Manufacturing Technology Journal, 2016 (vol. 16), issue 2
Possibilities of Using Al-Si-Mg Alloys with Higher Fe Content for Demanding Castings
Dana Bolibruchová, Lukáš Richtárech
Manufacturing Technology 2016, 16(2):317-323 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/317 
The present article describes the effect of adding iron into melt, and its impact on the microstructure, chemical composition and mechanical properties of AlSi7Mg0.3 alloy. Higher iron content is typical of the so-called secondary alloy, which becomes increasingly used by a growing number of manufacturers in the production process of high-quality castings. The behaviour of AlSi7Mg0.3 alloy with high Fe content has not been scientifically investigated and sufficiently described, therefore working with secondary alloy is very problematic when focusing on high-sophistication castings for the automotive industry. In general, iron is unwanted in aluminium...
Hot Tearing Evaluation of Al - Based Alloys
Marek Bruna, Augustín Sládek
Manufacturing Technology 2016, 16(2):323-327 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/323
Hot tearing during solidification of aluminium alloys castings can be a serious problem. This phenomenon is well known but still insufficiently investigated. Hot tearing occurs in form of irregular cracks in metal castings that develop during solidification and cooling (typically while the casting is still inside the mold or die cavity). The cause of hot tearing is generally attributed to the development of thermally induced tensile stresses and strains in a casting as the molten metal contracts during solidification and solid state shrinkage. Submited paper consists of two parts. The first part introduces the reader to the phenomenon of hot tearing....
Impact of Silica Sand Granulometry on Bending Strength of Cores Produced by ASK Inotec Process
Martin Conev, Iveta Vasková, Martina Hrubovčáková, Peter Hajdúch
Manufacturing Technology 2016, 16(2):327-334 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/327
Nowadays, constant pressure on enviromental aspects in the foundry industry is calling for an improvement in casting production. The almost not used inorganic binders are coming back to the fore. Into this group, among others, belong binders based on alcali silicate solutions, known as water glass. The new hot-curing binder systems were introduced by different binder manufacturers. In order to compensate dissadvantages of alkalic silicate binder, the systems and processes are working with additives and adjuvants which are contained in a binder itself or added in liquid or powder form to the sand mixture. This paper presents the ASK Inotec process and...
Influence of Finishing Operations and Melt Flow Index on Surface Quality of Injection Molded Parts
Jiří Čop, Ladislav Fojtl, Ondřej Bílek, Vladimír Pata
Manufacturing Technology 2016, 16(2):334-338 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/334
In the production of polymer parts, great emphasis is placed on the quality of polymer product in terms of dimensional accuracy and optimally surface quality. Achievement of high surface quality of injection molded products correlate to the high surface quality of core or cavity in injection molds. This surface is copied during injection of polymer material. The kind of polymer material and its rheological properties can strongly influence this surface copying. Production of cores and cavities takes in the manufacturing process a considerable part of time, where some finishing technologies are more economically and time consuming than other processes....
Influence of Morphology of Carbide Phase in Chromium Cast Iron on Wear Resistance
Malwina Dojka, Andrzej Studnicki
Manufacturing Technology 2016, 16(2):338-342 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/338
The article presents results of M7C3 carbides stereological parameters measurement and wear tests of chromium cast irons. There are two types of material were compared: not inoculated chromium cast iron and the same material about 4% addition of titanium by weight. The samples for studies were taken from casting formed by pouring into ATD-Is tester mould. Then they were properly prepared for testing. Stereological analysis was conducted in ImageJ software, where the following parameters of carbides was measured: area, width, length, perimeter, and circularity. Wear test was executed using pin-on-disk method on Tribotester 3-POD. Results of research...
Ultrasonic Identification of Weld Defects Made by Butt Welding with Hot Plate on Plastic Pipelines
Martin Faturík, Miloš Mičian, Radoslav Koňár
Manufacturing Technology 2016, 16(2):343-348 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/343
This article describes usage of ultrasonic method TOFD for testing of welds on plastic pipelines welded with butt fusion with hot plate. As an artificial defects were selected cold fusion and inclusion in the weld area, by using metallic tape and wire as a mentioned defects. To test defects was necessary to use wedges with water as a bonding agent. Results of testing are proof of usefulness of this method. It can severely reduce risks of accidents caused by unidentified defects, which can occur in welded joints. Since plastic pipelines are used even in nuclear industry as a replacement for metal pipelines for its resistance against radiaton decay,...
Material Analysis of Nickel Superalloy for Military Technology
Petr Jonšta, Irena Vlčková, Zdeněk Jonšta
Manufacturing Technology 2016, 16(2):348-354 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/348
In the aerospace industry, the nickel-based superalloys are often used due to their ability to withstand extreme conditions. They find their use particularly as turbine blades in jet engines. An important example of this type of superalloy is INCONEL. This construction material must meet a wide range of complex requirements with regard to its properties and technological and operational characteristics that are required by the heavy duty in extreme conditions.The INCONEL Superalloys represent multicomponent and multiphase materials with their complex alloying base and structure with distinct dendritic segregations. Their long life and reliability...
Measurement of Noise during the Process of Cutting Materials by Water Jet
Jan Kmec, Daniel Kucerka, Miroslav Gombar, Monika Karkova, Alena Vagaska
Manufacturing Technology 2016, 16(2):354-360 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/354
Water jet technology material cutting is analyzed from the point of view of environment, namely of an impact of noise to production process working conditions. Except noise, vibrations also influence working environment but this problem in this text is not dealt with. Measuring of noise level was focused on one working shift at a production workplace of a firm WATING Prešov. Two workers were chosen for this puprouse - operators who operate two cutting desks during a common working shift. In accordance of given methodics, measuring microphones were placed on the operators and on selected places of the workplace. The recorded results of measuring were...
Finite Element Modeling and Numerical Simulation of Welding at the Repair of Gas Pipelines with Steel Sleeve
Radoslav Konar, Milos Mician, Marek Patek, Dalibor Kadas
Manufacturing Technology 2016, 16(2):360-365 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/360
This article deals with simulations of the welding process for applications of practice using SYSWELD software. Simulation of welding at the repair of high-pressure gas pipeline with steel sleeve with composite filling is presented in this paper. Two welds connecting the distance ring and gas pipe were simulated. Structure of programme SYSWELD and repair of high pressure gas pipeline with steel sleeve is described in theoretical part of article. Preparation of boundary conditions for numerical simulation on real sample and numerical simulation of welding is in experimental part. Thermal fields, residual stresses and hardness were simulated. The results...
Prediction of Hardness and Residual Stresses of Dissimilar Weld Joint
Radoslav Konar, Marek Patek
Manufacturing Technology 2016, 16(2):365-371 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/365
Welding of the dissimilar weld joints is allied with some technological difficulties that might affect the operational time of the construction. Between the main problems belong presence of residual stresses and inappropriate microstructure of the heat affected zone on the side of ferritic steel resulting to increased hardness. These factors are significantly influenced by heat input during welding, its appropriate control and welding sequence. Optimisation of the heat input and welding sequence requires large amount of experimental work. Recently, numerical analysis of welding based on finite element models became a successfull tool for prediction...
Digital Factory Simulation Tools
Jiří Kyncl
Manufacturing Technology 2016, 16(2):371-375 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/371
The article deals with the use of Siemens digital factory concept for production capacity planning. In the increasing competitive environment of globalized world economy, pressure to grow effciency of production pro-cesses and systems greatly increases. In addition the increasing cmplexity of product requires appropriate as well as-sembly and logistic processes as production process planning and control. These requirements in the production process planning and cotrol may be due to its complexity filled only with appropriate instruments provided by comprehesive concept of the digital factory, which allow effective use of information on production,...
Reparation by Hard Facing of the Damaged Secondary Stone Crushers
Vukić Lazić, Dušan Arsić, Ružica Nikolić, Milan Mutavdžić, Jozef Meško
Manufacturing Technology 2016, 16(2):375-380 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/375
The possibilities for reparation by hard facing of the damaged working parts - the hammers of the secondary stones crusher are investigated in this paper. The analyzed crusher is stationary and it belongs into a group of the process equipment aimed for producing the crushed stone. The produced stone is later used for manufacturing various construction materials like asphalt, concrete, etc. Wear of the crusher's working parts occurs during the exploitation due to operation with very hard materials. That wear is usually abrasive and of high intensity what causes failure of the working parts and consequently the machine's downtimes and appearance of various...
Analysis of Heat Transfer Conditions in the Sand and Metal Moulds and Their Effect on the Solidification of the Casting
Jiri Machuta, Iva Nova
Manufacturing Technology 2016, 16(2):380-384 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/380
The article deals with heat transfer in the casting - mould system. There are characteristics of sand and metal mould. The sand mould is a dispersion system, respectively - a capillary-porous body. In sand mould are heat transfers shared by all three ways: conduction, convection and radiation. These individual elementary processes of heat transfer are only theoretical significance, as very often processes are taking place simultaneously in different intensities or interact. The maximum effects of these processes are in a certain temperature range. From temperature 200 °C dominates conduction heat transfer. Between of temperatures 200 to 600 ° C is...
FEM/AI Models for the Simulation of Precision Grinding
Angelos P. Markopoulos, János Kundrák
Manufacturing Technology 2016, 16(2):384-390 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/384
Simulation of grinding is a topic of great interest due to the wide application of the process in contemporary industry. Up to date, several modelling methods have been utilized in order to accurately describe the complex phenomena taking place during grinding, the most common being the finite element method and artificial intelligence techniques, e.g. soft computing methods. The present paper proposes a new hybrid model for precision grinding, more specifically the combination of finite elements with neural networks. The model possesses the advantages of both the aforementioned methods, for the prediction of several grinding features that define the...
Determination of Stiffness of Triple Spring Built in a Bogie of a Rail Vehicle
Mária Maňurová, Andrej Suchánek
Manufacturing Technology 2016, 16(2):390-396 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/390
The article deals with the calculation of stiffness of a secondary suspension spring built in a bogie of a rail vehicle with a tilting car body. The vertical stiffness of the springs was calculated using the ANSYS program. The results were compared with calculated values afterwards. The lateral stiffness was evaluated in a similar manner. Analytical method by Gross, Wahl, Budrick, Timoshenko and Ponomarev was used for comparison with numerical values. The ANSYS simulation was performed for calculating the vertical stiffness of the triple springs. The most suitable analytical method is a method by Timoshenko and Ponomarev, where the percentage difference...
Evaluation of MRR after WEDM Depending on the Resulting Surface
Katerina Mouralova, Josef Bednar, Jiri Kovar, Jindrich Mach
Manufacturing Technology 2016, 16(2):396-401 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/396
The aim of this article is to evaluate the material removal rate (MRR) after wire electrical discharge machining (WEDM) and subsequent characteristics of the machined surface. For efficient processing, the aim is to achieve the highest MRR values but with regard to the preserving of required quality and functional characteristics of the surface. During the electrical discharge of material removal craters occur on the workpiece surface and due to diffusion process here premixed and melted material of fodder and wire electrodes cling. As a result of melting and fast cooling down of the workpiece material microcracks may occur on its surface.
Laser Cutting of Non-Metallic Material - PMMA
Rastislav Nigrovič, Jozef Meško
Manufacturing Technology 2016, 16(2):402-406 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/402
The presented article describes and characterizes laser cutting of PMMA, the impact of the laser beam on the PMMA material and compares it with a conventionally using cutting of plastic material - milling. In the experimental part is compare sample shown in Fig. 4 which was cutting by using a laser beam, milling and the sample which has been cut by laser but was modified by drying, which change properties of the material after cutting.
Fatigue Durability of Ductile Iron in Very-High-Cycle Region
František Nový, Peter Kopas, Otakar Bokůvka, Adriana Savin
Manufacturing Technology 2016, 16(2):406-409 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/406
In this work there are published results about fatigue resistance of ductile iron with various types of matrix obtained at cyclic loading in very-high-cycle region. The results show continuous decrease of the stress amplitude with increasing of cycles number to the failure. The tensile strength increase is not accompanied with corresponding increase of fatigue properties. The fatigue durability decreases while the tensile strength increases.
Influence of High-Pressure Die-Casting Second Stage Parameter on Structure Of AlSi9Cu3(Fe) Alloy
Łukasz Pałyga, Mateusz Stachowicz, Kazimierz Granat
Manufacturing Technology 2016, 16(2):410-416 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/410
In the paper, results of a research on influence of piston stroke rate on structures of AlSi9Cu3(Fe) (EN AB-46000 group) castings manufactured at constant intensification pressure of 290 bar are presented. Relation between piston speed (0.3-2.3 m/s) and casting structure was evaluated after a series of trial high-pressure castings. The examinations were carried-out on properly prepared samples taken from the castings in places with the largest cross-section area. The effect of pouring rate was evaluated on the grounds of metallographic observations on a light microscope and a scanning electron microscope. It was found that larger grains of the very...
The Heat Flux at the Crystallization Under Pressure
Richard Pastirčák, Ján Moravec, Eva Kucharčíková
Manufacturing Technology 2016, 16(2):417-420 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/417
This article deals with the influence of different specific pressures on the heat flux from the casting into the mould. The determination of the heat flux at different crystallization conditions will be the basis for the simulation calculation of the solidification with the crystallization under pressure.The article presents the results of the measured temperatures inside of the mold and casting by influencing of the crystallization pressure of 100 MPa. For comparison, results are also presented in gravity cast specimens. Also are presented pictures of microstructure that were observed near the surface of the casting. On the basis of the measured...
Design and Testing of the Novel Split Sleeve for Branch Connection Repairs Based on Internal Pressure
Marek Patek, Augustín Sládek, Miloš Mičian
Manufacturing Technology 2016, 16(2):421-425 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/421
Presented article deals with designing of the novel technology for repairing of the defects in branch connections of the gas pipelines. Until now, defects of the branch connections could be repaired mainly by replacing of the damaged area, especially those allied with gas leakage. The most important requirement of new type of repairing technology is maximal allowable operational pressure, which has to be the same as for repaired pipeline. Dimensions of the split sleeve should be thus designed according to required pressure value. In the case of split sleeve for branch connections, dimensions were determined by the static analysis in ANSYS software....
Tool Geometry Influence on Surface Integrity of Machined Austenite Stainless Steel
Zdeněk Pitrmuc, Jiří Čapek, Kamil Kolařík, Libor Beránek, Jan Urban
Manufacturing Technology 2016, 16(2):425-431 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/425
The goal of this contribution was to describe the microstructure and properties changes of difficult to cut materials after turning. Surface residual stresses, roughness, microstructure of AISI 304 type stainless steel were studied as a function of side rake angle o. Residual stresses and phase composition of surface and sub-surface layers were determined using X-ray diffraction techniques. The presence of strain-induced martensite was investigated using Barkhausen noise, optical microscope, and microhardness measurement.
Appliciation of Heat Treatment for Elimination of Iron in Secondary Al-Si Alloy
Lukáš Richtárech, Dana Bolibruchová, Eva Kucharčíková
Manufacturing Technology 2016, 16(2):431-436 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/431
This paper deals with possibility of changing of shape of iron based phases in the secondary alloy AlSi7Mg0.3 microstructure by heat treatment. The Al-Si alloy usually has some other coexisting elements such as copper, magnesium, manganese, zinc, and iron. The solubility of these elements in aluminum usually increases with increasing temperature. This decrease from high concentrations at elevated temperatures to relatively low concentrations during solidification and heat treatment results in the formation of secondary intermetallic phases. For instance, the precipitation of Si, Mn, and Fe forms an Al12(Fe,Mn)3Si phase. The wide variety of intermetallic...
Development and Production of Prototype Model of Axial Fan
Josef Sedlak, Jiri Malasek, Martin Ondra, Ales Polzer
Manufacturing Technology 2016, 16(2):436-444 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/436
Additive technologies belong to modern trends in production of prototype components. They include e.g. sintering of powders with a various chemical composition, granularity, physical, chemical and other usable qualities. There belong to additive technologies especially a technology of Rapid Prototyping that use various principles to make components. According to the used technology photopolymers, thermoplastics, a specially modified paper or metal powders are used in a Rapid Prototyping machinery.An article deals with a characteristic, concept, calculation and production of a prototype model of an axial fan that enables quick build-up time of fan...
Ausferrite Flake Graphite Cast Iron at the Thermal Fatigue
Břetislav Skrbek, Jiří Hampl
Manufacturing Technology 2016, 16(2):444-448 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/444
The automotive brake (clutch) disks are produced almost exclusively from flake graphite cast iron. These disks must fullfil a variety of strictly controlled parameters - high wear resistance, hardness, resistance against thermal fatigue and good thermal conductivity. The microstructure is created by the IA graphite in pearlite matrix. The isothermal hardening to ausferrite structure (AGI) was made in order to improve standard flake graphite cast iron properties. New methods and procedures of non-destructive structuroscopy, magnetoinductive, ultrasound and magnetic spot methods were used to compare material properties of flake graphite cast iron and...
Electro-Erosive Wire Cutting of Aluminum Foam
František Špalek, Jana Petrů, Tomáš Zlámal, Ivan Mrkvica, Robert Čep, Jiří Kratochvíl
Manufacturing Technology 2016, 16(2):449-453 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/449
This contribution deals with experimental cutting of samples made of special Alporas aluminum foam. This foam has been made by a powder metallurgy method and the foam resulting structure features very diverse material porosity. Test cuts through the aluminum foil were done using an non-conventional WEDM wire electro-erosive cutting technology. Monitoring and analysis of effects of proposed processing parameters on the resulting cut quality was done as a follow-up. Achieved accurracy of individual samples and its repeatability was also evaluated. At the end of the contribution wire cutting of aluminum foam technology findings are summarized and possible...
Effect of Pre-Wetting of High-Silica Sand on Parameters of Dried Moulding Sands Bonded with Selected Grades of Water-Glass
Mateusz Stachowicz, Kazimierz Granat, Łukasz Pałyga, Michał Kamiński
Manufacturing Technology 2016, 16(2):454-460 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/454
Within the research, an attempt was made to determine influence of preliminary wetting of high-silica based eco-friendly moulding sands containing sodium water-glass on effectiveness of their hardening by traditional drying. Effectiveness of adding water to the base during stirring was evaluated by comparing mechanical and technological parameters after traditional drying at 100 °C. Medium high-silica sand and two grades of hydrated sodium silicate 149 and 150 were used in the examinations. It was found that modification of preparation procedure by adding a proper quantity of water to high-silica base before adding binder (1.5 wt%) favourably affects...
Influence of Cutting Conditions on Profile Milling of INCONEL 738LC Alloy
Jan Tomíček, Alexey Molotovnik
Manufacturing Technology 2016, 16(2):461-467 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/461
This article presents particular results from a long term research focused on machining of INCONEL alloys. As a representative of this group of material INCONEL 738LC is selected and the article presents results of different experiments conducted. The behavior of material under different conditions was evaluated with focus to define cutting condition that can be recommended as suitable cutting conditions for profile milling of material. Basic problems of profile milling are exposed with focus to the respective material. Several machining experiments are explained and archived results are discussed. Effect of tool geometry and geometrical constraints...
Improvements in Material Characteristics Core Centrifugally Cast Rolls
Tomáš Válek, Jiří Hampl, Jakub Rušaj
Manufacturing Technology 2016, 16(2):468-471 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/468
The paper describes the influence of metallurgical processing on the microstructural characteristics of spheroidal graphite cast iron. The iron is used for casting the core of double layer centrifugally cast rolls. Low carbon content in the core spheroidal graphite cast iron supporting metastable solidification was eliminated by managing of metallurgical processing of spheroidal graphite cast iron. The metallurgical quality of the cast iron was controlled by using thermal analysis during all time i.e. melting furnace, through modification and inoculation. The metallurgical quality is documented by metallographic analysis, determination of surface proportion...
Evaluation of Vanadium Influence in AlSi10MgMn Alloy with Increased Iron Level
Maria Zihalova, Dana Bolibruchova
Manufacturing Technology 2016, 16(2):471-475 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/2/471
Final properties of castings made of aluminium alloys strongly depend on amount of impurities. Production of high quality parts thus requires strict control of impurity level or elimination of detrimental effects caused by presence of impurities. Such requirements are even more important in case of castings made of recycled materials. In Al-Si based alloys is very important awareness of the problems with the presence of iron as an impurity. Negative iron effect is expressive even in low amounts, and with higher level becomes more harmful. Elimination of its effects can be performed by several techniques, from which no one have general implementation....