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1

Selected Aspects of 3D Printing for Emergency Replacement of Structural Elements

Jasiński Krzysztof, Murawski Lech, Kluczyk Marcin, Muc Adam, Szeleziński Adam, Muchowski Tomasz, Chodnicki Marek

Advances in Science and Technology. Research Journal

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2023

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Vol. 17, no 1

274--289

EN

The paper presents a synthetic characterization of modern methods of manufacturing or regenerating machine elements. Considered methods are machining and additive methods, in particular 3D printing in the FDM/FFF technique. For the study, the authors made samples of the holder bracket using selected methods. Samples made by machining operations, 3D printing with various filling were tested. The paper contains a technical and economic analysis of the production of a holder bracket using the discussed methods. The dynamics of steel and FDM/FFF printed samples were also assessed by determining their resonance curves. The vibration magnification fac-tors were analyzed - the quotient of the vibration amplitudes in the resonance to the static deformations that occurred under the influence of the constant force and the location of the vibration resonances - the natural frequencies for individual vibration modes. The study's main objective is to assess the possibility of emergency changing the manufacturing technology of selected machine components. The authors were interested in partially replacing costly and not environmentally friendly milling with 3D printing. Machine elements can be manufactured by printing in classical machine building and emergency conditions to replace a damaged component temporarily (e.g., on a ship, for the time of arrival at a port or shipyard). The main assumption guiding the authors during the preparation of this publication was the analysis of the possibility of using the production of "ad hoc" prepared spare parts and their use in the event of a lack of access to parts made of the intended materials.

2

Comparison of calculating algorithms for logarithmic decrements applied to welded joints assessments

Szeleziński Adam, Muc Adam, Murawski Lech, Muchowski Tomasz, Kluczyk Marcin, Jasiński Krzysztof, Antczak-Jarząbska Romana

Scientific Journal of Gdynia Maritime University

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2022

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nr 124

7--19

EN

There are numerous non-destructive methods in welded joints investigation, but the most promising, especially in applications with steady monitoring of the structure, is the vibro-diagnostic approach. In the course of the research work, the responses were obtained and detected by accelerometers, providing valuable diagnostic information, which later was mathematically processed in the field of time or frequency. The mathematical processing aimed to distinguish significant characteristics embedded in the processes typical of the investigated joints and allow an assessment of how they were made. For this purpose, two methods were proposed, based on determining the logarithmic decrement as a function of time. Due to the complicated course of the impact responses, the method of calculating the logarithmic decrement has been suggested, involving the approximation of responses with various functions. According to the research, the analysis of changes in the logarithmic decrement as a function of time applied to welded plates was proposed, as it enables the initial assessment of joint quality.

3

The process of acquiring, collecting, processing and archiving data for the SHM system designed to identify defects in thin-walled structures

Muchowski Tomasz, Szeleziński Adam, Murawski Lech, Muc Adam, Kluczyk Marcin

Journal of KONBiN

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2022

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Vol. 52, iss. 4

135--142

EN

The article shows the results of the preparatory steps taken to create the artificial intelligence used in the automatic recognition of defects in ship thin-walled structures. The above steps are used to create a university private cloud and a computer system maintaining a dataset of vibration signal samples. In the article, a prototype of the private cloud was designed and developed, a model of the vibration sample was prepared, and a microservice was designed aimed at sharing the obtained data. The article demonstrates the results of the completed development.

PL

W artykule przedstawiono wyniki przeprowadzonych działań przygotowawczych do stworzenia sztucznej inteligencji wykorzystywanej w automatycznym rozpoznawaniu defektów okrętowych konstrukcji cienkościennych. Przeprowadzone kroki służą stworzeniu uczelnianej chmury prywatnej oraz systemu informatycznego utrzymującego zbiór danych próbek sygnałów drganiowych. W ramach artykułu zaprojektowano oraz stworzono prototyp chmury prywatnej, przygotowano model próbki drganiowej oraz zaprojektowano mikroserwis służący udostępnianiu uzyskanych danych. Artykuł przedstawia wyniki wykonanej pracy.

4

Influence of the numerical modelling methods on dispersions and errors of analysis results of ship hull and deckhouse vibrations

Murawski Lech

Journal of KONBiN

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2022

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Vol. 52, iss. 4

207--222

EN

Ships' (especially containers) vibrations significantly impact navigation safety. The presented analyses aims to identify the main forces exciting the ship's superstructure and hull vibrations, test their influence on vibration levels, and verify the assumptions of the computational methodology. Two container ships were analysed. The influence of different modeling methods on the obtained calculation results was investigated. The impact of various operating parameters on the vibration level was also analysed. The numerical analyses results are compared with some empirical formulas. As a result, the calculation confidence level was estimated. The calculation results have been verified by comparison with measurement tests carried out on the real ship.

PL

Drgania statków (zwłaszcza kontenerowców) mają duży wpływ na bezpieczeństwo żeglugi. Celem przedstawionych analiz jest identyfikacja głównych sił wymuszających drgania nadbudówki i kadłuba statku, zbadanie ich wpływu na poziom drgań oraz weryfikacja założeń metodyki obliczeniowej. Przeanalizowano dwa kontenerowce. Zbadano wpływ różnych metod modelowania na wyniki obliczeń. Przeanalizowano również wpływ różnych parametrów eksploatacyjnych na poziom drgań. Wyniki analiz numerycznych porównano z niektórymi wzorami empirycznymi. W rezultacie oszacowano poziom ufności obliczeń. Wyniki obliczeń zostały zweryfikowane poprzez porównanie z badaniami pomiarowymi wykonanymi na rzeczywistym statku.

5

Analysis of the possibility of using vibration parameters for diagnostics of selected defects in welded joints of the hull plating elements

Muchowski Tomasz, Szeleziński Adam, Murawski Lech, Muc Adam, Kluczyk Marcin

Journal of KONBiN

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2022

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Vol. 52, iss. 3

165--174

EN

The article presents results of vibration tests of thin-walled plates used in shipbuilding for plating hulls of vessels. The conducted tests were aimed at determining the possibility of using measurements of vibration acceleration recorded on the tested objects as parameters enabling the detection of damages in the performed welded joints. Seven plates were compared, six of which had joints in different technical conditions, and one was a board without a weld. The quality of the welds was verified using X-ray methods. The adopted research methodology and the obtained results were presented.

PL

W artykule przedstawiono wyniki badań drganiowych płyt cienkościennych wykorzystywanych w okrętownictwie jako poszycie kadłubów jednostek pływających. Przeprowadzone badania miały na celu określenie możliwości stosowania pomiarów przyspieszeń drgań rejestrowanych na badanych obiektach jako parametrów umożliwiających wykrycie uszkodzeń w wykonanych połączeniach spawanych. Porównano siedem płyt, z czego sześć miało spoiny w różnym stanie technicznym, a jedna była bez spawu. Jakość spoin zweryfikowana została metodami RTG. Przedstawiono przyjętą metodykę badawczą oraz uzyskane wyniki.

6

Providing the Ability of Working Remotely on Local Company Server via VPN

Muc Adam, Muchowski Tomasz, Murawski Lech, Szeleziński Adam

Multidisciplinary Aspects of Production Engineering

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2020

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Vol. 3, Iss. 1

195--205

EN

Increasingly popular remote work requires the use of modern network technologies to provide employees in a remote location with access to the company’s IT resources. The answer to the needs of remote access to files and server services can be the use of clouds and VPS. However, this involves high costs and requires entrusting the enterprise’s data to the providers of these services. Both for reasons of data security and too high costs, enterprises sometimes cannot use these technologies. The solution to the problem may be the use of encrypted VPN tunneling, which allows the device to be connected at a remote location to the company’s local network and use its resources as if it was connected to the local network with physical transmission medium.

7

Diagnostic benchmarks on dynamic characteristics of thin-walled marine damaged structures

Szeleziński Adam, Murawski Lech, Muc Adam

Multidisciplinary Aspects of Production Engineering

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2019

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Vol. 2, Iss. 1

38--52

EN

Among structural health monitoring (SHM) methods of thin-walled structures, a vibrodiagnostic method is one of the most promising. The accelerometer recorded responses provide diagnostic information that requires mathematical processing to extract the essential dynamic characteristics. The authors have been looking for new parameters - diagnostic benchmarks which can be applied to non-destructive, automatic testing of thin-walled marine structures (especially their welded joints) like ship hulls. All characteristics have been based on recorded data generated during the vibration tests of welded joints with and without failures. For this purpose, the authors proposed method based on: FFT windowing analysis, benchmark with using 2D or 3D time – frequency dynamic characteristics and the determination of damping decrement in function of time. The work presents the algorithm and exemplary results obtained from the application of proposed method to several selected sample plates with different type of welds.

8

Ograniczenia modelowania na przykładzie analiz dynamiki wału korbowego

Murawski Lech

Journal of Polish CIMEEAC

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2019

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Vol. 14, no 1

147--155

PL

Analizowane zjawiska fizyczne należy upraszczać maksymalnie mocno, ale tak, żeby powstałe modele dawały poprawne przewidywania wyników eksperymentalnych. Naukowiec powinien jednak zdawać sobie sprawę z ograniczeń i zakresu stosowalności danego modelu. Inżynier nie może zapominać, że posługuje się tylko modelem rzeczywistości, który ma swoje ograniczenia - zakres stosowalności. W pracy przedstawiono analizy dynamiki układu tłokowo-korbowego silnika okrętowego ze szczególnym uwzględnieniem ruchu wału korbowego. W świetle współczesnych badań, świat fizyczny jest nieliniowy i dynamiczny w stanach dalekich od stanu równowagi. Jednakże większość problemów inżynierskich jest modelowanych liniowo, jako zjawiska statyczne bądź quasi-statyczne. Podejście to jest użyteczne i optymalne, ale nie można zapominać o ograniczeniach takich modeli. Wykazano, że pomimo przyjęcia ściśle deterministycznych oraz w pełni liniowych równań mechaniki, przewidywalność dokładnych parametrów ruchu jest ograniczona. Rozważono ruch prostego obiektu mechanicznego: obrót wału korbowego silnika. W rozważanym przypadku jest to wał korbowy 10-cylindrowego, okrętowego silnika wolnoobrotowego: 10K98 firmy MAN B&W. Założono, że znana jest z nieskończoną (!) dokładnością prędkość obrotowa wału, która jest dodatkowo niezmienna. Przyjęto, że również czas jest możliwy do wyznaczenia nieskończenie dokładnie. W takim przypadku względne położenie wykorbienia określa w pełni deterministyczna prosta zależność. W celu znajomości położenia danego wykorbienia w dowolnej chwili czasu musimy jeszcze znać warunki początkowe. Kąt obrotu w chwili t=0 wyznaczono niezwykle dokładnie, ale ze skończoną dokładnością. Wykazano, że po pewnym czasie położenie wykorbienia jest całkowicie niezdeterminowane. Co więcej, ruch układu tłokowo-korbowego charakteryzuje się naturalną zmiennością, nawet po pominięciu zmienności sił wymuszających. Wpływa to dodatkowo na ograniczenia modelowania rozważanego deterministycznego układu fizycznego.

9

Modelling method of dynamic characteristics of marine thin-walled structure

Doan Do Van, Szeleziński Adam, Murawski Lech, Muc Adam

Journal of KONES

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2019

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Vol. 26, No. 4

39--46

EN

Thin-walled structures are very popular in industries, especially in the field of shipbuilding. There are many types of equipment and structures of ships, which are made up of thin-walled structures such as hull, deck and superstructure. Therefore, the analysis and understanding of the static and dynamic characteristics of a thin-walled structure are very important. In this article, we focus on vibration analysis of a typical thin-walled structurerectangular plate, a basic structure of the hull. Vibration analysis of a rectangular thin plate is conducted by two methods: numerical modelling method of the finite element on Patran-Nastran software platform and experimental method implemented in the laboratory of Gdynia Maritime University. Thin rectangular plate is fixed one end by four clamping plates and is modelled with finite elements and different meshing densities. The numerical model of thin rectangular plate is divided into four cases. Case 1, thin rectangular plate, and clamping plates are modelled with two-dimensional elements. Case 2, the rectangular thin plate is modelled with two-dimensional elements; the clamping plates are modelled with three-dimensional elements. Case 3, both the rectangular thin plate and clamping plates are modelled with three-dimensional elements. Case 4, the rectangular thin plate, and clamping plates are modelled with three-dimensional elements with larger mesh density to increase the accuracy of the calculation results. After that, the results of vibration analysis according to the numerical modelling method on Patran-Nastran software platform for these cases were compared with the measurement results. From there, assess the accuracy of analysis results of selected numerical model methods and the ability to widely apply this numerical model method to other marine structures

10

Introduction to the examination of thin-walled structures using the vibrodiagnostic method

Szeleziński Adam, Muc Adam, Murawski Lech, Doan Do Van

Journal of KONES

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2019

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Vol. 26, No. 4

241--248

EN

The article presents a methodology of non-destructive diagnostic vibratory tests of welded plates with geometrical parameters that classify them into a group of thin-walled panels. On the basis of such plates, most ship constructions are created. In previous works, the authors dealt with the study of welded joints in plates with significant thicknesses and developed for them a number of methods for assessing the quality of welded joints. Vibrodiagnostics is a NDT method that allows the use of a variety of techniques and tools. It enables measurements to be made in both a contact and non-contact way depending on the requirements of the structure and the environment. Vibrodiagnostic method is one of the most modern NDT methods, which uses modern measurement tools and computer analysis of data. On the basis of the developed methods, the authors intend to verify their application to plates from real welded constructions, which will be performed in typical shipyard conditions by welders. Such tests are important due to their use for the construction of a real SHM ship construction monitoring system. These methods allow for the examination of the condition of ships’ structural plates and can detect defects in welded joints that prevent ships from operating under severe sea conditions. The article presents the laboratory stand, the sensor layout, results, and their initial analysis.

11

Influence of marine main engine foundations on the results of vibration calculations

Murawski Lech

Journal of KONES

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2019

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Vol. 26, No. 1

95--101

EN

The article presents an influence of foundations of slow-speed main engine body on the results of numerical analysis of the engine dynamic stiffnesses and thermal deformations. The engine body is much stiffer than its foundation pads and ship hull (double bottom) – boundary conditions of the engine. Especially for the high power, marine engines, the correct model of the boundary conditions plays a key role during the analyses. Therefore, modelling method of engine foundation (boundary conditions) of that kind of model is essential during the analyses. During shaft line alignment and crankshaft springing analyses, knowledge of dynamic stiffnesses characteristics and thermal displacements of radial (main) bearings is significant. Those data of marine main engine body are difficult to estimate because of lack of available documentation and complicated shape of the engine and ship hull. The article presents the methodology of the characteristics determination of the marine engine’s body as well as the example of computations for a MAN B&W K98MC type engine (power: 40000 kW, revolutions: 94 rpm) mounted on a 3000 TEU (twenty-foot container equivalent unit) container ship (length: 250 m). Numerical analyses were performed with usage of Nastran software based on Finite Element Method. The FEM model of the engine body comprised over 800 thousand degree of freedom.

12

Calculation reliability of natural vibrations of ship hull and superstructure

Doan Do Van, Murawski Lech

Journal of KONES

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2019

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Vol. 26, No. 1

31--38

EN

The ship hull vibration has a great impact on the performance, safety of the devices, structures, and the sailor's comfort when working on the ship. With increases in ship sizes and speeds, shipboard vibration becomes a significant concern in the design and construction of ships. Therefore, designing a ship without any excessive vibration is an important issue and should be studied through analysis right in the design phase. To ensure minimum vibration in a proposed new design; avoid damage to structures, machinery or equipment (mechanically suitable); meeting the requirements of the crew's living environment and working conditions. The ship's natural vibrations are determined to right from the design stage, which will help ship designers and structures avoid dangerous resonance areas. In this study, a three-dimensional finite element model representing the entire ship hull, including the deckhouse and machinery propulsion system, has been developed using numerical modelling implemented in Patran-Nastran software for local and global vibration analyses of the container ship 2000 TEU. Vibration analyses have been conducted under two conditions: free– free (dry) and in-water (wet). The wet analysis has been implemented using Mfluid elements in Nastran software. Because of the global ship free vibration analysis, global natural frequencies and mode shapes have been determined. Combined with the frequency of the main engine and the propeller, the resonant regions with higher frequencies are determined by the resonant graph of the hull. The application of the finite element method for ship vibration analysis shows the optimal of numerical modelling method compared to other traditional methods. This will help other technical problems to be solved with the support of the finite element method.