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1

Conceptualization of Industry 4.0 technology for the production of tailor-made furniture – a case study

Łukaszewicz Krzysztof, Urban Wiesław, Krawczyk-Dembicka Elżbieta

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2023

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Vol. 71, nr 1

art. no. e144587

EN

Production is becoming more customer-focused as it departs from delivering standardized mass products to market segments, and the emerging Industry 4.0 technologies render this much easier than before. These technologies enable two-way information exchange with customers throughout all the steps of product development, particularly in terms of tailor-made products. This study aims at presenting proposals of implementing Industry 4.0 technologies into the process of tailored products, where the product is customized for the customer from the start and where adjustments are also made at the manufacturing stage. The study also aims to build a concept of intensification of customer contact and to improve the process flow by applying Industry 4.0 technologies. The study’s subject is tailor-made furniture production, with individually designed products that are manufactured and installed at a customer’s facilities. The company in the study operates on a small scale. The study employs a case study methodology that shows how the process can be improved in terms of real-time effective customer contact and process flow. The huge potential of 3D visualization as well as augmented and virtual reality technologies are also demonstrated. The study concludes with several directions for further development of existing technology solutions.

2

Rozwój konstrukcji murowych w Polsce

Drobiec Łukasz, Jasiński Radosław

Materiały Budowlane

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2022

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nr 4

12--14

PL

Konstrukcje murowe w Polsce przez ostatnie dwadzieścia pięć lat mocno się rozwinęły. Wprowadzono nowe elementy murowe i zaprawy, dzięki czemu mury wznosi się obecnie szybciej i dokładniej. Zwiększono wymagania dotyczące parametrów mechanicznych, cieplnych i akustycznych ścian murowanych. Opracowano zaprawy do cienkich spoin oraz kleje do łączenia elementów murowych. W artykule przedstawiono stan obecny i perspektywy rozwoju konstrukcji murowych.

EN

Masonry structures in Poland have developed significantly over the last twenty-five years. New masonry elements and mortars were introduced, thanks to which the walls are now erected faster and more accurately. The mechanical, thermal, and acoustic parameters of masonry walls were increased. Mortars for thin joints and adhesives for joining masonry elements have been developed. The article presents state and development prospects of masonry structures.

3

The Effect of the Return Material Implementation into the Production of Silumin Casts on Technological and Economic Indicators of Production Process

Gaspar S., Majernik J., Trytek A., Podaril M., Benova Z.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 1

69--76

EN

The production of high pressure die casts also brings difficulties regarding the processing of the waste material. It is mainly formed by runners, overflows and other foundry supplements used and, in the case of machines using the cold chamber, also the remainder from this chamber. As this material is often returned to the production process, we refer to it as return material. In the production process, it is therefore essential to deal with the proportion issue of return material against primary material that can be added to the melt to maintain the required cast properties. The submitted article monitors the quality properties of the alloy, selected mechanical properties of casts and porosity depending on the proportion of the return material in the melt. At the same time, the material savings are evaluated with regards to the amount of waste and the economic burden of the foundries. To monitor the above-mentioned factors, series of casts were produced from the seven melting process variants with a variable ratio of return to the primary material. The proportion ratio of return material in the primary alloy was adjusted from 100% of the primary alloy to 100% of the return material in the melting process. It has been proven that with the increasing proportion of the return material, the chemical composition of the melt changes, the mechanical properties of the alloy decrease and the porosity of the casts increases. Based on the results of the tests and analyzes, the optimal ratio of return and primary material in the melting process has been determined. Considering the prescribed quality of the alloy and mechanical properties, concerning the economic indicator of the savings, the ratio is set at 70:30 [%] in favor of the primary material.

4

Cast Structures Improving Thermalm Conductivity for Energy Storage

Raźny Natalia M.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 2

11--16

EN

Thermal energy encounters a huge demand in the world, part of which can be met by renewable energy sources, such as solar energy, and storage of thermal energy surplus from industrial processes. For this purpose, thermal energy storage (TES) units, in which heat is stored, are developed. The energy is accumulated by phase change materials (PCM) characterized by high phase transition enthalpy. PCMs have poor thermal conductivity; therefore, to take full advantage of their capabilities and to accelerate the charging and discharging cycle, metallic structures are used. These structures are manufactured using investment casting technology. Creating models with additive methods, such as 3D printing, allows obtaining complex shapes with high accuracy, such as thin-walled castings. At a large scale, the method may not be cost-effective. In this paper, the heat exchanger models were made from PLA and the castings - from AC44200 aluminum alloy. Investment casting requires the proper selection of parameters, such as the right material for the model, the selection of the firing temperature, the adjustment of the temperature of the molten metal, the temperature of the mold, and the pressure in it. Misaligning any of the parameters can lead to imperfections on the finished casting. Based on the model roughness study, it was found that minor roughness and higher accuracy are presented by the lower parts of the casting, while weaker performance is observed for the upper parts. Metal castings in a salt PCM environment may be subjected to corrosion. Therefore, the authors proposed to produce protective coatings on aluminum castings by the PEO method - plasma electrolytic oxidation. Porous ceramic thin films consisting mainly of alumina were obtained. The next tests will be aimed to confirm whether this layer will not negatively influence the thermal conductivity of the thermal energy storage.

5

Innovative Development of a Flying robot with a Flexible Manipulator for Aerial Manipulations

Yotov Yavor, Zlatov Nikolay, Hristov Georgi, Zahariev Plamen, Le Chi Hieu, Gao James, Chu Anh My, Nguyen Ho Quang, Huynh Le Minh, Bui Trung Thanh, Mahmud Jamaluddin, Packianather Michael S.

Annals of Computer Science and Information Systems

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2022

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Vol. 33

49--54

EN

This paper presents an innovative development of a flying robot or an aerial robot, with a flexible manipulator, called the Dexterous Aerial Robotic System (DFTS), for aerial manipulations, especially for inspections and reparations of various structures such as wind turbines, power lines and open gas pipelines, decorations and painting of high industrial chimneys and walls of high buildings, as well as transport and delivery of courier shipments, relocation and manipulation of assemblies and units in inaccessible or dangerous environments. The proposed DFTS consists of two independent but interconnected systems or functional units, which have two main separate functions respectively, including a basic carrying function, and a precise positioning and stabilization function. The system with a basic carrying function is actually the main flying system, the un-manned aerial vehicle (UAV); it is remotely controlled and piloted. Meanwhile, the aerial manipulation platform, called the vertical take-off and landing platform VTOL, which is an active flying platform with 6 degrees of freedom (DOF) is used for positioning and stabilization; and it is attached to the UAV via the soft link. With the use of a long soft link, the problems which are caused by the air turbulent flows generated by the UAV are minimized, and the aerial manipulations of objects are safely controlled and operated. The VTOL which is equipped with a grasping mechanism was successfully developed, prototyped and tested. The experimental results showed that, the developed VTOL can self-stabilize with the inclination angle of being up to 8 degrees.

6

Integration of Virtual Engineering and Additive Manufacturing for Rapid Prototyping of Precision Castings

Krutiš V., Šprta P., Kaňa V., Zadera A., Cileček J.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 1

51--55

EN

The present paper is concerned with the practical interconnection between virtual engineering tools and additive model manufacturing technologies and the subsequent production of a ceramic shell by rapid prototyping with the use of Cyclone technology to produce the aluminium casting prototype. Prototypes were developed as part of the student formula project, where several parts originally produced by machining were replaced by castings. The techniques of topological optimization and the combination with the tools of the numerical simulation were used to optimise the virtual prototype before a real production of the first prototype. 3D printing of wax pattern ensured direct and fast assembly of the cluster without any additional operations and troubles during dewaxing. The shell was manufactured in 6 hours thanks to a system of quick-drying of individual layers of ceramic shell. It has been verified that the right combination of individual virtual tools with the rapid prototyping can shorten the development time and delivery of the first prototypes from a few months to a few weeks.

7

Robotization of the process of removal of the gating system in an enterprise from the automotive industry

Bucior Magdalena, Kluz Rafał, Kubit Andrzej

Technologia i Automatyzacja Montażu

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2020

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nr 1

10--15

EN

Cleaning and removal of components of the gating system, and finishing of castings are the most labor-consuming and damaging to health foundry processes. This paper presents the results of an analysis of labor consumption of the process of removal of gating systems of aluminium castings, which were carried out in a conventional manner using a band saw and a boring machine, and using an industrial robot. In the final part of this paper the analysis of occupational hazard of work-stands is presented. It has been shown that the use of robotization leads to an increase both the productivity of the process and work safety. The use of an industrial robot allows to reduce the labor consumption of the process of removal of gating systems by 29,5% in relation to the non-robotized stand. Furthermore, on the robotized stand almost all the time needed for the process of removal of the gating system is connected with the machining. It represents 98.7% of the production cycle. In the case of non-robotized stand, the machining takes 79% of the total time required for treatment of one piece of the casting.

PL

Oczyszczanie, usuwanie elementów układu wlewowego oraz wykańczanie odlewów należą do najbardziej pracochłonnych, szkodliwych dla zdrowia oraz niebezpiecznych procesów odlewniczych. W pracy przedstawiono analizę pracochłonności procesu usuwania układów wlewowych odlewów aluminiowych, realizowanego w sposób konwencjonalny z zastosowaniem pilarki taśmowej i wytaczarki oraz z zastosowaniem robota przemysłowego. W końcowej części pracy dokonano analizy ryzyka zawodowego stanowisk pracy i wykazano, że wprowadzenie robotyzacji procesu prowadzi do zwiększenia jego wydajności oraz bezpieczeństwa pracy. Zastosowanie robota przemysłowego umożliwia zmniejszenie pracochłonności procesu usuwania układów wlewowych o 29,5% w stosunku do stanowiska niezrobotyzowanego. Na stanowisku zrobotyzowanym, niemalże cały czas potrzebny na realizację procesu usuwania układu wlewowego jest poświęcony na obróbkę właściwą. Stanowi ona 91% cyklu produkcyjnego. W przypadku stanowiska niezrobotyzowanego, obróbka właściwa zajmuje 80% całego czasu potrzebnego na obrobienie jednej sztuki odlewu.

8

How to measure the supplier involvement?

Wieteska Grażyna

Gospodarka Materiałowa i Logistyka

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2019

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nr 8

29--39

EN

Increasing a degree of supply chain integration is a common strategy today. Therefore, more and more companies decide to implement joint projects with their first tier suppliers. One of the examples of such projects is the joint product development. The purpose of this paper is to present a comprehensive framework of the measurement of supplier involvement (SI) in product development based on the systematic literature review. SLR covered 126 papers published between 1989 and August 2018 in three databases of well-known journal publishers. The results of in-depth analysis of previous quantitative and qualitative research allowed to develop the proposition of supplier involvement measurement. It consists of three constructs, which are: 'degree of supplier involvement', 'partnership in product development process' and 'communication during product development'. They are all expressed with the twenty six different items. The developed SI measurement approach can be used for quantitative research on NPD or other projects implemented in cooperation with suppliers as well as different business partners. The paper is a result of the project "Flexibility in relationships with suppliers in terms of supplier-purchaser models of cooperation on product development in the B2B market", no. 2016/21/B/HS4/00665, that is financed by the National Science Centre (NCN) in Poland.

PL

Firmy ukierunkowują dziś swoje działania na zwiększanie stopnia integracji w łańcuchu dostaw. W związku z tym, coraz więcej przedsiębiorstw decyduje się na realizowanie wspólnych projektów razem ze swoimi bezpośrednimi partnerami gospodarczymi. Jednym z przykładów takich projektów jest rozwój produktów z dostawcami (ang. Supplier Involvement, SI). Celem artykułu jest zaprezentowanie ram kompleksowego pomiaru włączania dostawców w rozwój produktów w oparciu o systematyczny przegląd literatury. Badanie objęło 126 artykułów opublikowanych pomiędzy 1989 a 2018 rokiem w trzech znanych międzynarodowych bazach czasopism. Rezultaty pogłębionej analizy poprzednich, zarówno ilościowych jak i jakościowych, badań pozwoliły na opracowanie kompleksowego podejścia do pomiaru SI. Składa się on z trzech konstruktów, którymi są: „stopień włączenia dostawcy w rozwój produktu”, „partnerstwo w procesie rozwoju produktu” oraz „komunikacja podczas rozwoju produktu”. Wszystkie trzy konstrukty wyrażone zostały dwudziestoma sześcioma zmiennymi. Zaproponowany pomiar może być wykorzystywany w przyszłych badaniach ilościowych, których przedmiotem są nie tylko projekty o tematyce rozwijania produktów w relacjach z dostawcami, ale także projekty o innej tematyce prowadzone z pozostałym interesariuszami. Artykuł napisany został w ramach realizowanego projektu o numerze 2016/21/B/HS4/00665, pt. „Elastyczność w relacjach z dostawcami a rodzaje współpracy dostawca-nabywca w zakresie rozwijania produktów na rynku B2B”, który uzyskał finansowanie z Narodowego Centrum Nauki.

9

The Influence of Abrasive Paste on the Effects of Vibratory Machining of Brass

Bańkowski D., Spadło S.

Archives of Foundry Engineering

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2019

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iss. 4

5--10

EN

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

10

Influence of Runner Geometry on the Gas Entrapment in Volume of Pressure Die Cast

Majernik J., Podařil M.

Archives of Foundry Engineering

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2019

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iss. 4

33--38

EN

The high pressure die casting technology allows the production of complex casts with good mechanical properties, with high production repeatability within narrow tolerance limits. However, the casts are somewhat porous, which may reduce their mechanical properties. There are several recommendations for reducing the porosity of casts, which are aimed at setting the technological parameters of the casting cycle. One of the primary and important ways to reduce the porosity and air entrapment in the melt is a suitable gating system design. Submitted contribution is devoted to assessing the influence of the runner branching geometry on the air entrapment within the cast volume during the filling phase of the casting cycle. Four variants of the gating system for a particular cast are compared with different design of main runner branching. The initial design is based on a real gating system where the secondary runner is connected to the main runner at an angle of 90 °. The modified designs are provided with a continuous transition of the main runner into the secondary ones, with the change in the branching runner radius r1 = 15 mm, r2 = 25 mm and r3 = 35 mm. The air entrapment in the melt is assessed within the cast volume behind the cores, which have been evaluated as a critical points with respect to further mechanical treatment. When designing the structural modification of geometry it was assumed that by branch changing using the radius value r3 = 35 mm, the melt flows fluently, and thus the value of the entrapped air in the volume of the cast will be the lowest. This assumption was disproved. The lowest values of entrapped air in the melt were found in the casts with runner transition designed with radius r1 = 15 mm. The conclusion of the contribution explains the causes of this phenomenon and from a designing point of view it presents proposal for measures to reduce the entrapment of the air in casts.

11

Analysis of Interaction between Position of Gate and Selected Properties of Low-Weight Casts on the Silumin Basis

Majernik J., Gaspar S.

Archives of Foundry Engineering

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2019

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iss. 3

106--110

EN

Final quality of casts produced in a die casting process represents a correlation of setting of technological parameters of die casting cycle, properties of alloy, construction of a die and structure of gating and of bleeding systems. Suitable structure of a gating system with an appertaining bleeding system of the die can significantly influence mechanical and structural properties of a cast. The submitted paper focuses on influence of position of outfall of an gate into the cast on its selected quality properties. Layout of the test casts in the die was designed to provide filling of a shaping cavity by the melt with diverse character of flowing. Setting of input technological parameters during experiment remained on a constant level. The only variable was the position of the gate. Homogeneity represented by porosity f and ultimate strength Rm were selected to be the assessed representative quality properties of the cast. The tests of the influence upon monitored parameters were realized in two stages. The test gating system was primarily subjected to numerical tests with the utilization of a simulation program NovaFlow&Solid. Consequently, the results were verified by the experimental tests carried out with the physical casts produced during operation. It was proved that diverse placement of the gate in relation to the cast influences the mode of the melt flowing through the shaping cavity which is reflected in the porosity of the casts. The experimental test proved correlation of porosity f of the cast with its ultimate strength Rm. At the end of the paper, the interaction dependencies between the gate position, the mode of filling the die cavity, porosity f and ultimate strength Rm.

12

Optimisation of a Production System in the Process of Remelting of Post-Reduction Slag by Applying New Physical and Chemical Conditions

Bydałek A. W., Wołczyński W., Wędrychowicz M., Holtzer M., Basiura B., Palimąka P.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 4

5--8

EN

Production processes at KGHM are complex and require from customers products of constantly higher quality at relatively lowest prices. Such situation results in an increase of the importance of optimisation of processes. As products and technologies change rapidly, technologists at the plant in Głogów have less time to achieve optimisation basing on own experiences. Analysing a particular process, we can e.g. detect occurring disturbances, find factors having an influence on quality problems, select optimal settings or compare various production procedures. Analysis of the course of production process is the basis of process optimisation. One optimisation in case of the process of decopperisation of flash slag can be a change of a technological additive to a less energy-consuming one, and its final result can be an improvement of the productivity index, a change of the relation between final effects and born expenditures, as well as optimisation of production costs.

13

Monitoring of Manufacture Stability of Large Turbine Blades Using Infrared Thermography (IRT) in Investment Casting Technology

Herman A., Vrátný O., Kubelková I.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 4

9--14

EN

With increasing technology development, an increasing emphasis is placed on the precision of products, but cannot be guaranteed without a stable production process. To ensure the stability of the production process, it is necessary to monitor it in detail, find its critical locations and eliminate or at least control it. With such a precise manufacturing method as investment casting, such a process is a must. This paper therefore deals with monitoring the production process of wax models of large turbine blades using infrared thermography. The aim was to evaluate the critical locations of this production and to propose recommendations for their elimination or, at the very least, significant mitigation of their impact on the final quality of the large turbine blade casting.

14

Increasing the Capability of the Process of Placing Inserts in Foundry Moulds

Jaworski J., Kluz R., Trzepieciński T.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 2

187--190

EN

This article discusses the issue of the preparation of the foundry moulds with the use of an industrial robot. The methodology is presented for the determination of the process capacity index for placing inserts with flat and cylindrical faces. On the basis of the relationships developed, the process capability indices were determined at various points in the workspace, which are characterised by different values of the repeatability positioning error. It was shown that the value of the process capacity index can be increased by the selection of a suitable location for the process of placing the inserts in the workspace. It should also be noted that the value of the process's capability index depends on the selection of the place in the robot workspace where the process is carried out. Implementation of the joining process at an analysed point in the robot workspace leads to an increase of the process capability index MCp for inserts with flat faces up to 1.1 (+4.5%) and for inserts with cylindrical faces up to 1.3. This results in an increase of 13% to a level corresponding to the global standard for process reliability (MCp = 1.33).

15

Challenges in Producing Reliable Tensile Properties by SIMA 7075

Erzi E., Gursoy O., Yüksel Ç.O.K., Kirtay S., Dispinar D.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 3

71--75

EN

Aluminium alloys are one of the preferred materials especially for land and air transportation because of their high strength and low-density properties. Although production using casting method is economical yet it has some disadvantages. Shrinkage which is occurred due to the density difference between the solid and liquid metal is prevented by feeders which need to be calculated. Liquid metal should be transferred to the mould without any turbulence. As a result, sprues are needed to be designed precisely. On the other hand, aluminium alloys can also be shaped by forging at semi-solid temperatures. There are some advantages compared to the traditional forging methods of improving die life due to the lower tonnage values. In this study, semi-solid produced 7075 aluminium alloy die filling capabilities were investigated. To achieve semisolid structure strain induced melt activated method (SIMA) was used. The desired structure was achieved at 635°C and 30 minutes of duration of heat treatment. After determining the optimum parameters, metallographic analysis, density calculations, porosity distribution and tensile tests were carried out. It was found that the reproducibility of SIMA produced 7075 alloy was quite low. A proper tensile test result was achieved only 7 of the total 15 tests and the mean value was 386 MPa. The main reason for this scattered in mechanical properties could be the chemical composition of the alloy and the rapid solidification of the liquid eutectic phases. It is important to define the best fitting process parameters and controlling them precisely will be the most important factors for future studies.

16

Stimuli of collaboration in product development: a case study in a project manufacturing company

Jääskeläinen A., Heikkilä J., Hiidensalo A., Thitz O.

Management and Production Engineering Review

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2017

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Vol. 8, No. 4

13--26

EN

There is already a wide acceptance on the importance of involving supplier and customer companies in product development. Decent understanding prevails on the relationshiporiented approach to product development including various collaboration forms. However, there is less research on the factors explaining the decision of attending to joint product development. In addition, less studies have examined the integrated role of both suppliers and customers in product development initiatives. This study searches answers to the following research questions: 1. What is the role of different actors in product development initiatives? 2. What factors motivate suppliers and customers to participate in product development? The research is carried out as an in-depth qualitative single case study in a large project manufacturing company. It takes the perspective of a focal company striving for product improvements. The first part of the empirical study consists of 15 semi-structured interviews. The second part includes two discursive workshops and builds upon the results of the interviews. This study contributes to the existing research by explaining the challenges and conditions facilitating joint product development with supplier and purchaser companies. The results highlight the role of customers in improving the effectiveness of product development. As a practical contribution, the paper reports the application of workshop method as a facilitator of collaboration between supplier, purchaser (focal company) and customer companies.

17

Computer aided adaptive system design with engineering systematics and manufacturing

İrsel G.

Advances in Science and Technology. Research Journal

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2017

|

Vol. 11, no 4

83--96

EN

This research practically discusses and presents the stages of design process in product development. Design process was realized through CATIA. The product developed is an agricultural device called as “disc harrow”. Therefore, agricultural details are presented together with machine design. A roller system is added to disc harrow in this study. Thus; the current system and the additional roller system are discussed with the principles of methodological construction and design objectives are defined. Both the current system and the additional roller system are designed in parallel with these objectives. Structural stress analysis is performed at different kinetic positions of the disc harrow connection of the roller system. System design is achieved by considering the feedback from such analyses and design objectives. The hereby design is obtained. The additional roller system is mounted and field survey is carried out. Contribution of the roller to disc harrow process, defined design objectives, ratio of the realization of design objectives and results of stress analyses are evaluated.

18

Analysis of axle shaft fatigue failure and anti-fatigue system design

İrsel G.

Advances in Science and Technology. Research Journal

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2017

|

Vol. 11, no 3

150--163

EN

In this study, an axle shaft subjected to static deformation and fatigue damage was considered by using computer-aided engineering. This shaft system was modeled with CATIA and subjected to dynamic fatigue analyses with Ansys workbench. The damaged fracture surfaces of the shaft have been examined. Thus, the fatigue and damage was revealed in greater detail. For the present system, a design with a minimum cost, short production process, minimum weight was sought together with methodical construction principles. By means of CATIA and ANSYS, the product development design with reasonable tension and deformation values was formed for endless life fatigue. A design was produced in a short space of time with the help of 2D CATIA drawings and field tests were carried out. The design was used through 560.000 cycles and damage was not observed.

19

Zagadnienie ryzyka w rozwoju produktu

Siuta-Stolarska B.

Zarządzanie Przedsiębiorstwem

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2016

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Vol. 19, nr 1

29--36

EN

The paper shows specifics of product development process, its unique character and changing conditions influencing its realisation. It also points most important risks, that might significantly influence efficiency of product development process. In the paper, author suggested three strategies (Postponement, Mass Customization and Collective Customer Commitment) that allow to reduce risks in the product development process and consequently may increase products’ success chance and efficiency of product development process itself. The paper emphasises also the meaning of appropriate risk management in reducing consequences and chances of occurring risks during product development process. Special attention was given to engaging the client into the process of creating products’ value, so that both his and producers’ expectations can be met much more effectively.

20

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

Wołczyński W., Bydałek A. W.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 1

95--98

EN

The suspension of copper droplets in the slag is considered. The copper/slug suspension is delivered as the product from the direct-to-blister process which is applied in the KGHM – Polska Miedź (Polish Copper) S.A. factory. The droplets / slag suspension was treated by a special set of reagents (patented by the authors) to improve the coagulation process. On the other hand, the observations are made to estimate if the melting / reduction process in the furnace is sufficiently effective to avoid a remaining of carbon in the copper droplets. The coagulation process was carried out in the crucible (laboratory scale). However, conditions imposed to the coagulation / solidification process in the laboratory scale were to some extent similar to those applied usually in the industry when the suspension is subjected to the analogous treatment in the electric arc-furnace. Some suggestions are formulated how to improve the industrial direct-to-blister process.