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  1. 4 Hutnik, Wiadomości Hutnicze
  2. 4 Mechanik
  3. 3 Journal of Achievements in Materials and Manufacturing Engineering
  4. 3 Rudy i Metale Nieżelazne
  5. 2 Archives of Foundry Engineering
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  1. 5 Władysiak R.
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  4. 2 Libura W.
  5. 2 Pietrowski S.
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1
Content available Characterization of tool clamping conditions in forging hammers
Wagner Nico, Tehel Robert, Kurth Robin, Ihlenfeldt Steffen
Journal of Machine Engineering
|
2022
|
Vol. 22, No. 4
95--114
EN
The present work addresses the topic of die clamping at the forging hammer in the context of the definition of a current requirement profile as well as the evaluation of individual influencing variables on the clamping process. In addition to the presentation of survey results for the requirements profile, the first part focus on the sensible minimization of influencing variables to be investigated and on the verification of a possible evaluation method. Based on this, in the second part exemplary influencing variables on the clamping condition are investigated by means of FEM. Thereby it can be shown by way of example, that the heat flow of the forging process and the friction conditions between the clamping elements have a noteworthy influence on the clamping condition of the dies and that deviations in the clamping force can lead to significant damage.
2
Content available Enhanced of Tool Management Based on Machine Vision in the Field of Metal Forming Technology
Świłło Sławomir, Cacko Robert
Archives of Metallurgy and Materials
|
2022
|
Vol. 67, iss. 4
1419--1425
EN
In this article, the authors focused on the widely used aluminium extrusion technology, where the die quality and durability are the essential factors. In this study, detailed solutions in the three-key area have been presented. First is applying marking technology, where a laser technique was proposed as a consistent light source of high power in a selected, narrow spectral range. In the second, an automated and reliable identification method of alphanumeric characters was investigated using an advanced machine vision system and digital image processing adopted to the industrial conditions. Third, a proposed concept of online tool management was introduced as an efficient process for properly planning the production process, cost estimation and risk assessment. In this research, the authors pay attention to the designed vision system’s speed, reliability, and mobility. This leads to the practical, industrial application of the proposed solutions, where the influence of external factors is not negligible.
3
Content available remote Researching the profile of normal wear of die face
Melnyk V. O.
Journal of New Technologies in Environmental Science
|
2018
|
Vol. 2, nr 3
116--120
EN
In the article the geometrical form of natural wear of working surface of die is investigated. The research had done with using of the measuring system on the base of three-coordinate machine-tool with numerical program control. As a result of measuring were obtained set of points on which was built the experimental cross-sectional profile of the working surface of worn dies. It was found that profile of natural wear of die is described by the polynomial of the third order with the high degree of authenticity.
4
Content available Badania nad kształtowaniem wykroju matrycy do kucia zaczepu budowlanego metodą wgłębiania na gorąco
Pachutko B., Szkudelski S., Czartoryski B., Chruściński M.
Obróbka Plastyczna Metali
|
2017
|
T. 28, nr 2
133--146
PL
W publikacji opisano wyniki prac konstrukcyjnych i technologicznych dotyczących modyfikacji sposobu wytwarzania wykroju matryc do kucia kołnierza zaczepu budowlanego Putanker 2,5 T poprzez wgłębianie na gorąco. Hartowanie matrycy następowało z temperatury wgłębiania, aby wyeliminować dodatkowy proces nagrzewania do temperatury hartowania matryc. W celu oceny, czy nie wystąpiły pęknięcia po próbie wgłębiania oraz skutków procesu hartowania i odpuszczania, wykonano badania metalograficzne (obserwacje struktury za pomocą mikroskopu świetlnego – LM i skaningowego mikroskopu elektronowego – SEM oraz pomiary twardości metodą Vickersa HV 1). Materiałem matryc była stal narzędziowa do pracy na gorąco Orvar Supreme (odpowiednik stali WCLV). Zaprojektowano przyrząd do prowadzenia prób wgłębiania na próbkach krótkich o wymiarach φ64x35 mm z otworem φ14 mm, które służyły do wstępnych prób wgłębiania. Celem tych prób była weryfikacja konstrukcji przyrządu ze względu na zniekształcenia próbek na średnicy zewnętrznej po próbie wgłębiania oraz ocena skutków procesu hartowania i odpuszczania prowadzonych bezpośrednio po wgłębianiu na gorąco. Docelowe próby wgłębiania prowadzono na próbkach długich o wymiarach φ64x109 mm z otworem φ14 mm mocowanych w przyrządzie w tulei ustalającej. Próbki te po próbie wgłębiania, usunięciu warstwy odwęglonego materiału, korekcie płaskości powierzchni czołowej oraz po przecięciu na pół stanowiły gotowe matryce do kucia zaczepów budowlanych Putanker 2,5 T. W wyniku hartowania próbek długich z temperatury wgłębiania wynoszącej 1050°C w oleju, a następnie ich odpuszczaniu przy temperaturze 570°C w ciągu 2 godzin uzyskano materiał o średniej twardości wynoszącej 607 HV 1 (ok. 56 HRC), która jest wymagana dla matryc do kucia zaczepów Putanker 2,5 T.
EN
This article describes the results of design and technological work concerning modification of the method of manufacturing die impressions for forging the flange of a Putanker 2.5 T construction anchor by hot hobbing. Die quenching took place from hobbing temperature in order to eliminate the additional process of heating to die quenching temperature. In order to assess whether cracks occurred after the hobbing trial and the effects of the quenching and tempering process, metallographic studies (observations of structure using a light microscope – LM and scanning electron microscope – SEM as well as Vickers HV 1 hardness measurements). The die material was Orvar Supreme hot-work tool steel (the counterpart of WCLV steel). An instrument was designed for conducting hobbing tests on short samples with dimensions φ64x35 mm with a φ14 mm hole, which served for preliminary hobbing tests. The goal of these tests was to verify the instrument’s design in terms of sample deformation on the exterior diameter after the hobbing test as well as to assess the effects of the quenching and tempering process performed immediately after hot hobbing. The target hobbing tests were conducted on long samples with dimensions φ64x109 mm and φ14 mm hole fastened in the instrument’s fastening sleeve. After the hobbing tests and removal of the layer of decarbonized material, correction of face surface flatness and being cut in half, these samples constituted ready dies for forging of Putanker 2.5 T construction anchors. As a result of quenching of long samples from hobbing temperature equal to 1050°C in oil, followed by their tempering at 570°C for 2h, material with an average hardness of 607 HV 1 (approx. 56 HRC) was obtained, and this hardness is required for dies used to forge Putanker 2.5 T anchors.
5
Content available Cluster and R&D affecting the competitive advantage of the mould and die sector in the Thai automotive industry
Fongsuwan W., Chamsuk W., Tawinunt K., Tiengtavaj S., Dansomboon S., Takala J.
Management and Production Engineering Review
|
2017
|
Vol. 8, No. 4
3--12
EN
This study concerned clusters as well as research and development affecting the competitive advantage of the Thai automotive industry’s mould and die sector. The study of development, examination of the consistency of the structural equation model, and the direct influence of linkage and association of cluster, as well as research and development for competitive advantage of operational locations in the Thai automotive mould & die sector was carried out as well. Data was collected from 320 mould and die industry operators in Thailand with the goal of obtaining key information to align the business direction in response to market opportunities. An additional goal was to elevate the competitiveness of the Thai automotive mould and die industry toward positive growth and continual sustainability.
6
Zwiększenie żywotności matryc poprzez proces napawania
Bednarek S., Chyła P., Burdzy D.
Prace Naukowe Politechniki Warszawskiej. Mechanika
|
2013
|
z. 253
95--100
PL
Analizowano zużycie matryc w wykroju na gotowo w trójzabiegowym procesie kucia odkuwki kołnierza w warunkach dynamicznych. W tym celu posłużono się obliczeniami numerycznymi, które pozwoliły określić obszary narażone na największe zużycie. Drugim etapem badań był proces napawania zużytych matryc metodą Weld Mold oraz określenie ich trwałości po tym zabiegu.
EN
The die wear in three-operation process of flange forging in dynamic conditions was analyzed. For this purpose, numerical calculations were used, which helped to determine the areas most exposed to wear. The second stage of the study was the deposition process for worn dies by means of Weld Mold method and determination of their durability after the treatment.
7
Content available Wpływ geometrii profili aluminiowych na trwałość matryc do ich wyciskania
Laurentowska-Tyczka A., Wendland J., Borowski J., Jurczak H.
Obróbka Plastyczna Metali
|
2013
|
T. 24, nr 4
303--315
PL
W pracy analizowano wpływ geometrii matryc do wyciskania profili aluminiowych na ilość wyciśniętego materiału oraz trwałość matryc. Matryce przekazane do badań były poddawane cztero- lub pięciokrotnemu azotowaniu gazowemu i eksploatowane do końcowego zużycia w firmie Albatros Aluminium. W artykule podjęto próbę wyjaśnienia wpływu geometrii matryc na grubość warstwy azotowanej, a tym samym na wzrost ich trwałości. Uzyskane wyniki badań pozwoliły stwierdzić, że ilość wyciśniętego materiału, niezależnie od kształtu matrycy, zwiększa się prawie dwukrotnie po trzecim azotowaniu i dwuipółkrotnie po czwartym azotowaniu. Matryca do wyciskania profilu o płaskim kształcie pozwoliła osiągnąć dwuipółkrotny wzrost ilości wyciśniętego materiału już po trzecim azotowaniu.
EN
In this work, the influence of the geometry of dies for extrusion of aluminum profiles on the amount of extruded material and durability of dies was analyzed. The dies that were provided for study were subjected to four- or five-fold gas nitriding and were exploited until they were finally worn out at the Albatros Aluminium company. In this article, an attempt was made to explain the influence of die geometry on the thickness of the nitrided layer, and thus, on the increase of their durability. Obtained results of studies made it possible to state that the amount of extruded material increases almost twice after the third nitriding and 2.5 times after the fourth nitriding, independently of the shape of the die. The die for extrusion of a flat-shaped profile made it possible to achieve a 2.5-fold increase of the amount of extruded material after only the third nitriding.
8
Content available Wear of tool during extrusion of materials with different properties – comparative numerical analysis
Nowotyńska I., Kut S.
TTS Technika Transportu Szynowego
|
2012
|
R. 19, nr 9
2763--2770, CD
EN
In this paper comparative numerical simulation of wear die during extrusion of metals with different properties was presented. Description of working condition, geometry and material of tools has been given. Simulation of tool wear during extrusion with using MSC MARC program based Finite Element Method has been carried out. As a result of such studies was determined dies at the depth of their wear of various metals.
PL
W pracy zaprezentowano numeryczną analizę porównawczą zużycia matrycy podczas wyciskania współbieżnego różnych metali. Podano warunki pracy, geometrię oraz materiał, z którego wykonano badane narzędzie. Symulację zużycia narzędzia w procesie wyciskania współbieżnego przeprowadzono przy użyciu programu MARC/Mentat, bazującego na Metodzie Elementów Skończonych. W wyniku przeprowadzonych badań wyznaczono m.in. głębokości zużycia matrycy podczas wyciskania różnych metali.
9
Content available Development of lapping tools for mirror-like surface processing of cemented carbide die
Soe Y. H., Tanabe I., Iyama T., Nishiyama S.
Journal of Machine Engineering
|
2012
|
Vol. 12, No. 1
66--75
EN
Recently, cemented carbide dies are used for many industrial products, due to their high stiffness and long life. Electric discharge machining is conventionally used and then, hand lapping is finally undergoes for mirror-like finishing of these products. In privious research, a simple lapping system for only plane surfaces of cemented carbide die was developed. In this study, several lapping tools for lapping of side, edge and corner were developed and evaluated by experiments. The system consists of a lapping tool, lapping vessel and conventional NC milling machine. The lapping vessel is placed on the table of the NC machine and the lapping tool is fitted with the spindle of the NC machine. Cemented carbide work piece is sunk and fitted in the lapping slurry and lapping processing is taken using the developed tools. Each lapping tool consists of a coil spring for supplying lapping pressure and the NC program was made possible to move the lapping head to contact and leave the work surface regularly for catching new grains and dressing. These lapping tools were finally evaluated by experiments. It is concluded from the results that the developed lapping tools were capable of lapping side, edge and corner of the cemented carbide work pieces for mirror-like surface finishing.
10
Numeryczna analiza porównawcza zużycia matrycy podczas wyciskania metali o różnych właściwościach
Kut S., Nowotyńska I.
Hutnik, Wiadomości Hutnicze
|
2011
|
Vol. 78, nr 11
925--929
PL
W pracy zaprezentowano numeryczną analizę porównawczą zużycia matrycy podczas wyciskania współbieżnego różnych metali (Pb1, OT3, Al1, M1E). Podano warunki pracy, geometrię oraz materiał, z którego wykonano badane narzędzie. Symulację zużycia narzędzia w procesie wyciskania współbieżnego przeprowadzono przy użyciu programu MARC/Mentat, bazującego na Metodzie Elementów Skończonych. W wyniku przeprowadzonych badań wyznaczono m.in. głębokości zużycia matrycy podczas wyciskania różnych metali.
EN
In this paper comparative numerical simulation of wear die during extrusion of metals with different properties was presented. Description of working condition, geometry and material of tools has been given. Simulation of tool wear during extrusion with using MSC MARC program based Finite Element Method has been carried out. As a result of such studies was determined dies at the depth of their wear of various metals.
11
Numeryczna analiza wpływu kąta matrycy na deformację narzędzia podczas wyciskania
Nowotyńska I., Kut S.
Rudy i Metale Nieżelazne
|
2010
|
R. 55, nr 6
337-340
PL
W artykule zaprezentowano numeryczną symulację deformacji narzędzia (matrycy o różnym kącie stożka roboczego) podczas wyciskania współbieżnego. Podano warunki pracy, geometrię oraz materiał, z którego wykonano badane narzędzia. Symulację przemieszczenia narzędzia w procesie wyciskania współbieżnego przeprowadzono przy użyciu programu MARC/Mentat, bazującego na Metodzie Elementów Skończonych.
EN
In this paper numerical simulation of deformation tool (different die geometry) during extrusion was presented. Description of working condition, geometry and material of tools has been presented. Simulation of displacement tool during extrusion with using MARC/Mentat program based Finite Element Method has been carried out.
12
Content available remote Przenośna obrabiarka do reperowania dużych matryc
Szafarczyk M.
Mechanik
|
2010
|
R. 83, nr 2
100-100
13
Czy HSM wyprze EDM?
Dąbrowski L.
Świat Obrabiarek
|
2009
|
R. 4, nr 11-12
14-18
PL
W ramach obecnej, globalnej gospodarki światowej, produkcja w strefie europejskiej stale musi się przeciwstawiać rosnącemu naciskowi na globalne rynki ze strony głównie krajów azjatyckich, a tym samym podwyższać ciągle produktywność, jakość i elastyczność produkcji. Nie tylko poszczególne procesy rozwojowe czy produkcyjne, ale kompletne łańcuchy procesowe muszą ustawicznie podlegać całościowej optymalizacji w celu otwierania dalszych, potencjalnych możliwości ich racjonalizacji.
14
Ocena stanu stempla w procesie wykrawania
Czyżewski P., Moszczyński L.
Prace Naukowe Politechniki Warszawskiej. Mechanika
|
2009
|
z. 226
149-154
PL
W pracy podjęto próbę komputerowej symulacji zużycia stempla i matrycy wykrojnika połączoną z doświadczalną weryfikacją uzyskanych wyników. Do symulacji użyto pakiet MSC.Marc wsparty wysokorozdzielczą techniką pomiarową. Do analizy zarejestrowanych przebiegów wykorzystano transformację falkową, pozwalającą na precyzyjną lokalizację procesu pękania.
EN
At the work an attempt of the computer simulation to wear the blanking punch and the blanking die out was taken connected with the experimental verification of achieved results. For the simulation a MSC.Marc package backed up with the high-resolution measuring technique was used. Wave transformations were used for analysis of recorded courses, allowing for the precise localization of the process of cracking.
15
Content available remote Some aspects of designing process self piercing riveting
Mucha J.
Archiwum Technologii Maszyn i Automatyzacji
|
2009
|
Vol. 29, nr 4
91-101
EN
The self piercing riveting is a process of cold plastic joint shaping under pressure, where pressed tubular rivet cuts the upper sheet piece, and then interferes in the lower sheet pieces while expanding, locking the joint. The example analysis of effect of die impression form change on riveting force reduction and joint quality indicator change has been presented in this paper. The analysis of such a joining process has been performed using commercial MSC software. The numerical modeling enables effective tool form selection in terms of reduction of the energy consumption during joining process. The numerical simulation results are very valuable when designing such modern joints.
PL
Nitowanie bezotworowe jest procesem plastycznego kształtowania złącza pod naciskiem na zimno. Wtłaczany nit rurkowy przebija górną blachę, a następnie, rozszerzając się, wciska się w dolną blachę, blokując je. W artykule przedstawiono przykład analizy wpływu zmiany kształtu wykroju matrycy na zmniejszenie siły nitowania oraz zmianę wskaźników jakościowych złącza. Do analizy tego zagadnienia wykorzystano komercyjne oprogramowanie firmy MSC. Modelowanie numeryczne umożliwia efektywny dobór kształtu narzędzi pozwalający zmniejszyć energochłonność łączenia. Rezultaty symulacji numerycznej są nieocenione na etapie projektowania tych nowatorskich połączeń.
16
Content available remote Analiza montażu stempla z matrycą podczas procesu wyciskania drążonych torusów
Paszta P.
Technologia i Automatyzacja Montażu
|
2008
|
nr 2
28-31
EN
Theoretical investigation has been undertaken into the possibility of utilizing changes in the eccentric eye positioning relative to the axis of the whole container (receptacle) during direct extrusion in order to achieve a change in the radius of hollow product profile.
17
Content available remote Water mist effect on cooling range and efficiency of casting die
Władysiak R.
Archives of Foundry Engineering
|
2008
|
Vol. 8, iss. 4
213-218
EN
This project is showing investigation results of cooling process of casting die in the temperature range 570÷100 °C with 0.40 MPa compressed air and water mist streamed under pressure 0.25÷0.45 MPa in air jet 0.25÷0.50 MPa using open cooling system. The character and the speed of changes of temperature, forming of the temperture’s gradient along parallel layer to cooled surface of die is shawing with thermal and derivative curves. The effect of kind of cooling factor on the temperature and time and distance from cooling nozzle is presented in the paper. A designed device for generating the water mist cooling the die and the view of sprying water stream is shown here. It’s proved that using of the water mist together with the change of heat transfer interface increases intensity of cooling in the zone and makes less the range cooling zone and reduces the porosity of cast microstructure.
18
Content available remote Variation cutting speed on the five axis milling
Boujelbene M., Moisan A., Bouzid W., Torbaty S.
Journal of Achievements in Materials and Manufacturing Engineering
|
2007
|
Vol. 21, nr 2
7-14
EN
Purpose: The aim of this research is to make a study of the effective cutting speed variation in milling with a ball end tool. Then an experimental study of the effect of finishing strategies on surface texture, roughness is described. The material of a specific HB 300 pre-hardened mould steel Super Plast (SP 300). Design/methodology/approach: The methodology has consisted to determine cutting speed of each mode of tilt tool in five axes machining, and of proving a series of configurations and parameters combinations: cutting speed Vc, feed rate Vf, and tilt tool in multi-axis milling. Findings: This paper has investigated the effect of the tool orientation on the variation effective cutting speed, on the surface texture, while multi-axis milling. Experimental results have shown that disadvantages of three axes machining results from the existence of very low cutting speeds, even null when the tool axis is normal to the machined surface. This mode of machining generates a bad surface quality. Surfaces have a poor topography and important anisotropy. A suitable slope of the cutting tool by the means of the fifth machine tool axis, improves considerably work piece machined surface quality; Good micro-geometrical surface topography and lower surface roughness. Research limitations/implications: A possible future work would be the development of a general the phenomenal of the residual stress of the cutting on the five axis machining. The behavior of the residual stress studies are planed in the future. Practical implications: The relationship found between the effective cutting speed and surface texture work piece has an important practical implication since it allows selecting the best cutting condition combination from the points of view both the security and the economy for the established requirements in each case. Results are of great importance in for aerospace and automotive industry. Originality/value: The paper is original since the bibliographical review has allowed testing that, although works about these themes exist, none approaches the problem like it has been made in work.
19
Content available remote Turning-form electrode in ultrasonic-aided electrochemical finishing
Pa P. S.
Journal of Achievements in Materials and Manufacturing Engineering
|
2007
|
Vol. 21, nr 2
77-80
EN
Purpose: The ultrasonic-aided electrochemical finishing following traditional turning by a turning-form electrode for several die materials is demonstrated. Design/methodology/approach: A guide line for the design process is followed a scientific method including the design requirement, design development, detail design, and experimental analysis is adopted in the current study. The proposed design of turning-form electrode combined with the ultrasonic-aided electrochemical finishing is presented. Findings: Smaller end radius and smaller declination angle are associated with higher current density and provides larger discharge space and better polishing effect. The plate-shape electrode with small end radius and decreasing the surface area of top-view performs the best. The ultrasonic assistance can avoid the difficulty of dreg discharge in the electrochemical finishing, thus increasing the finishing effect. Research limitations/implications: The potential for electrode design and using ultrasonic energy transmitted to the electrolyte to assist discharging dregs out of electrode gap during the electrochemical finishing is yet to be explored. Practical implications: This process can be used for various turning operations including end turning, form turning, and flute and thread cutting. Through simple equipment attachement, the electrochemical finishing can follow the cutting on the same machine and chuck. Originality/value: It is great contribution that the ultrasonic-aided electrochemical finishing after turning process just needs quite short time than manual or machine finishing to make the surface of workpiece smooth and bright. An effective and low-cost finishing method after turning process is presented.
20
Content available remote Results of cooling of dies with water mist
Pietrowski S., Władysiak R.
Journal of Achievements in Materials and Manufacturing Engineering
|
2007
|
Vol. 25, nr 1
27-32
EN
Purpose: Intensification of die casting of car silumins wheels with use of the water mist instead of compressed air dies cooling in low pressure casting process were presented in the paper. Design/methodology/approach: Examinations of casting process parameters were carried out on the industrial workstation of casting car wheels under the low pressure and also with Magma computer simulating system. Findings: The temperature and the range of its variation were presented in characteristic points of the casting and the cooled die with use the compressed air and with the water mist. A scheme of the device for generating the water mist cooling the die and also the pictures of simulation of wheels casting process for researched cooling methods was given. Research limitations/implications: The manufacturing technologies with the permanent mould. Practical implications: Using the water mist to cooling of dies in die casting and low pressure casting process to intensify of cooling the die and to reduce the amount of casting spoilage. Originality/value: Using the water mist to cooling increases intensity of cooling of the die and the cast. It makes shorter the cycle of casting process as well as reduces the porosity of casts and increases mechanical properties: RP0,2, Rm, A5 and HB.
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