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1

Methods and conditions of neutralizing the bending of strips resulting from milling of one of their sides

Krugiołka Tomasz

Mebutra

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2026

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No. 5

153--184

EN

The paper describes the problem of deformation of a strip that occurs when one of its sides is milled. Particular attention is paid to the residual stress occurring in the surface layer of the machined objects. Analyzed were causes of residual stress and its influence on deformations. Furthermore, experimental verification was carried out. Strips milling tests were carried out and then deformation measurements were taken. Attempts were made to find cutting parameters that ensure neutralization of deformations in the workpieces being machined. As a result of the Author's many years of experience in the field of machining it was noticed that when milling one side of the strip there is a problem of deformation of the workpiece. Plastic deformation significantly changes the geometric dimensions and shape of the machined strip. In order to obtain the desired dimensions the workpiece must be subjected to additional operations which extends the production process and its costs.

2

Correlation of cutting speed and deflection in milling processing

Mikołajczyk Jarosław, Krugiołka Tomasz

Mebutra

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2026

|

No. 5

236--254

EN

The paper determines the correlation between cutting speed and deflection during milling processing. The tests performed on milling the strips and the subsequent deformation measurements made it possible to calculate the relationship between both variables. Based on the actual tests performed, determined were also mathematical models for the studied variables.

3

Methodology of backcasting of manufacturing process on the example of implementation of advisory systems in manufacturing processes

Matuszny Marcin

Polish Technical Review

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2025

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No. 1

7--17

EN

In the present paper, the methodology of the backcasting of manufacturing process and the possibilities of the application of Bizagi Modeler software with the utilization of BPMN notation with the aim to show the analyzed manufacturing processes in the conceptional aspect was submitted. As the example, the problem of the choice of filament in the incremental manufacturing process and the issue of selection of semi-fabricate in the machining process were discussed. The implementation of advisory systems based upon the simulation model in Flexsim software with the application of method of backcasting was analyzed. In the conducted simulation, the times for two analyzed variants in the both mentioned above manufacturing processes were compared. The first variant considered the employment of advisory systems and the second one assumed the standard run of the process, with the verification of senior technologist.

PL

W rozdziale przedstawiono metodykę wstecznego prognozowania procesu produkcyjnego oraz możliwości wykorzystania oprogramowania Bizagi Modeler z wykorzystaniem notacji BPMN w celu przedstawienia analizowanych procesów produkcyjnych w ujęciu koncepcyjnym. Jako przykład w rozdziale wykorzystano problem doboru filamentu w procesie wytwarzania przyrostowego oraz problem doboru półfabrykatu w procesie obróbki skrawaniem. Wdrożenie systemów doradczych przeanalizowano w oparciu o model symulacyjny w oprogramowaniu Flexsim z wykorzystaniem metodyki wstecznego prognozowania.

4

3D printing in prototyping a car drive adapter

Grochowalski Eryk

Mebutra

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2025

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No. 4

90--99

EN

The article presents the results of work on the design and manufacture of a drive adapter for a passenger car. The reason for its making was a change in the type of gearbox in the car, and thus a change in the dimensions of the interacting components. The work was carried out in two stages, i.e. first a prototype was made on a 3D printer and then, after it had been tested, a finished drive adapter was made. The use of 3D printing in prototyping new construction elements allows to avoid many errors that may occur during the design process.

5

Stochastic Diagnostics of Tool and Workpiece Interaction

Bratan Sergey, Sága Milan, Yakimovich Boris, Bozek Pavol, Pokintelista Nikolay, Yakubov Chingiz

Management Systems in Production Engineering

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2025

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nr 1 (33)

39--45

EN

Development is an integral part of research, since the study of specifics and characteristics in such a unique topic as the quality of processed products cannot be done without extraordinary equipment, fixtures and a laboratory. Laboratory equipment has been created that combines all hardware aspects of the development of the quality of processed products, where it analyzes the quality of workpieces that depend on the processing technology. However, this depends largely on the technological system used. The paper includes measurements, data acquisition and back-checking of the logic of the study of grinding operations. In the introduction, it must be shown that the correct selection and strength characteristics of the tool associated with the cutting mode of grinding determine the accuracy and quality of the surfaces of the ground part. The impact on the service life of the grinding tool was also monitored. The 4th partial result is also the knowledge that the correct selection of the tool characteristics and cutting mode predicts the quality of the workpiece surface. The operating conditions of the manufactured parts significantly affect the operating values of the production parameters. By appropriate diagnostics in the research process and precise measurements using sensitive sensors, deviations can be minimized. Without this apparatus, it is possible that deviations increase significantly during the operation of the technological system. The size of the deviation during grinding is explained in practice by the presence of vibrations in technological processes. They cause instability of the parameters of the technological system. To stabilize the quality indicators, a mathematical apparatus was also used, which takes into account changes in the technological regime. They are determined by designing adverse conditions, e.g. restoration of the cutting properties of a worn grinding wheel. Therefore, its replacement is logically carried out earlier than its replacement is planned.

6

A Comparative Study of Tool Wear for Niobium Carbide and Tungsten Carbide-Based Cutting Materials in Dry Cylindrical Turning

Uhlmann Eckart, Schneider Christoph

Journal of Machine Engineering

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2025

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Vol. 25, No. 2

64--73

EN

Using niobium carbide (NbC) for cutting materials is a promising alternative to tungsten carbide (WC) based cutting materials for metal machining due to the inherent material properties of NbC. These include increased hot hardness and reduced chemical wear compared to WC. This study examines the application behaviour at varying cutting speeds of the cutting material composition NbC-12Ni4Mo4VC produced on a laboratory scale as well as an industrial reference cutting material based on the tungsten carbide WC-6Co. A series of measurements and analyses are conducted during the machining tests in order to evaluate the tool life, the growth of the flank wear, the cutting force and the achieved roughness of the machined surface. For NbC-12Ni4Mo4VC an increase in cutting speed correlates with an increase in tool life. As for higher cutting speeds a superior tool life of NbC-12Ni4Mo4VC is achieved compared to the industrial reference cutting tool material WC-6Co.

7

Optimization of the Register of Environmental Aspects with Regard to the Aging of Machines in the Machining Process Format

Tomaskova Tetjana, Bicova Katerina

Inżynieria Mineralna

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2025

|

Vol. 3, no. 2

art. no. 36

EN

In recent decades, the state of the environment has deteriorated significantly, leading to increasing pressure for its protection and sustainability. Air, water and soil pollution have a negative impact on biodiversity and the health of ecosystems. Industrial companies are forced to comply with strict environmental regulations and voluntarily implement environmental management systems to minimize their impact on the environment. This trend has a significant impact on social and economic development, as well as on the quality of life and health of the population. The aim of this article is to expand the basic register of environmental aspects identified in machining according to ISO 14001, regarding the aging of machines in the machining process. Expanding the basic register of environmental aspects according to ISO 14001 is important for improving environmental performance and compliance with legislation, leading to cost savings and strengthening the reputation of the company. Identifying and managing aspects associated with the aging of machines helps prevent environmental accidents and supports long-term sustainability. The research focused on analyzing the impact of aging machine tools on emissions and energy consumption. The research was carried out in the following steps: defining parameters, collecting and analyzing data, interpreting results, conclusions and recommendations. Furthermore, the possibilities of recycling older machines and implementing new technologies were examined. The result of the research work was a register of environmental aspects for the machining hall, where it can be observed that older machine tools have higher emissions and energy consumption, require more frequent maintenance, but can be recycled. On the contrary, new technologies, such as energy-efficient machines, advanced cutting tools, energy recovery, low-impact cooling systems, automation and digitalization, and adhesive machining, can significantly reduce environmental impacts. The implementation of these new technologies and processes not only contributes to environmental protection but also increases the efficiency and competitiveness of industrial enterprises, which is key to their long-term sustainability, growth and continuous improvement. Sustainable development makes it possible to meet the current needs of the human population without compromising the living standards of future generations and the preservation of the planet's ecosystem.

8

Machining Behaviors and Surface Investigation on Udimet L-605 Alloy

Paulsingarayar S., Kumar S.J.D.V., Marichamy S., Anandavelu K.

Archives of Metallurgy and Materials

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2025

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Vol. 70, iss. 1

351--357

EN

This article is primarily concerned with the turning of Udimet L-605 alloy, which is crucial for a variety of applications, including the production of parts for the automotive, marine, and aircraft sectors. According to the researchers’ recommendation, dry machining was preferable for this machining, and the studies were conducted using a PVD-coated TiAlN-TiN tungsten carbide cutting tool insert. Depth of cut during the machining process is essential for enhancing surface smoothness and reducing tool wear during the turning process. Increased cutting zone temperature brought on by deeper cutting causes increased tool wear and subpar surface finish. In this study, a greater emphasis was placed on the surface morphology for the machined surface’s better and worse surface finishes. The peak and valley profiles created on the machined surface are mostly determined by kurtosis and skewness. The AFM study offered a clear indication of it. The average roughness of 34.77 nm was attained. Nearly 23% tool tip interface temperature was increased with increase of depth of cut.

9

Full-Field Force Mapping of Cutting Forces Driven by Local Density Variations in Norway Spruce Wood

Mellqvist Daniel, Buck Dietrich, Johansson Jimmy

Annals of Warsaw University of Life Sciences - SGGW. Forestry and Wood Technology

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2025

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No. 131

44--53

EN

Full-Field Force Mapping of Cutting Forces Driven by Local Density Variations in Norway Spruce Wood. Local density variations in wood influence cutting performance. In this study, full-field force mapping was applied to investigate the relationship between density distribution and cutting forces. Cutting forces were measured using piezoelectric transducers during cutting of Norway spruce. X-ray computed tomography (CT) scans of the workpiece provided spatially resolved density data. Force maps were constructed by aligning recorded forces with kerf positions and CT data. Results showed that cutting forces increased in regions of higher density, particularly near knot boundaries and latewood zones. Inner knot areas exhibiting lower density correlated with reduced cutting forces. Normal-force patterns were less responsive to local density changes. No self-feeding behaviour was observed. The integrated CT–force mapping technique enables spatial analysis of cutting responses in relation to anatomical wood features.

10

Prediction of tool wear based cutting forces during end milling of Inconel 718 using artificial neural networks

Felusiak-Czyryca Agata, Twardowski Paweł

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 7

394--405

EN

During the research, correlation between the input parameters (cutting parameters and cutting forces measure like peak to peak, root mean square and root mean square of ripple) and the variables were searched for, and the sensitivity of the network to input parameters was determined. In this paper artificial neural networks (ANNs) to prediction of tool wear based on cutting forces were used. Multilayer perceptron (MLP) networks with backward error propagation were used. The research shows that for the tested material and in the tested range, the cutting parameters are not diagnostically significant for the prediction of VBC (band width of the corner wear). The authors of this article focus on simplifying the model and analyzing the influence of variables on the prediction error. Neural networks show a correlation of about 95% for test sets.

11

Analysis of the tooth profile of the ZA cylindrical worm manufactured using universal tools and cutting inserts

Wydrzyński Dawid

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 12

454--463

EN

This study presents a method for turning cylindrical worms using universal turning tools. The surface preparation for testing was conducted using a point method, employing V–shaped cutting inserts to turn the worm thread, which has a profile angle of 20 degrees. To facilitate the turning of the thread, we analytically derived a formula to determine the distance from the corner of the insert to the side of the thread at the contact point. Additionally, we presented a theoretical calculation for the height of the roughness profile. The mean absolute error between our predicted Rt roughness parameter and the measured value is 2.8 μm, which results in a mean absolute percentage error of 13.6%. We developed special software to assist in preparing NC code for a numerically controlled machine tool. Ultimately, we obtained a theoretical profile that will be used to assess the size of deviations. The results of the thread profile measurements conducted on a coordinate measuring machine, along with the surface quality evaluation from roughness measurements, classified the worm within the 9th accuracy class. This confirms that our method is appropriate for roughing or semi–finishing operations. The analysis of the results validates the use of this method in machining worm gears, and the findings from our experimental studies align closely with theoretical expectations.

12

Effect of shells number and machining on selected properties of 3D-printed PLA samples

Kowalska Natalia, Szczygieł Paweł, Skrzyniarz Michał, Błasiak Sławomir

Polimery

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2024

|

Vol. 69, nr 3

186--190

EN

Effect of shells number (1–5) on tensile properties of PLA samples printed using the FDM/FFF technique was investigated. The crack surface was also analyzed. The best properties were obtained for 4-shell sample. However, due to the large coefficient of variation (>> 10%) in the case of elongation, 3-shell sample was selected for testing the machining impact. Such a large coefficient of variation can be explained by the presence of voids between the layers. The greater the number of layers, the greater the structure defects. Machining increases surface smoothness while reducing tensile strength and practi¬cally unchanged elongation at break.

PL

Zbadano wpływ liczby warstw (1–5) na właściwości mechaniczne przy rozciąganiu próbek PLA otrzymanych techniką FDM/FFF. Analizie poddano także powierzchnie pęknięć. Najlepsze właściwości uzyskano dla próbki 4-warstwowej. Jednak, ze względu na duży współczynnik zmienności (>> 10%) w przypadku wydłużenia, do badań wpływu obróbki skrawaniem wytypowano próbkę 3-warstwową. Tak duży współczynnik zmienności można wyjaśnić obecnością pustych przestrzeni pomiędzy warstwami. Im większa liczba warstw, tym większe defekty struktury. Obróbka skrawaniem zwiększa gładkość powierzchni przy jednoczesnym zmniejszeniu wytrzymałości na rozciąganie i praktycznie niezmienionym wydłużeniu przy zerwaniu.

13

An Attempt for Numerical Optimisation of a Micro-Groove Geometry at the Rake Face when Turning Ti6Al4V Alloy with Indexable Inserts

Klippel Hagen, Kneubühler Fabian, Haudenschild Livia, Zhang Nanyuan, Kuffa Michal, Wegener Konrad

Journal of Machine Engineering

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2024

|

Vol. 24, No. 3

47--63

EN

Machining of Ti6Al4V is considered difficult because the material removal rates are relatively small if the tool wear shall be low. In recent years the reduction of process forces as well as tool wear have been investigated by introducing textures (pockets) into the tool surface. To advance the understanding how those textured tools function and to reduce the experimental effort, a smoothed particle hydrodynamics (SPH) model of the orthogonal cutting process with a parametrised tool containing a single pocket on the rake face with variable position and depth is presented. This simulation model is used to enhance the understanding of rake face textures in order to design optimum cutting tools for given process parameters. Using an optimisation algorithm, an optimum texture geometry is determined numerically and is then experimentally validated, followed by a discussion, why process force reductions are lower than predicted.

14

Mechanical and tribological properties of Ti1-xZrxB2 coatings deposited by magnetron sputtering on hot work steel

Cieniek Łukasz, Kopia Agnieszka, Kot Marcin, Cempura Grzegorz, Gruszczyński Adam, Kopyściański Mateusz, Smolik Jerzy, Kacprzyńska-Gołacka Joanna

Archives of Civil and Mechanical Engineering

|

2024

|

Vol. 24, no. 3

art. no. e166, 2024

EN

Low fracture toughness is a common problem encountered by many researchers in the application of pure TiB2 coatings. To improve their properties, a convenient and useful method is the use of doping, so this study proposes the deposition of TiB2 enriched with Zr on a steel substrate. The objective of the research was to investigate the impact of Zr addition to TiB2 coatings on both their mechanical and tribological properties. Four coatings with varying compositions (pure TiB2; TiB2 doped with 3, 6, and 10 at.% Zr) were deposited using magnetron sputtering from TiB2 and Zr targets. The coating structures were analyzed by means of X-ray diffraction (XRD), transmission electron microscopy (TEM), and atomic force microscopy (AFM). Nanoindentation, scratch test, and ball-on-disk test were used to determine the mechanical and tribological properties. In most cases, only two factors have a significant impact on the mechanical and tribological properties of the Zr-doped coating. Firstly, a change in the preferred orientation of the coating from (102)(111) to (100) results in increased hardness and wear resistance. Secondly, a reduction in crystallite and column size enhances ductility and fracture toughness by impeding or altering the direction of crack propagation. Based on the study, one can conclude that the optimal Ti1-xZrxB2 properties were obtained for 6 at.% Zr content.

15

Development of an office-friendly CNC mill

Prostak Aleksandra, Uszok Remigiusz, Kolimas Łukasz

Przegląd Elektrotechniczny

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2023

|

R. 99, nr 12

211--214

EN

In this paper we describe the development of a small, office-friendly CNC machine. We compare popular CNC archetypes and their ability to be operated in a non-workshop environment. We have made an enclosed machine that is safe both for the operator and people nearby and clean to use, with outer walls fully integrated into the frame for improved rigidity. We made some unique design decisions for increasing the working area without sacrificing stiffness in a small form factor CNC.

PL

W tym artykule został opisany proces tworzenia małego plotera przystosowanego do pracy w biurze. Zostały porównane popularne konstrukcje maszyn frezujących oraz ich możliwości pracy poza warsztatem. Skonstruowaliśmy maszynę czystą i bezpieczną dla osób znajdujących się w jej pobliżu, dzięki w pełni wbudowanej w ramę obudowie, która jednocześnie dodaje sztywność do naszej maszyny. W trakcie projektowanie zastosowaliśmy parę niestandardowych rozwiązań mających na celu zwiększenie pola roboczego, nie wpływając na sztywność konstrukcji.

16

Wpływ dodatku modyfikującego cechy płynu obróbkowego na zmianę temperatury w strefie kontaktu współpracujących powierzchni

Mikołajczyk Jarosław Robert

Obróbka Metalu

|

2023

|

nr 2

43--46

PL

W artykule przedstawiono rezultaty badań ukazujących wpływ dodatku eksploatacyjnego do płynu roboczego na temperaturę styku powierzchni współpracujących w węźle tarciowym. Stwierdzono zróżnicowany wpływ zależny od stężenia tego dodatku.

EN

In this paper the results of studies showing the effect of the operating additive to the working fluid on the contact temperature of the cooperating surfaces in the friction pair were presented. Differentiated effects, depending on the concentration of the additive, were observed.

17

Specyfika procesu wytwarzania elementów o dużych gabarytach

Gründer Joachim, Matuszewski Maciej, Otto Peter, Styp-Rekowski Michał

Obróbka Metalu

|

2023

|

nr 1

26--29

PL

W artykule przedstawiono specyficzne cechy procesu produkcyjnego elementów o dużych gabarytach. Wskazano cechy specyficzne obróbki dużych elementów. Wnioski sformułowano na podstawie własnych badań autorów: eksperymentalnych i analitycznych.

EN

In this paper the specific features of the production process of elements with large dimensions were presented. Specific features of machining large machines’ elements were indicated. The conclusions were formulated on the basis of the authors’ own research: experimental and analytical.

18

Towards sustainable and intelligent machining: energy footprint and tool condition monitoring for media-assisted processes

Dogan Hakan, Jones Llyr, Hall Stephanie, Shokrani Alborz

Journal of Machine Engineering

|

2023

|

Vol. 23, No. 2

16--40

EN

Reducing energy consumption is a necessity towards achieving the goal of net-zero manufacturing. In this paper, the overall energy footprint of machining Ti-6Al-4V using various cooling/lubrication methods is investigated taking the embodied energy of cutting tools and cutting fluids into account. Previous studies concentrated on reducing the energy consumption associated with the machine tool and cutting fluids. However, the investigations in this study show the significance of the embodied energy of cutting tool. New cooling/lubrication methods such as WS2-oil suspension can reduce the energy footprint of machining through extending tool life. Cutting tools are commonly replaced early before reaching their end of useful life to prevent damage to the workpiece, effectively wasting a portion of the embodied energy in cutting tools. A deep learning method is trained and validated to identify when a tool change is required based on sensor signals from a wireless sensory toolholder. The results indicated that the network is capable of classifying over 90% of the tools correctly. This enables capitalising on the entirety of a tool’s useful life before replacing the tool and thus reducing the overall energy footprint of machining processes.

19

Ebrahimi Araghizad Arash, Tehranizadeh Faraz, Kilic Kemal, Budak Erhan

Journal of Machine Engineering

|

2023

|

Vol. 23, No. 4

18--32

EN

In this paper a novel approach for monitoring tool-related faults in milling processes by utilizing process simulation-based machine learning algorithms, specifically Random Forest algorithms, for fault detection is presented. In order to train machine learning models in tool condition monitoring, laboratory tests have traditionally been required. This method eliminates the need for costly, time-consuming laboratory tests. The training process has been simplified by utilizing analytical simulation data and provides a more cost-effective solution by leveraging analytical simulation data. Based on the results of this study, the proposed approach has been demonstrated to be 94% accurate at predicting tool-related faults, demonstrating its potential to serve as an efficient and viable alternative to conventional methods. These findings have been supported by actual measurement data, with a notable accuracy rate of 93% in the predictions. Furthermore, the results indicate that process simulation-based machine learning algorithms will have a significant impact on the tools condition monitoring and the efficiency of manufacturing processes more generally. To further enhance the capabilities of the proposed fault monitoring system, process-related and machine-related faults will be investigated in future research. Several machine learning algorithms will be explored as well as additional data sources will be integrated in order to enhance the accuracy and reliability of fault detection.

20

A study of low-frequency vibration-assisted bandsawing of metallic parts

Tandler Tobias, Stehle Thomas, Möhring Hans-Christian

Journal of Machine Engineering

|

2023

|

Vol. 23, No. 2

110-122

EN

Sawing is often the first work step in the metal cutting production chain. Especially for larger workpieces, bandsawing is used for this purpose. Nevertheless, studies on sawing have led a niche existence in the research landscape for a long time. However, as a result of the optimization of manufacturing processes in terms of economic efficiency, bandsawing is increasingly becoming the focus of research, since there are still saving potentials here. The aim of this paper is to investigate the extent to which the bandsawing process can be influenced by active, low-frequency vibration superimposition in the feed direction. First, analogue tests were carried out and parameter combinations were determined which have a positive influence on the process. Subsequently, these parameter combinations were investigated on a real sawing machine with an excitation unit, analysing the extent to which the results from the analogue tests could be transferred to the real process.