Manufacturing Technology Journal - Latest articles
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Enhancing Durability of Multi-Cavity Forging Tools through Process Automation
Artur Meller, Stanisław Legutko, Adrian Mróz, Mariusz Piechowski, Hubert Kędziora, Vit Cernohlavek
Manufacturing Technology 2024, 24(6):929-939 | DOI: 10.21062/mft.2024.105 
The article highlights the promising potential of automating the forging process to enhance the durability of multi-cavity forging tools. Entrepreneurs aim to boost production efficiency by increasing output per unit of time and reducing the degradation of forging dies and punches. The high costs associated with specialized materials and complex manufacturing processes for these tools elevate the final product price. Automation offers a viable alternative, ensuring consistent process parameters and reducing the physical strain on workers. This consistency leads to extended tool durability, even without the use of special manufacturing techniques for...
Nonlinear Stochastic Dynamics Analysis of Vehicle Bodies Based on the Direct Probability Density Integral Method
Qiangqiang Chen, Jilei Zhou, Chunkai Mu
Manufacturing Technology 2024, 24(6):886-900 | DOI: 10.21062/mft.2024.104
Manufacturing inaccuracies in vehicle suspension systems inevitably lead to uncertainties in the parameters of their structural components. Simultaneously, the road excitation impacting nonlinear vehicle systems exhibits pronounced randomness and time-variant characteristics. Consequently, it is crucial to conduct a stochastic dynamics analysis on nonlinear suspension systems, taking into account these uncertain factors. In this paper, a seven-degree-of-freedom (7-DOF) nonlinear suspension system dynamics model has been established. The stochastic process of road irregularities is simulated using the harmonic superposition method. Moreover, based on...
Technological Considerations in WEDM of Carbon Fiber Reinforced Silicon Carbide Composites (Cf-SiC)
Dariusz Poroś, Hubert Skowronek
Manufacturing Technology 2024, 24(6):940-951 | DOI: 10.21062/mft.2024.103
Wire electrical discharge machining (WEDM) was employed to process thin-walled, multidirectional carbon fiber-reinforced silicon carbide (Cf-SiC) composites. This study investigates the effects of key WEDM parameters, including gap voltage (Vg), pulse on-time (Ton), pulse off-time (Toff), and wire electrode type on material removal rate (MRR) and surface roughness (SR). All experimental planning, data analysis, optimization, and result visualization were conducted using MATLAB software. Results indicate that using CuZn50-coated wire electrodes increases MRR by 11% compared to CuZn37 bare brass wire. Scanning electron microscopy (SEM) confirmed the...
Studies of Nanoscratching in the Aspect of Homogeneity of Adhesive Joints
Kamil Anasiewicz
Manufacturing Technology 2024, 24(6):856-864 | DOI: 10.21062/mft.2024.102
This paper presents the results of nanoscratch tests conducted on adhesive bond thickness, analyzed in terms of material property heterogeneity within adhesive bonds. Nanoscratch tests were performed on adhesive layers made from rigid and elastic adhesives with thicknesses of 0.05 mm and 0.1 mm, under constant load conditions. Penetration depth and residual depth results were analyzed for potential varia-tions in hardness along the adhesive layer thickness. The findings clearly indicate some differences in the material properties of adhesive layers within bonded joints. These results can also be correlated with the phenomenon of apparent Young's modulus,...
Advanced Manufacturing Techniques for Lightweight Muon Spectrometer Support Structures in the FCC Project
Jan Brajer, Martin Dub, František Lopot, Pavel Malý
Manufacturing Technology 2024, 24(6):879-885 | DOI: 10.21062/mft.2024.101
With the rising demand for efficient, lightweight support structures in high-energy physics experiments, advanced manufacturing techniques and material optimization are key to achieving high-performance designs. This study focuses on the application of generative design and topological optimization in the development of support structures for the FCC muon spectrometer. By leveraging these methods, we maximized material efficiency and minimized weight while ensuring structural integrity and meeting strict design constraints, including non-magnetic properties, minimal deformation, and high precision. A detailed evaluation was conducted with respect to...
Analysis of the Influencing Factors on the Oil Film Uniformity of Hydro-viscous Drive Clutch
Xiangping Liao, Langxin Sun, Shaopeng Kang, Kailei Liu, Xinyang Zhu, Ying Zhao
Manufacturing Technology 2024, 24(6):992-1000 | DOI: 10.21062/mft.2024.100
Hydro-viscous drive (HVD) clutch is a type of power transmission device by using shear stress of oil film. Whether the oil film between friction pair are uniformly distributed is the key factor that affecting the perfor-mance of HVD clutch. However, it is hard to make sure that the uniformity of oil film between friction pair are the same, which can lead to uneven wear problem for the frictional plates of HVD clutch. In order to study the uniformity of oil film of HVD clutch, the distribution regularity of oil films between friction pair of HVD clutch is researched by establishing the mathematics model. and a new HVD clutch with double-piston structure...
Structure Evolution of Multi-Alloyed Iron Aluminides during Two-Step Annealing
Vera Vodickova, Pavel Hanus, Petra Pazourkova Prokopcakova, Martin Svec
Manufacturing Technology 2024, 24(6):985-991 | DOI: 10.21062/mft.2024.099
The microstructure of single-phase (as-cast) and two-phase (after heat treatment processes) Fe3Al-based alloys doped with silicon, molybdenum, and vanadium/tungsten have been studied. The grain size and phase composition have been determined. The evolution of the secondary phase amount, morphology, and distribution during the heat treatment process has been investigated. Both alloys were heat treated at 1200°C/2 h and, subsequently, at 900 °C. For both alloys, the secondary phase formation started after heat treatment at 900°C /4h, and their amount depended on the annealing time. Vanadium atoms remain in the solid solution, while tungsten atoms partially...
The Influence of the Crane Track Unevenness on the Load of the Supporting Crane Structure
Ján Vavro, Ján Vavro jr., Ľuboš Marček, Jana Kuricová, Miloš Taraba, Lukáš Klimek, Pavol Čerňava
Manufacturing Technology 2024, 24(6):969-976 | DOI: 10.21062/mft.2024.098
The paper presents the analysis of the gantry crane loading when driving along the crane track, using a 3D model, for which the analysis of the gantry crane frame loading was performed. The gantry crane is designed to remove dirt that is in front of the turbine under the water surface. For the gantry crane which moves along a track, the directional and vertical unevennesses were determined by experiment and are given in graphic and numerical form in (mm), relating to A track and B track with a total track length of 450 (m). Based on the knowledge of the unevenness of the rail track, the four random functional dependencies defining the irregularities...
Effect of Heat Treatment and Corrosion Load on the Microstructure of the Ti6Al4V Alloy
Roman Horký, Sylvia Kuśmierczak, Nataša Náprstková, Iryna Kambarová
Manufacturing Technology 2024, 24(6):914-928 | DOI: 10.21062/mft.2024.097
Titanium and its alloys are an important structural material in all sectors of industry. Thanks to its mechanical properties. One of the most widely used titanium alloys is the Ti6Al4V alloy. If we heat alloys for a long time in an air atmosphere, TiO2 is formed on the surface of the parts. The Ti6Al4V alloy, also referred to as Ti64, is a two-phase alloy formed by α+β solid solutions from the point of view of microstructure, it is characterized by corrosion resistance and good biocompatibility. Through heat treatment, we can improve the mechanical properties of the alloy, improve the fracture toughness, influence and reduce the internal...
Structural Design of a Rotary Valve Manipulator of Bulk Materials – Strength Design of Connecting Elements of the Frame and Trolley
Miroslav Blatnický, Ján Dižo, Alyona Lovska, Vadym Ishchuk
Manufacturing Technology 2024, 24(6):871-878 | DOI: 10.21062/mft.2024.096
The paper is a further step in ongoing research on the incorporation of the proposed bulk material rotary valve assembly into an existing production line serving the food industry in bagging milk powder. The main objective of the present paper is the strength static analysis of the previously presented structural design of the trolley and attachment of the frame structure as a track for the travel. Moreover, analytical engineering calculations whose results provide boundary conditions for the numerical strength design of the assembly of the rotary valve for transporting of bulk materials are included in the paper. The pro-posed mechanism allows precise...
Statistical Analysis and Machine Learning-based Modelling of Kerf width in CO2 Laser Cutting of PMMA
Ema Vasileska, Ognen Tuteski, Boban Kusigerski, Aleksandar Argilovski, Mite Tomov, Valentina Gecevska
Manufacturing Technology 2024, 24(6):960-968 | DOI: 10.21062/mft.2024.095
Recently, engineering polymers like PMMA have increasingly replaced traditional materials in industry where feasible, with CO2 laser cutting gaining attention for its high quality and speed in processing these materials. Achieving precise cuts is crucial for product accuracy, with kerf width serving as a key quality attribute to ensure quality and functionality of the final product. This study focuses on the im-pact of three critical process variables: stand-off distance, laser power, and cutting speed, on the kerf width in CO2 laser cutting of PMMA. Through a full-factorial experiment, the process parameters are systematically varied to understand...
Analysis of the Torsional Strength of Selected Photopolymers Additively Manufactured Using Polyjet Technology
Jacek Bernaczek, Mariusz Dębski, Małgorzata Gontarz-Kulisiewicz
Manufacturing Technology 2024, 24(6):865-870 | DOI: 10.21062/mft.2024.094
PolyJet technology, based on the printing and photopolymerization of model material, is currently, along with stereolithography or 3SP (Scan, Spin and Selectively Photocure), the most commonly used rapid prototyping method based on optically active resin. The article presents the results of torsional strength tests of samples made of optically active resins VeroDentPlus-MED690, VeroClear-RGD810, and Rigur-RGD450 by Stratasys in PolyJet technology. The samples were prepared in HQ (High Quality) mode with a layer height 0.016 [mm]. The tests included a static torsion test using a specialized research stand by the Department of Mechanical Engineering...
Investigation of the Tool Wear Progression in Parting Technology
Martin Drbal, Stepan Kolomy, Josef Sedlak, Jan Zouhar, Jiri Vitek
Manufacturing Technology 2024, 24(6):901-913 | DOI: 10.21062/mft.2024.093
Parting-off stands as a fundamental method of turning, involving the cutting of the workpiece. The tool is most frequently a replaceable insert secured in a clamping bed. A pivotal set of observable metrics that ascertain the efficacy of a tool and its appropriateness for machining a specific material under defined cutting conditions is its durability. These durability parameters need to be determined for all new tools to ensure optimal performance and application in various machining scenarios. The primary objective of this research was analysis of the wear experienced by replaceable cutting inserts within the realm of parting technology. There were...
Influence of Aluminium Waste Chips Content from the Machining Technology in the Batch on the Final Properties of the AlSi7Mg0.3 Alloy Casts
Tomáš Vlach, Jaromír Cais, Roman Horký
Manufacturing Technology 2024, 24(6):977-984 | DOI: 10.21062/mft.2024.092
The aim of the research was to assess the influence of additions of different proportions of alumini-um waste chips from the machining technology on the melt quality and final properties of AlSi7Mg0.3 alloy casts. All casts were created using by gravity casting technology into preheated metal mold. The first cast was a pure AlSi7Mg0.3 alloy, followed by other samples with contents of 10, 30, 50, 70 wt.% of aluminum waste chips in the batches. All the samples were subjected to the Brinnel hardness and Vickers microhardness of solid solution of α(Al). Also, Density index was measured. At the end of research, the microstructures of the samples were...
Reconstruction of 3D Models of Fishing Boat Propellers Using Photogrammetry and Reverse Engineering Techniques
Tuong Nguyen Van, Natasa Naprstkova
Manufacturing Technology 2024, 24(6):952-959 | DOI: 10.21062/mft.2024.091
The conventional method for measuring propeller geometric parameters involves utilizing specialized equipment or 3D measuring devices. Currently, specific propeller geometry parameters can be as-sessed by employing virtual measurements performed on a virtual propeller model generated using reverse engineering methods. This paper introduces a novel approach to constructing 3D models of small fishing boat propellers using photogrammetry and reverse engineering techniques. In this method, the propeller is captured through photographs taken with a smartphone camera employing special techniques. Subsequently, these images are processed using Agisoft Metashape...
Advancing the ductile behaviour of heavy-wall API X70 pipeline steel by a “Slab/Sheet” thickness ratio increase
Vadym Zurnadzhy, Yuliia Chabak, Ivan Petryshynets, Alexey Efremenko, Ivan Sili, Ruslan Sagirov, Vasily Efremenko
Manufacturing Technology 2024, 24(5):843-854 | DOI: 10.21062/mft.2024.090
The present work was aimed at studying the effect of a “Slab/Sheet” thickness ratio (SSTR) on the microstructure and mechanical properties of API 5L X70 steel sheets intended for heavy-wall oil/gas pipelines. The 25 mm-thick and 40 mm-thick steel sheets were rolled from the cast slabs of different thicknesses (250 mm and 300 mm) and their mechanical properties were compared. The sheets were subjected to thermo-mechanical controlled processing followed by accelerating cooling, resulting in the structure of quasi-polygonal/acicular ferrite with minor amounts of granular pearlite and martensite-austenite constituents. Increasing the cast slab...
Numerical Simulation of a Cylindrical Outer Flanging Spinning
Xuhui Yang, Zhen Jia
Manufacturing Technology 2024, 24(5):827-833 | DOI: 10.21062/mft.2024.089
The use of spinning technology for the outer flanging of cylindrical parts can save moulds, reduce labour intensity, and improve production efficiency. Therefore, two finite element models for the outer flanging spinning with the flange radius of 4 mm and 5 mm are established in this article. The deformation process, stress-strain field, and wall thickness distribution of the flange during the spinning period are analyzed. It can be found from the simulation results that, the blank of both working conditions cannot fit the contour of the roller until the until 2.5 s before the end of the spinning process, and it is more difficult to achieve fitting...
Effect of Normal Ageing in Bundle on the Mechanical Properties of Tempcore Treated Reinforcing Steel Rebar
Mohamed Karroum, Marwa A. Abbas, Ahmed Ramadan, Mohamed A. Gepreel
Manufacturing Technology 2024, 24(5):779-790 | DOI: 10.21062/mft.2024.088
Reinforcement steel rebar is produced by several ways but most importantly the tempcore process. Due to mass production in steel rolling plants, the rebars are gathered after tempcore process at a specific temperature in bundles stack in the warehouse. The bundling temperature varies from 200 to 300 o C. The rebars need relatively long time, up to one day, to reach the room temperature in the bundles stack. This work investigates the effect of prolonged ageing time on the rebars mechanical properties after the tempcore process of both ageing in bundle and designed artificial ageing. The results of mechanical properties of ageing in bundle compared...
Corrosion of Inconel 800HT Alloy in Molten Fluoride Salts
Zdeněk Fulín, Josef Strejcius, Zbyněk Špirit
Manufacturing Technology 2024, 24(5):755-764 | DOI: 10.21062/mft.2024.087
Molten salt reactors are one of the technologies developed under GEN IV nuclear research. The mol-ten mix of LiF and BeF2, LiF, NaF nad KF, or NaBF4 and NaF act both as a reactor coolant both in primary and secondary loop. The combination of molten fluorides and high temperature creates high-ly corrosive environment. The aim of this work was to test corrosion resistance of Inconel 800HT alloy in molten FLiNaK, FliBe and NaBF4-NaF mix. The testing tube was filled with salt mixture and heated to 600-725 °C for a total of 1800 hours. The material exposed to NaBF4-NaF mix shoved mild corrosion attack on grain boundaries. Samples exposed to FLiNaK salt...
Identification of Internal Defects in Forged Shafts by Measurement of Residual Stresses Using X-Ray Method
Kamil Anasiewicz, Jerzy Józwik, Michał Leleń, Paweł Pieśko, Stanisław Legutko, Janusz Tomczak, Zbigniew Pater, Tomasz Bulzak
Manufacturing Technology 2024, 24(5):711-720 | DOI: 10.21062/mft.2024.086
The present paper discusses important aspects of residual stress measurements in forged shafts with defects using the X-ray method. A random population of shafts was selected for the study, for which, depending on the type of rolling process, turning was performed, measuring stress changes after successive machining passes. In the forged shafts studied, the existence and location of internal defects were identified using computed tomography. The impact of internal defects on the stress distribution on the surface of the machined workpiece was observed. It was observed that the use of the X-ray method to measure residual stresses makes it possible to...
Quantification and Verification of Swingarm Structural characteristics through Numerical Simulation and Photogrammetry
Lukas Gregor, Jan Zouhar, Radim Kupcak
Manufacturing Technology 2024, 24(5):765-778 | DOI: 10.21062/mft.2024.085
Composite materials have consistently been applied in areas where a combination of properties such as strength, stiffness, and low weight is crucial. Motorcycle construction is no exception, as these parameters significantly impact riding characteristics, safety, and overall performance. This article focuses on quantifying the torsional and vertical stiffness of a single-sided swingarm made of carbon fiber reinforced polymer (CFRP) using finite element analysis (FEA) and verifying these results through experimental measurements. To enhance the accuracy of the simulations, which involve complex geometries and anisotropic materials, the material properties...
Evaluation of the Degradation of Combustion Engine Valves
Pavel Novak, Jan Růžička, Ester Duchková
Manufacturing Technology 2024, 24(5):811-816 | DOI: 10.21062/mft.2024.084
This work aims at the description of the degradation of the intake and exhaust valve of the combus-tion engine during operation. For the experiments, new valves from Ford Fiesta were used, as well as the used ones with known mileage. In order to simulate the valve long-term operation and to esti-mate the temperature of the valve during the use, the new valves were annealed at 700 – 900 °C for 1000 h (corresponding to the mileage of 70,000 km with average speed of 70 km/h) and the grain size was compared with the used valves. It was found that this model experiment can easily predict the operation temperatures of the exhaust valves, which were...
The Influence of Temperature on the Production of Antioxidant Tin-Phosphorus Alloy
Jana Körmendy, Ján Vavro jr., Ján Vavro
Manufacturing Technology 2024, 24(5):791-801 | DOI: 10.21062/mft.2024.083
The restriction of lead content in alloys for the production of the solder based on the Directive of the European Parliament and of the Council of the European Union of 08.06.2011 which is also known as RoHS (Restriction of the use of certain Hazardous Substances in electrical and electronic equipment), had a very positive impact on the research of lead-free solder alloys as well as on the economic impact on the production of solders. It opened the door to issues relating to the mechanical properties of lead-free solders and the microhardness of formed joints, increasing their quality and efforts to reduce production costs. Lead, as an element that...
Possibility of Eliminating Iron in Aluminium Alloy Through Sedimentation
Štefan Michna, Anna Knaislová, Jaroslava Svobodová, Jan Novotný, Lenka Michnová
Manufacturing Technology 2024, 24(5):802-810 | DOI: 10.21062/mft.2024.082
The article is dedicated to research on the elimination of high iron content (above 3-4%) in aluminium alloys through sedimentation. The aim was to determine the effect of sedimentation time on reducing the iron content in material from a refining bath with high iron content and to identify the phases formed in the structure. Melts were prepared from the material obtained from the refining bath, which consisted of an AlSi12 alloy with 3-4% Fe content. After melting, sedimentation was carried out for 2 hours, 4 hours, and 6 hours. Sedimentation was conducted while maintaining the alloy in a liquid state throughout the entire sedimentation period. After...
Possibilities of Analyzing Sources of Impurities in Hydraulic Oil
Alena Breznická, Pavol Mikuš, Ľudmila Timárová, Marcel Kohutiar, Michal Krbaťa
Manufacturing Technology 2024, 24(5):721-730 | DOI: 10.21062/mft.2024.081
The task of comprehensive machine care, monitoring of reliability and maintenance is currently a priority not to wait for a malfunction, but to prevent malfunctions before they occur. In the possibilities of mod-ern diagnostic tools, this activity is the task of oil analysis, which is a highly effective tool for monitoring the condition of hydraulic oils during their long-term operation. It is possible to prevent the failure of the entire system by regular monitoring of the technical condition of oils based on the analysis of hydraulic oil pollution. Oil analysis can reveal the amount of additive elements, oil pollution, the amount of addi-tives and...
Effects of Laser Shock Peening Technology on Stress Corrosion Cracking of Austenitic Steel
Jana Zavitkovská, Zdeněk Fulín, Zbyněk Špirit
Manufacturing Technology 2024, 24(5):834-842 | DOI: 10.21062/mft.2024.079
This article deals with the modification of surface properties of austenitic steels using laser shock peening (LSP) technology. This technology introduces residual compressive stresses into the surface layer. These stresses improve the technical properties of the material not only by affecting the re-sistance of corrosion cracking under stress. The aim of the work was to influence the austenitic steel 08CHN10T by LSP technology, to perform a corrosion test in a boiling MgCl2 solution and the sub-sequent evaluation of these tests. Furthermore, the hardness was measured of the peened part of the material by LSP technology and unpeened part.
Effect of Solubility of Alloying Elements on Selected Properties and on the Structure of AlSi5Cu2Mg
Martina Sýkorová, Dana Bolibruchová, Marek Brůna, Mária Chalupová
Manufacturing Technology 2024, 24(5):817-826 | DOI: 10.21062/mft.2024.078
The paper deals with the solubility and influence of the melting method of alloying elements (Zr, Mo and Sr) on selected properties and structure of the hypoeutectic aluminum alloy AlSi5Cu2Mg. Alloy-ing elements in the form of master alloys (AlZr20, AlMo10, and AlSr10) were melted in two different methods. The first method consisted in melting the master alloy together with the batch material in an electric resistance furnace, the second method consisted in separately melting the master alloy in an induction electric furnace and then introducing the master alloy into the molten batch. The presence of alloying elements led to an increase in the porosity...
Flexible Strain Sensor Based on Metallized Polyurethane Conductive Sponge Using Laser Direct Writing Process
Liang Dong, Chen Li, Peiying Han, Longgang Song, Yangyang Chen
Manufacturing Technology 2024, 24(5):747-754 | DOI: 10.21062/mft.2024.080
Flexible strain sensors show great potential in the field of wearables and health monitoring. However, the application of traditional strain sensors on flexible substrates is still limited, and the development of sensors with high sensitivity, excellent stability and good durability is a current research focus. Aiming at the limitation of traditional strain sensor in flexible materials, a flexible strain sensor based on Kirigami structure is proposed. In this study, a Metallized Polyurethane Conductive Sponge (MPCS) was used as the sensor substrate. In the preparation process, we used laser direct writing process to achieve the preparation of highly...
Optimizing Manufacturing Technology: Unraveling Symmetry in Cubic Equation Roots
Vít Černohlávek, František Klimenda, Marcin Suszynski, Jan Štěrba, Tomáš Zdráhal
Manufacturing Technology 2024, 24(5):731-737 | DOI: 10.21062/mft.2024.077
In the realm of engineering the quest for optimization is ceaseless. This article explores the intricate relation-ship between cubic equations and the practical world of production technologies, unearthing the profound connections that underpin mathematical symmetry and its role in engineering. Cubic equations, often arising in the analysis of mechanical systems, electric circuits, and robotics, serve as indispensable tools for under-standing and enhancing real-world applications. This study delves into the methods for finding the roots of cubic equations, shedding light on the vital role of mathematics in engineering and manufacturing technology.
Abrasion Wear Analysis of Commercial Cutting Inserts by Ball-on-disc Method
Tomasz Dembiczak, Robert Kruzel, Nataša Náprstková, Zbigniew Bałaga, Sylvia Kuśmierczak, Joanna Wachowicz, Piotr Reszka
Manufacturing Technology 2024, 24(5):738-746 | DOI: 10.21062/mft.2024.076
Today's machining requirements cannot be met without the right tool materials. An ideal universal tool material should combine the highest abrasive wear resistance and hardness with high strength and good toughness, while being chemically inert to the workpiece material. Despite the intensive development of materials sciences the fundamental contradiction between hardness, which guaran-tees resistance to abrasive wear, and toughness, which determines impact and fatigue strength, has not been satisfactorily resolved on a global scale. This paper presents the results of tribological wear testing of commercial cutting inserts of S20S, U10S and CC6090...