Manufacturing Technology Journal - Latest articles

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Experimental Identification of Gear Mesh Stiffness and Verification by Theoretical Models

Jan Flek, Tomas Karas, Martin Dub, Frantisek Lopot, Vit Ripa, Josef Kolar

Manufacturing Technology 2024, 24(4):552-566 | DOI: 10.21062/mft.2024.069  

When analyzing the natural frequencies of a gear mechanism, it's crucial to consider the mesh stiffness, which is influenced by the number of teeth in the mesh. Mesh stiffness behaves as an internal excitation source for the dynamic system, affecting the resulting frequency spectrum. This paper presents an experimental determination of gear mesh stiffness supported by analytical-simulation models of mesh stiffness, outlining common modeling methods and detailing the experimental setup and test specimens. The obtained data are then compared with simulation models of mesh stiffness, discussing the significance of this comparison and emphasizing the role...

An Investigation into Forming of Gears Using Rotary Forging Process

Ayman Ali Abd-Eltwab, Walid Elsyed Ayoub, Mohamed N. El-Sheikh, Essam Khalaf Saied, Nouby M. Ghazaly, Gomaa A. A.

Manufacturing Technology 2024, 24(4):539-551 | DOI: 10.21062/mft.2024.068  

Gears and toothed parts are significant components in power transmission systems. These parts usu-ally manufactured by traditional methods such as machining by milling or forming by rotary forging. In this study, the forming of solid gears or toothed parts using a forging process that combines rotary forging and ballizing technique. The specimens were placed inside the die with excessive volume to fill the toothed part in the die. The forming tool applies pressure to the specimen while rotating it together with the die by the lathe machine chuck, while the tool advances continuously in the direc-tion of the die. This reduces height of the specimen...

Linear Motor System Identification and Simulation Experiments Based on LabVIEW

Xiaoyan Wu, Shu Wang

Manufacturing Technology 2024, 24(4):692-699 | DOI: 10.21062/mft.2024.067  

There are currently many control methods for linear motors, and the focus of controlling the motor should be different for different application needs. In general applications, simple PID control can meet the application requirements, but in precision motion situations with high requirements for motion accuracy, response speed, and stability, PID control is often difficult to achieve satisfactory control results, which requires the application of more advanced control strategies to complete. At present, combining multiple control algorithms and concentrating the advantages of each algorithm while trying to overcome each other's disadvantages has become...

Mechanical Properties, Structure and Machinability of the H13 Tool Steel Produced By Material Extrusion

Martin Maly, Stepan Kolomy, Radek Kasan, Lukas Bartl, Josef Sedlak, Jan Zouhar

Manufacturing Technology 2024, 24(4):608-617 | DOI: 10.21062/mft.2024.066  

The study focuses on an evaluation of mechanical properties of the H13 tool steel manufactured by the material extrusion and further comparison with conventionally produced material. Notably, for achieving sufficient surface quality of functional parts further post-processing is required. Thus, a comprehensive investigation, encompassing hardness, ultimate tensile strength (UTS) and yield strength (YS) measurement, microstructure, and machinability was performed. The material extrusion, an increasingly utilized additive manufacturing (AM) technique, offers a viable alternative to the prevalent laser powder bed fusion (LPBF) methods. This method enables...

Experimental Investigation of Thermofriction’s Impact on Surface Hardness of Steel Products'

Falah Mustafa Al-Saraireh

Manufacturing Technology 2024, 24(4):645-651 | DOI: 10.21062/mft.2024.065  

The impact of thermofriction on surface hardness has been investigated in this study. The metal disk method, which hardens parts' surfaces utilizing a metal disk, creates a hardened layer with the re-quired mechanical characteristics at a precise depth. The surface of treated products is one indica-tion of quality indicators. It has been noted that the thermal conductivity of the workpiece and tool material affects the irregular dispersion of heat in the processing zone. For evaluating the average integral rates of heating and cooling of the layer, the metal dependences have a significant impact on the form and properties of the friction-strengthened...

Study on Multi-Objective Optimization of Milling Process of Powder Metallurgy Titanium Aluminum Alloys

Wenbing Tian, Wenhu Wang, Yuanbin Wang, Shengguo Zhang

Manufacturing Technology 2024, 24(4):652-667 | DOI: 10.21062/mft.2024.064  

Currently, there is a demand in the aerospace industry for a more effective and non-invasive milling technique for powder metallurgy γ-TiAl alloy. The primary objective of this research is to examine the surface milling process of a γ-TiAl alloy generated by powder metallurgy. The primary objective of this study is to examine the impact of process parameters on the surface roughness and cutting force of the alloy, with the aim of optimizing both surface roughness and cutting force. The response surface method was implemented to examine the milling process, and the NSGA II algorithm was employed to optimise surface roughness, cutting force,...

The Impact of Pre-Existing Surface Texture on Laser Cladding of 316L Cladding

Chen Ma, Weilong Du, Zice Yu, Zihao Zhang, Changlong Zhao

Manufacturing Technology 2024, 24(4):594-607 | DOI: 10.21062/mft.2024.063  

Laser cladding technology, a novel surface modification technique, is widely employed in tasks such as metal surface strengthening and repair. However, the quality post-cladding often falls short of usage requirements, harbouring defects like cracks and pores. In pursuit of a crack-free cladding method, surface texture technology is integrated with laser cladding technology to establish a multi-field coupled numerical simulation model. This model investigates the temperature, stress, and fluid fields during laser cladding with and without texture, aiming to identify the optimal cladding parameters. The results indicate that the optimal cladding parameters...

Microstructural Analysis, Corrosion Resistance, and Wear Performance Study of Al0.8FeCoNiCrCu0.5Si0.2 High-Entropy Alloy

Peng Zhang, Yanzhou Li

Manufacturing Technology 2024, 24(4):700-709 | DOI: 10.21062/mft.2024.062  

The high-entropy alloy with the composition Al0.8FeCoNiCrCu0.5Si0.2 was produced through a pro-cess in-volving a vacuum arc melting method. Comprehensive characterization was performed through techniques such as XRD, SEM, and TEM. The findings revealed that the alloy primarily con-sists of Fe-Cr and Al-Ni phases, displaying predominantly two body-centered cubic structures. The alloy exhibited a characteristic dendritic cast structure. The alloy predominantly has high-angle grain boundaries accounting for 96.1%. Its grains demonstrate minimal internal strain and reduced lattice anomalies. The alloy showcased resistance with a corrosion current density...

Thermal – Static Analysis of the Brake Disc in SolidWorks

Daniela Koštialiková, Mariana Janeková, Petra Dubcová, Marek Hulc

Manufacturing Technology 2024, 24(4):588-593 | DOI: 10.21062/mft.2024.061  

The work deals with the creation of 3D model of a disc brake of a personal vehicle, followed by a simula-tion of thermal and strengh analysis during car braking in the SolidWorks program. The disc brake is made of a gray cast iron, the most common material for this application. Cast iron discs offer excellent performance, making them suitable for various types of vehicles. The deformation of a brake disc was analyzed by using the program SolidWorks, where the first a simulation of the thermal load was per-formed, the aim of which was to determinate the temperature distribution on the brake disc and display the temperature rise during braking. In the...

Modern Conversion Layers as High-Performance Alternatives to Aluminum Anodizing and Its Alloys

Martin Chvojka, Viktor Kreibich, Jan Kudláček

Manufacturing Technology 2024, 24(4):532-538 | DOI: 10.21062/mft.2024.060  

The paper focuses on a novel and perspective surface treatment technology called Plasma Electrolytic Oxidation (PEO) applied to aluminium and its alloys. This innovative technology generates layers with specific properties, particularly suitable for tribological and heat-resistant applications. Plasma Electro-lytic Oxidation technology represents an alternative to conventional oxidation methods, offering high utility properties and presenting a completely new approach to surface modification.

Variable Excitation Piezoelectric Energy Capture Device for Powering Scraper Conveyor Tension Detection Systems

Zhang Hezhe, Wang Cong

Manufacturing Technology 2024, 24(4):578-587 | DOI: 10.21062/mft.2024.059  

Past efforts which focused on the essential monitoring of the chain tension of scraper conveyers employed in fully mechanized coal mining operations have developed innovative power solutions based on the incorporation of piezoelectric devices that generate the electrical power required for the wireless transmission of chain tension data based solely on the vibrations of the scraper conveyor itself. However, these past studies have failed to evaluate the effects of different environmental factors on the electricity generating capacity of the piezoelectric devices. The present work addresses this issue by evaluating the maximum peak-to-peak voltage generated...

Effect of Filler Content and Treatment on Mechanical Properties of Polyamide Composites Reinforced with Short Carbon Fibres Grafted with Nano-SiO₂

Dana Bakošová, Alžbeta Bakošová, Petra Dubcová, Daniela Koštialiková, Andrej Dubec, Mariana Janeková

Manufacturing Technology 2024, 24(4):521-531 | DOI: 10.21062/mft.2024.058  

The polyamide PA6 composites reinforced with carbon fibres (CF) are widely studied due to their properties and their high strength to weight ratio. Good adhesion between a filler and a matrix is es-sential for enhancing properties of a resulting composite. This study investigates the effect of the short CF content and the used CF treatment on mechanical properties of the PA6-CF composites. The composites were subjected to tensile, flexural, compression, hardness and Charpy tests as well as dynamical mechanical analysis. An atomic force microscopy was employed to investigate topography of the CF and the composites. Initially, the properties of the composites...

The Impact of Cryogenic Temperatures on the Hardness and Tribological Properties of Cobalt Alloys

Jakub Mráz, Totka Bakalova

Manufacturing Technology 2024, 24(4):626-635 | DOI: 10.21062/mft.2024.057  

This article explores the effect of cryogenic temperatures on the properties of cobalt alloys, specifically Stellite 6 and Stellite 12. These alloys are commonly used in applications that require resistance to me-chanical, thermal, and chemical wear. In this study, the focus is on the valve seats for internal combus-tion engines, which are made from cobalt alloys and undergo a freezing process before assembly into the cylinder head. The purpose of freezing is to reduce the diameter of valve seats, making them easier to fit into the cylinder head. However, the length of time spent in freezing can significantly affect the hardness and tribological characteristics...

The Effect of Additive Manufacturing on the Utility Properties of the Reducing Valve Rezistor

Jan Řiháček, Michaela Císařová, Eva Peterková

Manufacturing Technology 2024, 24(3):429-439 | DOI: 10.21062/mft.2024.043  

The article is focused on the analysis of the additive technology (3D printing) applicability by using DMLS in the production of the reducing valve part, i.e. atmospheric resistor. Currently, the men-tioned part is produced by EDM in combination with soldering from the Inconel 718 steel. The use of additive technologies brings the assumption of greater flexibility and economy of production, which is verified by a set of analyzes focused on the accuracy of production and the utility properties of the mentioned part. In addition to technological aspects, such as individual production processes, economic aspects are also compared. Individual comparisons...

Experimental Study of Tool Life Depending on Cutting Speed for 100CrMn6 Materials & Statistical Processing Using Linear Regression Analysis

Ľudmila Timárová, Michal Krbaťa, Marcel Kohutiar, Jana Escherová, Milan Jus

Manufacturing Technology 2024, 24(3):448-457 | DOI: 10.21062/mft.2024.044  

To increase the service life of the cutting tool, various types of coatings are used in modern times, which have a beneficial effect on extending the service life of the tools. Which contributes to reducing the eco-nomic costs of production. The present article examines the effect of cutting speed on the durability of a cutting tool. In the experimental measurements, three types of replaceable cutting inserts were used, without coating, with TiC and TiN coating. The measurements were carried out during technological operations of longitudinal turning on bearing steel 100CrMn6 without the use of coolant. The durability of the cutting discs was evaluated...

Effects of Filler Modification on the Properties of Elastomeric Composites

Róbert Janík, Ivan Labaj, Petra Skalková, Silvia Ďurišová, Katarína Moricová

Manufacturing Technology 2024, 24(3):365-377 | DOI: 10.21062/mft.2024.056  

The application of cellulose (CEL) as a filler in elastomeric composites (ECs) was studied, with cellulose examined in its untreated form (RAW), after DCSBD plasma modification, and ozone pre-treatment. Changes in surface fluorescence demonstrated that DCSBD plasma-modified cellulose achieved better dispersion in the elastomeric composite mixture, which also showed improved strength and elongation in static tensile tests. DMA analysis confirmed changes in visco-elastic properties, with DCSBD plasma-modified cellulose altering the glass transition temperatures of the Elastic and Loss modulus, as well as Tan Delta. SEM microscopy did not conclusively...

Identification of Machine Tool Defects Using Laser Interferometer

Miroslav Matuš, Vladimír Bechný, Richard Joch, Mário Drbúl, Andrej Czán, Michal Šajgalík

Manufacturing Technology 2024, 24(3):420-428 | DOI: 10.21062/mft.2024.052  

The geometric accuracy of a machine is primarily determined by the accuracy of assembly, manufactur-ing, and overall setup. Standardized procedures for assessing geometric accuracy are established and detailed in delivery protocols for various types of machining machines. To effectively monitor and ana-lyze machining machine errors, the most suitable approach is to construct a comprehensive error balance that accounts for the overall performance of the machine. This error balance methodology, a tool within the realm of system analysis, is utilized for predicting and managing systemic errors. The errors ob-served in machined components are intimately...

Analysis and Experimental Verification of Human-Robot Coupling Collaboration Characteristics for Lower Extremity Exoskeleton Rehabilitation Robot Based on ADAMS

Peiqin Wang, Hui Song, Runqiang Liu, Yun-chun Jiang, Yi Zheng

Manufacturing Technology 2024, 24(3):467-477 | DOI: 10.21062/mft.2024.055  

Motor rehabilitation contributes to neural remodeling in individuals with motor disabilities, which is crucial for their recovery of motor ability. In addressing the No. of human-machine coupling and synergistic motion characteristics in motor rehabilitation, this study analyzes the collaborative motion characteristics of each joint in the lower limbs. A virtual human-machine coupling system is proposed, and the driving functions of the human-machine coupling system are designed. By utilizing ADAMS motion simulation software, the motion characteristics of the human-machine system are analyzed, and the variation patterns of motion parameters at key...

Mechanical Properties and Compression Performance of 3D Printed HIPS Polymer Lattice Structure

Feng Jin, Wanqing Lu, Xu An, Haifeng Zhu, Jun Wang

Manufacturing Technology 2024, 24(3):378-392 | DOI: 10.21062/mft.2024.054  

With the development of 3D technology, more and more materials are being used for manufacturing and used in many fields, such as factory manufacturing, workshop manufacturing, food packaging, and even architectural design and civil engineering design. In particular, the mechanical properties of the 3D printed HIPS polymer unit cell structure are worthy of research and analysis, providing more valuable references for future material development. This study focused on the properties of HIPS polymer materials and the performance of HIPS polymer 3D printed lattice structures after Instron instrument compression testing. The experimental samples were divided...

Analysis of Static and Dynamic Characteristics and Lightweight Design of Titanium Alloy Frame

Bin Zheng

Manufacturing Technology 2024, 24(3):507-519 | DOI: 10.21062/mft.2024.053  

In response to the problems of insufficient strength and stiffness, as well as large weight in traditional car frames, this article takes titanium alloy frames as the research object. Based on the analysis of static and dynamic characteristics, a lightweight design is carried out to meet the design requirements. Firstly, static analysis was conducted on the frame structure under four different working conditions using the finite element analysis method to study its stress distribution and deformation under different loads and road conditions. Study the natural frequency and vibration mode of the frame through modal analysis, providing a basis for subsequent...

Influence of Thermal-mechanical Coupling of Single Particle on Grinding Surface Roughness

Lai Hu, Zixi Wang, Yuming Wang

Manufacturing Technology 2024, 24(3):344-354 | DOI: 10.21062/mft.2024.051  

Grinding is one of the most important processes in machining precision rotating parts. GF & GT (grinding force and grinding temperature) of single particle in grinding wheel have great influence on surface roughness. This study established the GF & GT models of single particles. Abaqus was used to analyze the coupling between GF & GT of single particle. Combined with grinding parameters (grinding depth and grinding speed), the influence of GF & GT on the range of surface roughness of single particle abrasive was comprehensively studied. The machining and experimental analysis of precision aerospace bearings were carried out through...

Proposal for Evaluating the Efficiency of Production Processes Using External and Internal Key Performance Indicators

Erika Sujová, Daniela Vysloužilová, Ivan Babic

Manufacturing Technology 2024, 24(3):440-447 | DOI: 10.21062/mft.2024.050  

The paper focuses on proposing a method for implementing key performance indicators (KPIs) to assess the effectiveness of manufacturing processes. For the evaluated processes of precision parts machining, the share of non-conforming products was proposed as a KPI, evaluated as both an exter-nal and an internal indicator. The external indicator EXTppm expressed the quantity of faulty prod-ucts to the volume of production. Its monthly development during 2022 was evaluated. The internal KPI represented the internal share of non-conforming products INTppm during 2022 which was re-lated to the order of part A. Towards the conclusion causes for not attaining...

Study on the Mechanism of Improving Surface Roughness of Gray Cast Iron Machining by Wiper Inserts

Liang Wang, Lei Han, Long He, Kan Wang, Xiaoxin Zhu

Manufacturing Technology 2024, 24(3):478-482 | DOI: 10.21062/mft.2024.049  

Based on the high hardness, poor thermal conductivity, and easy detachment of graphite in cast iron materials. Traditional rough machining inserts cannot achieve good machining surface quality, while the use of precision machining inserts results in rapid tool wear due to excessively sharp rake angles, limiting feed rates and reducing machining efficiency. In order to solve these problems, this paper proposes a method of cutting cast iron with coarse and wiper insert mixed cutting tools, aiming to improve the surface quality of machining and enhance machining efficiency. By studying the mecha-nism and cutting experiments of the wiper inserts, it was...

Accuracy of Photogrammetric Models for 3D printed Wrist-hand Orthoses

Tuong Nguyen Van, Natasa Naprstkova

Manufacturing Technology 2024, 24(3):458-464 | DOI: 10.21062/mft.2024.048  

Today, 3D printed wrist-hand orthoses can be used to immobilize the arms instead of plaster or fi-berglass casts. Typically, 3D arm models for modelling wrist-hand orthoses can be created using a 3D scanning system. Our previous study shows that smartphone cameras and photogrammetry tech-niques can be used instead of professional 3D scanning systems, but the accuracy of the photogram-metric models has not yet been fully investigated. This paper presents the results of accuracy verifica-tion of arm models reconstructed from 2D images captured with a smartphone camera. The forearm and wrist-hand parts of a photogrammetric model were subjected to a virtual...

Dynamic Analysis of the Propulsion Process of Tunnel Boring Machines

Xiangping Liao, Ying Zhao, Shaopeng Kang, Kailei Liu, Xinyang Zhu, Langxin Sun

Manufacturing Technology 2024, 24(3):410-419 | DOI: 10.21062/mft.2024.047  

In response to the need for trajectory correction during the excavation of curved tunnels by tunnel boring machines(TBM), as well as the impact of interference forces generated by the propulsion sys-tem on the design and service life of key components, as well as the low propulsion efficiency of TBM, a dynamic model of the propulsion mechanism during the excavation process is established, and the variation law of the angle between the key components of the thrust hydraulic cylinder and the gripper shoe hydraulic cylinder under the propulsion force of the hydraulic cylinder (1500KN) and three steer-ing angles of 0.5 °, 1 °, and 2 °, as well as the relationship...

Static and Modal Analysis of the Wheel-side Reducer Cover Plate Based on ANSYS

Zhang Yan

Manufacturing Technology 2024, 24(3):483-491 | DOI: 10.21062/mft.2024.046  

The three-point front-mounted electric forklift is an important logistics tool nowadays. The wheel-side reducer is a vital power unit of the electric forklift. The cover plate of the reducer casing, as a key component, bears significant external loads. The cover plate of the casing is prone to deformation under the action of loads, leading to part scrapping and reducing the service life of the entire machine. Additionally, as the cover plate directly connects with the vehicle body, vibrations produced by the electric forklift during operation can affect the working stability of the reducer through the cover plate, reducing its lifespan. When designers...

Development and Simulation of a Hybrid Extrusion Mechanism for Enhanced Surface Quality and Precision in FDM 3D Printing

Qing Ge, Yin Wang

Manufacturing Technology 2024, 24(3):338-343 | DOI: 10.21062/mft.2024.045  

FDM forming 3D printers may encounter problems such as rough printing surface and poor accuracy during operation. This study mainly utilizes the complementary advantages of piston extrusion mechanism, sliding vane pump extrusion mechanism, and plunger pump extrusion mechanism to design a parallel combination of three nozzle extrusion mechanism, and conducts simulation experiments to verify its effectiveness based on temperature distribution data comparison. It basically avoids the irregular voids and faults caused by the thermal phase change of materials passing through the nozzle during the printing process.

Investigation of Printing Speed Impact on the Printing Accuracy of Fused Filament Fabrication (FFF) ABS Artefacts

Vasiliki E. Alexopoulou, Ioannis T. Christodoulou, Angelos P. Markopoulos

Manufacturing Technology 2024, 24(3):333-337 | DOI: 10.21062/mft.2024.042  

This paper introduces a customized Fused Filament Fabrication (FFF) printer, featuring an advanced electromechanical system that achieves a substantial 500% increase in printing speed compared to con-ventional FFF printers. This research scrutinizes the printer's capabilities, emphasizing the dimension-al accuracy. Specifically, this study focuses on the investigation of the effect of high printing speeds on the dimensional accuracy of linear artifacts. The material selected is Acrylonitrile Butadiene Styrene (ABS) and the FFF-fabricated parts are designed and measured based on the ISO ASTM 52902-2021 standard. Last but not least, statistical analysis...

Rolling Bearing Fault Diagnosis Based on Multi-scale Entropy Feature and Ensemble Learning

Mei Zhang, Zhihui Wang, Jie Zhang

Manufacturing Technology 2024, 24(3):492-506 | DOI: 10.21062/mft.2024.041  

Aiming at the problem of feature extraction and fault recognition for rolling bearings, a fault diagnosis mthod based on multi-scale entropy and ensemble learning is proposed in this paper. Firstly, the variable mode decomposition algorithm is used to decompose the vibration signal, and then the cross-correlation number method is used to reconstruct the signal to realize the signal denoising. Subsequently, in order to improve the effectiveness of feature extraction for rolling bearings, a feature extraction method based on Refined Composite Multiscale Reverse Permutation Entropy (RCMRPE) is proposed. Then, in order to improve the accuracy of rolling...

Deformation and Velocity Wave Propagation in a Thin Isotropic Plate

Frantisek Klimenda, Blanka Skocilasova, Jan Skocilas, Josef Soukup

Manufacturing Technology 2024, 24(3):393-409 | DOI: 10.21062/mft.2024.040  

The propagation and velocity of the deformation wave in the thin isotropic plate is investigated. The deformation is induced by the stroke of impact body onto the facial surface of the plate. The plate is supported perpendicularly. The excitation of the plate oscillation is initialized by a unit force (Heavi-side’s jump). The impact body has a rounded facet by radius c = 2.5 mm. Hook's material model and Kirchhoff’s and Flüegge’s geometric model have been investigated. The analytical solutions for both models are presented. The MATLAB script has been assembled to solve material and geometrical mod-els. The results were compared for...