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Studies of mechanical and technological parameters and evaluation of the role of lustrous carbon carriers in green moulding sands with hybrid bentonite

Kamińska Jadwiga, Stachowicz Mateusz, Puzio Sabina, Angrecki Michał

Archives of Civil and Mechanical Engineering

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2023

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Vol. 23, no. 1

art. no. e11, 2023

EN

Green moulding sands containing special carbonaceous additives, which are the source of lustrous carbon (LC), are discussed in this paper. Five potential lustrous carbon carriers, i.e., two types of hard coal dust (No.1 and No.2), amorphous graphite (No.3) and two hydrocarbon resins (No.4 and No.5), were selected for tests as carbonaceous additives to conventional moulding sands. To better emphasize the differences in the additives used, reference green moulding sand (GMS1) was prepared and subjected to a wide range of basic tests focussed on technological parameters, such as permeability (Pw), friability (Fw), Dietert mouldability test (PD) and compactability (Z) and mechanical parameters, such as compressive strength (Rcw), tensile strength (Rmw), strength in the transformation zone (Rkw). The proposed comprehensive spectrum of tests was repeated on sands with five carbonaceous additives. The most important for the use of additives as carbon carriers was to interrelate the content of lustrous carbon (LC), loss on ignition (LOI) and the obtained results of mechanical and technological tests carried out on conventional moulding sands with the surface quality of iron castings. For this purpose, a series of iron castings was made in the prepared moulding sands and used for the assessment of surface quality based on a number of roughness parameters (Ra, Rz, Rp, Rq, Rv, Rlr, RSm). As a result of the studies it was found that the carbonaceous additives proposed for use help to obtain high-quality surfaces in iron castings.

2

Influence of reduced cutting speed values on operator safety and cutting tool life in the processes of manufacturing and regeneration of marine machinery parts

Labuda Wojciech, Charchalis Adam

Journal of KONBiN

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2022

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Vol. 52, iss. 3

1--25

EN

The research used shafts made of X5CrNi18-10 (AISI 304L) stainless steel, which is used, among others in the shipbuilding industry. The turning process was carried out on the CU500MRD universal lathe with the use of cutting inserts with a corner radius of 0.2; 0.4 and 0.8 mm. The measurement of the forces during machining was recorded using a Kistler dynamometer. Surface roughness measurements were made with a Waveline W20 profilometer. The research results are the basis for determining the safe range of application of stainless steel cutting parameters on conventional lathes, with the simultaneous analysis of the quality of the machined surface.

PL

W badaniach wykorzystano wały wykonane ze stali nierdzewnej X5CrNi18-10 (AISI 304L), która znajduje zastosowanie między innymi w przemyśle okrętowym. Proces toczenia zrealizowano na tokarce uniwersalnej CU500MRD z wykorzystaniem płytek skrawających o promieniu naroża 0,2; 0,4 oraz 0,8 mm. Pomiar sił podczas obróbki skrawaniem rejestrowano z wykorzystaniem siłomierza firmy Kistler. Pomiary chropowatości powierzchni wykonano profilometrem Waveline W20. Wyniki badań są podstawą do wyznaczenia bezpiecznego zakresu stosowania parametrów skrawania stali nierdzewnej na tokarkach konwencjonalnych, przy jednoczesnej analizie jakości powierzchni obrobionej.

3

The influence of changing of treatment condition on surface roughness parameter during turning process by wiper insert

Labuda Wojciech

Journal of KONES

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2019

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Vol. 26, No. 1

81--88

EN

One of the greatest problems of modern production techniques is the achievement of an appropriate quality at minimal costs and accompanied by the production efficiency increase. Therefore, while designing the production process. The technology used should have a considerable influence on the durability and reliability of machine parts to be produced. During finish treatment, the final dimensions as well as functional properties are imparted to a given element by application of proper treatment type. The engineer has a range of production techniques to choose for the proper surface layer formation. It is crucial to find a suitable solution which will meet the requirements as well as the work conditions of a given machine part. The article presents the results of influence of change of cutting parameters on surface roughness parameter during turning process of stainless steel. A shaft made of 304L stainless steel was used for the research. The chemical composition of steel was measured by Solaris-ccd plus optical spectrometer. The cutting process was carried out on a universal CDS 6250 BX-1000 centre lathes. Measurement of surface roughness was carried out by T8000 profilometer. The turning process was conducted by a cutting tool with Wiper insert. During the turning, the following machining parameters were used: cutting speed Vc [m/min], feed f [mm/rev], cutting depth ap [mm] and additionally changed nose radius r [mm], and tool cutting edge angle ϰr [º]. The results of measurements of Ra parameter underwent statistic analysis. The calculations were conducted by Statistica software.

4

Wpływ zmiany głębokości skrawania na wartość sił skrawania i parametr chropowatości powierzchni podczas toczenia czopów wałów

Labuda W., Kozyra D.

Zeszyty Naukowe Akademii Morskiej w Gdyni

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2016

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nr 96

82--92

PL

W artykule przedstawiono wyniki badań wpływu zmiany głębokości skrawania na wartość sił skrawania oraz parametr chropowatości powierzchni czopów wałów. Badania przeprowadzono na wałku o średnicy 50 mm wykonanym ze stali konstrukcyjnej S235JR. Proces toczenia czopów wału przeprowadzono na tokarce uniwersalnej kołowej CU500MRD. Podczas badań wykorzystano nóż tokarski z wymienną płytką skrawającą CCMT09T304 PF. Natomiast pomiar sił skrawania podczas toczenia rejestrowano przy użyciu siłomierza firmy Kistler. Pomiar parametrów chropowatości wykonano na profilometrze W20. Do badań wykorzystano również współrzędnościową optyczną maszynę pomiarową Baty Venture Plus oraz optyczny spektrometr emisyjny Solaris.

EN

The paper presents the results of influence of changes in the depth of cut on the value of the cutting forces and surface roughness parameters of shaft pins. The turning process of shaft pins φ 50 mm in diameter, made of S235JR steel was carried out on a CU500MRD universal machine. The lathing process was conducted by a cutting tool with CCMT 09T304 PF removable inserts. The measurement of cutting forces during turning was recorded using a dynamometer made by Kistler. The measurement of surface roughness parameter was performed by W20 profilometer. For research also used the Baty Venture optical coordinate measuring machine and the Solaris optical emission spectrometer.

5

The influence of treatment conditions on cutting forces and surface roughness

Labuda W.

Journal of KONES

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2016

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Vol. 23, No. 1

207--213

EN

One of the greatest problems of modern production techniques is the achievement of an appropriate quality at minimal costs and accompanied by the production efficiency increase. Therefore, while designing the production process, the technology used should have a considerable influence on the durability and reliability of machine parts to be produced. During finish treatment, the final dimensions as well as functional properties are imparted to a given element by application of proper treatment type. The engineer has a range of production techniques to choose for the proper surface layer formation. It is crucial to find a suitable solution which will meet the requirements as well as the work conditions of a given machine part. The article presents the results of influence of treatment conditions during turning of shafts on the cutting forces and surface roughness parameter. A roller made of S235JR steel was used for the research. The cutting process was carried out on a universal CDS 6250 BX-1000 and CU500MRD centre lathes. Measurement of cutting forces during lathing process used DKM 2010 and Kistler turning dynamometers. The turning process was conducted by a cutting tool with CCMT09T304 PF removable plate. During the turning, the following machining parameters were used: cutting speed Vc = 150 m/min, feed f=0.106 mm/rev and cutting depth ap = 0.5, 0.75, 1.0, 1.25, 1.5, 1.75 mm. The surface roughness was measured by T8000 profilometer.

6

Experimental study on the influence of burnish parameters on the surface roughness reduction index

Polanowski S., Labuda W.

Journal of KONES

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2016

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Vol. 23, No. 3

395--402

EN

The paper presents the research results of relationship between surface roughness reduction index KRa and three input parameters: burnishing speed Vn, feed fn and burnishing force Fn., and all combinations of levels of yields N measured for 48 points of experiment. The experiment was repeated 3 times. In order to select the model describing the results of tests, the stepping approximation analysis was performed. It relayed at incorporated into the model in following steps approximation elements function, giving the biggest decrease of the sum of squared deviations. The first approximation was based on the ternary monomial of the powers from 0 to 3 for each input value. This approximation aim was to show, that the index of surface roughness reduction does not depend on the burnishing speed in the made in the area of research. The reduced input parameters to two, i.e. fn and Fn. The plan of the experiment was brought to N = 12 and M = 12. The best approximation of test results obtained in the case of Laurent polynomial with stepping selection of elements. The biggest contribution to the decrease in the sum of squared deviations was element 𝑓𝑓𝑛𝑛 −1 ∙ 𝐹𝐹𝑛𝑛 3 , and then fn 2. The article shows that in the range fn {0.6:1.2} there was not information on the successful model and the lack of influence of f and Fn on the results of the experiment. It is postulated to retry the experiment for the feed f <0.6.