Manufacturing Technology Journal, 2016 (vol. 16), issue 1
Influence of Abrasive - Free Ultrasonic Finishing Process of Steel on Wear
Zdeněk Aleš, Jindřich Pavlů, Miroslav Müller, Jaroslava Svobodová, Anatolii Lebedev, Alexander Yurov, Martin Pexa, Miloslav Linda
Manufacturing Technology 2016, 16(1):4-12 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/4 
The intensity of wear and particles formation are important factors at practical application of rotating machine components, because of negative effects on operability of the machines. The presence of undesired wear particles, for example in lubricating systems, poses a risk in terms of subsequent accelerated wear of lubricated points. In the extreme case, the negative impact of the wear particles leads to seizure of lubricated points. The aim of the research was to compare the classical machining and abrasive - free ultrasonic finishing (bufo) of steel. Ultrasonic set I-4 consisting of the ultrasonic generator (output power 630 W) with working frequency...
Cutting Tool Performance in End Milling of Glass Fiber-Reinforced Polymer Composites
Ondřej Bílek, Milan Žaludek, Jiří Čop
Manufacturing Technology 2016, 16(1):12-16 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/12
The article deals with the machining of glass fiber-reinforced thermoset composite. Emphasis is placed on the selection of cutting tools for end milling. Experiment involved slot milling by special tools for composite machining with different geometries and surface coating. Further, the quality of the machined surface, cutting performance, dimensional accuracy, delamination factor and tool wear were evaluated. The results were compared with the end milling of carbon fiber-reinforced polymer composites.
Review of Processing Technologies for Spent Zinc Batteries
Katarína Blašková, Jarmila Trpčevská, Tomáš Vindt
Manufacturing Technology 2016, 16(1):16-20 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/16
This paper deals with the possibility of spent portable batteries treatment with the aim of zinc recovery. Perspective of pyrometallurgical and hydrometallurgical process is described. Samples of zinc based portable batteries were submitted under the investigation. Aim of the work was to find the best conditions for zinc recovery. Experimental work focused on hydrometallurgical process was conducted. Results have shown 100 % zinc recovery under these conditions: leaching in medium 2 M (NH4)2CO3, addition of 20 ml of NH4OH as reductant, leaching temperature 20°C, within 10 minutes.
The Impact of Sr Content on Fe - Intermetallic Phase's Morphology Changes in Alloy AlSi10MgMn
Kamil Borko, Eva Tillová, Mária Chalupová
Manufacturing Technology 2016, 16(1):20-26 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/20
The effect of modification (with AlSr10) on the microstructure of hypoeutectic AlSi10MgMn cast was systematically investigated. The samples were studied in as cast state without Sr (0 % Sr) and after modification (0.05 % Sr; 0.1 % Sr and 0.15 % Sr). Iron is added to Al-Si alloy to increase hot tear resistance and to reduce die sticking, but can change the solidification characteristics by forming pre- and post-eutectic β-Al5FeSi phase or other Fe-rich phases, which can be very detrimental to the mechanical properties of the final cast part. A combination of different analytical techniques (light microscopy upon black-white etching; scanning electron...
Stability of the Casting Process According to the Method BOST
Stanisław Borkowski, Manuela Ingaldi, Piotr Sygut, Dorota Klimecka-Tatar
Manufacturing Technology 2016, 16(1):26-29 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/26
Process stability is one of the factors determining high quality of the products. By stable process, operations conducted in order to produce a given product are repeatable, and at the same time products manufactured in such process are repeatable and theirs quality is predictable. In the article the BOST method was used to evaluate casting process stability. The research in from of a survey was conducted in one of the Polish foundry. The results were presented in form of 2x2 matrix. This matrix has two variables: process stability (X axis) and product quality (Y axis). Employees quite highly evaluated the process stability, and medium and low product...
The Influence of Surface Modification Using Low-Pressure Plasma Treatment on PE-LLD/α-Cellulose Composite Properties
Martin Boruvka, Chakaphan Ngaowthong, Jiri Cerman, Petr Lenfeld, Pavel Brdlik
Manufacturing Technology 2016, 16(1):29-34 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/29
The use of plant source-based stiff fillers as reinforcement of polymer composite systems have attracted significant interests of researchers during last few decades. Unlike synthetic fibres, plant fibres are renewable, carbon neutral, biodegradable, non-petroleum based, and have low environmental, human health and safety risks. Moreover plant fibres have potential to reduce weight of composite parts up to 40% compared to the traditional synthetic composite reinforcement like glass fibres. The main disadvantage of plant fibres lies in combination of non-polar polymer matrix (hydrophobic) and polar plant fibres (hydrophilic). This combination creates...
Carbon Dioxide Internal Cooling Technology of Extrusion Blow Moulding Production
Pavel Brdlík, Martin Borůvka
Manufacturing Technology 2016, 16(1):34-38 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/34
The goal of every company is to be a successful producer. There are no easy ways because there are a lot of factors that have varying impacts on the final profit. One of the most significant factors is production time. If the processing phases of the production of polymer products are compared, cooling is clearly the most time-consuming. The reason lies in the poor thermal conductivity of polymers. Therefore is very important looking for the optimally way of cooling. One of the very interesting improvements of current production process is application of progressive internal cooling systems which using cold medium, such as deep-cooled air, the injection...
Grinding of Inconel 713 Superalloy for Gas Turbines
Jiří Čapek, Jiří Kyncl, Kamil Kolařík, Libor Beránek, Zdenek Pitrmuc, Jan Medřický, Zdenek Pala
Manufacturing Technology 2016, 16(1):38-45 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/38
From the viewpoint of residual stresses and microstructure of ground surface, Inconel 713 superalloy is an attractive material since it is frequently used in high temperature gas turbine applications where residual stresses are relevant for service life. The goal of this contribution is to find whether there exists a relation between grinding parameters and final surface integrity parameters such as residual stresses, roughness, crystalitte size, and generally, microstructure. Highly productive creep feed grinding has been applied to produce both simple flat areas and complex fir three blade root. It has been found that the used grinding method lead...
Evaluation of Cutting Forces and Surface Roughness after Machining of Selected Materials
Lenka Cepova, Dagmar Sokova, Sarka Malotova, Bartosz Gapinski, Robert Cep
Manufacturing Technology 2016, 16(1):45-48 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/45
This article deals with the evaluation of changes in mean values of the individual components of cutting forces and measuring the roughness parameters after machining variable cutting conditions such as cutting speed and feed rate. Were evaluated 3 materials from different classes' machinability: steel 14109, alloy CuZn40Pb2 and brass AlCu4PbMg. The materials have been chosen with respect to their use in the extrusion method of the ECAP. The experiment was carried out on the machine SUI 40, the forces were measured on a dynamometer KISTLER 9441 and on the roughness equipment Hommel Tester T2000. All measurements will be evaluated in tables and graphs....
Efficiency of Local Exhaust Ventilation System during Stainless Steel Grinding
Miroslav Dado, Marián Schwarz, Alena Očkajová, Richard Hnilica, Daniela Borošová
Manufacturing Technology 2016, 16(1):49-53 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/49
In order to ensure acceptable level of risk associated with exposure to airborne dust they should have been mainly technical and organisation measures at workplaces with enhanced occurance of dust. Local exhaust ventilation (LEV) belongs to principal engineering control for prevention of airborne spreading. The aim of the study was to assess the efficiency of LEV system used at mechanical workshop for controlling respirable fraction of dust during stainless steel grinding activities. Dust control effectiveness was assessed by determining personal exposure levels with and without the use of LEV system. Personal dust samples were collected using a photometer-type...
Simulation Possibilities of 3D Measuring in Progressive Control of Production
Mário Drbúl, Dana Stančeková, Ondrej Babík, Jozef Holubjak, Ingrid Görögová, Daniel Varga
Manufacturing Technology 2016, 16(1):53-58 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/53
The product price consists from several items. Time needed for adequate control of product is one of the most significant items, which can get expensive. So it is important, how the measurement strategy (measurement plan) is prepared. Time, which is not used for control of products by 3D measurement machine, is financial loss for company. This article deals with simulation of contact measurement, as a progressive tool, for preparation and creation of measurement plans for 3D coordinate measurement machines. Furthermore, the article deals with factors, that are not taken into account by offline programming during creation of measurement plan. Those...
Gauge Block Calibration by Interferometry
Štěpánka Dvořáčková
Manufacturing Technology 2016, 16(1):58-63 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/58
Absolute length calibration of gauge blocks traceable to the definition of meter is an important task of the national metrology institutes responsible for providing reliable length artifacts for industrial use. The length of a gauge block (henceforth, represented as GB) is defined in ISO 3650 as the distance between its one measuring face and the surface of an auxiliary platen on which the other measuring face has been wrung. Accordingly, in central length calibration of K-grade GBs using interferometry, it is required that they be wrung onto an auxiliary platen whose characteristics are the same as the measuring face of the GBs. According to this...
Mold Surface Contamination during Polymer Processing
Zdenek Dvorak, Eva Hnatkova, Michal Sedlacik
Manufacturing Technology 2016, 16(1):63-69 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/63
The aim of this work is concerned with a problematic adhesion of polymer materials on the surface of processing tools. Such phenomenon plays especially an important role in production of rubber components which creates an additional and considerable costs associated with mold cleaning. However, the origin of contamination is still not fully known yet. From production point of view, the attention should be paid to three fundamental aspects: processed material, material of processing tool, and processing conditions. This study describes the results of mold's surface contamination during processing a rubber compound in terms of material and surface treatment....
The Assessment of Tribiological Properties and the Condition of the Surface of Tool Steel for Hot Work 55nicrmov6 Subjected to the Process of Friction
Krzysztof Dziedzic, Jerzy Józwik, Marcin Barszcz
Manufacturing Technology 2016, 16(1):69-76 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/69
The paper presents the evaluation of tribiological properties and condition of the tool steel surface for hot work 55NiCrMoV6 (WNL). Due to the fact that the steel 55NiCrMoV6 is used for components operating at high temperature, the tribological tests were performed at the room temperature as well as higher temperature (150 °C). The wear tests were performer with help of ball-on-disc tribotester, according to the standard ASTM G-99. The applied load was 5 N and 20 N. The counter specimen consisted of balls with the diameter of 6 mm made of steel 100Cr6. Steel samples 55NiCrMoV6 undergone thermal improvement. The average hardness amounted to 57 HRC....
Ultrasonic Identification of Weld Defects Made by Electrofusion Welding on Plastic Pipelines
Martin Faturík, Miloš Mičian, Radoslav Koňár
Manufacturing Technology 2016, 16(1):76-81 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/76
In this article is described, how can ultrasonic method Phased Array be used for inspection of weld joints made by electrofusion welding on plastic pipelines. For purpose of testing and to develop a proper setup, several artificially made defects were created in the weld area to verify, if this method can be successfully used for this application, since standards for testing of plastic pipelines have no specific regulation for this method. Therefore we are trying to propagate this method for gas and water transport industry, because it can severely reduce risks of accidents caused by unidentified defects, which can occur in welded joints.
The Effect of Beam Curvature on Bending Properties of Sandwich Structures
Ladislav Fojtl, Sona Rusnakova, Milan Zaludek, Vladimir Rusnak
Manufacturing Technology 2016, 16(1):81-86 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/81
Sandwich composites are well known for many years and its place among the construction materials have they deserved mainly due to very good mechanical properties related to their weight. These materials have been a subject for many researches, but very few of them were focused on the behavior of curved constructions in bend with respect to their specific shape (curvature). With increasing number of new materials and resulting possible material combinations, it is necessary to characterize performance of new prepared structures and also evaluate the effect of a shape on the behavior of sandwich constructions with regard to their material composition....
Mold Surface Analysis after Injection Molding of Highly Filled Polymeric Compounds
Eva Hnatkova, Daniel Sanetrnik, Vladimir Pata, Berenika Hausnerova, Zdenek Dvorak
Manufacturing Technology 2016, 16(1):86-90 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/86
This work deals with an impact of abrasive particles used in powder injection molding (PIM) on a surface roughness of the tool. For this purpose, the surface of new mold cavity was compared with the same mold cavity after 2 000 injection molding cycles. Processed PIM compounds contained polymeric binder with around 60 vol. % of metal or ceramic particles (0.1 up to 20 μm). Surface analysis was performed on cavity impressions prepared from a special silicone imprinting substance in two directions by a 3D surface scanner. Investigated parameters were surface roughness (Ra) and roughness depth (Rz) which have an influence on flow instabilities of highly...
Use of Overlaying Technology in Area of Increasing Ploughshares Service Life
Petr Hrabě, Miroslav Müller, Petr Novák
Manufacturing Technology 2016, 16(1):90-94 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/90
A soil processing belongs among basic steps in an area of a crop farming. The research was focused on increasing a service life of ploughshares by an overlaying technology. The research within field conditions was focused on innovations of ploughshares in the area of a conventional processing of the soil by means of the overlaying technology. A new functional profile was created by means of overlaying electrodes on the conventional tool in order to respect drainage of the processed soil, i.e. oblique overlays. The overlaying material was put in the most stressed places of the ploughshare, i.e. parallel with a face and an edge and these both in a front...
New Application of Powder Injection Molded Product in Medical Field
Jakub Huba, Daniel Sanetrnik, Eva Hnatkova, Berenika Hausnerova, Zdenek Dvorak
Manufacturing Technology 2016, 16(1):94-98 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/94
Nowadays, majority part of powder injection molding (PIM) market in Europe consists in automotive (43 %). In contrast, to medical applications only 13 % of market is devoted. This paper is focused on a new design and production technology of the adenoid cutting curette used in otorhinolaryngology. In the theoretical part, the present design issues of the cutting curette are shown, and time consumption and wear problems of sterilisation are described. Experimental part consists in selection of suitable metal powder for medical application, computer-aided engineering (CAE) Moldflow analysis of proper gating system followed by construction of injection...
The Use of 3x3 Matrix to Evaluate a Manufacturing Technology of Aluminium Systems for Building Industry
Manuela Ingaldi, Stanisław Borkowski, Dorota Klimecka-Tatar, Piotr Sygut
Manufacturing Technology 2016, 16(1):99-102 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/99
Different types of aluminium systems are popular in building industry. Manufacturing technology of such products is a very important factor influencing the final result of production and hence the cost of production. Good quality of these systems results in good quality of investment where they are used. There is big competition on aluminium system market. The product competition decides about the existence of the manufacturer on the market. Therefore, it was decided to use the 3x3 matrix to evaluation manufacturing technology of aluminium systems produced by chosen Polish company for building industry. This matrix can be easily used to evaluate the...
The Influence of Nucleating Agents and Process Parameters on Phase Structure of Isotactic Polypropylene and its Copolymer with 3% Ethylene
Josef Jakubíček, Martina Hřibová, Jaroslav Kučera, Milena Kubišová
Manufacturing Technology 2016, 16(1):103-106 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/103
The homopolymer of the isotactic polypropylene (iPP) and the random copolymer of the isotactic polypropylene and 3% ethylene (iPPE) were used in this study. Isotactic polypropylene can be prepared in α, β and γ morphological phases depending on its crystallization conditions. The phase β content has a strong influence on mechanical, optical and thermal properties. The samples with nucleating agents (NA) α and β were used. Various process parameters were used to prepare melted samples: two thicknesses and three different cooling regimes. Wide-angle X-ray scattering (WAXD) and scanning electron microscopy (SEM) were used...
Optimizing Management of the Measurement System of the Technological Process
Dana Jenčuráková, Rudolf Palenčár
Manufacturing Technology 2016, 16(1):107-113 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/107
The present contribution represents the analysis and optimizing management of the measurement system of the technological process of pressing. It has been chosen the combination of appropriate methods for achieving the objective to minimize the cost of quality assurance of the measurement process by means its management. The quality of the measurement process has been verified by the reference standard (etalon). The optimization of evaluation measurement has been searched by utilizing QFD method (Quality Function Deployment). The subsequent optimization has been implemented by the taking into account the results of the use of the control charts and...
Vibration of Thin Walls during Cutting Process of 7075 T651 Aluminium Alloy
Jerzy Józwik, Dariusz Mika, Krzysztof Dziedzic
Manufacturing Technology 2016, 16(1):113-120 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/113
The subject of this study is the analysis of vibrations induced during milling of a thin-walled element. The milling was performed with a 2-flute custom end mill for machining Al alloys (FENES, 12x22x80-45°W-Z2), diameter d=12 mm. The rectangular 7075-T651 aluminium alloy workpiece of the following original dimensions: 120x60x12, was machined in a DMG MORI DMU 65 MonoBLOCK 5-axis milling machine. The vibrations of the aluminium alloy test plate were identified with Siemens LMS Scadas Mobile system and LMS Test Lab software. A PCB Piezotronics triaxial ICP accelerometer (model 356B21), offering sensitivity of 10mV/g, was employed. The sampling frequency...
Continuous Production of Nanocrystalline TiO2 Nanofibers
Pavel Kejzlar, Radovan Kovář
Manufacturing Technology 2016, 16(1):121-124 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/121
Titanium dioxide in its anatase allotropic modification is well known for its photovoltaic and photocatalytic activity. Through a modification of Nanospider™ device it was achieved a continuous production of nanocrystaline anatase nanofibers. These inorganic fibres have a huge specific surface area due to their fine diameter and structure and thus offer a promising potential in many applications. In this article it is described the device allowing continuous production of inorganic TiO2 nanofibers by the use of electrospinning process and optimization of following calcination process leading to obtaining of almost pure nanocrystaline anatase structure.
Deformation of Aluminium Thin Plate
Frantisek Klimenda, Josef Soukup, Milan Zmindak
Manufacturing Technology 2016, 16(1):124-129 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/124
The article is deals by an introduction to the theory of impact load for thin plates. This is the plates that are characterized by a structure which is bounded by upper and lower surface plane. These surfaces are spaced by a distance h, which is substantially smaller in comparison which other dimensions of the plate (a × b). The impact causes a deformation of the plate which is vibrated. The deformation is only within the limits of Hook's law. Therefore there is not permanent deformation of the plate. In the plate is induced shear stress, bending stress and shear forces. The second part of the article is focused on the numerical solution of thin isotropic...
Indirect Measurement of Effective Throat Thickness in T-joint Weld by Ultrasonic Method Phased Array
Radoslav Konar, Michal Sventek, Miroslav Bucha
Manufacturing Technology 2016, 16(1):129-132 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/129
The article deals with non-destructive measurement of the effective throat thickness of fillet weld with deep penetration in T-joint. Ultrasonic Phased Array technology is used to indirectly measurement of effective weld throat thickness. Phased Array ultrasonic systems utilise multi-element probes, which are individually excited under computer control. By exciting each element in a controlled manner, a focused beam of ultrasound can be generated. Software enables the beam to be steered. Two and three dimensional views can be generated showing the sizes and locations of any flaws detected. The results of Phased Array ultrasonic measurements are compared...
Inserts Coating Influence on Residual Stress of Turned Outer Bearings
Marek Kordik, Jozef Struharnansky, Anton Martikan, Dana Stancekova, Sylvia Kusmierczak, Juraj Martinček
Manufacturing Technology 2016, 16(1):132-136 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/132
Residual stresses significantly affect the life of parts material, especially in bearing manufacturing, where the stress introduced into the material in the manufacturing process affect the component throughout its whole operating life. It is therefore important to know the size and orientation of these stresses and to optimize the production process of the bearing rings, in order to eliminate as many of these undesirable stresses. The subject of the article is chosen at demand of practice and has to correlate coating cutting tool for residual stress and microstructure in turning the outer bearing rings made of material 1.3520, which is widely used...
Deformation of Print PLA Material Depending on the Temperature of Reheating Printing Pad
Jan Krotký, Jarmila Honzíková, Pavel Moc
Manufacturing Technology 2016, 16(1):136-140 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/136
The article presents results of research in the field of prototyping - 3D printing. The authors are focused on polylactic acid material known by the abbreviation PLA, which is widely used in 3D printing method to produce objects. The tech-nology of successive layering of plastics and its solidification causes states of tension in printed objects and subsequently their deformation. That may even lead to torn the object from the print pad. The article deals with dimensions of the deformations at the specimen just in dependence on heating of the print pad. The authors also suggest a compromise solution between excessive deformation of underlying layers...
Metallography of 3D Printed 1.2709 Tool Steel
Ludmila Kučerová, Ivana Zetková
Manufacturing Technology 2016, 16(1):140-144 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/140
3D printing is a new and advanced technology of material processing, which belongs to additive manufacturing process. Products with complex geometries can be produced quickly with high precision from powder materials on the base of a CAD-model. Layers of powder particles are successively molten by laser beam. There are several metallographic issues connected with 3D printed microstructures. Laser beam processing is usually accompanied with high heating and cooling rates and therefore also with high thermal gradients. This is the reason why nonequilibrium phases and structural components can occur in the final microstructure. The microstructure could...
Influence of Nb Micro-alloying on TRIP Steels Treated by Continuous Cooling Process
Ludmila Kučerová, Hana Jirková, Bohuslav Mašek
Manufacturing Technology 2016, 16(1):145-149 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/145
TRIP (transformation induced plasticity) steels are low alloyed steels with multiphase microstructure consisting of ferrite, carbide-free bainite and retained austenite. They are typically produced by thermo-mechanical treatment, which involves the hold in bainite transformation region. The hold ensures enough bainite in the final microstructure and also helps to stabilize higher amount of retained austenite. Due to transformation induce plasticity effect; TRIP steels possess very good combination of high strength and high ductility. In response to industrial demands, C-Mn-Si and C-Mn-Si-Nb TRIP steels were subjected to thermo-mechanical treatment...
Chemical Analysis and Mechanical Properties of Selected Safety Components of Lifts
Petra Kvasnová, Daniel Novák, Viktor Novák
Manufacturing Technology 2016, 16(1):149-154 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/149
This paper deals with materials of selected safety components of lifts and it describes their mechanical and chemical testing. It particularly concerns with chemical analysis of two basic types of pulleys from gray and ductile cast iron, and subsequently with the measurement of the hardness and the strength of these materials. The aim of the research was to prove if these types of pulleys, widely used as safety components in the lift industry, meet the current law requirements. Finally, the results of the research are briefly discussed as well as their application in the university education.
Influence of Laser Shock Peening Surface Treatment on Fatigue Endurance of Welded Joints from S355 Structural Steel
Ján Lago, Mario Guagliano, František Nový, Otakar Bokůvka
Manufacturing Technology 2016, 16(1):154-159 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/154
This work deals with fatigue testing of the EN S355 structural steel welded joint. The weld was manufactured by the MIG welding technology and as the filler material was used the G3Si1 wire. The fatigue tests were carried out in the rotating bending mode on the specimens manufactured from the welded joint of the S355 steel. The main aim was to evaluate the fatigue endurance of the weld material and for this reason were used machined axis symmetrical specimens to remove the notch effect of the weld shape. In order to increase the fatigue endurance of the weld, the Nd-YAG laser was used for laser shock peening (LSP) of specimens surfaces, which lead...
Grinding of Titanium Alloy Ti6Al4V with Silicon Carbide Grinding Wheel
Radek Lattner, František Holešovský, Martin Novák, Marek Vrabeľ
Manufacturing Technology 2016, 16(1):159-162 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/159
Grinding is one of the technologies for surface finishing of large scale of material. This paper deals with grinding of titanium alloy Ti6Al4V with silicon carbide grinding wheel. Ti6Al4V is the most widely used titanium alloy. Its utilization can be found in medical, aerospace, chemical and other industries. This experiment deals with evaluating of surface roughness after grinding. The roughness parameters (Ra, Rz) were measured on each specimen ten times. Also cutting forces were measured while grinding each specimen. All these measured values were evaluated and presentated in graphs.
Assessment of the Procedural Gases Influence at Turning Technology
Miloslav Ledvina, Štěpánka Dvořáčková
Manufacturing Technology 2016, 16(1):162-168 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/162
This paper deals with the assessment of the procedural gases progressive cooling methods and cooling by procedural liquids at turning technology on the final workpiece surface quality. Turning by using liquefied CO2, liquefied nitrogen and subcooled air supplied through the vortex tube was compared with the turning without process medium (taken as reference conditions) and with two procedural liquids EOPS 1030 and HOCUT 795 B. At evaluation effect of procedural gases there were monitored acting forces, cutting tool cooling rate and the machined layer of the material, cutting tool durability and cut surface quality which was characterized by surface...
Roughness Evaluation of the Machined Surface at Interrupted Cutting Process
Sarka Malotova, Robert Cep, Lenka Cepova, Jana Petru, Dana Stancekova, Ladislav Kyncl, Michal Hatala
Manufacturing Technology 2016, 16(1):168-173 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/168
The article deals with the evaluation of the roughness of the machined surface, steel ISO C45 and ISO 11CrMo9-10 after machining at interrupted cutting conditions. A regular interrupted cut and irregular interrupted cut can have significant effect on the resulting surface of components. Parameters of roughness were measured on the slats, which was machined with using the interrupted cutting simulator. The slats were gradually machined - 4, 3, 2 and 1 slat for getting irregular interrupted cut. Selected parameters of roughness which were tested; Ra - an average arithmetic deviation, Rq - an average quadratic deviation and Rz - the maximum height of...
The Effect of Different Modifiers in AlSi7Mg0.3 Alloy on Built-up Edge Formation in Machining
Michal Martinovský, Jan Madl
Manufacturing Technology 2016, 16(1):173-178 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/173
Aluminium and silicon alloys are widely used in practice. But there is increasingly more emphasis placed on the research and development of these materials. The aim of this article is to analyse modified aluminium alloy AlSi7Mg0.3. The paper is focused on the effect of particular modifiers in AlSi7Mg0.3 alloys on built-up edge formation in machining. Four variants of castings (unmodified alloy and alloy modified by chemical elements - strontium, calcium and antimony) were used. All alloys were compared with non-modified alloy. There were moulded castings from each modified variant and the casting of non-modified alloy. It was casted using a gravity-die...
Barkhausen Noise Emission of Surfaces after Plasma Beam Machining
Anna Mičietová, Miroslav Neslušan, Mária Čilliková, Kamil Kolařík
Manufacturing Technology 2016, 16(1):178-183 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/178
This paper deals with analysis of surface integrity of steel after plasma beam machining (PBM). The paper discusses surface integrity expressed in term of rms values of Barkhausen noise and reports about variables affecting Barkhausen noise emission such as plasma current, nozzle distance, thickness of machined surface and feed speed. The paper demonstrates variable degree of surface hardening due to elevated temperatures and the following rapid cooling. Except magnetic investigation of surface also stress state and structure observation are reported.
Influence of Stylus System Configuration on the Variability of Measurement Result on CMM
Petr Mikeš
Manufacturing Technology 2016, 16(1):184-188 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/184
The article deals with the measurement on CMMs with tactile stylus system. Accuracy of CMM is mostly indicated by the parameter MPEE (Maximum Permissible Error for length measurement). This parameter refers to an errors during the measurement of distance between two points in space. Verification of MPEEparameter is described in an ISO standard 10 360-2 Acceptance and re-verication tests for coordinate measuring machines. These acceptance and re-verification tests are often conducted with a short and stiff reference stylus which is not and also mostly cannot be used in real measurements. On the contraryin applications such as a measurement of engine...
Creep Behaviour of the Polymer Composite with False Banana's Fibres (Ensete Ventricosum)
Čestmír Mizera, Petr Hrabě, Miroslav Müller, David Herák
Manufacturing Technology 2016, 16(1):188-192 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/188
This study was focused on the analysis of creep behaviour of the polymer composite with continuous phase in the form of two-part epoxies and discontinuous phase (reinforcing particles) in the form of fibres of false banana (Ensete ventricosum). The aim of the experiment was to describe the short term flexural creep behaviour, flexural strength and Charpy impact strength of polymer composite reinforced by fibres of false banana. The fibres of Ensete ventricosum, originally from Ethiopian region Hawassa, were used for this experiment. Reinforcing fibres were prepared in size of length 1-2 mm with randomly fibres arrangement in matrix. The amount of reinforcing...
Effect of Age Hardening Conditions on Mechanical Properties of AW 6082 Alloy Welds
Jaromír Moravec, Iva Nováková, Josef Bradáč
Manufacturing Technology 2016, 16(1):192-198 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/192
The present paper expands the knowledge in the field of welding of age hardening aluminium alloys using MIG method. Aluminium alloy AW 6082 (AlSi1MgMn) according to the specification standard CSN 42 4400 was used for the experiment. This type of alloy is used in industrial practice e.g. for medium stressed parts in railway and motor vehicles and in water, oil or petrol pipes. For the purpose of assessing the impact of multiple cycles on the properties in the heat affected zone the weld was designed as a multi-layer weld. The objective of this paper is not only the impact assessment of the degradation of the mechanical properties, but also the possibility...
Design of Control Jig for Inserts Measurement
Ivan Mrkvica, Vojtech Sleha, Jana Petru, Miroslav Neslusan, Jozef Jurko, Anton Panda
Manufacturing Technology 2016, 16(1):198-204 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/198
This paper aims to design a control jig for cutting inserts measurement. These inserts are made from standardized inserts by grinding. The control jig is intended to be used on two different types of measuring devices and it has to meet the functional requirements of these devices.The intoduction describes specific functional requirements on the jig, provides information about measuring devices and examples of cutting edges grinded on inserts. Next part describes the design of several variants of jig parts and reasons for their application. Paper is focused specifically on design of jig body variants, description of measuring arm and the way of clamping...
Influence of Cyclic Degradation in Saline Solution on Mechanical Properties of Adhesive Bonds
Miroslav Müller
Manufacturing Technology 2016, 16(1):204-209 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/204
The adhesive bond is the complex of three layers - adhesive bonded material (called adherent), adhesive layer and cohesive layer. Degradation aspects act all parts of the adhesive bond. The aim of this research was the evaluation of influence of degradation environment on the strength of structural two-component epoxy adhesives. Adhesive bonds and process of testing the adhesive bonds were in accordance with standard ČSN EN 1465. The degradation environment in form of 5 % saline solution was used within this experiment. Adhesive bonded testing samples were subjected to cyclic loading of saline solution. On the basis of evaluation of performed experiments...
Modification of AlSi9CuMnNi Alloy by Antimony and Heat Treatment and Their Influence on Tool Wear after Turning
Natasa Naprstkova, Jaromir Cais, Manuela Ingaldi
Manufacturing Technology 2016, 16(1):209-214 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/209
Modification alloy is an important part of the metallurgical process, and this also applies, of course, for aluminum alloys, particularly for Al-Si (silumins). As a modification of the material we can use the modification using the selected element or heat treatment of alloys, or a combination of both processes. One of the elements that it is possible to modify the alloy of Al-Si used is antimony (Sb). The paper examines the possible effect of the modification that element and heat treatment on the final tool wear after machining of the alloy AlSi9CuMnNi. In the experiments were made three castings from the alloy AlSi9CuMnNi without modification, three...
Barkhausen Noise Emission in Case - Hardened Bearing Steels
Miroslav Neslušan, Róbert Farda, Kamil Kolařík, Jiří Čapek
Manufacturing Technology 2016, 16(1):214-220 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/214
This paper deals with detection of surface burn after grinding operations on bearing rings made of case - hardened steels. The paper reports about Barkhausen noise technique employed for non destructive monitoring of grinding burn and discusses the main aspects affecting the Barkhausen noise emission such as thickness of heat affected zone, micro hardness, stress state, carbides, dislocation density and volume of retained austenite. Results of experiments indicate that the influence of stress state on Barkhausen noise is only minor whereas influence of structure features dominates. On the other hand, it is difficult to unwrap influence microstructure...
Evaluation of Applicability of Unconventional Cooling Method in Injection Mould
Thang Nguyen Vo, Martin Seidl
Manufacturing Technology 2016, 16(1):220-225 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/220
To increase the intensity of cooling the unconventional methods can be used, which enable to achieve quick and steady heat transfer from the injection mould and from the plastic product. This paper is devoted to the cooling method based on high cooling potential of liquid carbon dioxide that is included among the unconventional methods of mould temperature control system. The main objective of this paper is to evaluate the applicability of cooling with using liquid CO2 in the injection mould with regard to several aspects that have a direct impact on the final cooling efficiency. The practical experiment deals with the design of the shaped mould insert...
Monitoring of the Diffusion Processes during Carburizing Automotive Steel Parts
Iva Nová, Jiri Machuta
Manufacturing Technology 2016, 16(1):225-230 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/225
The article deals with the prediction of diffusion process of steel components, respectively diffusion of carbon during carburizing. The calculation was made on the basis of the solution diffusion in semi-infinite space. For the calculation there was used the II. Fick's law. For the reason that the transfer medium is formed at the interface environments diffusion boundary layer, for the more accurate calculations, it is necessary to consider the coefficient of transfer of β atoms of carbon. For the calculation of the diffusion coefficient D was used Arrhenius's equation, which is based on the rate of diffusion processes (diffusion). It was calculated...
Dilatometric Measurements of Austenitic Stainless Steel as a Function of Temperature
Monika Oravcová, Peter Palček, Máriusz Król
Manufacturing Technology 2016, 16(1):230-234 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/230
Many solid materials are subjected to structural changes, e.g. phase transformations within temperature change. These phase transformations are usually accompanied by a significant change in particular volume. The change in volume of a solid material is measured by the corresponding change in length of a specimen of the material. The experimental method which is based on measurement of volume/ length change during linear heating or cooling is dilatometry. Dilatometry is characterised by the linear thermal expansion coefficient which can be described as the relative length-change divided by the corresponding temperature interval. The basis of the thermal...
Numerical Analysis of T-Joint Welding with Different Welding Sequences
Marek Patek, Miloš Mičian, Augustín Sládek, Dalibor Kadáš
Manufacturing Technology 2016, 16(1):234-238 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/234
Numerical simulation of welding is an efficient tool for prediction of temperature distribution during welding process, residual stresses and final distortions of the welded parts. Importance of numerical analysis can be even higher during optimization of the large structures welding, in which preparing of the experimental samples is more expensive. Numerical analysis of T-joint welding for bridge construction parts in SYSWELD software is presented in the article. Welding simulation was prepared for two welding sequences with the same welding parameters required to ensure penetration of the weld metal. Obtained thermal analysis results were compared...
Influence of the Selected Technological Factors on the Elimination of Misruns
Radka Podprocká, Jozef Malik, Dana Bolibruchová
Manufacturing Technology 2016, 16(1):239-243 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/239
High pressure die-castin of aluminum alloys is a complicated process depending on a number of factors which relate between each other. That is why these factors must be regulated in the process of casting. This contribution focuses on the possibilities of eliminating the defects of short run. This defect is located on the edge of the flow opening of the casted body STIRNPLATTE 033. From the view of functionality this kind of defect is inadmissible. Experimental castings from the AlSi12CuNiMg alloy were casted by using different technological parameters where the work surface temperature of the mould and the profile layout of the piston path differed....
Effect of Nickel on the Properties of the AlSi10MgMn Alloy with Increased Iron Content
Ján Ščury, Dana Bolibruchová, Mária Žihalová
Manufacturing Technology 2016, 16(1):243-247 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/243
The article deals with the issue of secondary aluminum alloys with higher iron content and the possibility of reducing the negative impact of the iron by adding certain elements (correctors of iron). This paper evaluated the impact of nickel on amount of gas and mechanical properties of AlSi10MgMn alloy with increased iron content. For evaluation purposes master alloy AlNi20 with concentrations of 0.1, 0.3 and 0.5 wt. % was used. The main conclusion is that the addition of nickel corrector appears to have positive influence on reducing the negative effects of iron. The next conclusion is that the addition of 0.5 wt. % AlNi20 according to the results...
Laser Hardening of the Functional Surfaces of Machine Tools
Karel Šramhauser, Sylvia Kuśmierczak
Manufacturing Technology 2016, 16(1):248-253 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/248
The purpose of using modern technology is to reduce costs, facilitate the work and simplify as far as the most comprehensive set of operations. One of many modern technological processes involved in the refining of materials are technologies of surface hardening using a laser beam. This method can harden precisely defined areas with minimal thermal influence of surrounding areas it is possible to achieve less residual stress and less distortion of components compared the volumetric hardening, it is also possible to use controlled robotic units and all for the absence of cooling, which proceeds spontaneously to the surrounding material itself and atmosphere....
Influence of Manufacturing Parameters on Final Quality of Lapped Parts
Dana Stancekova, Mario Drbul, Miroslav Janota, Natasa Naprstkova, Albert Kulla, Jozef Mrazik
Manufacturing Technology 2016, 16(1):253-259 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/253
For a variety of engineering technologies, machining has a specific position because it is a technology that meets the highest requirements on accuracy and quality of products and involves processes that are final, i.e. the last in the production processes of parts machining. Therefore, these processes largely affects the final shape and dimensional requirements of high quality components and hence their performance characteristics, particularly the accuracy and durability. Such production methods designed to achieve high dimensional and shape accuracy is grinding and other finishing methods (superfinishing, polishing, lapping) involved in a high percentage...
Research of Chemical Pre-treatment Created by Sol-gel Process on the Polished Surface of Aluminium Substrate
Jaroslava Svobodova, Pavel Kraus, Jaromir Cais, Radek Lattner
Manufacturing Technology 2016, 16(1):259-264 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/259
This paper reports the preparation and characterization of thin transparent nanolayers with phase composition ZrF4 and different modification of SiO2 with special focus on the affecting the surface roughness of the material and the way of exclusion of the thin nanolayer on the surface of the polished aluminium material. The thin nanolayer was prepared by the sol-gel method. The final treatment based on PTFE was applied on the surface of some samples. This treatment is suitable for the increasing of the wear resistance. The films were characterized with help of SEM microscopy and EDS analysis. The surface roughness was measured with classical surface...
The Use of BOST Method as a Tool to Standardize Tasks in Hot Dip Galvanizing Process Improvement
Piotr Sygut, Dorota Klimecka-Tatar, Manuela Ingaldi, Stanisław Borkowski
Manufacturing Technology 2016, 16(1):264-267 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/264
Standardization is the basis for improvement in the company. This allows for repeatability performance of activities and thus the stability of the process. This chapter presents the standardization as part of Toyota's production system. Standardization is also one of the elements examined using the method BOST, because it was used for hot dip galvanizing process improvement. The research was carried out in one of the national companies producing steel products and providing services in the field of modern anti-corrosion protection, in particular hot-dip galvanizing.
Improving the Quality of Castings Using Thermovision
Miroslava Ťavodová, Daniela Kalincová
Manufacturing Technology 2016, 16(1):268-273 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/268
The paper gives practical using of thermovision for quality casts assessment, which are casting to permanent moulds. Thermovision allows monitoring temperature of moulds and their cooling process by refrigerant medium in foundry engineering. It helps when the problems with elimination internal defects exist. Tests in experiment were implemented by DAS scan and local surface modification of water cores of cylinder heads. Cylinder heads are produced by ROTACAST foundry technology. Results of experiment showed that in location of defects is no directionally solidified. It is necessary to modify tools to defect eliminate. Tests consist of four parts. Each...
The Research of Options for the Innovation Heat Treatment of the Tools for Coinage in Order to Increase their Lifetime
Miroslava Ťavodová, Daniela Kalincová, Rudolf Kaštan
Manufacturing Technology 2016, 16(1):274-280 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/274
This paper describes research in technology of the heat treatment for tool steel Böhler K455 designed for cold work. The aim of the research was based on operational experiments to draft procedures for heat treatment of the tools in a vacuum hardening furnace. Testing of two alternative methods and comparison of the state of microstructure and the mechanical properties with the current state of these indicators of dies quality will highlight the importance of introducing innovations to achieve higher lifetime of dies and the justification for the purchase of new technological equipment.
A Measuring Device for the Checking of 3D Indicators
Šárka Tichá, Ondřej Srba, Jan Vavřina
Manufacturing Technology 2016, 16(1):280-284 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/280
This paper was based on the cooperation the Department of Machining, Assembly and Engineering Metrology with company accredited by Czech Institute for Accreditation. It deals with issues of calibration 3D indicators. Generally, the calibration of non-specified working gauges integral part of every company, which uses such gauges. Checking/calibration of measuring instruments is important for ensuring the uniformity and accuracy of measurements to ensure continuity of measurement results. The paper deals with streamlining the process of calibration of indicators 3D design and practical verification of appropriate gauge for the calibration. The target...
The Study of Deformation Behaviour of DC06 Deep Drawing Steel
Michal Tregler, Pavel Kejzlar, Tomáš Pilvousek, Zuzana Andršová, Lukáš Voleský
Manufacturing Technology 2016, 16(1):284-289 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/284
The occurrence of any cracks or defects in car body parts processed by deep drawing technology is not allowed by high quality standards. This kind of defect is considered as the most dangerous for the process quality and stability because it cannot be easily detected during the manufacturing in the steel plant and also in final inspection after pressing, that's why the occurrence of these defects has always to be studied in detail. For the prevention of defects, it is necessary to study the deformation behaviour of the material in the immediate vicinity the crack tip in detail. For the study the controlled scratched samples were tensile deformed and...
Research of the Chemical Heterogeneity during Crystallization for AlCu4MgMn Alloy and the Possibility of its Elimination
Viktorie Weiss
Manufacturing Technology 2016, 16(1):289-294 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/289
Crystal segregation is taken as chemical heterogeneity under the micro-scale and it develops during the crystallization process. Alloy crystallization does not take place under a particular temperature, as it happens in the case of pure metals, but it runs under a certain temperature interval. When cooling the melt, various places start development among dendritic cells which differ in their chemical composition. Crystal segregation can be generally defined as chemical heterogeneity developing during the alloy crystallization process, and it can be either en-riched or in contrast depleted with alloying elements and impurities, which are unevenly segregating...
Effect of Shot Peening on the Fatigue Properties of 40NiCrMo7 steel
Denisa Závodská, Mario Guagliano, Otakar Bokůvka, Libor Trško
Manufacturing Technology 2016, 16(1):295-299 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/295
Fatigue properties of 40NiCrMo7 low alloy steel in the high cycle region were tested by rotating bending fatigue loading (f = 40 Hz, T = 20 5 , R = -1) on notched specimens after application of shot peening surface treatment (cast steel balls with diameter of 0.43 mm, Almen intensity 12A, coverage 100 % and consequently the surface was re-peened with glass beads to decrease the final roughness). The compressive residual stresses created by shot peening increased the time necessary for fatigue crack initiation what in the final case increased fatigue properties. The fatigue limit σc was higher for almost 28 % in the case of notched shot peened...
Research on Mechanical Properties of Adhesive Bonds Reinforced with Fabric with Glass Fibres
Jan Zavrtálek, Miroslav Müller
Manufacturing Technology 2016, 16(1):299-304 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/299
In this paper the mechanical behaviour of structural two-component epoxy adhesives in T-joints is experimentally investigated. Laboratory experiments were performed on standardized test specimens of structural carbon steel S235J0 made according to standard ČSN ISO 11339.The aim of experiments was to confirm or disprove a hypothesis about a possibility to increase the adhesive bond peeling strength by means of an interlayer from glass fibres.The research was focused on an effect of an improving a resistance of the adhesive bond stressed by peeling by adding an interlayer created by fabric from glass fibres. The testing of these properties was...
Influence of Selected Iron Correctors to Solidification of Secondary AlSi10MgMn Alloy
Maria Zihalova, Dana Bolibruchova, Jaromir Cais
Manufacturing Technology 2016, 16(1):305-309 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/305
Secondary (recycled) aluminium alloys are still not widely used in the foundry industry, because of the higher amounts of impurities that require more strictly control of the manufacturing process. The most problematic impurity of aluminium cast alloys is iron, which is in alloy mostly present in form of hard and brittle intermetallic phases. Such phases are thought to be detrimental to alloy mechanical and foundry properties and have to be removed or modified to eliminate negative effects. Several techniques might be used to this purpose, from which the most beneficial seems to be addition of some elements, so-called "iron correctors". Influence of...
Contactless Thermal Bending of Steel Sheets
Andrej Zrak, Jozef Meško, Ján Moravec, Rastislav Nigrovič, Dalibor Kadáš
Manufacturing Technology 2016, 16(1):309-313 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/1/309
The article deals with contactless thermal forming of metals. In the introduction the bending theory of components by using flame technology is described. On the basics of information obtained from the analysis of previous research a technological procedure was developed. This technology uses gained characteristics of material behavior in the process of heterogeneous circumferential heating. The principal of material concentrating in the process of local heating the area which is placed in a quasi prism leads to a bending moment. This bending moment evokes deformation of the material which was compacted this way. Application of subscribed technology...