Manufacturing Technology Journal - Latest articles

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A Design of Experiment Analysis Approach to Improve Part Quality in 3D Printing

Mostafa Abbas Jabbar

Manufacturing Technology 2023, 23(3):290-297 | DOI: 10.21062/mft.2023.034  

Fused Deposition Modeling (FDM) is one of the widely used technologies of additive manufacturing. The concern over the surface quality and dimensional accuracy is getting increased among the research community. The design of the experimental methodology is based on the analysis of variance (ANOVA) of fractional factorial design. This analysis was used to study the effect of layer thickness, extrusion temperature, speed of deposition, and fill density on dimensional accuracy and surface roughness of the model developed by FDM. Polylactic Acid (PLA) material has been selected in this work as it is inexpensive, easy to print, and biodegradable. The results...

The Effect of Mixing the Additive Material with the Substrate During the Renovation of the Foundry Mold by TIG Welding Hardfacing

Jozef Sutka, Radoslav Konar

Manufacturing Technology 2023, 23(3):341-347 | DOI: 10.21062/mft.2023.033  

The article is focused on the effect of mixing the additional material with the substrate (base materi-al) on the properties of the weld metal during arc welding with TIG technology. The research is aimed at the use of arc welding with TIG technology in the repair of foundry molds. These are repairs of permanent steel foundry molds. The parts of the mold in contact with the liquid metal are subject-ed to heat-chemical-mechanical stress. This load causes mold wear, which causes a decrease in sur-face quality and a change in the dimensional accuracy of the casting. The main cause of wear on the functional surfaces of the mold cavity is tribological processes....

The Biomechanics of Head Injuries during Tram-Pedestrian Accidents

Karel Jelen, Eva Tlapakova, Monika Sorfova, Ondrej Fanta, Petr Kubovy, Frantisek Lopot, Filip Hrusa, Lukas Fara, Roman Jezdik, Hynek Purs, Tommi Tikkanen, Martin Novak, Lubos Tomsovsky

Manufacturing Technology 2023, 23(3):298-306 | DOI: 10.21062/mft.2023.031  

The goal of the study was to analyze the kinematic and dynamic response of the human head during the primary impact of tram-pedestrian collisions. The anthropomorphic test device (dummy) was used for two collision scenarios: the frontal (dummy facing the approaching tram) and side impact (dummy standing with its shoulder towards the tram). The crash tests were conducted with four different types of tram, typical for Prague’s public transportation, and at four different impact speeds (5, 10, 15, and 20 km/h). The primary outcome variable was the resultant head acceleration. The risk and severity of possible head injuries were analyzed using the...

Effect of Temperature and Deformation on the Stability of Retained Austenite in Closed-die Forgings from High-strength Martensitic Manganese-silicon Steels

Dagmar Bublíková, Hana Jirková, Adam Stehlík, Štěpán Jeníček

Manufacturing Technology 2023, 23(3):269-275 | DOI: 10.21062/mft.2023.030  

In advanced steels, retained austenite is an important phase in the final microstructure, which provides a favourable combination of strength and ductility. Advanced methods capable of achieving this include the Q-P process (Quenching and Partitioning). By this means, strength of around 2000 MPa and elongation of 10-15 % can be obtained. The main factors that determine whether retained austenite remains stable in the mar-tensitic matrix include its morphology, particle size and distribution. A closed-die forging was made from an experimental steel containing 0.42 % C, 2.45 % Mn, 2.09 % Si, 1.34 % Cr and 0.56 % Ni and Q-P processed. Based on previous...

Design of Dual-Head 3D Printer

Vlastimil Chalupa, Michal Stanek, Jiří Vanek, Jan Strnad, Martin Ovsik

Manufacturing Technology 2023, 23(2):177-185 | DOI: 10.21062/mft.2023.032  

Fused Filament Fabrication (FFF) printers are usually designed to create a product with one single ma-terial. Some of them allow fabricate items in multiple colours but creating a single product consisting of two different materials remains an advantage of industrial 3D printers only. The aim of this research was to develop a design of a device with two printheads which enables to print products with two different materials, compatible with a cheap and commonly available FFF device Prusa i3MK2S, and the subse-quent production of a prototype. A key aspect of the design was the hardware compatibility of the device with the given printer while maintaining...

Comparison of Mechanical and Tribological Properties of TiN and ZrN Coatings Deposited by Arc-PVD

Michal Krafka, Ladislav Lemberk, Nikolay Petkov, Lucie Svobodová, Totka Bakalova

Manufacturing Technology 2023, 23(2):194-203 | DOI: 10.21062/mft.2023.029  

The continuous development of thin coatings for different applications and using various coating meth-ods require the characterization of these newly formed surfaces to evaluate their utility properties. Binary thin coatings of titanium (TiN) and zirconium (ZrN) nitrides were prepared using the Arc-PVD (Ca-thodic Arc Deposition) method. Differences were observed in the structure and morphology of the thin coatings and the change in tribological properties at room and elevated temperatures (150 °C and 300 °C). The research is focused on evaluating the frictional properties of the coating using the Ball-on-Disc method in the dry friction mode. The emphasis...

Analysis of the Substitutability of Conventional Technologies in the Design of a Clamping Vise for Measurement Using an Optical Measuring System

Miroslav Cedzo, Jozef Holubják, Tatiana Czánová, Pavol Timko, Peter Kozový, Mário Drbúl

Manufacturing Technology 2023, 23(2):136-142 | DOI: 10.21062/mft.2023.028  

The work deals with the possibility of using additive technology in the production of positioning and clamping device. The designed clamping device will facilitate and accelerate the measurement of samples with inclined or different irregular surfaces. The designed device is manufactured by additive technology using composites. Onyx material reinforced with Kevlar fibers was used as material for composite printing. The designed device should achieve the required properties for the firm and stable clamping of the components during the measurement process, and its weight should be significantly reduced with the use of composite material.

Geometric Accuracy of Components Manufactured by SLS Technology Regarding the Orientation of the Model during 3D Printing

Miroslav Matuš, Vladimír Bechný, Richard Joch, Mário Drbúl, Jozef Holubják, Andrej Czán, Martin Novák, Michal Šajgalík

Manufacturing Technology 2023, 23(2):233-240 | DOI: 10.21062/mft.2023.027  

Selective Laser Sintering (SLS) or sintering of polymer powders is one of the most well-known additive technologies for printing 3D components. The properties of individual polymer powder materials have a significant impact on the quality of the manufactured part. Potential deformation and shrinkage can occur during printing if a significant number of parts are piled on top of one another or are oriented incorrectly, accumulating thermal energy in certain areas. The aforementioned research focuses on an experimental study to investigate the impact of the distribution and orientation of printing samples in the build chamber on the accuracy of dimensions...

Fire Resistance Test of Geopolymer Coatings on Non-Metallic Underlying Substrates

Filip Mamoń, Martin Jaskevič, Jakub Mareš, Jan Novotný

Manufacturing Technology 2023, 23(2):225-232 | DOI: 10.21062/mft.2023.026  

This article summarizes the results from the fire resistance test of geopolymer suspensions in the form of coatings on non-metallic substrates. Their heat resistance was evaluated based on the burn-through time compared to the uncoated substrate. Non-metallic substrate materials, extruded polystyrene (XPS) and chipboard (DTD) were chosen as the underlying substrates for GP suspension research. Parameters from the fire resistance test as fire test duration of geopolymer coatings and percentage increase in burn time of geopolymer coatings on an XPS and DTD substrates compared to an uncoated substrate were evaluated. One of the discussed point was also...

Material Properties of High-strength High Chromium TWIP Steel with Increased Corrosion Resistance

Pavel Podaný, Tomáš Studecký, Aleksandra Kocijan

Manufacturing Technology 2023, 23(2):241-246 | DOI: 10.21062/mft.2023.025  

Twinning induced plasticity (TWIP) steels are a class of high-strength steels that have been devel-oped for their outstanding ductility and strength properties. TWIP refers to the fact that these steels display an unusually high degree of deformation before fracture due to the formation of twins during deformation. TWIP steels could be used in a variety of industries for structural applications or com-ponents that need to withstand high levels of stress and deformation. This article deals with the de-velopment of high strength with fully austenitic microstructure and high chromium content. Micro-structure, mechanichal and corrosion properties of this...

Investigation and Measurement of Nanomechanical Properties of the HSS Powder Metallurgy ASP2017 and ASP2055 Steels

Jana Escherová, Juraj Majerský, Jozef Majerík, Igor Barényi, Henrieta Chochlíková

Manufacturing Technology 2023, 23(2):143-152 | DOI: 10.21062/mft.2023.022  

The intention of the team of authors in the presented scientific article was experimental measurement with subsequent evaluation of nanomechanical properties of selected microstructural components of the investigated high-speed steels type ASP2017 and ASP2055 produced by powder metallurgy. The whole experiment was performed under laboratory conditions on an experimental apparatus called Hysitron TI 950 Triboindeneter. The used device is a part of the laboratory equipment of the Center for Diagnostics and Quality Testing of Materials. The proposed process of experimental research of the mentioned properties of PM steels was carried out precisely because...

Effect of Laser Traverse Speed during Laser Hardening on Hardness Distribution and Microstructure of Hot Work Tool Steel H11

David Hradil, Zbyšek Nový, Josef Hodek, Martina Koukolíková, Adam Szyszko

Manufacturing Technology 2023, 23(2):153-160 | DOI: 10.21062/mft.2023.021  

The paper describes the effect of laser traverse speed during laser hardening on hardness and micro-structure. The experimental material is hot work tool steel AISI H11 with samples sized 100×100×35 mm. The initial state of the material before laser hardening is quenched and tempered. The laser hardening temperature is constant at 1100 °C, selected laser traverse speed was 1, 2, 4, and 6 mm/s. A numerical simulation performed in DEFORM-3D software before the experiment showed tendencies of temperature displacement and expected course of hardness. Increasing traverse speed leads to de-creased laser-hardened depth and decreased hardness drop in the heat-affected...

Analysis of Cutting Forces during Machining with Additive-Produced Milling Head

Silvia Slabejová, Michal Šajgalík, Pavol Timko, Peter Kozový, Martin Novák, Miroslav Cedzo

Manufacturing Technology 2023, 23(2):254-259 | DOI: 10.21062/mft.2023.020  

Today's milling cutting tools are produced in various types and shapes for a wide variety of machining processes. Development continues and offers new technological solutions. The design of replaceable milling heads offers a significant cost reduction, as only the worn-out part is replaced instead of the en-tire tool. The tough connection between the tool and the shank achieves stable performance in roughing and finishing milling. Because of the possibility of using different milling inserts, the number of neces-sary tools will also be reduced and the flexibility of using milling tools will increase. The article exam-ines the cutting forces when machining...

Smartphone-based Data Acquisition Method for Modelling 3D Printed Arm Casts

Tuong Nguyen Van, Truong Le Thanh, Trong Nguyen Van, Natasa Naprstkova

Manufacturing Technology 2023, 23(2):260-267 | DOI: 10.21062/mft.2023.019  

In recent years, 3D printed arm casts can replace traditional arm casts to treat bones fractures. 3D printed arm cast modelling often uses professional 3D scanning systems to capture 3D data of the arm. These systems are very expensive and may not be available in many hospitals. In order to over-come this disadvantage, inexpensive methods should be developed. This paper introduces a new data collection method based on smartphones. The photos of an arm were taken with a smartphone cam-era using some special techniques that could facilitate the process of image processing and 3D mod-elling in Agisoft Metashape and CATIA. To validate the proposed method,...

Influence of Structural State prior Quenching in Spring Steel

Jakub Kotous, Pavel Salvetr, Daniela Nacházelová

Manufacturing Technology 2023, 23(2):186-193 | DOI: 10.21062/mft.2023.018  

Various structure states before quenching significantly influence final mechanical properties as well as the dispersion of chemical composition at the same steel grade. Therefore heat treatment with mechanical properties is specified in the technical delivery conditions. Even if the heat treatment is determined, different mechanical properties can be achieved. These differences are increasing in im-portance in high-strength applications like springs, cutting tools, safety, and load-bearing parts of automotive design et al. Because it has a direct impact on their lifetime. The structure consists of ferrite and cementite after spheroidization annealing...

Use of Electron Microscopy in the Analysis of the Influence of Roughness on the Corrosion Behavior of Selected Ti Alloys

Iryna Hren, Sylvia Kuśmierczak, Roman Horký

Manufacturing Technology 2023, 23(2):161-176 | DOI: 10.21062/mft.2023.017  

Titanium alloys are among the biocompatible materials that are used for biomedical implants. From the point of view of the reactivity of the human body, it is important to know the state of the surface of these materials, which in technical practice is represented by the term surface integrity, which includes a complex of evaluated properties. One of the classic approaches is the evaluation of the surface roughness and the properties of the stable oxide layer, which influence the formation of the connection of the implant with human tissues and influence its acceptance. Another frequent approach is the use of optical metallography, especially for the...

Influence of the Mn Content on the Corrosion Behaviour of HEA CoCrFeN-iMnX (X=5, 20, 35 at.%) Prepared via MA+SPS

Filip Průša, Petr Kratochvíl, Hana Thürlová, Darya Rudomilova, Šárka Msallamová

Manufacturing Technology 2023, 23(2):247-253 | DOI: 10.21062/mft.2023.016  

The high entropy alloys with intended chemical compositions of CoCrFeNiMnX (X=5, 20 and 35 at.%) were prepared by the means of mechanical alloying. Prepared powders were then compacted using the progressive spark plasma sintering, which minimizes the deleterious microstructural coarsening. The compacts were, regardless of the actual chemical composition, composed of a solid solution with FCC crystallographic lattice and a small amount of carbides identified as Cr7C3. The dimensions of those carbides increased with the content of Mn, which was confirmed also by atomic force microscopy (AFM) and scanning kelvin probe microscopy (SKPM). The surface topography...

Influence of Cutting Tool and Drilling Process on the Machinability of Inconel 718

L.J. Ma, H. Yu, X.H. Mao, C.R. Li, C.Y. Feng, F.N. Li

Manufacturing Technology 2023, 23(2):204-215 | DOI: 10.21062/mft.2023.013  

Nickel-based superalloy is a kind of metal material that is widely used to manufacture high-temperature parts in the fields of aviation and aerospace, but it is also a typical difficult-to-machining material. The precision cutting of nickel-based superalloy has always been an important manufacturing problem. Based on the tests of conventional drilling with three kinds of twist drills, the machinability of Inconel 718 was evaluated comprehensively by drilling force, tool wear and machining quality, and the cutting tools suitable for drilling nickel-based superalloy were chosen. Then the experiments of peck-drilling for Inconel 718 were carried out,...

Challenges in Tensile Testing of Thermoplastic Composites Reinforced with Chopped Carbon Fibre Produced by Fused Filament Fabrication Method

Jaroslav Majko, Milan Vaško, Marián Handrik, Milan Sága

Manufacturing Technology 2023, 23(2):216-224 | DOI: 10.21062/mft.2023.010  

Additive manufacturing is a relatively new technology that has recently undergone noticeable develop-ment, which includes several types of technologies based on the gradual deposition of material in layers. The most widespread method is Fused Filament Fabrication, which belongs to an extrusion technique. The typical feature of extrusion methods is material deposition in the filaments form. Therefore, printer users cannot apply the same approach to products as with conventional technologies. The authors of the paper have been working with the mentioned technology for several years. The primary goal of the research is the investigation how printing parameters...

Topology Optimization of Gripping Jaws of Industrial Robot

Miroslav Cedzo, Richard Joch, Pavol Timko, Jozef Holubják, Tatiana Czánová, Michal Šajgalík

Manufacturing Technology 2023, 23(1):25-31 | DOI: 10.21062/mft.2023.009  

There is a lot of applications for manipulating industrial robots nowadays. Maximizing the tasks that can be assigned to robot manipulators is one of the criteria for deciding if their application is appropri-ate. The article discusses the topology optimization of the gripping jaws of an industrial robot to reduce the jaws' weight. The previously used gripping element made of C50E steel was optimized to reduce the weight of the jaws. Shape optimization was performed based on analysis from CAD programs Inventor Professional 2022, Autodesk Fusion 360, and Ansys Discovery. The new jaws were manufactured by the additive technology of selective laser sintering...

Surface Analysis and Digitization of Components Manufactured by SLM and ADAM Additive Technologies

Pavol Timko, Jozef Holubjak, Vladimír Bechný, Martin Novák, Andrej Czán, Tatiana Czánová

Manufacturing Technology 2023, 23(1):127-134 | DOI: 10.21062/mft.2023.008  

The presented article focuses on the surface analysis of the components manufactured by different additive technologies and their reverse digitization. Sintered components were manufactured by SLM and ADAM technologies, while their surface was analyzed using a progressive optical measurement method. To examine the possibility of reverse engineering, the components were optically scanned with a laser scanner and compared to their CAD model. Based on empirical experience, to scan opti-cally the metal and lustrous surfaces is a challenge. The components were manufactured from anti-corrosion materials 17-4 PH and 316L–0407.

Adhesion of Various Geopolymers Coatings on Metal Substrates

Jakub Mares, Filip Mamon, Martin Jaskevic, Jan Novotny

Manufacturing Technology 2023, 23(1):81-87 | DOI: 10.21062/mft.2023.024  

This article deals with adhesion of various alkali-activated metakaolin-based geopolymer coatings on structural steel 1.0038 (according to EN 10025-2). This steel alloy was chosen in order to analysis ad-hesion of prepared geopolymer coatings. Our samples were characterized by laser and SEM micros-copy and grid test was performed. Microscopy was performed to get knowledge about visible charac-terization and overall quality of prepared coatings. Based on previous research SEM results corre-spond with properties changes in coatings and their classification of grid test. Grid test was per-formed and results was evaluated. These results show potential...

Measuring the Quality of Driving Characteristics of a Passenger Car with Passive Shock Absorbers

Martin Svoboda, Milan Chalupa, Vít Černohlávek, Adam Švásta, Artur Meller, Václav Schmid

Manufacturing Technology 2023, 23(1):118-126 | DOI: 10.21062/mft.2023.023  

The article deals with the quality of the driving characteristics of a passenger car with passive shock absorbers depending on the tire pressure. The work was solved using experimental methods using the AHS test bench. The main goal of the work was to assess the vehicle suspension system using acceleration sensors and pressures between the wheel and the road using shock absorber test benches using the EUSAMA and CAP methodology. The results of the work demonstrated the possibilities of using the measurement of acceleration values in selected places in the vehicle. The obtained results were also verified for the possibilities of further development...

Surface Roughness, Topography, Accuracy, Chip Formation Analysis & Investigation of M390 and M398 Steels after Hard Machining

Jozef Majerík, Juraj Majerský, Igor Barényi, Henrieta Chochlíková, Jana Escherová, Mária Kubasáková

Manufacturing Technology 2023, 23(1):60-72 | DOI: 10.21062/mft.2023.015  

Article deals with processing of intermetallic materials produced by powder metallurgy M390 and M398 Microclean® produced by Böhler. Main interest is the analysis & measurement of their surface rough-ness and topography after the processing by DNMG and WNMG geometry of cutting inserts with 0.4 and 0.8 mm radius after hard turning at the same process parameters for both materials and all types of cutting inserts. The comparative studies were carried out for the microgeometrical and chip formation research on the machined surfaces and the technological processes were assessed, including chip dia-grams. Spectral analysis was used to verify the...

Computer Simulation of Heating Cycle of Aluminum Alloys Using Friction Stir Welding Technology

Petra Kvasnová, Daniel Novák, Viktor Novák, Milan Ďuriš

Manufacturing Technology 2023, 23(1):47-52 | DOI: 10.21062/mft.2023.014  

The paper deals with welding of aluminum alloys using Friction Stir Welding technology. This repre-sents one of the solid-state welding technologies in which the base materials are not melted. This pro-vides new possibilities for the use of special and hybrid manufacturing technologies. The article presents the current progress in the Friction Stir Welding technology, a microstructure analysis of a weld joint created by the FSW method and a heat-deformation computer simulation of an aluminium alloy speci-men in the program Ansys.

Effect of Refined Spheroidizated Structure on Mechanical Properties of Spring Steel 51CrV4

Jakub Kotous, Daniela Nacházelová, Jaromír Dlouhý, Martin Rund

Manufacturing Technology 2023, 23(1):40-46 | DOI: 10.21062/mft.2023.012  

The steel 51CrV4 is widely used for production of springs. Materials research into spring steels aims to meet the requirements of industry, which mainly concern high yield and tensile strengths. Ductility has to be retained as the strength is increased. Also, the resistance against brittle fracture is im-portant, measured as fracture toughness. Enhancement of the mentioned mechanical properties can be accomplished by structural refinement. One possible way to refine the final quenched and tem-pered structure is to refine the soft annealed structure before quenching. The article is devoted to the Accelerated Carbide Spheroidisation and Refinement (ASR)...

Evaluation of Riveting Force Influence on the Quality of Riveted Joint of Aluminium Alloy EN AW - 6016

Josef Bradáč, Jiří Sobotka

Manufacturing Technology 2023, 23(1):2-10 | DOI: 10.21062/mft.2023.011  

Joining technologies are very important aspects of production process in the automotive. Especially regarding the use of newly developed types of materials (e.g. ultra high-strength steels or aluminium alloys), in addition to welding technology, e.g. riveting or adhesive bonding technologies are used. Submitted article evaluates the effect of the riveting force on the final quality of riveted joint when joining aluminium alloy EN AW-6016 (thickness 2 mm). The actual evaluation of the riveted joint was carried out using a shear test, measuring the hardness HV01 and deformation analysis of specimen using non-contact optical scanning (ATOS III Triple...

Research of Robots in Cooperative Mode in Human Body Part Detection

Josef Ponikelský, Vít Černohlávek, Jan Štěrba, Pavel Houška

Manufacturing Technology 2023, 23(1):99-109 | DOI: 10.21062/mft.2023.007  

The aim of this article is to approach the measurement of forces and pressures of collaborative robots. In the article, research will be carried out on measuring the forces and pressures of a collaborative robot before putting it into real application. Force and pressure values will be measured using appropriate measuring devices. The measured results will be compared with the ISO/TS 15066:2016 technical specifi-cation and subsequently evaluated.

Influence of Using Cutting Fluid under the Effect of Static Magnetic Field on Chip Formation in Metal Cutting with HSS Tools (turning operation)

Umidjon Mardonov, Saidamin Khasanov, Andrey Jeltukhin, Shakhrizoda Ozodova

Manufacturing Technology 2023, 23(1):73-80 | DOI: 10.21062/mft.2023.006  

This paper presents a new method of improving the material removal process in metal cutting. Chip formation plays an important factor in the metal cutting process and increasing its condition has a great impact on cutting machine details. Based on lubricating cooling conditions in the metal cutting process, a novel methodology is proposed to decrease the deformation that emerged in the material removal process while cutting cylindrical details in lathes. Application of stating magnetic field on flowing cutting fluids decreased the shrinkage of the chip in turning operation. Analytical and practical experiments show that the effect of cutting fluid...

Topology Optimization of Static Turbomachinery Components

Francesco Buonamici, Enrico Meli, Nicola Secciani, Alessandro Ridolfi, Andrea Rindi, Rocco Furferi

Manufacturing Technology 2023, 23(1):11-24 | DOI: 10.21062/mft.2023.005  

Additive Manufacturing has enabled the design of complex components in several technical fields. Considering turbomachinery components, additive manufacturing has unlocked the achievement of significant performances for dynamic rotoring components. The application of topology optimization methods is one of the main factors accelerating the technological development of this sector. This paper presents a procedure for the optimization of static turbomachinery components. The frame-work proposed compares the results obtained by introducing a lattice structure and a solid optimized shape. The procedure is presented with reference to a specific case study....