Manufacturing Technology Journal - Latest articles

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Advancing the ductile behaviour of heavy-wall API X70 pipeline steel by a “Slab/Sheet” thickness ratio increase

Vadym Zurnadzhy, Yuliia Chabak, Ivan Petryshynets, Alexey Efremenko, Ivan Sili, Ruslan Sagirov, Vasily Efremenko

Manufacturing Technology 2024, 24(5):843-854 | DOI: 10.21062/mft.2024.090  

The present work was aimed at studying the effect of a “Slab/Sheet” thickness ratio (SSTR) on the microstructure and mechanical properties of API 5L X70 steel sheets intended for heavy-wall oil/gas pipelines. The 25 mm-thick and 40 mm-thick steel sheets were rolled from the cast slabs of different thicknesses (250 mm and 300 mm) and their mechanical properties were compared. The sheets were subjected to thermo-mechanical controlled processing followed by accelerating cooling, resulting in the structure of quasi-polygonal/acicular ferrite with minor amounts of granular pearlite and martensite-austenite constituents. Increasing the cast slab...

Numerical Simulation of a Cylindrical Outer Flanging Spinning

Xuhui Yang, Zhen Jia

Manufacturing Technology 2024, 24(5):827-833 | DOI: 10.21062/mft.2024.089  

The use of spinning technology for the outer flanging of cylindrical parts can save moulds, reduce labour intensity, and improve production efficiency. Therefore, two finite element models for the outer flanging spinning with the flange radius of 4 mm and 5 mm are established in this article. The deformation process, stress-strain field, and wall thickness distribution of the flange during the spinning period are analyzed. It can be found from the simulation results that, the blank of both working conditions cannot fit the contour of the roller until the until 2.5 s before the end of the spinning process, and it is more difficult to achieve fitting...

Effect of Normal Ageing in Bundle on the Mechanical Properties of Tempcore Treated Reinforcing Steel Rebar

Mohamed Karroum, Marwa A. Abbas, Ahmed Ramadan, Mohamed A. Gepreel

Manufacturing Technology 2024, 24(5):779-790 | DOI: 10.21062/mft.2024.088  

Reinforcement steel rebar is produced by several ways but most importantly the tempcore process. Due to mass production in steel rolling plants, the rebars are gathered after tempcore process at a specific temperature in bundles stack in the warehouse. The bundling temperature varies from 200 to 300 o C. The rebars need relatively long time, up to one day, to reach the room temperature in the bundles stack. This work investigates the effect of prolonged ageing time on the rebars mechanical properties after the tempcore process of both ageing in bundle and designed artificial ageing. The results of mechanical properties of ageing in bundle compared...

Corrosion of Inconel 800HT Alloy in Molten Fluoride Salts

Zdeněk Fulín, Josef Strejcius, Zbyněk Špirit

Manufacturing Technology 2024, 24(5):755-764 | DOI: 10.21062/mft.2024.087  

Molten salt reactors are one of the technologies developed under GEN IV nuclear research. The mol-ten mix of LiF and BeF2, LiF, NaF nad KF, or NaBF4 and NaF act both as a reactor coolant both in primary and secondary loop. The combination of molten fluorides and high temperature creates high-ly corrosive environment. The aim of this work was to test corrosion resistance of Inconel 800HT alloy in molten FLiNaK, FliBe and NaBF4-NaF mix. The testing tube was filled with salt mixture and heated to 600-725 °C for a total of 1800 hours. The material exposed to NaBF4-NaF mix shoved mild corrosion attack on grain boundaries. Samples exposed to FLiNaK salt...

Identification of Internal Defects in Forged Shafts by Measurement of Residual Stresses Using X-Ray Method

Kamil Anasiewicz, Jerzy Józwik, Michał Leleń, Paweł Pieśko, Stanisław Legutko, Janusz Tomczak, Zbigniew Pater, Tomasz Bulzak

Manufacturing Technology 2024, 24(5):711-720 | DOI: 10.21062/mft.2024.086  

The present paper discusses important aspects of residual stress measurements in forged shafts with defects using the X-ray method. A random population of shafts was selected for the study, for which, depending on the type of rolling process, turning was performed, measuring stress changes after successive machining passes. In the forged shafts studied, the existence and location of internal defects were identified using computed tomography. The impact of internal defects on the stress distribution on the surface of the machined workpiece was observed. It was observed that the use of the X-ray method to measure residual stresses makes it possible to...

Quantification and Verification of Swingarm Structural characteristics through Numerical Simulation and Photogrammetry

Lukas Gregor, Jan Zouhar, Radim Kupcak

Manufacturing Technology 2024, 24(5):765-778 | DOI: 10.21062/mft.2024.085  

Composite materials have consistently been applied in areas where a combination of properties such as strength, stiffness, and low weight is crucial. Motorcycle construction is no exception, as these parameters significantly impact riding characteristics, safety, and overall performance. This article focuses on quantifying the torsional and vertical stiffness of a single-sided swingarm made of carbon fiber reinforced polymer (CFRP) using finite element analysis (FEA) and verifying these results through experimental measurements. To enhance the accuracy of the simulations, which involve complex geometries and anisotropic materials, the material properties...

Evaluation of the Degradation of Combustion Engine Valves

Pavel Novak, Jan Růžička, Ester Duchková

Manufacturing Technology 2024, 24(5):811-816 | DOI: 10.21062/mft.2024.084  

This work aims at the description of the degradation of the intake and exhaust valve of the combus-tion engine during operation. For the experiments, new valves from Ford Fiesta were used, as well as the used ones with known mileage. In order to simulate the valve long-term operation and to esti-mate the temperature of the valve during the use, the new valves were annealed at 700 – 900 °C for 1000 h (corresponding to the mileage of 70,000 km with average speed of 70 km/h) and the grain size was compared with the used valves. It was found that this model experiment can easily predict the operation temperatures of the exhaust valves, which were...

The Influence of Temperature on the Production of Antioxidant Tin-Phosphorus Alloy

Jana Körmendy, Ján Vavro jr., Ján Vavro

Manufacturing Technology 2024, 24(5):791-801 | DOI: 10.21062/mft.2024.083  

The restriction of lead content in alloys for the production of the solder based on the Directive of the European Parliament and of the Council of the European Union of 08.06.2011 which is also known as RoHS (Restriction of the use of certain Hazardous Substances in electrical and electronic equipment), had a very positive impact on the research of lead-free solder alloys as well as on the economic impact on the production of solders. It opened the door to issues relating to the mechanical properties of lead-free solders and the microhardness of formed joints, increasing their quality and efforts to reduce production costs. Lead, as an element that...

Possibility of Eliminating Iron in Aluminium Alloy Through Sedimentation

Štefan Michna, Anna Knaislová, Jaroslava Svobodová, Jan Novotný, Lenka Michnová

Manufacturing Technology 2024, 24(5):802-810 | DOI: 10.21062/mft.2024.082  

The article is dedicated to research on the elimination of high iron content (above 3-4%) in aluminium alloys through sedimentation. The aim was to determine the effect of sedimentation time on reducing the iron content in material from a refining bath with high iron content and to identify the phases formed in the structure. Melts were prepared from the material obtained from the refining bath, which consisted of an AlSi12 alloy with 3-4% Fe content. After melting, sedimentation was carried out for 2 hours, 4 hours, and 6 hours. Sedimentation was conducted while maintaining the alloy in a liquid state throughout the entire sedimentation period. After...

Possibilities of Analyzing Sources of Impurities in Hydraulic Oil

Alena Breznická, Pavol Mikuš, Ľudmila Timárová, Marcel Kohutiar, Michal Krbaťa

Manufacturing Technology 2024, 24(5):721-730 | DOI: 10.21062/mft.2024.081  

The task of comprehensive machine care, monitoring of reliability and maintenance is currently a priority not to wait for a malfunction, but to prevent malfunctions before they occur. In the possibilities of mod-ern diagnostic tools, this activity is the task of oil analysis, which is a highly effective tool for monitoring the condition of hydraulic oils during their long-term operation. It is possible to prevent the failure of the entire system by regular monitoring of the technical condition of oils based on the analysis of hydraulic oil pollution. Oil analysis can reveal the amount of additive elements, oil pollution, the amount of addi-tives and...

Effects of Laser Shock Peening Technology on Stress Corrosion Cracking of Austenitic Steel

Jana Zavitkovská, Zdeněk Fulín, Zbyněk Špirit

Manufacturing Technology 2024, 24(5):834-842 | DOI: 10.21062/mft.2024.079  

This article deals with the modification of surface properties of austenitic steels using laser shock peening (LSP) technology. This technology introduces residual compressive stresses into the surface layer. These stresses improve the technical properties of the material not only by affecting the re-sistance of corrosion cracking under stress. The aim of the work was to influence the austenitic steel 08CHN10T by LSP technology, to perform a corrosion test in a boiling MgCl2 solution and the sub-sequent evaluation of these tests. Furthermore, the hardness was measured of the peened part of the material by LSP technology and unpeened part.

Effect of Solubility of Alloying Elements on Selected Properties and on the Structure of AlSi5Cu2Mg

Martina Sýkorová, Dana Bolibruchová, Marek Brůna, Mária Chalupová

Manufacturing Technology 2024, 24(5):817-826 | DOI: 10.21062/mft.2024.078  

The paper deals with the solubility and influence of the melting method of alloying elements (Zr, Mo and Sr) on selected properties and structure of the hypoeutectic aluminum alloy AlSi5Cu2Mg. Alloy-ing elements in the form of master alloys (AlZr20, AlMo10, and AlSr10) were melted in two different methods. The first method consisted in melting the master alloy together with the batch material in an electric resistance furnace, the second method consisted in separately melting the master alloy in an induction electric furnace and then introducing the master alloy into the molten batch. The presence of alloying elements led to an increase in the porosity...

Flexible Strain Sensor Based on Metallized Polyurethane Conductive Sponge Using Laser Direct Writing Process

Liang Dong, Chen Li, Peiying Han, Longgang Song, Yangyang Chen

Manufacturing Technology 2024, 24(5):747-754 | DOI: 10.21062/mft.2024.080  

Flexible strain sensors show great potential in the field of wearables and health monitoring. However, the application of traditional strain sensors on flexible substrates is still limited, and the development of sensors with high sensitivity, excellent stability and good durability is a current research focus. Aiming at the limitation of traditional strain sensor in flexible materials, a flexible strain sensor based on Kirigami structure is proposed. In this study, a Metallized Polyurethane Conductive Sponge (MPCS) was used as the sensor substrate. In the preparation process, we used laser direct writing process to achieve the preparation of highly...

Optimizing Manufacturing Technology: Unraveling Symmetry in Cubic Equation Roots

Vít Černohlávek, František Klimenda, Marcin Suszynski, Jan Štěrba, Tomáš Zdráhal

Manufacturing Technology 2024, 24(5):731-737 | DOI: 10.21062/mft.2024.077  

In the realm of engineering the quest for optimization is ceaseless. This article explores the intricate relation-ship between cubic equations and the practical world of production technologies, unearthing the profound connections that underpin mathematical symmetry and its role in engineering. Cubic equations, often arising in the analysis of mechanical systems, electric circuits, and robotics, serve as indispensable tools for under-standing and enhancing real-world applications. This study delves into the methods for finding the roots of cubic equations, shedding light on the vital role of mathematics in engineering and manufacturing technology.

Abrasion Wear Analysis of Commercial Cutting Inserts by Ball-on-disc Method

Tomasz Dembiczak, Robert Kruzel, Nataša Náprstková, Zbigniew Bałaga, Sylvia Kuśmierczak, Joanna Wachowicz, Piotr Reszka

Manufacturing Technology 2024, 24(5):738-746 | DOI: 10.21062/mft.2024.076  

Today's machining requirements cannot be met without the right tool materials. An ideal universal tool material should combine the highest abrasive wear resistance and hardness with high strength and good toughness, while being chemically inert to the workpiece material. Despite the intensive development of materials sciences the fundamental contradiction between hardness, which guaran-tees resistance to abrasive wear, and toughness, which determines impact and fatigue strength, has not been satisfactorily resolved on a global scale. This paper presents the results of tribological wear testing of commercial cutting inserts of S20S, U10S and CC6090...

Navigating the Fourth Industrial Revolution: SBRI - A Comprehensive Digital Maturity Assessment Tool and Road to Industry 4.0 for Small Manufacturing Enterprises

Ludek Volf, Gejza Dohnal, Libor Beranek, Jiri Kyncl

Manufacturing Technology 2024, 24(4):668-680 | DOI: 10.21062/mft.2024.074  

This article presents the development and validation of SBRI (Small Business Digital Maturity Assessment and Road to Industry 4.0), an innovative methodology for assessing digital maturity and supporting digital transformation specifically designed for small manufacturing enterprises in the context of Industry 4.0. Unlike existing models, which are often too complex or unsuitable for smaller organizations, SBRI considers the unique characteristics and constraints of small businesses. The methodology includes five key dimensions: Strategy, Technology, Process, People, and Organization, elaborated into 25 subdimensions with specific maturity criteria...

Optimizing the Position of a Robotic Arm Using Statistical Methods

Miroslav Marcaník, Milena Kubišová, Vladimír Pata, Jana Knedlová, Oldřich Šuba, Hana Vrbová

Manufacturing Technology 2024, 24(4):618-625 | DOI: 10.21062/mft.2024.073  

Robotics plays a key role in industry and its use continues to grow. Robots are used in many industries to increase efficiency, productivity, and safety of work processes. This manuscript focuses on the spatial calibration of collaborative robot arms using appropriate statistical tools. Nowadays, there are many special programming languages, simulations or virtual realities (VR), which in most cases perform calibration using matrix relations. The mathematical-statistical solution is not solved very often, and the use of linear relationships is valid only in certain parts of the workspace of the collaborative robot. The purpose of this article is to...

Design and Simulation of Secondary Acceleration Type Rotor for Vertical Shaft impact Crusher

Canhui Wu, Limei Zhao, Cheng Zhang

Manufacturing Technology 2024, 24(4):681-691 | DOI: 10.21062/mft.2024.072  

In order to improve the crushing effect of the rotor of vertical shaft impact crusher on the particle, the design method of secondary accelerated rotor based on kinematics theory is proposed. And the operation effect of the secondary acceleration type rotor was verified using a combination of computational fluid dynamics and discrete element method (CFD-EDM). First, the kinematics of the particles thrown by the rotor throwing head was analyzed. On this basis, the structure of the secondary acceleration type rotor was designed by comprehensively considering factors such as the motion, friction, and collision recovery coefficient of particles; Then,...

Ultimate Response of Strengthened RC Beams in the Flexural Using Plain Cementitious Composites Layer

Ashraf M. Heniegal, Hamdy M. Afefy, Ahmed T. Baraghith, Mostafa Eldwiny, Omar Mohamed Omar Ibrahim

Manufacturing Technology 2024, 24(4):567-577 | DOI: 10.21062/mft.2024.071  

This paper aims to study the efficiency of using prefabricated layers made from plain cementitious composite materials for enhancing the flexural behavior of reinforced concrete (RC) continuous beams. The strengthening system was applied at 20 mm thickness, 150 mm width, and adequate development length. The prefabricated layers were placed in the tension cover in the positive and negative zones. All beams have the same geometric dimensions and positive and negative steel reinforcement ratios. The results showed that the prefabricated layer was deformed with the RC specimen without debonding, which enhanced the cracking patterns and distributed the...

The Effect of a Mixture of Methanol and Gasoline on the Operation of an Engine in an Electric Power Generator System

Jaroslav Mrázek, Martin Pexa, Jakub Čedík

Manufacturing Technology 2024, 24(4):636-644 | DOI: 10.21062/mft.2024.070  

Methanol, a type of alcohol, with gasoline, a conventional fossil fuel used in internal combustion engines. This blending process is often done to create an alternative fuel that may have certain advantages over using gasoline alone. The combination of methanol and gasoline can offer benefits such as improved combustion efficiency, reduced emissions, and potentially lower overall fuel costs. Methanol has a high-octane rating, which can enhance the combustion characteristics of the fuel mixture. This can lead to more efficient and cleaner combustion in internal combustion engines. Conducting this research is essential to explore potential improvements...

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.