Manufacturing Technology Journal, 2016 (vol. 16), issue 4
Mechanical Properties of Titanium-Aluminium Base Nanomultilayer Coatings
Totka Bakalova, Nikolay Petkov, Tetiana Cholakova, František Kaván, Hristo Bahchedzhiev
Manufacturing Technology 2016, 16(4):657-662 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/657 
Titanium-aluminium base nanomultilayer (NML) coatings are deposited by cathodic arc evaporation using pure titanium and aluminium with eighteen percent silicon cathodes. Each multilayer Ti-Al-Si-N structure consists of 49 bi-layers with different thickness. The external deposited layer is with five times longer growing period. The coatings are deposited at the pressure of 2 Pa and the substrate temperature of 400 °C. Polished steel discs (Ø 20 mm × 5 mm thick) are used as the substrate material.This article presents an investigation of the surface morphology and mechanical properties of the coatings, particularly the adhesion and nanohardness....
Resistance Spot Welding of Steel Sheets
Milan Brožek
Manufacturing Technology 2016, 16(4):662-666 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/662
Resistance welding ranks among progressive and in practice often used manufacturing techniques of rigid joints. The basis of this method is in the utilization of the Joulean heat, which arises at the passing of current through jointed sheets at collective influence of compressive force. The aim of the carried out tests has been to evaluate the rupture force of spot welded steel sheets of various thickness using short-time spot welding and long-time spot welding. For test specimens welding the parameters recommended by the spot welder producer were used. After welding all assemblies were loaded using the universal test machine up to their rupture. The...
Analysis of a Goods Wagon Running on a Railway Test Track
Ján Dižo
Manufacturing Technology 2016, 16(4):667-672 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/667
An intermodal transport is nowadays an inseperable part of a transport system. Designs of longer wagons are the result of efforts to achieve universality, transport capacity increase, reducing of noise and maintenance needs. In this paper are presented results of selected parametres of a long goods wagon driving on a test track. The long goods wagon and test rings models have been created by using the ADAMS/Rail software. The analysed wagon has been equipped by the Y25 bogie. Simulations of the long goods wagon running have been performed on the model of railway test rings - VÚŽ Velim, Cerhenice. For the dynamic analysis of the long goods wagon have...
Assessment of Complex Free Form Surfaces with Surface Profile Deviation
Miroslav Dovica, Ján Buša, Emil Spišák, Michal Fabian, Peter Ižol, Jana Fabianová
Manufacturing Technology 2016, 16(4):673-680 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/673
Accuracy of work-pieces of complex free form surfaces is achieved by tolerancing, producing and metrology of workpieces. The tolerance zone is defined by form tolerances, their orientation and location on the work-pieces. Tolerances for complex form surfaces are specified by line profile tolerance or surface profile tolerance. These tolerances control form or combination of size, form, orientation and location. In a machining process the impact of machining parameter settings on the final surface quality will be researched. The influence of toolpaths in connection with the SH (Scallop Height) parameter setting on production accuracy and quality of...
Preparation of WE43 Using Powder Metallurgy Route
Drahomir Dvorsky, Jiri Kubasek, Dalibor Vojtěch, Filip Prusa, Katerina Nova
Manufacturing Technology 2016, 16(4):680-687 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/680
Magnesium alloy WE43 is well known for its low density and good mechanical properties. It has also fair corrosion resistance and relative usability up to 300 °C. All those properties are connected with the content of rare earth elements and determine this alloy not only for automotive and aviation industry, but also for applications as biodegradable materials. In this work, WE43 alloy prepared by powder metallurgy methods is characterized. Final products are prepared by cold uniaxial pressing with subsequent extrusion or spark plasma sintering (SPS). Present paper deals with the characterization of processing methods used for the WE43 alloy preparation...
Evaluation of Selected Properties of Steel 100Cr6 at Different Ways of Heat Treatment
Peter Fabian, Andrej Zrak
Manufacturing Technology 2016, 16(4):687-691 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/687
This study discusses the impact of heat treatment conditions on the final properties of quenched and low-tempered bearing components in terms of microstructure, hardness and impact strength. Technological process of heat treatment must be done rationally and in addition to the required hardness must also ensure the dimensional precision of bearings components. Different austenitization conditions have a great influence on the phenomena which takes place in the material during the austenitizing. Heat treatment of rolling bearing components is an indispensable part of their production and it is also an unavoidable item of the price calculation of bearings....
Titanium Alloy Ti-6Al-4V Prepared by Selective Laser Melting (SLM)
Michaela Fousová, Dalibor Vojtěch, Jiří Kubásek
Manufacturing Technology 2016, 16(4):691-697 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/691
Selective laser melting (SLM) as a representant of additive manufacturing technology brings about many advantages into production, which are appreciated especially in the field of biomedical applications and implantology. Our paper is focused on characterization of titanium alloy Ti-6Al-4V (Ti Grade 5) widely used for orthopaedic implants produced by this novel method. Microstructure and mechanical properties are compared with the same material prepared by conventional way of casting, forging and machining. Results show these are almost equivalent. Microstructure is in both cases formed by two phases +, but possesses different morphology....
Distortion after Case Hardening of Steels
Jiří Hájek, Antonin Kříž, Tomáš Jirka
Manufacturing Technology 2016, 16(4):697-702 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/697
Dimensional changes, or distortion, play a very important role in carburizing. To keep carburizing process productive and profitable, it is crucial that the resulting distortion is minimized. The purpose of this experiment was to carry out low-pressure carburizing and measure dimensional changes, residual stresses, characterize the resulting microstructures, and determine hardness in the specimens. These are the most important clues to the quality of the carburized layer. Experimental materials were the most widely-used carburizing steels: C15, 16MnCr5 and 15NiCr13. Residual stresses in the surface were determined by X-ray stress measurement.
Influence of the Welding Process on the Martensitic and Dual Phase High Strength Steels
Petr Hanus, Eva Schmidová
Manufacturing Technology 2016, 16(4):702-707 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/702
The subject of the study are martensitic 22MnB5 steel and dual phase steel with the ferrite-martensitic structure, which are used in the automotive industry. The main purpose of the performed analyses is a study of strength differences in heat affected zones of the spot welding. For the needs of the strength decrease assessment, the critical layer of the heat affected area was experimentally simulated by different thermal influence procedures. The aim of the work is to determine the most suitable methodology for evaluating the local changes of the elastic-plastic material response. The yield strength and the deformation hardening are required constructions...
Numerical Optimization of Large Shade Sail Support
Jakub Javorik
Manufacturing Technology 2016, 16(4):707-712 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/707
To design an optimal support of a large shade sail it is necessary to determine forces in wire ropes that support the sail. Relations between a sail loading and ropes reaction forces, rope diameters and sail stresses were investigated. To simulate the sail behavior and set up these relations, numerical (FEM) models were created and analyzed. Most of the results show nonlinear relations between above mentioned parameters and they depend on the sail geometry, applied loads and the rope diameter. It means that for every specific geometry and loading of particular sail an optimal rope diameter and support should be designed. The nonlinear numerical analysis...
Cr2N - Ag Thin Films - a Short Review
Peter Jurči, Pavel Bílek
Manufacturing Technology 2016, 16(4):712-720 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/712
The current paper summarizes briefly the results obtained by comprehensive investigations of magnetron sputtered Cr2N thin films with small additions of silver, whereas the pure Cr2N is used as a reference material. The main aspects reported here are: growth rate of the films, their growth manner, phase constitution, mechanical properties being represented by Young modulus and nanohardness, adhesion on the substrate made from Cr-V ledeburitic steel having a hardness of 60 HRC, tribological performance and effect on the mechanical properties of the substrate.
Nonlinear Dynamic Analysis of the Aircraft Impact to the NPP Structures
Juraj Králik, Juraj Králik jr.
Manufacturing Technology 2016, 16(4):720-726 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/720
This paper presents the nonlinear analysis of the reinforced concrete buildings of nuclear power plant under the aircraft attack. The response from the nonlinear analysis was considered taken the deterministic calculation procedures. The dynamic load is defined in time on base of the airplane impact simulations considering the real stiffness, masses, direc-tion and velocity of the flight. The dynamic response is calculated in the system ANSYS using the transient nonlinear analysis solution method. The damage of the concrete wall is evaluated in accordance with the standard NDRC consid-ering the spalling, scabbing and perforation effects. The simple...
Processing of Al-Fe Scraps by Powder Metallurgy
Vojtěch Kučera, Filip Průša, Dalibor Vojtěch
Manufacturing Technology 2016, 16(4):726-732 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/726
Iron has a low solubility in aluminium solid solution even at elevated temperatures and forms brittle intermetallic phases with needle-like or platelets-like morphology when it is produced by conventional casting technologies. These phases have a detrimental effect on mechanical properties. Therefore with increasing significance of recycling and also amount of aluminium scrap that needs to be recycled, it is necessary to find a promising ways of processing such waste materials. Powder metalurgy leads to intensive microstructural refinement, increases solid solubility of alloying elements and overall to improvement of mechanical properties. Hence, it...
Freight Car Bogie Properties Analysis by Means of Simulation Computations
Tomas Lack, Juraj Gerlici, Maria Manurova
Manufacturing Technology 2016, 16(4):733-739 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/733
The article deals with the results of the simulation analysis of a railway wagon bogie model. We analysed four freight wagon bogie variants for its dynamics properties research. The bogie models correspond in general to the Y25 bogie concept. The models were created in SIMPACK software enhanced by the RAIL module. From the research results depicted in the graphs we found out, that the newly designed bogie variant gives the best results when compared to the other analysed versions. The newly designed model consists of a standard Y25 bogie frame with two Lenoire friction dampers. This bogie is equipped with longitudinal linkages on both sides. These...
Occupational Health and Safety Hazards in Machining
Danuse Madlova, Vlastislav Gebhart
Manufacturing Technology 2016, 16(4):740-743 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/740
This paper is focused on occupational health and safety hazards in machining processes. Problem is specified on employs and employers. Occupational health and safety is based on legislative regulations. Safety rules are usually formulated generally. But it is necessary to formulate safety rules more precisely for different production processes and even for different production machines. And this has not been fully satisfactory solved, especially from the point of view of the development of machine tools, their automation and also from the viewpoint of the development of cutting materials. In the paper principal occupational health and safety hazard...
Electron Beam Surface Quenching of X37CrMoV51 Tool Steel Swages
Jiří Matlák, Pavel Doležal, Josef Zapletal, Filip Vančura, Ivo Dlouhý
Manufacturing Technology 2016, 16(4):744-749 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/744
X37CrMoV51 tool steel for plastic working and heat cutting is usually used in whole volume quenched state for secondary hardness. Using high-energetic sources like electron beam or laser is possible repeated surface quenching of chosen surface localities with complicated geometry. The treatment leads to local hardness improvement which results in local wear damage decrease.Delivered specimens were surface quenched using electron beam technology. The paper deals with influence of individual technological parameters of the treatment on final properties of treated localities. Final properties of treated surface were examined by light and electron...
Effect of Wirefeed Rate On The Morphology Of A Surface Machined Using WEDM
Katerina Mouralova, Jiri Kovar, Libor Benes, Karel Osicka
Manufacturing Technology 2016, 16(4):750-754 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/750
Wire electrical discharge machining (WEDM) is an unconventional technology of machining that uses physical phenomena for material cutting. During wire electrical discharge machining craters are formed on the workpiece surface, and blended and molten material of both workpiece and wire electrode get stuck here due to diffusion processes. The study deals with the assessment of the influence of wire feed rate on quantitative and qualitative evaluations of craters on the workpiece made of X155CrVMo12-1 alloy tool steel. The diffusion phenomena that had occurred on the surface during the process of cutting were studied using light microscopy. Attention...
Effect of Nickel Particle Size on Eactive Sintering Production of Niti Shape Memory Alloy
Pavel Novák, Ivo Marek, Petr Dvořák, Tomáš Veselý, Vladimír Vojtěch, Andrea Školáková, Adriana Bernatiková
Manufacturing Technology 2016, 16(4):754-757 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/754
This work is focused on the description of the influence of the particle size of nickel on the synthesis of NiTi shape memory alloy by reactive sintering with high heating rate (300 °C.min-1). It was found that coarse nickel powders undergo only a limited thermally-activated reaction. On the other hand, too fine powders support the low-temperature (500-800 °C) diffusional formation of Ni-Ti intermetallics which could then suppress the rapid thermally-activated reaction. The optimum powder fraction of nickel to obtain the material with the lowest porosity and fraction of undesirable Ti2Ni phase is 25-45 μm.
Investigation of the Effects of Smart Ultrasound Wave on Surface Roughness during Turning Operation of Mild Steel
Anayet Ullah Patwari, Md. Shariful Islam Chowdhury, Mohammad Ahsan Habib, Afzal Hossain Neelav, Md. Sharfat Latif, T. M. Moniruzzaman Sunny
Manufacturing Technology 2016, 16(4):757-765 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/757
Turning is one of the most widely accepted metal cutting processes in manufacturing industry. Due to global competitiveness, there is an increasing demand for product quality. Surface roughness represents the dimensional accuracy of the finished product and is one of the most important quality requirements of the finished product. Surface roughness is generally detrimental to the efficient performance of machined parts, especially where relative motion between parts is concerned. In this paper, a new novel technique has been proposed and adopted with an aim to reduce surface roughness of the machined surface. External ultrasonic sound waves were applied...
Biaxial Test of Tubes Using Elastomer
Eva Peterkova
Manufacturing Technology 2016, 16(4):765-771 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/765
To obtain the values of material characteristics of tubes such as the strain hardening exponent n and the strength coefficient K is most frequently used the hydraulic bulge test. The tool and an additional equipment are often complicated and very expensive for this test. This article deals with the question whether it would be possible to obtain the corresponding values n and K by the simple biaxial test of tube using elastomer. To solve this problem, a simple tool was designed and the verification tests were realized for thin-walled tubes from material AISI 321. The results showed that it's not possible to obtain real values n and K by biaxial test...
The Indentation Size Effect (ISE) and the Speed of the Indenter Penetration into Test Piece
Jozef Petrík, Pavol Palfy, Peter Blaško, Lenka Girmanová, Milan Havlík
Manufacturing Technology 2016, 16(4):771-777 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/771
The aim of the submitted paper is to study the influence of the speed of the penetration of the indenter into the test piece ranging from 0.302 μm s-1 to 1.089 μm s-1 and applied load ranging from 10 g to 100 g on measured values of micro-hardness. Whereas certified reference material with defined specified hardness and its uncertainty was used as a test piece, the measurement involved indirect calibration of the tester. The influence of observed factors on measured value of the micro-hardness was evaluated by Meyer's index n, PSR method and by Analysis of Variance (ANOVA). The influence of the load on the measured value of micro-hardness is...
Numerical Model Description of Fibres Winding Process for New Technology of Winding Fibres on the Frames
Michal Petru, Tomas Martinec, Jaroslav Mlynek
Manufacturing Technology 2016, 16(4):778-785 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/778
Currently, traditional materials are very often replaced by composite materials in many industrial areas. The advantages of these materials consist mainly in their lightweight, high strength and flexibility, corrosion resistance and a long lifespan. The use of composites reaches its large development in the field of aerospace. This article discusses quality of the manufacturing process technology of a specially shaped composite frame in 3D space. The used technology is based on a winding of carbon, glass, organic filament rovings on a polyurethane core. Polyurethane core which is a geometry of frame with and without a circular cross section. Quality...
Tensile Properties of AA6156-T4 Friction Stir Welded Joints in As-Welded and Post-Weld Aged Condition
Umberto Prisco, Fabio Scherillo
Manufacturing Technology 2016, 16(4):786-792 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/786
The effect of the T62 post-weld heat treatment on the tensile strength of AA6156-T4 friction stir welded joints is studied. To this aim, the 0.2% proof stress and the tensile strength of as-welded and post-weld treated joints as function of the rotating and welding speed was analyzed performing a complete factorial design with three levels for each studied parameter. Statistical analyses were carried out to establish empirical models of the tensile properties of the joints as a function of the studied welding parameters. The obtained models were validated through statistical tools such as Mallow's CP, S, R2 and R2(adj). The developed regression models...
The Influence of Process Fluids on the Machining Process and Forming Internal Threads
Miroslav Rejzek, Jan Jersák, Jaroslav Votoček
Manufacturing Technology 2016, 16(4):793-799 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/793
Using cutting or forming taps during the production of internal threads represents the basic method of manufacturing these coupling structural components, which - in the case of smaller dimension internal threads - can be encountered in many manufacturing processes. To optimize the cutting process and forming of internal threads, and in favour of the final results of these operations, the right choice of technological conditions, process fluids and methods of their application in areas where the technological process is realized, is needed. An important aspect of the use of process fluids are relatively large operating costs, and in some cases also...
Technology and Mold Design for Production of Hollow Carbon Composite Parts
Sona Rusnakova, Alexander Capka, Ladislav Fojtl, Milan Zaludek, Vladimir Rusnak
Manufacturing Technology 2016, 16(4):799-804 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/799
This essay aims to describe technology and mold design for production of hollow composite parts like carbon rims or sport rackets. Tested materials correspond to those used for composites in sport applications. Production technology called inflatable bladder molding (IBM) is describe with respect to used material, molds and process parameters. Furthermore, prototype mold for verification of flexible bladder, inner pressure and curing conditions is constructed and tested. Construction design of manufacturing mold together with description of technological steps is proposed.
Preparation of Ni-Ti Shape Memory Alloy by Spark Plasma Sintering Method
Pavel Salvetr, Tomáš František Kubatík, Pavel Novák
Manufacturing Technology 2016, 16(4):804-808 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/804
This paper aims to describe powder metallurgy methods of production Ni-Ti shape memory alloy - self-propagating high-temperature synthesis (SHS) and spark plasma sintering (SPS). There are compared microstructures and phase compositions of alloys produced by SHS and by a technology containing SHS, milling and SPS. At the same time there is determined the influence of the SPS sintering temperature on the structure of Ni-Ti alloy. Self-propagating high-temperature synthesis was initiated at 1100°C with process duration 20 minutes the heating rate of approx. 300 °C/min. The product is highly porous and contains undesirable Ti2Ni phase. The SPS technique...
Influence of Elements with High Affinity to Oxygen on Microstructure and Phase Composition of Ni-Ti Alloy
Andrea Školáková, Pavel Novák, Pavel Salvetr
Manufacturing Technology 2016, 16(4):808-814 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/808
Approximately an equiatomic alloy of nickel and titanium is known as nitinol. Nitinol possesses a lot of interesting properties such as shape memory, pseudoplasticity, superelasticity and corrosion resistance. NiTi alloys are usually industrially produced by melting process, but the products have not good quality and purity. Powder metallurgy with reactive sintering is considered as one of the route of production of NiTi alloys. However, the other phases are formed during this process (Ti2Ni, Ni3Ti). The presence of Ti2Ni phase is unwanted in this alloy. It is stabilized by oxygen and its main disadvantage is brittleness. In this work we prepared NiTi...
Model of Unique Material Flow in Context with Layout of Manufacturing Facilities
Martin Straka, Peter Kačmáry, Andrea Rosová, Boris Yakimovich, Aleksander Korshunov
Manufacturing Technology 2016, 16(4):814-820 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/814
The situation of analysis and finding solution of unique material flow managing and planning in production company allows increasing the competitiveness company on the market. The uniqueness of the material flows is in its combination of metallurgical and machinery character. There are continuous metallurgical and discrete mechanical material flow with even different speed which are joining at one place - aluminium casting. The research has brought also the recommendation of new layout of the company. Each company is original from the point of production processes. Application of standard enterprise information system (SAP, proAlpha, Baan, etc.) need...
Reactive Resins Filled with Microparticles Based on Iron Powder
Petr Valášek
Manufacturing Technology 2016, 16(4):820-825 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/820
Hard inorganics microparticles are added to the composite systems due to optimization of some mechanical properties among which is possible to rank hardness and resistance to abrasive wear. Advantage of interaction of metal powders with polymers is also their ferromagnetism which changes physical properties of resulting composite systems. This paper is focused on evaluation of mechanical properties of epoxy resin filled with microparticles on the basis of iron powder (20.6 μm), mainly on resistance to abrasive wear, hardness and on adhesive and cohesive characteristics. The experiment evaluates composite systems prepared without using controlled...
Theoretical and Practical Relationship Rz = f(f;rε)
Karol Vasilko, Zuzana Murčinková, Jozef Nosáľ
Manufacturing Technology 2016, 16(4):826-830 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/826
Development of methods for machined surface identification has reached a stage when real surface shape can be visualised more precisely. Mechanical tools for measuring roughness have shown misrepresented profile considering the fact that the tip of diamond sensor is not "ideally sharp", it only follows the outline of actual profile. Profile details can be followed by optical scanning. During observation of profile records and theoretically defined rounded tool tip copying considerable disproportions can be found. This fact leads to incorrectly determination of feed with defined value of Rz and selected tool tip radius in practice. The aim of the paper...
Effect of Machined Surface Shape on Sound Reflection
Martin Vasina, Ondrej Bilek
Manufacturing Technology 2016, 16(4):830-834 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/830
Sound reflection of materials is influenced by many factors, e.g. by material type, density, thickness, porosity, angle of sound incidence, surface shape and excitation frequency of acoustic wave. The aim of the paper is to investigate the surface shape effect of expanded polyvinylchloride material on sound reflection. For this reason polyvinylchloride samples of different surface shapes and perforations were produced on universal and CNC machine tool. The material ability to reflect sound of the investigated polyvinylchloride samples was experimentally measured by means of the transfer function method on Kundt's impedance tube. The material samples...
The Effect of Artificial Neural Network Architecture on Surface Roughness Parameter Prediction Capability when Turning Inconel 718
Marek Vrabeľ, Ildikó Maňková, Miroslav Paľo, Radek Lattner
Manufacturing Technology 2016, 16(4):834-839 | DOI: 10.21062/ujep/x.2016/a/1213-2489/MT/16/4/834
This paper investigates the influence of Artificial Neural Network (ANN) architectures on its prediction capability when machining nickel based super alloy. The ANN was employed to determine surface roughness parameter Ra through cutting conditions, tool wear and process monitoring indices such a cutting force components. The ANN structure was optimized by methods like a reduction of input vector parameters, dimensions of input data pattern, combined reduction and modification of hidden layers. Calculated and experimentally measured values were compared for each optimized ANN model. The work concludes that optimization of ANN has significant influence...