Manufacturing Technology Journal, 2023 (vol. 23), issue 6
Melt Rheology of High-Density Polyethylene (HDPE) and Polypropylene (PP) using Single-Screw Extruder
Fadi Alzarzouri, Jan Skočilas
Manufacturing Technology 2023, 23(6):752-757 | DOI: 10.21062/mft.2023.103 
Melt rheological properties of HDPE and PP were studied using single-screw extruder equipped by capillary rheometer head. The rheological experiments were carried out at 210°C, 220°C, and 230°C. The screw rota-tional speed varied from 5 to 130 RPM. Power law index (n), consistency index (K), and flow activation ener-gy (E) were determined. The results showed that n values at 210°C, 220°C, and 230°C for HDPE were 0.72, 0.73 and 0.76 respectively, and for PP were 0.40, 0.44, and 0.45. The consistency index (K) values for HDPE and PP decreased with the increased in temperature and the flow activation energy of PP was greater than that of HDPE.
Influence of Draw-Beads Geometry on the Surface Quality of Zn-Mg Coating
Josef Bradáč, Jiří Sobotka
Manufacturing Technology 2023, 23(6):758-768 | DOI: 10.21062/mft.2023.088
In terms of surface protection of outer car body parts, zinc coatings are currently highly used in automotive industry. Concretely, hot dip galvanized (HDG) sheets are used in most cases. However, other possible alternatives such as zinc-magnesium coatings (Zn-Mg), which are usually referred to as ZM coatings, are also more frequently applied. Thanks to magnesium, the corrosion resistance is significantly increased, which also positively influences the coating thickness. On the other hand, the presence of magnesium makes this coating harder and brittle, which significantly limits its use to produce complex car-body stampings. To prevent the stamped...
Comparative Evaluation of Working Accuracy in the Atomic Diffusion Additive Manufacturing (ADAM) Process and the Binder Jetting (BJ) Process by Analysing Key Characteristics
Andrej Czan, Tatiana Czanova, Jozef Holubjak, Martin Novak, Natalia Czanova, Andrej Czan, Dominik Krisak
Manufacturing Technology 2023, 23(6):769-780 | DOI: 10.21062/mft.2023.108
This research focuses on comparing the working accuracy of two additive manufacturing processes, Atomic Diffusion Additive Manufacturing (ADAM) and Binder Jetting (BJ). Through the analysis of key characteristics of these processes, we aim to evaluate which one yields better results in terms of working accuracy. ADAM is a process that involves the gradual deposition of metallic materials using a plastic binder, whereas BJ is a process where the binder is applied to powder material, followed by the removal of excess binder. This work conducts a detailed examination of the properties of the ADAM and BJ processes, with a focus on surface texture and microstructure...
Cooling Ability of Smooth and Dimpled Surfaces determined by Experiment and Numerical Simulation
Lenka Dobsakova, The Duy Nguyen
Manufacturing Technology 2023, 23(6):781-787 | DOI: 10.21062/mft.2023.097
The study of the cooling process of a gun barrel is of great importance in the field of ballistics and weaponry. This is because the cooling process directly impacts the gun's accuracy, precision, and longevity. To minimize these effects, the geometry of the barrel is optimized, among other things. The article examines the cooling process of the copper plate and barrel with a structured surface. The study aims to determine the structured surface's effects on heat transfer through radiation and convective components. The work focuses on conducting experiments and numerical simulations to observe and evaluate the cooling process of the studied objects...
An Investigation into Conventional Spinning Process Using Ball Shaped Rollers as Forming Tool
Ayman Ali Abd-Eltwab, Gamal I. Helal, Mohamed N. El-Sheikh, Essam Khalaf Saied, Ahmed M. Atia
Manufacturing Technology 2023, 23(6):788-800 | DOI: 10.21062/mft.2023.084
Conventional spinning is one of the oldest processes used widely in manufacturing to obtain cup shape products. Conventional spinning is the technique that produce axisymmetric part or component over rotating mandrel with the help of rigid tool known as rollers. The shape of roller is very important parameter for the success of the spinning process. This paper datils about using ball shaped rollers as forming tool in conventional spinning process experimentally. The experimental work was carried out on the center lathe machine as forming machine, the spinning tool or spinning rollers was installed on a dynamometer replaced the tool post while the mandrel...
Design Modification of the Combi-type Body Considering the Impact on Vehicle Aerodynamics – Case Study
Michal Fabian, Róbert Huňady, Orlando Lagos
Manufacturing Technology 2023, 23(6):801-809 | DOI: 10.21062/mft.2023.099
Car manufacturers are constantly looking for new options to make the vehicle more attractive to the cus-tomer. In terms of design, this is usually done in the middle of a model's life cycle, when a so-called facelift of a production model is carried out. This involves small changes to the shape of the bodywork to improve the design of the vehicle until it is time for a new model range. This paper discusses a case study that focuses on the modification of the rear body components of a ŠKODA Superb III in Combi version. The aim of the study is to assess how the proposed modifications will affect the aerodynamics of the vehicle. The most sig-nificant...
FEM Simulation of the Flange Turning in the Production of Aluminium Aerosol Cans
Csaba Felhő, István Sztankovics, Zsolt Maros, Krisztina Kun-Bodnár
Manufacturing Technology 2023, 23(6):810-818 | DOI: 10.21062/mft.2023.104
Even today, there is an ever-increasing demand for the production of aerosol cans made of aluminium, as the cosmetics and other propellant-enriched products stored in them reach more and more people with the development of humanity. The production of these packaging materials is primarily carried out by plastic forming operations. However, during the production process of aluminium aerosol cans, tools with a defined edge geometry also perform cutting operations. The processes taking place here affect the quality of the final product. In this paper, the procedure and results of finite element modelling of the flange turning of aluminium aerosol cans...
Methodology of Analysis of Fibre Sedimentation in HPC mixtures
Dita Jiroutová, Tomáš Bittner, Karel Hurtig, Tomáš Jirout
Manufacturing Technology 2023, 23(6):819-826 | DOI: 10.21062/mft.2023.106
The aim of this work is to propose a methodology for evaluating inhomogeneity due to the sedimenta-tion of fibres in High-Performnce Concrete (HPC) mixtures. HPC mixtures makes better mechanical-physical properties than ordinary concrete. To achieve higher strengths, the fine-grained matrix is rein-forced with the reinforcement – fibres. The type of used fibres and their homogenization in mixture has an influence on the final mechanical properties of HPC mixture. Four concrete mixtures with same com-ponent proportion was chosen for experiments. Water was the only one component, that was changing in mixture recipes. Steel fibres with a ratio of...
Utilization of Metal Forming Process Mathematical Modelling to Predict the Spring-back of the Dual-phase Steel Stamping
David Koreček, Pavel Solfronk, Jiří Sobotka
Manufacturing Technology 2023, 23(6):827-836 | DOI: 10.21062/mft.2023.095
Nowadays, the digitalization of the production process is an indispensable part of the stampings production in the pre-series stage, but also as a subsequent support for series production. Automotive producers are under pressure to comply with the ever decreasing CO2 production standards for cars, which predicates the use of modern material types with an advantageous weight-to-strength ratio. This paper focuses on the use of mathematical modelling in a numerical simulation environment to predict the deformation process and subsequent material spring-back of dual-phase steel DP500. The material data and characteristics are used to define the material...
Influence of Thermomechanical Processing Parameters on Selected Properties of B-post Made of 22MnB5 Steel
Sylvia Kusmierczak, Radek Srb
Manufacturing Technology 2023, 23(6):837-845 | DOI: 10.21062/mft.2023.105
With regard to the current economic situation, which deals primarily with energy prices, companies are trying to find reserves within individual technologies. The automotive industry is still a very important industry. One of the ways to improve the material properties of a body part is thermomechanical processing. This is how the B-pillar, which serves as a safety structural element of the car, was processed. The presented article aims to investigate the influence of selected thermomechanical processing parameters on the resulting properties of a B-pillar made of high-strength steel 22MnB5. At the same time, energy saving in the given production process...
Structural and Mechanical Properties of CuZn30 Cartridge Brass in Real Production Conditions
Jan Luštinec, Miroslav Roško, Vladivoj Očenášek
Manufacturing Technology 2023, 23(6):846-852 | DOI: 10.21062/mft.2023.090
The paper deals with the technology of production of deep-drawn plates from alpha brass CuZn30. Surface and hidden defects are often observed in these deep-drawn sheets. The research was aimed at reducing the occurrence of these defects and subsequently reducing scrap and increasing the quality of these metallurgical products with a tighter tolerance of the required structural and mechanical properties throughout the length and width of the sheets. The production technology was monitored from the preparation of the batch and casting parameters on the existing operating equipment, through the processing of the ingots by hot and cold rolling, to the...
Machining of M390 Microclean® and M398 Mircoclean® PM Steels – the Comparison of Cutting Forces and Surface Roughness
Jozef Majerík, Juraj Majerský, Henrieta Chochlíková, Igor Barényi, Jana Escherová, Mária Kubasáková
Manufacturing Technology 2023, 23(6):853-860 | DOI: 10.21062/mft.2023.096
Article deals with comparison of cutting forces and surface roughness between materials produced by powder metallurgy M390 and M398 Microclean® from producer, company Böhler. Main interest is the analysis & comparison of the cutting forces and surface roughness after the processing by cutting in-serts with DNMG and WNMG geometry, radius 0.4 and 0.8 mm, after hard turning at the same pro-cess parameters for both materials and all types of cutting inserts. The comparative studies were car-ried out for cutting forces and surface roughness with the aiming to observe the difference between “old generation” M390 and “new generation”...
Evaluation of the Corrosion Resistance of the Al-Si-Cu-Mg Alloy with the Addition of Zirconium
Marek Matejka, Dana Bolibruchová, Daniel Kajánek
Manufacturing Technology 2023, 23(6):861-869 | DOI: 10.21062/mft.2023.085
Aluminum alloys are one of the most used materials today, and therefore great emphasis is placed on their continuous development. Improving the ratio of strength and stiffness to weight, improving plasticity, casting properties or resistance to corrosion are examples of properties of aluminum alloys that are constantly being improved. This work focuses on the evaluation of the corrosion resistance of the Al-Si5Cu2Mg alloy with graded addition of zirconium (0.05; 0.10; 0.15; 0.20 wt.%). Corrosion re-sistance was evaluated based on immersion, exposure and potentiodynamic polarization tests. The addition of Zr to the AlSi5Cu2Mg alloy improved the thermodynamic...
Effect of the Cutting Tool on the Quality of a Machined Composite Part
Magdalena Zawada-Michałowska, Paweł Pieśko, Stanisław Legutko
Manufacturing Technology 2023, 23(6):870-879 | DOI: 10.21062/mft.2023.107
The growing use of composite materials in various industries implies the necessity of conducting research on both their manufacture and subsequent machining. One of the main problems in composite machining is the selection of a suitable cutting tool. This study investigates the effect of the geometry and material of a milling cutter on the quality of a milled composite part. A carbon fiber-reinforced epoxy resin matrix composite was tested. Two cutting tools were used: an end mill with PCD inserts with a diameter of 12 mm and the number of teeth of 3 as well as a PCD-coated carbide end mill with a diameter of 12 mm and the number of teeth of 4. Variable...
3D printing of Copper by Electrochemical Deposition Method
Michal Mišurák, Jan Šerák, Dalibor Vojtěch
Manufacturing Technology 2023, 23(6):880-892 | DOI: 10.21062/mft.2023.089
Additive manufacturing commonly also called 3D printing is a process which creates 3D structures according to digital 3D models by successive deposition of material layer by layer. Electrochemical 3D printing is a relatively new form of additive manufacturing, which creates metallic structures by electrochemical reduction of metallic ions from the electrolyte onto a conductive substrate. Advantages of this technology are ability to produce structures of several materials, without inert atmosphere, thermal stresses and without using laser optics. Theoretical part was focused on introduction to additive manufacturing and overview on its technologies,...
Effect of PWHT of X6Cr-NiNbN 25-20 Steel on the Evolution of the Sigma Phase during Creep Exposure at 700 °C
Jakub Rehorek
Manufacturing Technology 2023, 23(6):893-899 | DOI: 10.21062/mft.2023.091
Superheaters and reheaters made of heat–resistant austenitic steels are being replaced in existing fos-sil fuel power plants to operate at Advanced Ultra Super Critical (A-USC) parameters of steam. New-ly developed and used high nickel content austenitic steels, such as in X6Cr NiNbN 25-20, are pre-dicted to significantly suppress the precipitation of a hazardous σ-phase during long-term creep expo-sure. The σ-phase causes premature failure of the component during creep, which is usually support-ed by a local change in hardness in the case of welded assemblies. Experimental results show that PWHT significantly improved reduction of...
Hydrogen Embrittlement of 11SMn30 Free-cutting Steel
Lukáš Šikyňa, František Nový, Peter Palček, Petra Drímalová, Martin Slezák, Milan Uhríčik, Veronika Chvalníková
Manufacturing Technology 2023, 23(6):900-908 | DOI: 10.21062/mft.2023.092
The main objective of the work was to describe the laboratory methods suitable for hydrogenation of free-cutting steels and to study the hydrogen embrittlement of 11SMn30 free-cutting steel. Hydrogenation and subsequent mechanical testing of hydrogenated steel is not common laboratory method as it requires precise and expensive equipment, is time consuming and dangerous as hydrogen is highly reactive and explosive. Currently, there are several theories of hydrogen embrittlement mechanisms of steels that describe the causes of material degradation by hydrogen. However, those theories are not universally valid; individual accounts have been developed...
Effect of Plasma Nitriding and Sensitization on the Microstructure and Microhardness of AISI 304 Austenitic Steel
Martin Slezák, Milan Uhríčik, Peter Palček, Veronika Chvalníková, Petra Drímalová, Lukáš Šikyňa
Manufacturing Technology 2023, 23(6):909-916 | DOI: 10.21062/mft.2023.087
This article deals with the influence of plasma nitriding and sensitization on the microstructure and microhardness of AISI 304 austenitic steel. The microstructure of AISI 304 austenitic steel in all states was observed on a Neophot 32 optical microscope. The initial structure consisted of polyhedral austenite grains of different sizes. The microstructure contained a large number of non-metallic MnS-based inclu-sions. After plasma nitriding, a continuous nitriding layer was formed under the steel surface, while the grain shape was preserved. After the processes of sensitization and plasma nitriding followed by sensiti-zation, carbides were excluded...
Wear Analysis of Indexable Inserts after Machining of Austenitic Steel 1.4404
Karel Sramhauser, Natasa Naprstkova, Iryna Hren, Frantisek Spalek, Tomas Vlach, Radim Kunes, Ondrej Tupy
Manufacturing Technology 2023, 23(6):917-926 | DOI: 10.21062/mft.2023.094
This article deals with the comparison of the wear of indexable CNMG carbide inserts from two dif-ferent manufacturers when turning austenitic stainless steel 1.4404, which is not intended as the pri-mary material to be machined from the point of view of the tested inserts. The main goal was to demonstrate the different course of wear by testing inserts of the same type according to ISO 6987 showing the connection between the design and processing of the inserts in connection with the se-lected cutting parameters. The monitored type of wear was the main flank wear VBmax, depending on the length of the machining time. Optical and electron microscopes...
Optimization of Threads Production on Thin – Walled Castings
Dana Stančeková, Jozef Mrázik, Anna Rudawska, Miroslava Ťavodová, Izabela Miturska-Barańska, Daniela Sršníková, Miroslav Špiriak
Manufacturing Technology 2023, 23(6):927-934 | DOI: 10.21062/mft.2023.078
This study focuses on the analysis and solution of thread production in thin-walled profiles. It explores three different threading technologies, including cutting, forming, and extrusion. The issue of a screw joint in a thin-walled component is complex due to the stiffness of the joint and the short length of the thread. Hence, the careful choice of a suitable manufacturing process for producing inner threads in thin-walled components holds significant importance. The study entails monitoring the hardening of surface layers of materials after thread production, in conjunction with the acquisition of microstructure images of the experimental material....
Experimental Investigation of Armour (Armox-Aramid-UHMWPE)
Jindřich Viliš, Roman Vítek, Jan Zouhar, Michal Stejskal, Vlastimil Neumann
Manufacturing Technology 2023, 23(6):935-948 | DOI: 10.21062/mft.2023.083
In this study, the ballistic resistance of multi-layered composite armour is experimentally investigated. The composition of this armour consisted of armour steel Armox 500T, para-aramid fabric Twaron CT 747 and ultra-high molecular weight polyethylene Endumax Shield XF33. To compare the ballistic resistance, the ballistic resistance of the armour with the perforated steel Armox 500T was tested. The rifle cartridges 7.62 x 51 mm FMJ NATO M80 were used to test this resistance. The aim of this experiment was to compare the ballistic resistance of unperforated and perforated steel Armox 500T. As part of the experimental part, the chemical composition...
Machinability of UMCo50 Cobalt Superalloy
Oskar Zemčík, Karel Kouřil, Martin Slaný, Jan Zouhar, Josef Sedlák, Štěpán Kolomý
Manufacturing Technology 2023, 23(6):949-957 | DOI: 10.21062/mft.2023.082
Testing of machinability of the UMCo50 superalloy was carried out within the project following the actual production of the semi-finished product by casting. Turning was chosen as the machining method to minimize the effect of an interrupted cut. Considering the machinability of a hard-to-machine alloy, the cutting material with the fine-grained WC-Co carbide with the TiN/TiAlN gradient PVD coating was selected. The progression of cutting forces, chip formation and tool wear were evaluated. Images of the material structure of the semi-finished product and the resulting chips were taken. From the measured values, graphs of the dependence of the chip...
Precision Forming Process Analysis and Forming Process Simulation of Integrated Structural Gear for New Energy Vehicles
Liyong Zhang, Tianle Zheng, Tongjie Li, Juan Wang, Changlu Wang, Yehu Jiang, Chengyu Li, Fengxia Yuan, Zhihua Yao
Manufacturing Technology 2023, 23(6):958-966 | DOI: 10.21062/mft.2023.102
New energy vehicles driven by electric motors have higher requirements for the lightweight and high reliability of their gear transmission devices. It is now necessary to optimize the precision forming process of their structural gears. The integrated structure gear without undercut produced by precision forming technology can reduce axial size while improving the strength and reliability of gear parts. Based on the performance requirements of integrated structural gear parts in practical applications, a process plan of "hot forging forming +cold trimming tooth shape" was developed, and compared with existing hot extrusion forming plans. Simulation...
Design and Algorithm Research of a Weight Sorting Transport Robot
Haojie Du, Guang Yang, Lele Pei
Manufacturing Technology 2023, 23(6):967-975 | DOI: 10.21062/mft.2023.113
In warehousing logistics, the sorting and transportation efficiency of goods is still one of the important factors limiting the rapid development of logistics. At present, most regions still use manual sorting with low efficiency and high cost. Especially in some special work areas, such as high temperatures, severe electronic radiation, and areas with heavy long-term work tasks, urgent need for small robots to replace manual labor. In order to solve the inconvenience that small places such as logistics only use manual sorting, It is necessary to design a small-sized weight sorting and transportation robot, which can wait for receiving goods at a designated...
Design of a Biped Climbing Robot: Simulation, Comparison and Implementation
Tao Huang, Rundong Cao, Xinliang Wu
Manufacturing Technology 2023, 23(6):976-988 | DOI: 10.21062/mft.2023.109
In this paper, the design of a robot is proposed to replace manual labor in completing tasks on vertical planes. The aim is to enhance automation in the workplace and eliminate direct human involvement to ensure personal safety. Firstly, the robot's structure is designed as a five-joint biped with vacuum adsorption capabilities. The forward and inverse kinematics of the robot are analyzed. Secondly, using simulation by ADAMS, five key performance metrics are quantitatively analyzed for both this robot and a Hexapod robot. These metrics include adsorption reliability, external load-bearing capacity, friction coefficient adaptability, obstacle-crossing...
Development of Particulate Matter Monitors based on Light Scattering Method
Junjie Liu, Laihua Yu, Jing Ye, Zhihuang Huang, Jiazhen Lu, Yue Liu
Manufacturing Technology 2023, 23(6):989-998 | DOI: 10.21062/mft.2023.110
PM2.5 and PM10 measurement technique based on light scattering usually exhibit inaccurate measurement results in their applications. For improving the reliability of this method for PM2.5 and PM10 measurement, systematic research on the structure optimization of single particle light scattering sensors (SPLSS), calibration of SPLSS, and PM2.5/PM10 monitor development are carried out. Frist, by simulating and optimizing light scattering parameters, light scattering signals varied monotonically with particle size could be obtained, and thereby capability of accurate size-identifying can be established. Then, by developing threshold comparison circuit...
Optimization and Experiment of Linear Motor Platform Servo Control Algorithm
Shu Wang, Xiaoyan Wu
Manufacturing Technology 2023, 23(6):999-1005 | DOI: 10.21062/mft.2023.114
In view of the linear motor servo control system has the advantages of high speed, high response characteristics, in order to adapt to the motion precision, response speed and stability requirements of high precision movement occasions, combined with fuzzy control theory, the design of linear motor platform servo control system fuzzy adaptive PID control algorithm. At the same time, based on LabVIEW software, combined with USB-6009 data acquisition card produced by NI company, the experimental platform for linear motor motion control is designed. Through simulation experiments, the position tracking accuracy, disturbance resistance and response speed...
Research on Elastic Characteristics of Negative Pressure Rubber Isolator
Jianwei Wang, Jinlong Feng
Manufacturing Technology 2023, 23(6):1006-1012 | DOI: 10.21062/mft.2023.115
Aiming at obtaining ultra-low kinematic stiffness and improving the isolation property of low frequency vibration, it is necessary to solve the coupling parameters and rated load of air negative pressure characteristics and rubber characteristics, in order to achieve an ideal elastic characteristic curve of air negative pressure spring. Firstly, the background and working principle of the negative pressure rubber isolation were introduced. In addition, the FEA model of isolator is built based on Mooney-Rivlin constitutive model of rubber. Furthermore, to testify the validity of the mathematical model, the static characteristic and simulation analysis...
Finite Element Optimization Analysis of the Frame Structure of the New Steel Mold Trolley
Shuai Yang, Xiangping Liao, Guoshen Zhi, Guiyang Liu, Jiao Zou
Manufacturing Technology 2023, 23(6):1013-1019 | DOI: 10.21062/mft.2023.112
In order to test whether the design of the new steel mold trolley meets the requirements of the working conditions,the ANSYS finite element simulation and optimization analysis of the frame system of the new steel mold trolley were conducted.After the analysis, the results show that the new steel mold trolley designed basically meets the requirements of strength and stiffness, but there are some problems of insufficient strength；Through the topology optimization of the gantry frame of the new steel mold trolley frame system, the "door shape" section gantry structure with better force structure was obtained.The influence of the specific structural...
Research on the Application of Mirror Moulds for Masks
Weiwen Ye
Manufacturing Technology 2023, 23(6):1020-1030 | DOI: 10.21062/mft.2023.111
Precision mirror mould CNC machining is a technology of great importance in industrial manufacturing. Precision mirror moulds are usually used to produce high-precision, high-quality parts and products, which are widely used in automotive manufacturing, aerospace, electronic equipment and other industries. However, the traditional mould polishing process often fails to meet the manufacturing needs of precision moulds, so the application of CNC machining technology has become an effective way to solve this problem. Through the use of CNC machine tools and computer control systems, etc., the detailed formulation of the process plan, so that precision...