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Methodology for Comprehensive Testing and Optimization of Gears for Torsional StrengthPawe³ Knast, Jana Petrù, Stanislaw Legutko, Lubomir Soos, Marcela Pokusova, Przemys³aw BoreckiManufacturing Technology 2025, 25(3):331-340 | DOI: 10.21062/mft.2025.031 The article described a new methodology for testing the torsional resistance of a single-stage gear transmission used in agricultural machinery. The analysis encompassed the entire mechanical system rather than focusing solely on its individual components. The research identified three key ranges of structural resistance. The first range, with twist angles from 0° to 1.85° and torques up to 1050 Nm, was associated with the elimination of structural play and the alignment of contact surfaces. The second range, from 1.85° to 4.76° and torques up to 3450 Nm, confirmed the resilient behavior of the gearbox according to Hooke's law. In this range, the system worked stably and maintained repeatability of parameters. The third range, above 4.76° and 3050 Nm, showed the presence of permanent but local deformations. However, these displacements did not affect the functionality of the system in less demanding applications. The maximum torque of 5500 Nm did not cause macroscopic damage or oil leaks, which proves the high quality of the design and the effectiveness of material optimization. The developed method allows for an accurate determination of the safety factor and a detailed assessment of the strength properties. It can be used to optimize transmissions in various sectors such as agriculture, automotive and aerospace. The results also form the basis for further experiments, including fatigue tests and contact stress analyses. The proposed methodology enhances the predictive accuracy of gearbox durability under various load conditions. These advancements support the development of sustainable and efficient mechanical systems across multiple industries. |
Research on Stator Thermal Fault Detection of Steam Turbine Generator Based on Improved Transformer and Gaussian Mixture ModelFengqin Cheng, Weinan ZhengManufacturing Technology 2025, 25(4):448-454 | DOI: 10.21062/mft.2025.051 This study proposes a multi-stage intelligent diagnostic approach integrating Physics-Guided Normalization (LPGN), enhanced Transformer networks, and Gaussian Mixture Models (GMM) for thermal fault detection in turbine generator stators. The methodology sequentially performs the following steps: (1) enhances localized anomaly features in temperature data through LPGN, (2) efficiently extracts temporal patterns via the optimized Transformer architecture, and (3) achieves unsupervised fault classification using GMM. Experimental results demonstrate the proposed method's superiority over conventional ARIMA and LSTM models across multiple evaluation metrics, exhibiting a lower RMSE and a higher detection accuracy. Ablation studies further validate the individual contributions of each component to performance improvement. This solution provides an efficient and reliable framework for intelligent thermal monitoring in large rotating electrical machinery. |
Elevator Vibrations and Ways to Reduce ThemTereza Jarosova, Lenka Rychlikova, Blanka Skocilasova, Frantisek KlimendaManufacturing Technology 2025, 25(5):597-606 | DOI: 10.21062/mft.2025.069 The article deals with the measurement of the vibrations in passenger elevators. The introduction of an article briefly discusses machine vibrations and their impact on machine design and the surrounding environment. The basic equations from which the equations of motion are derived are listed here. The importance of analyzing machine vibrations in their design, or rather proposing solutions to reduce vi-brations during machine reconstruction, is emphasized. Specifically, attention is paid to vibrations gen-erated during an elevator operation in the elevator shaft. This is an elevator for transporting people in a newly constructed 5-story building. Vibration values generated by an elevator operation were measured in order to assess the suitability of simple anti-vibration modifications. Vibration measurements were taken on an existing elevator without modifications, and after the initial measurements, modifications were made to attach the guides to the bracket and attach the bracket to the elevator shaft wall. After the adjustment, the vibration measurement was performed again and both measurements were compared with each other. |
Heat Treatment-Induced Microstructural Changes in Selectively Laser Melted AlSi10Mg AlloyAlice Chlupová, Jakub Poloprudský, Michal Jambor, Jaromír Brù¾a, Ladislav Poczklán, Jiøí ManManufacturing Technology 2025, 25(6):742-750 | DOI: 10.21062/mft.2025.077 The study examines the effect of various post-processing heat treatments on the microstructural evolution and hardness of the AlSi10Mg alloy produced by selective laser melting (SLM). The alloy was examined in the as-built (AB) condition and after three heat treatment regimes: direct aging (DA, 160°C/5 h), stress relieving (SR, 300°C/2 h), and solution annealing followed by artificial aging (SA, 520°C/2 h + 170°C/4 h) to better understand the solidification and consolidation processes. A multiscale characterization using OM, SEM, EBSD, TEM, and EDS was performed to reveal the changes in specific microstructures due to additive manufacturing and different levels of heat treatment. The AB state exhibited a fine cellular network of Si within an α-Al matrix, and high hardness (approx. 138 HV1). The DA treatment preserved cellular morphology with mild coarsening, whereas SR led to partial fragmentation of the Si network and a significant drop in hardness (approx. 83 HV1). The SA condition caused recrystallization, Si spheroidization, and formation of Mg- and Fe-rich precipitates, accompanied by moderate hardness recovery (approx. 104 HV1). The persistent crystallographic texture was confirmed across all states. |
Mechanical Properties of 3D Printed Porous Ti-6Al-4V Alloy for Biomedical ApplicationsMarkéta Straková, Jiøí Kubásek, Dalibor VojtìchManufacturing Technology 2026, 26(1):88-94 | DOI: 10.21062/mft.2026.005 Optimising the mechanical properties required for biomedical applications is something that porous Ti-6Al-4V structures offer the opportunity to do. Triply periodic minimal surface (TPMS) structures, such as the Diamond and Gyroid structures, provide interconnected pores that can be used to adjust strength, stiffness and deformation. The mechanical behaviour of these two architectures under compressive and bending loads is compared in this study, with the use of additively manufactured samples. The results demonstrate that pore geometry significantly impacts mechanical behaviour. Diamond structures exhibit higher stiffness and strength, whereas Gyroid structures provide a more isotropic and flexible response. These findings emphasise the importance of architecture when designing implants and other components for which optimised mechanical properties and geometry are essential. |
Surface Morphology and Ablation Efficiency in DUV Ultrafast Laser Micromachining of Fused SilicaJan Novotný, Libor Mròa, Josef Sedlák, ©tìpán KolomýManufacturing Technology 2025, 25(4):521-530 | DOI: 10.21062/mft.2025.057 Fused silica is a key material for high-precision applications such as micro-optics and microfluidics. One route to improving direct laser writing (DLW) of fused silica is the use of shorter laser wavelengths, which enable tighter focusing and enhanced absorption. In this study, the influence of process parameters on surface quality and material removal during DLW using a deep ultraviolet (DUV) ultrafast laser (257 nm, 1 ps) was investigated. A full-factorial design of the experiment was used to identify conditions that optimise both surface quality and ablation efficiency. Surface roughness as low as Sa ≈ 200 nm and material removal rates up to 0.048 mm³∙min-1 were achieved. Conditions that led to surface degradation were also identified. Finally, the optimised parameters were applied to fabricate a microfluidic demonstrator. These results confirm that DUV ultrafast DLW is a powerful technique for fabricating high-fidelity features in fused silica with exceptional precision and quality that can be used for micro-optics or microfluidics devices. |
Finite Element Secondary Development of Constitutive Model for Titanium Alloy Vibration-Assisted Cold Upsetting FormingXu Yani, Wang Ying, Wei Chuhan, Lin Kai, Shu XuedaoManufacturing Technology 2026, 26(2):239-248 | DOI: 10.21062/mft.2026.021 To achieve precise finite element simulation of the vibration-assisted cold heading process of titanium alloys, this study focuses on Ti-45Nb titanium alloy as the research object. A constitutive model for vibration-assisted cold heading is established, incorporating both viscoelastic and viscoplastic deformation. The model is transformed into a programmable incremental form, and the control equations for elastic-viscoplastic deformation are derived. Secondary development is conducted using the VUMAT interface of ABAQUS, and the model is applied in simulation. Multi-condition simulations of Ti-45Nb titanium alloy cold heading are performed, and the results are compared with experimental data. The average relative error is found to be within 5%, verifying the accuracy of the finite element numerical simulation based on the secondary development. The developed constitutive model is used to simulate the cold heading process of Ti-45Nb titanium alloy internal wire joint components. The significant effects of vibration assistance in reducing maximum stress, optimizing stress distribution, and improving material flow are intuitively observed. This study provides technical support for the application of vibration-assisted cold heading technology in the forming of difficult-to-deform materials. |
Analytic Solution of the Motion Equations of the Rolling Stock Chassis Incorporating the Effect of Asymmetry and Kinematics ExcitationBlanka Skocilasova, Frantisek Klimenda, Jan Skocilas, Tereza JarosovaManufacturing Technology 2025, 25(4):531-539 | DOI: 10.21062/mft.2025.052 The article provides an analytical solution for the dynamics of a vehicle chassis designed for both road and rail operation, featuring either single or multiple primary linear suspensions using coil springs. It derives the equations of motion for a simplified two-axle chassis model that includes both a basic primary suspension and a simplified chassis suspension. The study focuses on the simplest calculation model to analyze suspension behavior, taking into account the asymmetry in spring stiffness and geometric positioning. There is an unequal distribution of weight across the vehicle body. An analysis is conducted on a comprehensive vehicle model with nine degrees of freedom. The analytical solution is obtained using Lagrange equations of the second kind, alongside various calculation techniques such as Laplace transformation. Due to the scope of the article, calculations of all coefficients of the matrices are not presented, but a link to other works of the authors is given, where these procedures are presented. The proposed analytical solution makes it possible to derive an effective algorithm for the application of computer technology. The use of the proposed procedures allows determining the permissible asymmetry of vehicles for safe driving, taking into account structural asymmetry, kinematic excitation asymmetry (always occurs) and suspension asymmetry (almost always occurs). |
Hybrid ANN–GA Modeling and Experimental Optimization of GMAW-Based Additive Manufacturing of Aluminum 5083 for Enhanced Mechanical PropertiesTeephet Chaiyason, Suriya Prasomthong, Panuwat Thosa, Sittichai Charonerat, Phattharapong KeidlaphiManufacturing Technology 2026, 26(2):133-147 | DOI: 10.21062/mft.2026.016 Wire + Arc Additive Manufacturing (WAAM) based on Gas Metal Arc Welding (GMAW) has emerged as a cost-effective and high-deposition process for fabricating large-scale aluminum components. However, its application to non-heat-treatable aluminum 5083 remains limited by thermal-cycle in-stabilities, porosity, and non-uniform mechanical performance. This study presents an integrated experimental and artificial-intelligence framework for optimizing key GMAW parameters—welding current, wire-feed speed, and welding speed—to enhance the mechanical properties of WAAM-fabricated aluminum 5083 walls. An L9 Taguchi design was employed to quantify parameter effects, followed by analysis of variance (ANOVA) to identify dominant factors. Results indicated that weld-ing speed exerted the greatest influence on tensile strength (≈ 58.8 % contribution), whereas wire-feed speed and current primarily affected hardness through solidification behavior. An Artificial Neural Network (ANN) model was then developed to predict tensile strength and hardness with high accuracy (R > 0.99; MAPE < 1 %), demonstrating superior predictive performance over Taguchi and regression models. Integration of the trained ANN with a Genetic Algorithm (GA) enabled global optimization of process parameters, yielding an optimum set of 85.3 A current, 7.7 m/min wire-feed speed, and 3.8 mm/s welding speed, corresponding to predicted properties of 242.5 MPa tensile strength and 108.4 HV hardness. Experimental validation confirmed deviations below 1 %, verifying the model’s robustness. The proposed ANN–GA hybrid framework effectively captures nonlinear process–structure–property relationships, providing a reliable, data-driven pathway for achieving high-strength, defect-free aluminum components in WAAM and other additive manufacturing sys-tems. |
Study on the Effect of Aging Treatment on the Microtexture and Mechanical Properties of 6111 Aluminum AlloyJiechen Li, Yongqiang Pan, Quan Kang, Zhi JiaManufacturing Technology 2025, 25(2):215-221 | DOI: 10.21062/mft.2025.026 The effects of aging treatment temperature of 250°C on microstructure, mechanical properties characteristics of 6111 aluminum alloy sheet were investigated by mechanical testing, scanning electron microscopy, electron backscatter diffraction and other analytical methods. The results show that the aging treatment temperature has a significant effect on the yield strength of cold rolled 6111 aluminum alloy, and appropriate heat treatment can significantly improve the work-hardening properties of rolled 6111 aluminum alloy. The rolled sheet without heat treatment aging shows the highest strength values, with the yield strength reaching 140.2 MPa and the tensile strength 211.2 MPa, while the ten-sile strength decreases to 119.2 MPa and the yield strength to 35.1 MPa when the heat treatment aging temperature of the cold-rolled sheet is set at 250°C. In terms of the plastic behavior of the sheet, the elongation reaches a maximum value of 31.3% when aging at 250°C. The elongation of the cold-rolled aluminum alloy reaches a maximum value of 31.3% when aging at 250 °C. The elongation reached the maximum value of 31.3% at the aging temperature of 250°C. |
Crack Detection and Monitoring of their Growth in Critical Parts of Steam Pipeline by Electric Potential Drop MethodPetr ®ivný, Jindøich Jansa, Marek Mìkuta, Pavla Luká¹ováManufacturing Technology 2025, 25(4):569-574 | DOI: 10.21062/mft.2025.046 An innovative way of using DCPD (Direct Current Potential Drop) method for off-line and online monitoring of critical parts of energy equipment in operation is presented. There are only a few NDT methods that allow detection and monitoring of defect growth in components at high temperatures and pressures. Monitoring of steam pipes and critical pipeline components in operation has been carried out for several years with different results. a relatively new way of using the DCPD method outside the laboratory is described. The carried-out tests were intended to resemble operational loads as much as possible. Therefore, the tests were performed at a temperature of 20 °C and at an increased temperature of 550 °C. By gradually deepening the groove (slot) simulating the crack type defect in predefined steps, the growth of the defect was simulated up to the full wall thickness of the test sample. The primary evaluation was carried out from the absolute and relative values of measured resistance. The disadvantage of these values is their dependence on the temperature of the monitored area of the test sample and on possibly interfering DC voltages. |
Conceptual Design with Strength Analysis Based on the FOPS Test for a Tubular Cover Dedicated to the Kubota M135GX-IV Tractor£ukasz Gierz, Miko³aj Spad³o, Antoni KuchtaManufacturing Technology 2026, 26(1):26-33 | DOI: 10.21062/mft.2026.006 An agricultural tractor equipped with appropriately rated guards can often replace specialized forestry machinery. Currently, few authorized dealers on the Polish market offer tractors adapted to harsh forest conditions, so this work involved designing a tubular guard for the Kubota M135GX-VI agricul-tural tractor. The aim of this work was to develop a conceptual design for a tubular guard, together with a strength analysis based on FOPS procedures, dedicated to the KUBOTA M135GX-IV agricul-tural tractor. To properly design the tubular guard, applicable standards and regulations regarding the construction of cabs and tubular guards for agricultural and forestry machinery were first analyzed. Subsequently, the available solutions were analyzed and two original concepts were developed. These concepts were evaluated based on the adopted criteria, selecting the variant with the highest score. Furthermore, the most advantageous variant was subjected to a strength analysis using the finite el-ement method (FEM) in accordance with the FOPS procedure. The test results showed that all nodes included in the developed concept met the strength requirements. |
Push-Type Rotary Steering Mandrel Mechanical Analysis and Life PredictionWenzhe Li, Ye Chen, Jichuan Zhang, Xudong Wang, Pengcheng Wu, Chengyu Ma, Xiumei Wan, Xing ChenManufacturing Technology 2025, 25(5):645-654 | DOI: 10.21062/mft.2025.061 The push-type rotary steerable core bearing has high load capacity and high precision, and has been widely used in oil and gas drilling field. Its service life is difficult to predict due to various complex working conditions. Based on the finite element method, this paper establishes a three-dimensional rotating guide mandrel model to calculate and analyze the mechanical simulation of the guide mandrel under different working conditions, and establishes the corresponding life prediction model to predict its life. The results show that reducing the torque and speed in the range of drilling requirements is conducive to improving the overall life of the spindle, and the life matrix and life distribution are consistent with the characteristics of S-N curve, which is consistent with the characteristics of high cyclic stress of the spindle. The research results can be used to reliably predict the life of the push-type rotary steering mandrel and simulate its working state with high precision. This data is critical for reliability analysis and design optimization. |
SEM Analysis of Surface Layers with Variable Ra Parameters for Tribological Optimization in Design EngineeringPawe³ Knast, Jana Petrù, Stanislaw Legutko, Lubomir Soos, Marcela PokusovaManufacturing Technology 2025, 25(2):185-201 | DOI: 10.21062/mft.2025.022 In this study, the microstructure of surface layers with varying roughness (Ra parameters) was analyzed using scanning electron microscopy (SEM) to optimize tribological properties in engineering design. SEM revealed key microstructural features – sharp and mild protrusions, pitting, microcracks and contaminants – that were not available in traditional profilometry. Reducing the Ra value improved surface uniformity by reducing irregularities and defect lengths, which had a positive effect on tribological properties and surface durability. However, defects were still present even at Ra < 1.25 μm, indicating the "Law of Microstructural Roughness," which emphasizes the inevitability of surface irregularities despite minimizing roughness. The integration of SEM results with profilometric methods enabled comprehensive identification and assessment of defects, combining microstructure with tribological properties. Results suggest that controlled roughness is key in combining materials and optimizing functional surfaces, particularly in the aerospace, biomedical and automotive industries, where reliability under demanding operating conditions is a priority. |
Features of Locomotive Adhesive Mass Utilization in a Braking ModeStanislav Semenov, Evgeny Mikhailov, Oleksandr Spivak, Ján Di¾o, Miroslav Blatnický, Martin BuèkoManufacturing Technology 2025, 25(3):374-382 | DOI: 10.21062/mft.2025.040 The magnitude of a locomotive's traction and braking forces is directly related to its adhesive mass, which largely determines its tractive and braking characteristics. Therefore, an important task is to maximize the utilization of the locomotive's adhesive mass. The degree of adhesive mass utilization is determined by more factors and is quantitatively characterized by the Adhesive Mass Utilization Coeffi-cient (AMUC). One of the ways to increase the AMUC is to improve the locomotive's lever-type brake transmission. In braking mode, it interacts with the wheelsets and the bogie frame and may block the operation of the first stage of the suspension system. This research presents the results of a mathematical model-based study of the influence of certain parameters of the lever brake transmission on the utilisation of locomotive adhesive mass in braking mode. The calculations were carried out for various values of the vertical stiffness of the brake transmission. The results indicate that the distribution of vertical loads across the locomotive's wheelsets in braking mode significantly depends on the vertical stiffness of the brake transmission. |
Effect of Milling Parameters on the Surface Roughness of SiCp/Al MaterialsLiang Wang, Yongqiang Pan, Xiaoxin ZhuManufacturing Technology 2023, 23(4):545-550 | DOI: 10.21062/mft.2023.063 The presence of reinforcing particles SiCp seriously affects the cutting surface quality of SiCp/Al materials.In this study, different machining parameters were tested to obtain good surface quality, and the surface quality of SiCp/Al alloy material under different milling parameters was studied by using the surface profilometer and scanning electron microscope to explore the effect of cutting pa-rameters on surface quality. The results showed that the Surface roughness value increased with the increase of feed rate and milling speed, and milling speed was the dominant factor in the microstruc-ture evolution of the machined surface. In addition, an exponential model related to feed rate and milling speed was constructed. |
Damage assessment of the rolling bearing based on the rigid-flexible coupling multi-body vibration modelZhou Chang, Lai HuManufacturing Technology 2021, 21(3):340-348 | DOI: 10.21062/mft.2021.048 In the present study, local defects in deep groove ball bearings are studied as forward and inverse problems. To this end, the separation-integration method is applied for modeling the forward problem. It is assumed that the inner race of the rolling element is multi-DOF, while the outer race is deformable along the radial direction. Then the problem is modeled with concepts of the finite element method. The contact force for the rolling elements is described by the nonlinear Hertz contact deformation. Various surface defects originating from local deformations are introduced into the developed model. Since the outer ring can be coupled with the FE model of the housing, the developed bearing model is capable of considering the transmission path of the bearing housing. Then model parameters are modified to reach better performance in predicting local defects. Through translating the inverse problem into the comparison of the geometric distance, measured indicators are used in the defect detection process and the relative location and size of defects are predicted. Finally, the defect range is established to evaluate the fault severity. Obtained results demonstrate that the proposed method is effective and accurate in the studied cases. |
Material Properties of High-strength High Chromium TWIP Steel with Increased Corrosion ResistancePavel Podaný, Tomá¹ Studecký, Aleksandra KocijanManufacturing 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 steel were studied. |
The Power Load Model for Electric Vehicle Charging Modelling and its Utilisation for Voltage Level Studies and Cables Ampacity in Distribution GridVladislav Sí»aø, Tomá¹ Vyslou¾il, Lenka Raková, Tomá¹ Hru¹kaManufacturing Technology 2021, 21(1):132-140 | DOI: 10.21062/mft.2021.015 When electrical energy is drawn by electric vehicles from charging stations at charging process the voltage drops and increased current loading of cable lines in distribution grid occur. Inasmuch the electrical grid is insufficiently dimensioned or at large amount electric vehicles concurrently charges without controlled charging system, the voltages could decrease under desired level in grid points. This leads to the deterioration of voltage quality in given grid. The higher cables current loading leads to active power losses increase and decrease their service life. The paper describes the utilisation of modelling the electric vehicles when charging by power load model in physical diagram implemented into alternative simulation software. The created charging station load model is used for solving of voltage studies in distribution grid and for the analysis of cable lines ampacity. The grid contains a small number of points and low penetration of charging stations. Voltage levels are solved when random operation of charging stations during the working day without controlled system. For other loads, the typified daily loads diagrams of households are used. |
Melt Rheology of High-Density Polyethylene (HDPE) and Polypropylene (PP) using Single-Screw ExtruderFadi Alzarzouri, Jan SkoèilasManufacturing 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 Steel Fibers Content on Selected Mechanical Properties - Experimental TestsAgnieszka Czajkowska, Manuela IngaldiManufacturing Technology 2022, 22(3):267-278 | DOI: 10.21062/mft.2022.039 The continuous development of construction due to the great needs of society and industry, the need to build newer and more durable buildings have meant that scientists all the time look for new opportunities to improve the quality of materials used in this field. Above all, concrete, as material commonly used in construction, has been the subject of research for many years in order to improve the properties. Already in antiquity there were the first attempts to modify the building material with fibers. Initially, they were organic fibers. However, the first patent dates from 1874, when A. Bernard patented the idea of strengthening concrete with steel filings [1]. Then, attempts were made to strengthen the concrete with long steel fibers, which was done by H. Alfsen in 1918. Further researches led N. Zitkiewic to test the strength and impact toughness of concrete with the use of pieces of mild steel wire [2]. Steel fibers in concrete were used for the first time by Romuladi and Baston in 1963. In the paper a comparative analysis of selected mechanical properties for concrete and fiber-reinforced concrete, e.g. compressive strength and Young's modulus, was presented. It was checked how the value of Young's modulus and the compressive strength of concrete change depending on the content of steel fibers. Three types of samples were tested: 1 - concrete, 2 – fiber-reinforced concrete containing 0.25% of steel fibers, 3 – fiber-reinforced concrete containing 0.50% of steel fibers. As the analysis has shown, the greater number of steel fibers is not directly proportional to the increase in its compressive strength or the value of Young's modulus. |
Identification of Machine Tool Defects Using Laser InterferometerMiroslav Matu¹, Vladimír Bechný, Richard Joch, Mário Drbúl, Andrej Czán, Michal ©ajgalíkManufacturing 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 connected to the errors present in the machining ma-chines themselves. These errors are further intertwined with the design and physical properties of indi-vidual machine components, as well as their interactions. In the case of multi-axis machines, they col-lectively determine the overall accuracy of the produced components. The objective of this study is to analyze machining machine errors using the Renishaw XL-80 laser interferometric system. The findings of this study reveal that errors in machining machines can also be the result of the dynamics of the cut-ting process, which may have a significant impact on accuracy. |
Comparison of Optical Scanners for Reverse Engineering Applications on Glossy Freeform Artifact PharaohMichal Koptis, Jiri Resl, Jan Urban, Jan Simota, Jiri Kyncl, Petr Mikes, Libor BeranekManufacturing Technology 2025, 25(1):45-56 | DOI: 10.21062/mft.2025.015 Article deals with analysis on influence of post-process settings profiles in the Polyworks software and its influence on measuring bias (difference between average surface profile deviation and artifact reference value) and standard deviation of measured data. The comparison was evaluated on glossy artifacts with freeform surfaces. Setting with least bias and standard deviation was than used to evaluate repeatability and systematic measurement error and minimum tolerance bandwidth Tmin according to VDA 5 and MSA 4, respectively for three conceptions of laser scanning technologies available on today’s market. Cartesian CMM LK Altera S with laser scanner Nikon LC15Dx (automated technology), Measuring arm Nikon MCAx S30 with laser scanner Nikon H120 (manual technology) and optically tracked handheld device Metronor M-Scan with laser scanner Nikon H120 (manual technology). The conclusions of the study can serve as a guide in technology selection for reverse engineering input data acquisition. Subsequently, the optimal parameters of the post-process settings (for glossy surfaces) in the Polyworks software are listed. |
Comparison of Bearing Surface Quality Parameters for Wind TurbinesMariana Janeková, Daniela Ko¹tialiková, Dana Bako¹ová, Andrej Dubec, Al¾beta Bako¹ová, Jana KrálikováManufacturing Technology 2025, 25(3):297-306 | DOI: 10.21062/mft.2025.033 The thesis deals with the surface treatments of bearing steel processed for wind turbines, on which the quality parameters of the surface treatments performed were compared. This is blackening, which is a method of surface treatment that allows the protection of the base material from the negative effects of external influences, in particular from moisture and associated corrosion. The application of surface treatment by blackening contributes to a better and more efficient start-up of the bearing in service. In the experimental part, the individual results of the structural analysis carried out for all types of materials investigated are evaluated, with the analysis focusing on the structural properties, the quality of the adhesion properties and the influence on the service life of the machine components. Electron microscopy was used to investigate the structural properties of the layer as well as the base material, which allowed to obtain the necessary data to meet the objectives of this work. |
Evaluation of Dimensional Accuracy and Surface Topography of Plastic PartsEva Jurickova, Stepan Kolomy, Josef Sedlak, Denisa Hrusecka, Petra Sliwkova, Jiri VitekManufacturing Technology 2025, 25(5):607-617 | DOI: 10.21062/mft.2025.073 The objective of this paper is the evaluation of dimensional and geometric accuracy and surface to-pography of milled parts from plastic. This evaluation was done on 10 samples from various thermo-plastics made by extrusion and FDM 3D printing. The samples were then milled. One side was milled dry while the other was milled with cutting fluid, which has improved the texture of the result-ing machined surfaces in most cases, for example with printed PLA, where Ra was reduced by 1.8 µm. For determining the dimensional and geometric accuracy, two parameters were chosen, those being distance and parallelism. For evaluating the surface topography, 4 parameters were measured using 2D profile roughness and 3D surface texture. The surface of the prints was greatly improved by machining. The paper ends with practical recommendations for choosing different plastic materials for applications, requiring high dimensional accuracy and low surface roughness. |
A Synthetic Geometric Performance Index for Parts Manufactured by VAT PhotopolymerizationValentina Vendittoli, Wilma Polini, Walter Michael Simon Josef, Giovanni MoroniManufacturing Technology 2025, 25(2):244-251 | DOI: 10.21062/mft.2025.028 Geometric deviations play a crucial role in the quality of additive manufacturing, particularly in parts made with biodegradable resins. Accurately controlling dimensional and geometric variations in manufactured components is critical for achieving defect-free production and meeting functional standards. However, defining a final quality score can be challenging due to numerous dimensional and geometric deviations associated with a part. An innovative metric for evaluating geometric performance was created to measure dimensional precision in components produced through VAT photopolymerization. The index measures the dimensional and geometrical deviations, revealing that external surfaces exhibit greater precision than internal ones. This difference is likely due to internal surfaces overcoming heat dissipation challenges during the cooling process, resulting in less shrinkage for external surfaces. This index is essential in various stages of the manufacturing process, including part design, design for manufacturing and assembly, quality assurance, and process planning, helping to select the appropriate additive manufacturing technology and optimal process parameters. |
Optimizing Process Parameters during the Creation of Powder Laser Weld Cladding Coatings from a Nickel AlloyMartin ©vec, Libor DvoøákManufacturing Technology 2025, 25(4):540-548 | DOI: 10.21062/mft.2025.047 Nowadays, increasing emphasis is placed on the production of parts using additive technologies, particularly for alloys that are difficult to process. In addition to standard additive technologies, such as Selective Laser Melting (SLM), other additive technologies are increasingly being used, including Directed Energy Deposition (DED). DED offers several advantages and is utilized both for producing entire components and for repairing damaged parts through weld cladding. In this study, the possibility of weld cladding of nickel-based hard alloys using DED was tested using a laser as the energy source to melt the additive material. The tests performed showed that selected nickel alloys, suitable for mould repair, are difficult to weld. Therefore, the experiments sought optimal process parameters and defined the accompanying technological operations in order to produce a crack-free weld cladding. |
Research on Optimization Design and Processing Technology of Engine Intake System Based on NX and FluentJun Zhang, Ruqian Gao, Yangfang WuManufacturing Technology 2025, 25(5):711-719 | DOI: 10.21062/mft.2025.066 To design an engine intake system that complies with FSC racing regulations while achieving enhanced operational stability, this study conducts a comprehensive review of domestic and international research advancements in racing engine intake systems. Through computational fluid dynamics simulations performed in Workbench Fluent, critical structural parameters of the restrictor valve were optimized, resulting in a 12.06% improvement in outlet mass flow rate compared to the baseline design. A three-dimensional parametric model of the racing intake system was developed using Siemens NX platform. Taking the intake plenum chamber as a representative component, this research systematically analyzes the CNC machining process for the mold of the pressure stabilization chamber. The investigation encompasses toolpath generation, cutting simulation verification, and ultimately implements the optimized NC program on machining centers for physical manufacturing. The fabricated mold exhibits high dimensional accuracy and superior surface finish, providing both theoretical guidance and practical manufacturing references for intake system development. This integrated approach combining numerical optimization with advanced manufacturing techniques demonstrates significant potential for performance enhancement in motorsport engineering applications. |
Microtexturing for Enhanced Machining: Evaluating Tool Performance in Laser-Processed Cutting InsertsOndrej Bilek, Jan Ondrik, Petr Janik, Tomas KautskyManufacturing Technology 2024, 24(2):173-182 This article explores the significance of microtexturing on cutting tools for improved tribological performance and reduced friction in machining operations. Drawing inspiration from biomimetic structures, the study focuses on laser surface microtexturing and evaluates its impact on cutting forces and tool wear. Experiments involve microtextures of dots with a specific emphasis on a fiber laser-processed pattern. While long-term tests reveal the formation of negative protrusions on the textured tools, reduced variability in cutting forces suggests potential benefits for stable machining processes and increased tool longevity. The findings underscore the intricate relationship between microtexturing patterns and tool performance, offering insights into the broader implications for energy-efficient machining. |
Implementation of Mechanization into the Welding ProcessMilo¹ Taraba, Ján Vavro, jr., Jan VavroManufacturing Technology 2025, 25(1):120-130 | DOI: 10.21062/mft.2025.001 The article is focused on the investigation of the impact of the implementation of mechanization into the welding workplace, for the production of cylinders from austenitic X5CrNi18 10 chromium nickel steel. The welds are assembled into a production line for the processing of puff pastry. In addition to the technical improvement of the process and the verification of the sufficient quality of the welds, calculations were used to prove that after the implementation of the change, there was a significant reduction in the production time. By introducing a higher level of mechanization and necessary technological changes, the production time was reduced by up to half, compared with the original technological procedure, including an increase in quality parameters and it led to a reduction in the production costs of the welding workplace. A significant consequence of the proposed change was connected with its impact on workplace safety. |


