Manufacturing Technology Journal, 2017 (vol. 17), issue 6
Improving the Tribological and Mechanical Properties of an Aluminium Alloy by Deposition of AlSiN and AlCrSiN Coatings
Totka Bakalova, Nikolay Petkov, Hristo Bahchedzhiev, Pavel Kejzlar, Petr Louda, Marián Ďurák
Manufacturing Technology 2017, 17(6):824-830 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/824 
This paper presents an improvement to the mechanical and tribological properties of aluminium alloys. AlSiN and AlCrSiN coatings (with different Cr content) were deposited on substrates of Al-Cu-Mg alloy by the cathodic arc evaporation method at 400°C. Surface morphology and chemical composition were estimated by a scanning electron microscope equipped with an energy dispersive spectrometer and mechanical profilometer. The increasing chromium content in the coating led to an increase in the coating hardness. The tribological behaviour of the coated and uncoated Al-Cu-Mg alloy samples was examined using the "Ball-on-Disk" method (ASTM G99-95) at a load...
Deflection of Complex Geometry Cutting Tools
Ondřej Bílek, Pavel Smetka, Jitka Baďurová
Manufacturing Technology 2017, 17(6):830-836 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/830
Deflection of cutting tools under the action of cutting forces has a significant influence on the error of machined surface and the stability of cutting process. Considering the complex geometric structure of cutting tools lead to higher calculation accuracy of the tool deflection analysis. Therefore, CAD models of double-sided solid ball end mill and helical drill bit was created in this study. The impact of tool material and clamping of the tool under the influence of cutting forces individually in three axes was obtained via finite element analysis. An error of the numerical model was less than 7.2% and has been validated by analytical calculation....
Using the Fourier Transform in the Analysis of Vibration Load Tests of Heterogeneous Mechanical Systems
Václav Bittner, Richard Tuček, Šárka Panská, Martin Svoboda, Karel Jelen
Manufacturing Technology 2017, 17(6):836-841 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/836
The aim of this study was to find possibilities of using the Fourier transform in the analysis of vibration load tests of heterogeneous mechanical systems, especially those of a biological nature. The study applied the idea that the dispersion of a stationary stochastic signal depends on its power spectral density. We have verified that a sophisticated reduction in the spectral power of the ergodic signal may be used to filter it effectively. The proposed procedure is suitable for the detection and separation of harmonic artefacts. We have created an algorithm in the MATLAB environment and tested its functionality when analysing the vibration transfer...
Ultrasonic Testing of Butt Weld Joint by TOFD Technique
Michal Boháčik, Miloš Mičian, Radoslav Koňár, Ivo Hlavatý
Manufacturing Technology 2017, 17(6):842-847 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/842
The aim of the article was to check the internal defects in the butt welded joints by non-destructive TOFD (Time of Flight Diffraction) technique. Subsequently, the macrostructure from the defect indication site was evaluated and assigned to the TOFD ultrasound indication. Basic knowledge of ultrasonic TOFD testing are described in the theoretical part of a submitted paper. Ultrasound technique TOFD is non-destructive method that can detect internal defects inside test material without damaging it. It is a reliable method for detecting mainly flat internal defects such as incomplete root penetration, lack of fusion, etc. Ultrasonic test procedures...
Corrosion Properties of AlSi10Mg Alloy Prepared by Gravity Casting and 3D Printing Technology
Michaela Fousova, Drahomir Dvorsky, Dalibor Vojtech
Manufacturing Technology 2017, 17(6):847-853 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/847
Aluminium and its alloys are widely used in the transport industry. In combination with 3D printing technology, lightweight parts can be successfully achieved. 3D-printing of AlSi10Mg alloy is already well-managed. However, corrosion behaviour of such 3D-printed material has not been intensely studied yet. This paper is thus focused on a primary determination of corrosion properties of AlSi10Mg samples prepared by SLM technology and on comparison with conventionally gravity cast samples in thermally untreated and treated state (T6). Audi immersion test has revealed the 3D-printed samples are the most vulnerable to local corrosion attack, while the...
Issues of Lattice Structures Production via Metal Additive Manufacturing
Pavel Hanzl, Ivana Zetková, Milan Daňa
Manufacturing Technology 2017, 17(6):853-857 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/853
Metal additive manufacturing (MAM) is used in the production of parts, where a product is built layer by layer. MAM includes Direct Laser Metal Sintering (DMLS), which allows the production of complex metal parts directly from 3D software models without using sometimes expensive tools such as moulds, dies and cutting tools. New possibilities in the production of complicated components are made available using this advanced manufacturing technology. Nevertheless, this technology has limits, resulting from the method of melting in the powder bed. Therefore, this paper investigates the ability to produce fine cellular lattice structures. Some structures...
Determination of Oil Change Interval for Diesel Engines According to the Quantity of Non-Ferrous Metals
Vladimír Hönig
Manufacturing Technology 2017, 17(6):857-863 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/857
The article deals with the determination of the life of the lubricant based on the determination of the degree of wear or deterioration of the engine oil by wear particles. Non-ferrous particulates of a large diesel engine and their determination based on laboratory tribotechnical diagnostic tests are characteristic for the purposes of article. The combination of Atomic Absorption Spectrometry and Thin Layer Chromatography is used for measurements. The statistical method of discriminatory analysis is used to evaluate the article. The lifetime of the lubricant is thus determined according to objectively determined criteria realized by normalized and...
Dissemination of Waves in Thin Plates
František Klimenda, Lenka Rychlíková, Štefan Husár, Josef Soukup
Manufacturing Technology 2017, 17(6):863-869 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/863
The article deals with the wave propagation in thin plate. A wave was caused by the impact force. In the first part of an article the Kirchhoff's theory of thin isotropic plate is given. It is a vertical displacement w, angles of rotation tangent φx and φy, bending stresses σx, σy, shear strength τyx = τyx, shear strength from displacement forces τxz, τyz. In the second part of an article is solved a Kirchhoff's theory by analytically in MATLAB programme. Analytically were solved only displacements u, v and velocity u ̇,v̇ . The solution is performed for two plate materials - aluminium and steel. By result...
Theoretical Basis of Fractographic Methods and Their Application in Fracture Modelling for Cr-Ni Steels
Veronika Klopanová, Viktor Novák, Petra Kvasnová, Daniel Novák
Manufacturing Technology 2017, 17(6):869-876 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/869
Fractographic methods derive their knowledge from Euclidean geometry, set theory, metric theory and chaos theory. In engineering technology, the fractography is primarily used for modeling of fatigue and intergranular fractures. As such defects are not smooth due the principle of their origin, they cannot be described using ordinary mathematical tools. However, if the conditions of self-similarity are met, fractal geometry means can describe various irregular, incomprehensible, crooked or fragmented geometric shapes. Fractographic description of the fracture profile allows more accurate quantification of fractures and it also enables identifying possible...
Structure and Mechanical Properties of Aluminium Alloy Sampled from a Firefighter Ladder
Jiří Kubásek, Dalibor Vojtěch, Drahomír Dvorský
Manufacturing Technology 2017, 17(6):876-881 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/876
Firefighter ladders are manufactured of aluminium alloy AA 6063. These ladders are a widely used technical tool for firefighting, for intervening firefighters and for rescued persons. The quality of the ladders is checked by so-called "user test" which is a non-destructive deflection test defined by CSN EN 1147. Unfortunately, this test is not sufficiently conclusive in terms of safety. Therefore, the project called "Safety improvement of extension ladders for firefighters" (VI20162020021) is focused on the complex assessment of the existing firefighter ladders through mathematical modelling, material analysis and real testing. In the present work...
The Effect of Annealing Temperature on Microstructure and Mechanical Properties of Lightweight Steel with Increased Aluminium Content
Ludmila Kučerová, Martin Bystrianský, Štěpán Jeníček
Manufacturing Technology 2017, 17(6):881-887 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/881
A demand for enlightening of constructions in an automotive industry resulted in an intensive development of high strength steels and in attempts to decrease the weight of the steel by intensive alloying by lighter elements. This work used chemical concept of AHSS (advanced high strength steel) TRIP (transformation induced plasticity) steel with 0.2%C and micro-alloyed by 0.06%Nb and increased manganese content to 4% and aluminium to 6.5% to produce lightweight steel, which was cast and re-forged and subsequently annealed at various temperatures in the range of 300°C - 800°C. The resulting microstructures were analysed by light microscopy, laser scanning...
Tool Guarantee of Intermittent Cutting Processes
Evgeniy Alekseevich Kudryashov, Igor Mikhailovich Smirnov
Manufacturing Technology 2017, 17(6):887-892 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/887
Reforming obsolete technologies, increasing production of new machines and devices are impossible without modern and reliable instrumentation. The high structural complexity of the manufactured parts creates problems for the use of a blade tool that, along with high hardness, has considerable brittleness. As a rule, the processing of intermittent surfaces by turning is accompanied by chipping of the cutting edges.The disadvantages of alternative grinding technologies are the high cost of equipment, low productivity, as well as the problems of forming the required quality parameters of the surface layer due to the specificity of operation of the...
Laser Welding of Aluminium Alloys
Petra Kvasnová, Daniel Novák, Viktor Novák
Manufacturing Technology 2017, 17(6):892-898 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/892
Laser beam welding is an industrial technology that has seen a significant development from the early stages up to the present. Technological process management ensures high product quality as well as enhanced productivity and competitiveness. The aim of the research is to determine the impact of welding parameters by fiber laser beam on the quality of weld joints from aluminium. Basing on the presented quality assessment methods and computer simulation, we evaluate the weld joint samples. Finally, we discuss optimal welding parameters and conditions allowing the production of weld joints of the desired properties.
Comparison of the Effect of Process Fluid Using the Test by Drilling a Constant Feed Force
Roman Licek, Miloslav Ledvina
Manufacturing Technology 2017, 17(6):898-903 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/898
New types of process fluids is very broad. Drilling with constant feed force represents the experiment that follows different properties and effects in machining. The main aim of this scientific paper is to assess the speed of drilling holes by the drilling technology-constant feed force- with the drilling cutting tools made of uncoated high speed steel. Eleven different process fluids were compared used the during the experiment. There were compared eleven different process fluids. In the context of the thesis more process fluids from global suppliers have been tested. In the process of experiments there were used twist drills of high speed steel...
Hazards in Milling
Danuse Madlova, Vlastislav Gebhart
Manufacturing Technology 2017, 17(6):904-906 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/904
This paper is focused on hazards in milling processes. It continues in occupational health and safety in turning. Safety rules are based on general rules and specific ones which relate to milling. It is necessary to formulate hazard and safety rules more precisely for specific production processes and in some cases for different production machines. For satisfactory solution of this problem the rules are formulated on the base of laws, regulations and personal findings of the paper's authors in enterprises. In the paper occupational health and safety hazard rules in milling on these principles are formulated.
The Effect of Changes to Nickel Coating Machine on Surface Integrity and Microstructure after Grinding
Martin Marek, Martin Novák, František Holešovský, Numan M. Durakbasa, Eva Maria Walcher
Manufacturing Technology 2017, 17(6):906-912 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/906
Grinding is an overly used finishing technology, which can obtain very accurate surface integrity. The desirable surface quality after grinding is one of the most relevant parameters. In production, surface preparation such as chromium plating, nickel plating, etc. are more prevalent. These platings are used as protection against corrosion, erosion, abrasion and as a material for the renovation of worn parts. This paper discusses the change of nickel coating machines, which has an influence on surface integrity and microstructure after grinding. The team has built a completely unique and new technical solution for the covered equipment which had never...
Phase Analysis of EN AW 6023 Aluminum Alloy after Short Time Aging
Miloš Matvija, Martin Fujda, Ondrej Milkovič, Marek Vojtko, Miroslav Glogovský
Manufacturing Technology 2017, 17(6):912-916 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/912
The phase analysis of the EN AW 6023 aluminum alloy after the heat treatment by short time aging was investigated. The good machinability of this heat treatable and lead free Al-Mg-Si wrought alloy is achieved by alloying of tin and bismuth. In experimental procedure, the solution annealing at 550 °C for 1 hour and subsequent water quenching of the analyzed alloy was realized. The short time artificial aging at 190 °C for 1 hour was carried out immediately after quenching. The microstructure analyses, the EDS analyses and the phase analyses using the hard X-ray diffraction by synchrotron radiation in DESY Hamburg were realized. Significant changes...
Application Fractography and EDS Analyses for Quality Control of the Castings Made of AlSi7Mg0.3 Aluminium Alloy
Lenka Michnova, Ivan Lukac
Manufacturing Technology 2017, 17(6):916-918 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/916
Fractography is the study of the fracture surface and is concerned with the quantitative and qualitative evaluation of fracture surfaces [1]. It is based on the knowledge of the relationships governing the formation and propagation of fracture areas and is routinely used to determine the cause of failure of forensic engineering or failure analysis [2]. A large majority of casting defects can be detected in the fracture surface. In the technical practice, the formation of a fracture surface represents in most cases the unacceptable stage of mechanical loading or other damage, for instance corrosion damage, of material [3]. Fracture interpretation is...
Surface Machining after Deposition of Wear Resistant Hard Coats by High Velocity Oxygen Fuel Technology
Katarina Monkova, Peter Monka, Jan Matejka, Martin Novak, Jiri Cesanek, Vladimir Duchek, Marek Urban
Manufacturing Technology 2017, 17(6):919-925 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/919
The article deals with some aspects related to the machining of surfaces that have been deposited by wear-resistant hard coats using HVOF (high velocity oxygen fuel) technology. HVOF coating is a thermal spray process used to improve a component's surface properties, thus extending equipment life by significantly increasing errosion and wear resistance, along with corrosion protection. For a purpose of this research, the chromium-cobalt alloy - Stellite 6 was used as a sprayed material. Considering that the parts made of stellites are widely used in various industries and very popular in specific applications, it is a big drawback that adequate machining...
Research on Aluminium Alloy AlCu4Mg Surface Machined by Abrasive Water Jet
Miroslav Müller, Petr Valášek
Manufacturing Technology 2017, 17(6):925-930 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/925
The paper deals with a machining of the aluminium alloy by means of an unconventional technology, i.e. an abrasive water jet (AWJ). The paper deals with a study of an influence of the abrasive water jet at its impact on a surface of the machined material, i.e. the aluminium alloy AlCu4Mg of a thickness 20 mm. A topography of the machined surface is evaluated within the research by means of roughness parameters. A surface analysis is also evaluated by means of a scanning electron microscopy (SEM) depending on a cutting speed and a mass flow of the abrasivum. The research results proved an increased influence of the cutting speed and the mass flow of...
The Impact of Technological Parameters on Casting Integrity and Mechanical Properties of AlSi7Mg0.3 Alloy by Using Squeeze Casting Technology
Richard Pastircak, Jan Scury, Tomas Fecura
Manufacturing Technology 2017, 17(6):930-935 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/930
The article deals with the effect of variaton of the technological parameters on the change mechanical properties and density of the AlSi7Mg0.3 alloy using squeeze casting technology. The AlSi7Mg0.3 alloy has been chosen because the acting pressure has the most significant impact on Al-Si alloys. For the make a samples was used a direct squeeze casting technology. Differently casting temperatures and mold temperatures at the acting pressure of 30 MPa were varied for individual samples. From the mechanical properties was specifically evaluated tensile strength and elongation.
The Influence of SPS Compaction Pressure onto Mechanical Properties of Al-20Si-16Fe Alloy Prepared by Mechanical Alloying
Filip Průša, Gillet Oceáne, Adriana Bernatiková, Slawomir Cygan
Manufacturing Technology 2017, 17(6):936-940 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/936
The Al-20Si-16Fe alloy (wt.%) was prepared by a combination of short-term mechanical alloying and consequential compaction via spark plasma sintering. The compaction was done at two different pressures of 80 MPa and 6 GPa to describe the influence of pressure onto a resulting properties of prepared alloy. The microstructure of both the prepared compact alloys showed presence of sub-micrometre particles embedded in the Al-matrix while some residual porosity was also observed. This corresponded to the lower compaction pressure of only 80 MPa, which, in comparison to the 6 GPa allowed to retain some porosity. The higher compaction pressure of 6 GPa resulted...
Innovative Process to Eliminate Ledeburite Network in Tool Steel
Kateřina Rubešová, Michal Peković, Hana Jirková
Manufacturing Technology 2017, 17(6):940-945 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/940
Tool steels are a widely-used material with well-known heat treatment procedures for obtaining the desired mechanical properties. Their weakness is the presence of sharp-edged carbides which compromise the material's toughness. When produced by conventional metallurgical routes, high-alloy steels, such as X210Cr12 (1.2080) and X155CrVMo121, contain sharp-edged M7C3 carbides which remain stable even at high temperatures. As these carbides form as early as in the solidification stage, there is no practical conventional heat treatment for removing them or for converting them to more favourable carbide types. As a result, unconventional methods must be...
Shape Inspection of Gear Prototypes Using Reverse Engineering Method
Josef Sedlak, Ales Polzer, Josef Chladil, Martin Slany, Ales Jaros
Manufacturing Technology 2017, 17(6):945-952 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/945
Reverse engineering is a technology that enables acceleration of data collecting for CAD, CAM, CAE systems, which also means shortening time of development, construction and components production. It is a transfer process of a physical component to a digital format. Generally, the technology of reverse engineering means a conversion of analogue data to digital data that are further processed. Every single industry branch rising their requirements on accuracy, dimension, quality, etc. Therefore, digitisation is applied in many production fields such as an automotive industry, aircraft or shipping, medicine, industrial design, design, etc.An article...
Influence of Ground End Mill Surface Quality on Cutting Tool Life
Vaclav Schornik, Miroslav Zetek, Tomas Baksa
Manufacturing Technology 2017, 17(6):952-957 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/952
Cutting tools made of cemented carbides currently dominate the field of machining. This is due to their outstanding properties and applicability to various materials. However, there are still opportunities for enhancement in the field of cutting tool durability, particularly in the machining of highly resistant super alloys. Grinding critically affects the integrity of the machined surface, which has a significant impact on the durability of cutting tools. Certain cutting conditions and grinding strategies can lead to a sudden failure of the cutting tool in the cut. The main goal of this study is to investigate the influence of the cutting conditions...
Fatigue Properties of the Aluminium Alloy AW-5182 in dependence on Deformation
Jiri Sobotka, Pavel Solfronk, Michaela Kolnerova, David Korecek
Manufacturing Technology 2017, 17(6):958-962 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/958
Fatigue properties of the constructional materials belong among the very important material parameters, mainly because they are very closely related with the total fatigue life of the part. Knowledge of the boundary between limited and infinite (endurance) life represents a truly very important fatigue parameter. This paper deals with the influence of pre-deformation on aluminium alloy AW-5182 fatigue properties. These tests were performed under fully reversed harmonic cycle (max/min stress ratio R = -1). As a major aim there was determination of so-called S-N curves (stress vs. number of cycles) and their mathematical description by the Basquin's...
The Collision of Unbelted Passenger with Assessment of Various Vehicle Interior
Stanislav Špirk
Manufacturing Technology 2017, 17(6):962-969 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/962
This paper describes the conception of vehicle interior which can help decrease the injury risk of unbelted passenger. This paper is primarily aimed to the field of rail vehicles, but the results are useful for more transportation industries. Some computer simulations for passive safety performance assessment were conducted in previous years. The FE models of the interiors based on data from actually operated vehicles were prepared for this purpose. The newly prepared simulations are close to the real interior models. Combinations of rigid walls were used for modelling. Each model contains a short python code which allows change of interior disposition....
Failures Caused by Heat Treatment and Their Identification
Jaroslava Svobodova
Manufacturing Technology 2017, 17(6):969-972 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/969
The article deals with the failures caused by heat treatment and their identification. The various types of tool failure are occurring from the design through to the tool application stages. Heat treatment naturally plays a major role due to its significant influence on the tool properties, and indeed most defects appear after the heat treatment stages. There are many methods how to study failures of tools and gadgets. One of the most important is metallographic investigation. Metallography is very important part of failure analysis. Thanks to microstructure analysis can be evaluated crack morphology and relationship between the failure and microstructure....
Influence of Sr-Modification on Microstructure, Tensile, Impact and Hardness Properties of Secondary AlSi8Cu2Mn Cast Alloy
Eva Tillová, Mária Chalupová, Lenka Kuchariková, Juraj Belan, Alan Vaško, Denisa Závodská
Manufacturing Technology 2017, 17(6):972-978 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/972
Present work is focused on the study of recycled AlSi8Cu2Mn cast alloy. Furthermore, the effect of Sr-modification (0; 0.03 and 0.05 wt. %) on the microstructure, tensile and impact properties (UTS, ductility, hardness and impact energy) were investigated. For study and identification of intermetallic phases were utilized standard, colour and deep etching (in order to reveal the 3D-morphology of the Si-particles and intermetallic phases). For element composition of the specimen was used X-ray analysis. Finally, the effect of Sr-modification on silicon morphology was examined. The results show that the addition of Sr into AlSi8Cu2Mn cast alloy should...
Improvements of Prosthetic Limb Design: Cooling and Pressure Reduction in a Socket
Filip Tomanec, Sona Rusnakova, Milan Zaludek
Manufacturing Technology 2017, 17(6):978-981 | DOI: 10.21062/ujep/x.2017/a/1213-2489/MT/17/6/978
Although important improvements of prosthetic sockets has been implemented another investigation has been done also by solving problems with inadequate stump heating and from that resulting excessive sweating of limb. This phenomenon is further associated with leg volume changes. Therefore for realization of this research the model of prosthetic limb was created with socket that further addresses these issues of artificial limb. Throw the application of holes and tightening bells the pressure to remaining stump decreased and at the same time the heating of limb is lower. These results indicate that the implementation of these design modification will...