, Izabela Miturska-Barańska, Daniela Sršníková, Miroslav Špiriak

Manufacturing Technology 2023, 23(6):927-934 | DOI: 10.21062/mft.2023.078  

This study focuses on the analysis and solution of thread production in thin-walled profiles. It explores three different threading technologies, including cutting, forming, and extrusion. The issue of a screw joint in a thin-walled component is complex due to the stiffness of the joint and the short length of the thread. Hence, the careful choice of a suitable manufacturing process for producing inner threads in thin-walled components holds significant importance. The study entails monitoring the hardening of surface layers of materials after thread production, in conjunction with the acquisition of microstructure images of the experimental material....

Progress and Prospect of Ultrasonic Vibratory Cutting Research

Quyun Li, Xinyuan Cai, Wei Li, Zhenhua Tan, Canyu Yang

Manufacturing Technology 2023, 23(5):638-648 | DOI: 10.21062/mft.2023.101  

Ultrasonic vibration cutting technology for processing difficult-to-cut materials proposed a new machining method to improve the cutting performance, is an effective measure to improve the surface quality and cutting efficiency, widely used in titanium alloys and other difficult-to-cut materials. This paper is based on the development of related technology research at home and abroad, first from one-dimensional ultrasonic vibration cutting, two-dimensional ultrasonic vibration cutting, three-dimensional ultrasonic vibration cutting three dimensions to high-speed ultrasonic vibration cutting to carry out the analysis, and then from each dimension of...

Surface Defect Detection Method for Welding Robot Workpiece Based on Machine Vision Technology

Yun Shi, Yan-yan Zhu, Jun-qi Wang

Manufacturing Technology 2023, 23(5):691-699 | DOI: 10.21062/mft.2023.100  

With the development of welding technology and the improvement of automation level, welding robots are playing an increasingly important role in industrial production. However, during the welding process, due to factors such as material characteristics, welding parameters, or improper processes, defects may appear on the surface of the workpiece, which may reduce the quality and service life of the workpiece. In order to solve this problem, this article used frequency domain feature extraction and nearest neighbor classifier in workpiece detection algorithms under machine vision technology to extract and classify surface defect images of workpiece,...

Design of a Photoelectric Measuring Robot for Straightness of Deep/Blind Hole with Automatic Centering Function

Haifeng Zhao

Manufacturing Technology 2023, 23(5):739-749 | DOI: 10.21062/mft.2023.098  

In order to quickly measure the straightness parameters of the deep hole/blind hole axis, a robot for measuring the straightness of the deep hole/blind hole axis based on the photoelectric prin-ciple is designed. Using the linearity of the laser as a reference, the straightness of the inner hole can be detected through the function that the PSD sensor can accurately locate the position of the energy center of the light. By studying the relationship between the position of the light spot and the output voltage of the PSD device, the measurement model of the straightness of the deep hole axis is derived. During the measurement, the robot spiral driving...

Lithium Battery SOC Estimation Based on EKF-DEKF Composite Model

Shaohua Chen, Wei Kan, Yichen Yang, Shuyang Liu, Miaomiao Wang

Manufacturing Technology 2023, 23(5):613-622 | DOI: 10.21062/mft.2023.093  

According to the application requirements of SOC in lithium batteries of Unmanned Aerial Vehicle (UAV), an Extended Kalman filter-Double Kalman filter (EKF-DKF) composite model was proposed to optimize the accuracy of the last 20% stage of State of Charge(SOC) estimation. Based on the equivalent model of second-order resistance-capacitance (RC) circuit improvement, the developed method optimized the identification accuracy of parameters, and set up a MATLAB simulation platform to jointly estimate SOC online with EKF and DKF. The data obtained in laboratory test environment were used for simulation.

Austenitic Steel AISI 304 under Static and Cyclic Loading

Veronika Chvalníková, Milan Uhríčik, Peter Palček, Martin Slezák, Lukáš Šikyňa, Petra Drimalová

Manufacturing Technology 2023, 23(5):623-629 | DOI: 10.21062/mft.2023.086  

Austenitic steels are among the most widely used materials in industries such as automotive, food, energy, chemical, etc. They are mainly used due to properties such as corrosion resistance, good strength, hardness, or weldability. Microstructural analysis was performed on a light microscope Neo-phot 32. AISI 304 austenitic steel has a microstructure formed by a large number of polyhedral austenite grains of different sizes. The steel microstructure, mechanical and fatigue properties, and areas of the plastic zone after the bending impact test were investigated. The surface hardness of samples was measured on a Zwick Roell ZHVμ microhardness measuring...

Possibilities of Restoring the Plasticity of Operationally Degraded Steel EN ISO 14MoV6-3

Petr Beneš, Tomáš Vrána, David Bricín, Antonín Kříž

Manufacturing Technology 2023, 23(5):604-612 | DOI: 10.21062/mft.2023.081  

The article deals with the possibility of increasing mechanical and utility properties by means of regenerative heat treatment. Experimental program is focused on the heat treatment of low-alloy heat-resistant steel EN ISO 14MoV6-3. This steel has been used since the 1970s for high-temperature exposed components in practically all coal-fired thermal power plants in the Czech Republic. Thus, steel EN ISO 14MoV6-3 is currently the best studied refractory material whose data, collected from experimental creep behaviour tests, exceeds the computational service time 2.105 hours. In order to remain competitive in the new energy mix, conventional steam power...

Determination of the Effect of Deformation on the Corrosion Resistance of Zn-Al-Mg Coated Sheets

Martin Švec, Iva Nováková, Pavel Solfronk

Manufacturing Technology 2023, 23(5):709-716 | DOI: 10.21062/mft.2023.080  

In the automotive industry, deep-drawn sheet metals are widely used and protective coatings are ap-plied to its surfaces to improve certain performance properties (e.g. to increase corrosion resistance). Sheets with these coatings are stressed during the forming process of the part and cracking of the protective coating may occur. The main goal of this paper is to determine the resistance of a Zn-Al-Mg based protective coating to uniaxial and triaxial stresses, and also to determine how effective anticorrosion resistance the coating provides to the base steel matrix in the event that cracking occurs. It has been shown that both uniaxial and triaxial...

The Effect of Single-Wall Carbon Nanotubes Content on the Properties of Polyurethane Nanocomposite

Dana Bakošová, Alžbeta Bakošová

Manufacturing Technology 2023, 23(5):580-588 | DOI: 10.21062/mft.2023.079  

This study aimed to investigate the influence of single-wall carbon nanotube (SWCNT) content on the mechanical properties of polyurethane (PU) nanocomposites. The SWCNT content varied from 0 wt% (reference sample) to 2 wt%. Tensile, hardness and Charpy impact tests as well as dynamic me-chanical analysis (DMA) were performed. Based on the test results it was observed that an increase in the content of single-wall carbon nanotubes resulted in significant improvements in material strength and stiffness. Furthermore, atomic force microscopy (AFM) was used to examine microsurface to-pography of the samples and to obtain spectroscopic curves, based on which...

Microscopic Wear Analysis of Indexable Inserts after Machining of 34CrNiMo6 Steel

Nataša Náprstková, Karel Šramhauser, Iryna Hren, Jan Novotný, Jan Sviantek

Manufacturing Technology 2023, 23(5):676-684 | DOI: 10.21062/mft.2023.077  

Machining is an important part of the manufacturing process in the engineering field. Turning is one of these areas. At present, almost exclusively exchangeable cutting inserts are used in production machining. The article describes the research in the field of their wear, where the electron microscopy was used to evaluate the results. Electron microscopy is a very important aid in research in many are-as not only of human activity and also is the important aid in the field of mechanical engineering and manufacturing technologies. The results thus obtained can make in a given area it clearer and better document the resulting situation. Within the experiments,...

Predictive Modelling on Machining Performance of ECDM Using Artificial Neural Network and Particle Swarm Optimization

Nuraini Lusi, Anggra Fiveriati, Akhmad Afandi, I Gusti Ngurah Bagus Catra Wedarma, Herman Yuliandoko, Mahros Darsin, Syed Qutaba

Manufacturing Technology 2023, 23(5):649-662 | DOI: 10.21062/mft.2023.076  

The electrochemical discharge machining (ECDM) process is developing into a potentially useful method of performing micromachining in conductive or non-conductive materials. The materials are machined using a combination of chemical and thermal energy. This paper examines the effect of Artificial Neural Network (ANN) architectures combined with particle swarm optimization (PSO) on the predictive ability of tungsten carbide machining. Material removal rate (MRR) and surface roughness (SR) is the response used to evaluate the performance of the ECDM process. The four selected process parameters are voltage, gap width, electrode type, and type of electrolyte,...

The Mechanical Analyses and Structural Optimization of CSMC Preload System under Multi-load Cases

Xianewei Wang, Haikuo Zhao, Fei Xie, Chenyang Li, Xiulian Li

Manufacturing Technology 2023, 23(5):732-738 | DOI: 10.21062/mft.2023.075  

In order to accumulate experience in the design and manufacturing of the toroidal field coils for the China Fusion Engineering Test Reactor, a model coil of mixed Nb3Sn-NbTi superconducting magnet with a maximum magnetic field variation rate of 1.5 T/s has been developed at the Institute of Plasma Physics, Chinese Academy of Sciences. The preload system, as one of the key components of the model coil, plays a crucial role in maintaining the overall integrity and stability of the model coil. First the magnetic field and electromagnetic forces of the model coil under extreme conditions are calculated based on Maxwell's equations. Then, the mechanical...

Kinematic Parameters of the Biplanetary Mechanism (Intermittent Mixing Machines)

Erkin Nematov, Amon Berdiev, Peng Wang

Manufacturing Technology 2023, 23(5):685-690 | DOI: 10.21062/mft.2023.073  

The subject of research is the kinematic parameters of a biplanetary mechanism of the intermitted mixing machines. The article substantiates analytical expressions for determining the kinematic parameters of the drives of the working body of the intermitted mixing machines with planetary ones with double satellites and biplanetary mechanisms; the laws of change of displacements, velocities and accelerations of the points of the working body for drives with planetary one with double satellites and biplanetary mechanisms are determined; the regularities of the influence of the velocity parameters of the driving links on the kinematic characteristics...

Optimizing Shock Absorber Operation for Improved Hot Forging Efficiency

Artur Meller, Marcin Suszyński, Stanisław Legutko, Marek Trączyński, Adrian Mróz, Vit Cernohlavek

Manufacturing Technology 2023, 23(5):663-669 | DOI: 10.21062/mft.2023.074  

Article presents a novel approach to addressing the challenge of forge-free filling of gas cylinder valve knobs in the context of the pneumatic shock absorber utilized within elevator systems. The shock absorber is a critical component responsible for ensuring accurate and efficient transportation of charge material to the electric inductor of automatic hot forging presses. Precise control of the shock absorber's operation is essential for maintaining proper system functionality and minimizing deficiencies. To investigate the system's response to changes in shock absorber operating parameters, the authors conducted a comprehensive simulation. The simulation...

Design of an Injection Mould Utilizing Experimental Measurements and Reverse Engineering

Vladimír Bechný, Miroslav Matuš, Richard Joch, Mário Drbúl, Jozef Holubják, Andrej Czán, Michal Šajgalík, Jaromír Markovič

Manufacturing Technology 2023, 23(5):597-603 | DOI: 10.21062/mft.2023.072  

Casting with a disposable pattern is a method employed to produce intricate-shaped castings. This manufacturing technique falls into the near-net shape methods category, which ensures that the result-ing castings closely resemble the final components. Its primary application lies in industries where pre-cision and complex castings are of paramount importance. Typically, castings manufactured using this method utilize higher-cost materials. The focus of this study centres on the utilization of reverse engi-neering in the production, modification, and inspection of wax injection moulds during the casting pro-cess. Within the scope of this investigation,...

Characteristics of Coconut Fibre Combined with Vinyl Ester Composites Through Material Testing and Machining

Muhammad Wafiuddin Suhami, Norfariza Ab Wahab, H. Boejang, Khairum Hamzah, Hiroyuki Sasahara

Manufacturing Technology 2023, 23(5):700-708 | DOI: 10.21062/mft.2023.071  

In today's manufacturing industry, composites are widely used. This is primarily due to the highly variable material properties that can be obtained by combining various materials as reinforcements and matrices. However, modern environmental concerns have pushed researchers and engineers to seek materials from organic and renewable sources. The study will look into composite surface roughness during the cutting process, which will involve milling with a CNC router machine. A portable surface roughness tester will be used to obtain a surface roughness average (Ra) reading, and microscopes will be used to examine the composite surface roughness behaviour...

Head Impacts during the Direct Frontal (Forehead) and Side (Temple) Collision – Human vs. Hybrid III Dummy

Lubos Tomsovsky, Lucie Literova, Petr Kubovy, Frantisek Lopot, Martin Havlicek, Ondrej Stocek, Lukas Fara, Roman Jezdik, Hynek Purs, Tommi Tikkanen, Martin Novak, Karel Jelen

Manufacturing Technology 2023, 23(5):717-724 | DOI: 10.21062/mft.2023.048  

The paper is focused on the dynamic response of a Hybrid III crash-test dummy during low-severity frontal (forehead) and side (temple) head impacts. The measurements used a pedestrian dummy (Hybrid III 50th percentile male dummy, Jasti Co., ltd., Tokyo, Japan) and a unique pendulum impact testing machine (impactor) of own design and construction. The tests were conducted at two various impact intensities (velocities) that did not exceed the speed of 1.6 m.s^-1. The primary outcome variable was a resultant magnitude of acceleration measured on the vertex of the dummy’s head and the results were compared to 11 human volunteers. The goal...