Manufacturing Technology Journal, 2018 (vol. 18), issue 1
Effects of Grinding Conditions and Strategy on the Quality of the Cutting Edge
Tomas Baksa, Vaclav Schornik, Pavel Adamek, Ondrej Hronek, Miroslav Zetek
Manufacturing Technology 2018, 18(1):3-7 | DOI: 10.21062/ujep/43.2018/a/1213-2489/MT/18/1/3 
This article deals with the experimental grinding of cemented carbide cutting tools. Several carbide milling tools with the same geometry were ground under the different grinding conditions and strategy described in this research. The main aim is to determine the influence of the grinding process on the quality of the cutting edge. Different grinding conditions and strategies were used in grinding of the primary radial relief on the peripheral cutting edge. The cutting edge was analysed after grinding by an optical-scanning device and an electron microscope to determine the quality of the cutting edge and radial relief face of the tool. EDX analysis...
Structural Changes of TiAl-Based Alloys during Mechanical Alloying
Adriana Bernatiková, Pavel Novák
Manufacturing Technology 2018, 18(1):8-10 | DOI: 10.21062/ujep/44.2018/a/1213-2489/MT/18/1/8
Titanium aluminides represent a class of materials with unique mechanical and physical properties. This is reason why they are often used in aerospace or automotive industries. These materials form lamellar or nearly lamellar TiAl and Ti3Al phases. There are few methods how to synthesize Ti-Al based alloys, but they are often very difficult and expensive. In present work, a mechanical alloying which is probably best choice for synthesizing of Ti-Al intermetallic phases was used. Further, the most promising conditions of mechanical alloying allowing to create intermetallic phases were determined. It was shown, that by mechanical alloying allows to synthesize...
Briquettes Properties after Four Years Storage
Milan Brožek
Manufacturing Technology 2018, 18(1):11-15 | DOI: 10.21062/ujep/45.2018/a/1213-2489/MT/18/1/11
. The paper presents the results of laboratory tests intent on the study of storage place, placing manner and storage time on mechanical properties of briquettes made from poplar chips. For the briquettes production the briquetting press of the firm Briklis was used, type BrikStar 30-12, of 50 mm pressure chamber diameter. All briquettes were made at the briquetting press all parameters constant adjustment. The briquettes properties were evaluated by their density and rupture force determination. Moreover the mechanical durability, the gross calorific value, the total moisture and the ash content were determined. By the carried out tests it was univocally...
Effects of Cooling Rate in an Innovative Heat Treatment Route for High-Strength Steels
Dagmar Bublíková, Štěpán Jeníček, Josef Káňa, Ivan Vorel
Manufacturing Technology 2018, 18(1):16-21 | DOI: 10.21062/ujep/46.2018/a/1213-2489/MT/18/1/16
The requirement for high strength and ductility is usually associated with martensitic microstructure with a certain amount of retained austenite. One of the innovative heat treatment processes that can lead to such microstructure is the Q&P process (Quenching and Partitioning). It can produce microstructures consisting of martensite and a certain amount of retained austenite, which exhibit strengths above 2000 MPa and elongation levels of more than 10%. The objective of this research was to explore the effects of the cooling rate in the Q&P process and evaluate the effects of various microstructure constituents on mechanical properties of...
High-Temperature Processing and Recovery of Cu Catalyst Promoter
Mária Čarnogurská, Marián Lázár, Miroslav Příhoda, Blanka Skočilasová, Peter Kurilla, Jiří Marek
Manufacturing Technology 2018, 18(1):22-28 | DOI: 10.21062/ujep/47.2018/a/1213-2489/MT/18/1/22
The following article describes the results obtained from the plasma smelting reduction of a particular type of waste - catalyst with a Cu promoter. The catalyst is used for the process of a selective reduction of nitrobenzene (C6H5NO2) to aniline (C6H5NH2). The plasma smelting occurs in a reducing atmosphere. Six samples of the exhausted catalyst with a Cu promoter were used in the smelting process. The chemical composition of the promoter exhibited a presence of a wide range of elements. Fluorspar (fluorite) and calcium oxide (quicklime) were used as the slag-agent for the given testing. Reducing agent was the powdery graphite - waste from the manufacture...
The GRR a Fundamental Tool for Dealing with Measurement System Variability
Milan Dian, Lubomír Hodinář
Manufacturing Technology 2018, 18(1):29-34 | DOI: 10.21062/ujep/48.2018/a/1213-2489/MT/18/1/29
With increasing complexity of machinery and products manufacturing the strict requirements for quality and, reliability of the measurement equipment and systems plays significant role in production system and quality assurance in terms of customer satisfaction. In nowadays automotive industry in connection to ISO/TS 16949:2009 there has been observed a strong confrontation with request for proof of suitability for use of selected gauges for a specific operations. An appropriate methodology allowing to determine a gauge the most suitable for a given operation is Gauge Reproducibility and Repeatability study (GRR or R&R). The GRR takes into a consideration...
Assessment of Innovative Methods of the Rolling Stock Brake System Efficiency Increasing
Juraj Gerlici, Mykola Gorbunov, Kateryna Kravchenko, Olga Prosvirova, Tomáš Lack, Vladimír Hauser
Manufacturing Technology 2018, 18(1):35-38 | DOI: 10.21062/ujep/49.2018/a/1213-2489/MT/18/1/35
This paper deals with problem of brake elements unstable operation caused by temperature increase in the friction pair contact during braking. Analysis of constructive solutions for heat dissipation from the brake elements is carried out. It is known that the most used design of ventilated brake disks has disadvantage of creating resistance to movement, which reduces the power of the train. Methods and technical solutions for improving the braking system efficiency by stabilizing the friction contact temperature are investigated. Technical solution dealing with heat removing from the friction surfaces was proposed. Materials with phase transition is...
Surface Quality Analysis of Cutting Tool Microgeometry to Achieve Higher Durability
Ondřej Hronek, Miroslav Zetek, Tomáš Baksa, Pavel Adámek
Manufacturing Technology 2018, 18(1):39-46 | DOI: 10.21062/ujep/50.2018/a/1213-2489/MT/18/1/39
Mapping surface quality changes during modification of the cutting tool microgeometry and reflecting on overall quality is the main purpose of this article. A complex view of microgeometry brings together the effects of indvidual stages in the processes which increase the cutting tool properties. The main objective is to increase the durability of the cutting tool. Grinding, microgeometry modification and deposition of a thin resistant layer on the cutting tool are the basic stages during the experiment. These stages have a significant effect on microgeometry parameters. Cutting edge radius, cutting edge symmetry (K factor), roughness of chipping and...
Use of Metallographic Analysis for Evaluating Microstructures in Quenched and Tempered High-Strength Steel
Tomáš Janda
Manufacturing Technology 2018, 18(1):47-52 | DOI: 10.21062/ujep/51.2018/a/1213-2489/MT/18/1/47
The experiment described herein focused on quantitative evaluation of carbides in the martensitic microstructure of X105CrMo17 steel. Carbides form as a result of the varying solubility of carbon and alloying elements during solidification and cooling. They possess high strength and hardness and their morphology plays a major role in mechanical properties of steel. In order to determine the relationship between carbide morphology and mechanical properties, several characteristics must be measured accurately. In this case, quantitative evaluation of carbides by means of optical microscopy and image analysis software were employed. Samples of the above-identified...
Metallographic Observation for Evaluating Microstructural Evolution on Various Cross-Sections of Forged Part upon Air-Cooling from Finishing Temperature
Štěpán Jeníček, Ivan Vorel, Josef Káňa
Manufacturing Technology 2018, 18(1):53-56 | DOI: 10.21062/ujep/52.2018/a/1213-2489/MT/18/1/53
Utility properties of forgings, particularly the mechanical ones, are among the primary aspects of interest to the customers of forge shops. These properties arise from internal structure whose evolution depends predominantly on the combination of parameters of deformation processes applied during forging, on the temperature profile during cooling and on the shape of the forged part. As microstructural evolution depends on the shape of the particular cross section of the forged part, an appreciable inhomogeneity of mechanical properties occurs in forgings. This article deals with observation of microstructural evolution in a chosen forged part, depending...
Measuring of Vibration-Damping Properties of Cast Iron
Petra Kováčiková, Ján Vavro, Ján Vavro jr., Andrej Dubec
Manufacturing Technology 2018, 18(1):57-59 | DOI: 10.21062/ujep/53.2018/a/1213-2489/MT/18/1/57
Nowadays, ever increasing demands are being made on equipment and machine structures. This fact negatively affects their lifespan, reliability and security. Internal damping is caused by material malfunctions in the microstructure, thermoelastic effects, movement of dislocations or the effects of swirling currents. This paper deals with microstructure, chemical composition and mechanical properties of ductile iron. These data are required as input parameters for computational modeling and numerical analysis. The numerical part is focused on the modal analysis of the homogeneous beam sample by finite element method in the ADINA software environment.
Processing of Al-Si Waste Contaminated with Iron by Powder Metallurgy
Vojtěch Kučera, Vojtěch Dalibor
Manufacturing Technology 2018, 18(1):60-65 | DOI: 10.21062/ujep/54.2018/a/1213-2489/MT/18/1/60
Hot dip aluminizing of steel products leads to the contamination of the batch by iron, which could significantly exceed its admissible levels. The re-processing of thus-polluted Al-Si waste by conventional casting technologies requires extensive technological adjustments, which raise the cost. Therefore, powder metallurgy was used to process Al-Si15-Fe7 alloy (in wt. %) to refine the microstructure and improved mechanical properties without further modification of chemical composition. Mechanical machining (MM) followed by spark plasma sintering (SPS) led to strong improvement of ductility, whereas mechanical machining coupled with high-energy ball...
Experimental Investigation and Measurement of Surface Roughness and Cutting Forces while Turning AlCu3MgMnPb Aluminium Alloy
Jozef Majerík, Rozmarína Dubovská, Ivan Baška, Jaroslav Jambor
Manufacturing Technology 2018, 18(1):66-71 | DOI: 10.21062/ujep/55.2018/a/1213-2489/MT/18/1/66
The main aim of this scientific article is to assess the contribution of surface layers by determining the experimental investigation and practical measurement of surface roughness Ra and selected components of cutting forces while external turning of AlCu3MgMnPb aluminium alloy. In these experimental procedures, a number of turning tests have been carried out by using a universal lathe machine tool and cutting forces and surface roughness scientific measuring devices. These realized measurements have been successively investigated and experimentally verified with the prepared trial samples. These presented experimental measurements describes the authors...
Reduction of Ploughshare Wear by Means of Carbide Overlay
Miroslav Müller, Petr Novák, Rostislav Chotěborský, Petr Hrabě
Manufacturing Technology 2018, 18(1):72-78 | DOI: 10.21062/ujep/56.2018/a/1213-2489/MT/18/1/72
An intensive abrasive wear of agricultural machines and their parts occurs at the soil processing. An undesirable change of a tool surface occurs owing to the wear. Namely ploughshares of a plough are intensively abrasive worn. This undesirable change leads to a function loss. The paper deals with an evaluation of the ploughshare service life. The aim of the research was to evaluate the wear of the ploughshare with a layer of a carbide hardfacing OK Tubrodur 15.82 deposited on a bottom side of the ploughshare. The research was performed within a laboratory testing (a hardness HV30 and a wear) and field tests. Laboratory experiment results proved that...
Reducing Tram Car's Curve-Pasing Resistance by Double Treaded Wheel Profile
Olena Nozhenko, Vladimír Hauser, Kateryna Kravchenko, Mária Loulová
Manufacturing Technology 2018, 18(1):79-83 | DOI: 10.21062/ujep/57.2018/a/1213-2489/MT/18/1/79
Special attention is taking place in the environment of public transport, for which higher amount of small radius curves being applied is specific. The outcome of such operation of vehicles is an increase in vehicle's effects on the track in the rail-wheel contact resulting in increased ride resistance, creep in the rail-wheel contact patch, speeding up the process of wear in the contact pair as well as noise generation. At present, a variety of technical solutions for the vehicle bogie design as well as track designs focused on decreasing of these negative effects exists. Their use in smaller radius curves however, cannot give acceptable results and...
Welding of 42SiCr High-Strength Steel
Michal Peković, Štěpán Jeníček, Kateřina Rubešová, Ivan Vorel, Hana Jirková
Manufacturing Technology 2018, 18(1):84-89 | DOI: 10.21062/ujep/58.2018/a/1213-2489/MT/18/1/84
Various industry sectors are using advanced high-strength steels nowadays. Application of these steels are often constrained by the capabilities of their manufacturing and processing technologies. To deliver the required properties, advanced high-strength steels must possess the prescribed microstructures which can be achieved by specific heat treatment routes, such as intercritical annealing or the Q&P process. Difficulties, however, arise in these materials' joining, and welding in particular. Welding profoundly affects the microstructure and mechanical properties of the product due to the amount of heat input and subsequent rapid cooling. For...
Numerical Modelling for Optimization of Fibres Winding Process of Manufacturing Technology for the Non-Circular Aerospaces Frames
Michal Petru, Jaroslav Mlynek, Tomas Martinec
Manufacturing Technology 2018, 18(1):90-98 | DOI: 10.21062/ujep/59.2018/a/1213-2489/MT/18/1/90
This article deals with the issue of mathematical calculating the trajectory of the end-effector of an industrial robot in the manufacture of aerospace composites. Robots are used to define the winding orientation of the fibre strands on a non-bearing 3D core. The 3D core is attached to the robot-end-effector and is led through a fibre-processing head according to a suitably defined robot trajectory during winding of the fibre on the core. The quality of the composite depends greatly on the correct winding angles of the fibres on the frame and on the homogeneity of the individual winding layers. The implementation of these two conditions is related...
Reducing Labor Intensity in the Development of New Universal Cutting Fluids for Machining
Alexey Popov, Iuliia Krasnikova
Manufacturing Technology 2018, 18(1):99-105 | DOI: 10.21062/ujep/60.2018/a/1213-2489/MT/18/1/99
The process of developing new universal cutting fluids is labor-intensive due to the requirement of conducting experiments to determine the impact of numerous additives on tool life during different technological operations. Therefore, finding the best cutting fluid, the use of which will result in the longest tool life, is a long and laborious process. To reduce labor intensity while creating new cutting fluids accelerated methods are applied first, such as the method of determining the tribometric properties of a new fluid. Subsequently wear tests are carried out, using only those cutting fluids which show the best tribological behavior.The aim...
Experimental Study of the Process of Radial Rotation Profiling of Wheel Rims Resulting in Formation and Technological Flattening of the Corrugations
Ruslan Puzyr, Tetiana Haikova, Ján Majerník, Monika Karkova, Ján Kmec
Manufacturing Technology 2018, 18(1):106-111 | DOI: 10.21062/ujep/61.2018/a/1213-2489/MT/18/1/106
Experimental studies of the wheel rim workpieces with additional technological corrugations have been carried out the results of which showed the ineffectiveness of this technique in profiling to increase thickness of the radial profile junctions of the semi-finished product. The comparison of profiling methods was carried out according to the Cochran's criterion and Student t-test. The additional experiments aimed at the determination of the flexural strain on differently shaped workpieces confirmed the impossibility of creation of the upthrust in the meridional direction during the deformation of the closed shells with straightening of the technological...
Importance of Holistic Approach of Assembly Production Transformation in Manufacturing with Value Stream Mapping
Miroslav Sagan
Manufacturing Technology 2018, 18(1):112-116 | DOI: 10.21062/ujep/62.2018/a/1213-2489/MT/18/1/112
In the current world, the business faces different challenges, as it was in the 1950th. Today, most of the manufacturing companies have a very strict approach to increasing market needs of Safety, Quality, Delivery and Cost key performance indicators (KPI). To stay competitive, it is needed, that a holistic approach on the improvement of strategic KPIs is needed in order to be successful. The target of this paper is to show the application of the Value stream mapping methodology, used in a case study for a finish good assembly line in an Electronic Manufacturing Facility. The study is showing the improvement of quality, delivery and productivity KPIs...
A Special Tool for Making a Detail of the T-groove
Josef Sedlak, Radek Oprsal, Ales Polzer, Ales Jaros, Josef Chladil
Manufacturing Technology 2018, 18(1):117-123 | DOI: 10.21062/ujep/63.2018/a/1213-2489/MT/18/1/117
The paper deals with the design of a special machining tool for efficient production of detail on the T-groove of the clamping part. The introductory part of the paper is focused on introducing the Czech company. The practical part of the paper deals with the analysis of the existing state of machining of the clamping body and of the production of the T-groove detail and proposes an innovative solution in the form of more efficient machining process (partial production modification), which consists in the development and production of a special tool with replaceable inserts. The main reason for this partial modification is a significant reduction in...
The Role of Modelling of Road Unevennesses in Vehicle Dynamics
Stefan Segla, Jan Kampo
Manufacturing Technology 2018, 18(1):124-129 | DOI: 10.21062/ujep/64.2018/a/1213-2489/MT/18/1/124
It is well known that the dynamic behaviour of a vehicle is affected by the design parameters of its suspension system, especially by the stiffnesses of the suspension springs, damping coefficients and tire stiffnesses. Another important factor influencing vehicle vibration is kinematic excitation caused by uneven roads. It may significantly affect the comfort of the driver and passengers, safety of the ride and relative displacements between the sprung and unsprung masses. The paper presents mathematical models of both deterministic and random road unevennesses and numerical simulation of vertical dynamics of planar vehicle models with kinematic excitation...
The Influence of Casting Methods on Microstructure of Al-Mg-Sc-Zr Alloy
Michaela Šlapáková, Barbora Křivská, Olexandr Grydin, Miroslav Cieslar
Manufacturing Technology 2018, 18(1):130-134 | DOI: 10.21062/ujep/65.2018/a/1213-2489/MT/18/1/130
Two methods of fabrication of Al-Mg-Sc alloy are compared - conventional casting followed by cold-rolling and twin-roll casting. To the advantages of twin-roll casting belong the lower material and energy requirements during the production. However, twin-roll cast material exhibits different initial microstructure and routes established for conventionally cast materials cannot be applied. In twin-roll cast material the distribution of primary particles is more inhomogeneous - they form segregation near the center and edges of the sheet and their average size is smaller. On the contrary, the average sub-grain size is much higher in the twin-roll cast...
Suitable Pre-Treatment of Hot-Dip Zinc to Increase the Adhesion of Organic Coatings
Jakub Svoboda, Jan Kudláček
Manufacturing Technology 2018, 18(1):135-139 | DOI: 10.21062/ujep/66.2018/a/1213-2489/MT/18/1/135
The article describes the possibilities of pre-treatment of hot-dip galvanized parts and their influence on the adhesion of organic coating. The main objective of this work was to compare the current possibilities of pre-treatment of hot-dip galvanized parts, this means phosphating, chromating and mechanical pre-treatment by light blasting and compare these technologies with today's alternative pre-treatment technologies based on chemical substances containing fluorozirconates. The basic function of these pre-treatments is to increase the adhesion of the organic coatings and to increase the lifetime of the entire corrosion protection. Another objective...
Some Aspects of Plastic Strain in Chip Creation
Karol Vasilko
Manufacturing Technology 2018, 18(1):140-144 | DOI: 10.21062/ujep/67.2018/a/1213-2489/MT/18/1/140
The article presents an experimental method of tracking deformation domains in the formation of shavings in machining of metalical materials. The methodologies of the study of the mechanismus of lastic deformation in the zone of chip forming used hitherto were based on the observation of quasi-static states obtained by stopping the process of cutting. The methodology shown here rests in a dynamical study of the movement of grains or groups of grains in the area of chip forming. In the course of machining, the path of the movement of the particle is being recorded. This parth of the movement of the particle is being recorded. This part enables us to...
Dynamic Analysis of Lever Mechanism for Manufacturing of Raw Tyres
Ján Vavro, Ján Vavro jr., Beáta Pecušová, Matej Burget
Manufacturing Technology 2018, 18(1):145-148 | DOI: 10.21062/ujep/68.2018/a/1213-2489/MT/18/1/145
The give paper is closely connected with the analysis of the normal force relating to the winding mechanism referring to production or manufacturing of raw tyres. The attention is mainly paid to the calculation of normal force during the manufacturing process when the individual constituents of raw tyre are pressed-in. The dynamic analysis as well as the calculation of the given normal force was done for raw truck tyre. The simulation of the movement and dynamic analysis for the given kinematic conditions as well as appropriate input values were solved in Solid Works - modeling computer program. Courses of normal forces for the first one set and the...
Optimization of Controlled Cooling of Forgings from Finishing Temperature with the Use of Light and Electron Microscopy
Ivan Vorel, Štěpán Jeníček, Josef Káňa, Vratislav Kotěšovec
Manufacturing Technology 2018, 18(1):149-153 | DOI: 10.21062/ujep/69.2018/a/1213-2489/MT/18/1/149
Customer requirements represent the driving force in the market, dictating the directions of development, production and processing of forged parts. Meeting these requirements is of paramount importance to forge shops as a precondition for their continuing operation and competitiveness. Consequently, optimization of manufacturing operations and their rapid response to market requirements are necessary for the forge shops to survive. However, any production stoppage for optimization results in extra costs. Forge shops thus strive to carry out optimization in as few steps as possible and within the shortest possible timeframe. A viable solution emerges...
Research on the Design of a Mill-turn Center
Zhun Wang
Manufacturing Technology 2018, 18(1):154-159 | DOI: 10.21062/ujep/70.2018/a/1213-2489/MT/18/1/154
Mill-turn center is an advanced CNC machine tool. This paper presents a novel approach to the conceptual design of a mill-turn center. Firstly, the feature model of a mill-turn center is created based on a RW (representative workpiece) in a Top-down way. After that, two concurrent works are studied: the verification model of the machine tool is setup by transforming its finished feature model; the NC programming is done with the help of the technology of CAM (computer-aided manufacturing). Thirdly, the production verifying of the mill-turn center is fulfilled in the NVMS (NC verification manufacturing system). Lastly, the optimum structure dimension...
The Alternative Procedures of Fiber Volume Ratio Determination of Long-Fiber Carbon - Epoxy Composites
Radek Zbončák, Vlastimil Votrubec, Martin Švec
Manufacturing Technology 2018, 18(1):160-164 | DOI: 10.21062/ujep/71.2018/a/1213-2489/MT/18/1/160
The need to determine actual fiber volume ratio of the real composite part manufactured in the semi-closed mold led to application of the alternative procedures than the widely used Burn-off method. The low cost one, which is required preferably by any manufacturer, is based on Archimedes law (AL) and the most accurate determination of volume of displaced water. The more complex method which is based on the reverse engineering approach where the 3D scan technique is used to determine the volume of the part. Both are nondestructive methods. And finally the last method mentioned in this study is a sophisticated optical visualization technique and Figure...
Influences of Friction Condition and End Shape of Billet on Convex at Root of Spline by Rolling with Round Dies
Da-Wei Zhang, Sheng-Dun Zhao
Manufacturing Technology 2018, 18(1):165-169 | DOI: 10.21062/ujep/72.2018/a/1213-2489/MT/18/1/165
The rolling process is widely used to manufacture high-performance splined shaft components. However, there is a convex at root on free end of spline formed by rolling with round dies. However, the analysis and representation of this forming problem are difficulty due to the complexity of motion and multiplicity of processing parameters. This paper concentrates on the corner filling problem, and a physical analog experiment was designed to investigate the problem. The physical experimental results indicated that the designed experiment can reflect the formation of convex during spline rolling process. The finite element analysis of the physical analog...