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1

Experimental investigation and machining analysis of Mg/TiC composites during EDM

Dash Dharmeswar, Devarajaiah Devarasiddappa, Dash Santosh Kumar, Samanta Sutanu, Rai Ram Naresh

Composites Theory and Practice

|

2024

|

R. 24, nr 1

9--16

EN

Electrical discharge machining (EDM) is one of the prominent non-conventional machining processes used to machine metal matrix composites. Mg/TiC composites are found in many industrial applications and conventional machining of the same is highly challenging. This paper aims to study the machinability analysis of Mg/TiC composites using EDM with pulseon time (Ton), pulse-off time (Toff) and input current (I) as the process variables with the material removal rate (MRR) and surface roughness (SR) as the performance measures. Stir cast Mg-alloy reinforced with TiC (0, 5, 10, 15 and 20) by weight was used as the workpiece. The EDM experiments were conducted as per L25 orthogonal array (OA) and the results were analyzed to study the effect of the process variables on MRR and SR. The parametric study showed that SR increases linearly with Ton and is attributed to larger craters produced at a higher pulse energy. MRR was also observed to grows with the rise in Ton as more material melts due to high-intensity pulses. As per the ANOVA results, Ton was found to be the most influential process variable affecting SR and MRR with a 79% and 34% contribution, respectively. Surface morphology investigations using SEM micrographs revealed the presence of globules and sphere-shaped metal deposits and were found responsible for increased SR.

2

Evaluation of selected properties and surface quality of cured pre-impregnated carbon-fiber fabrics after exposure to sulphuric acid

Kojnoková Tatiana, Nový František, Markovičová Lenka, Harea Evgheni, Harea Evghenii

Production Engineering Archives

|

2023

|

Vol. 29, Iss. 1

1--6

EN

This paper deals with changes in selected properties of composite material and surface degradation after exposure to an acidic environment. A carbon fiber-reinforced composite (CFRP) produced from prepregs was tested. The weight change, micro-hardness, and surface degradation of the CFRP composite made of cured pre-impregnated laminates were evaluated in this study. Material consisting of a DT121R epoxy resin matrix with high reactivity and high viscosity, with two reinforcing carbon fabrics layers, is characterized by a low value of tensile strength. Evaluation of changes in the material properties was performed before and after exposure to specific environmental conditions, which are achieved by using a chemical solution of 15% H2SO4 at various temperatures. Subsequently, the effect of 15% H2SO4 at various temperatures on the material properties was monitored. The specimens were immersed in the solution for up to 3 and 6 weeks at the temperatures of 23°C, 40°C, and 60°C. It was found out, that the degradation of the composite material is conditioned by the aging of the epoxy resin (matrix). Carbon fibers (reinforcement) are relatively stable. The weight change, micro-hardness, and surface quality depend on the time of exposure to acidic solution and temperature. The micro-hardness tests show a significant influence on exposure time. The biggest changes in weight change and surface quality of the CFRP composite were observed after exposure at the temperature of 60°C.

3

Effects of EDM on the Chemical Composition and Microstructure of the Surface Layer of Alnico Alloys

Bańkowski Damian, Młynarczyk Piotr, Szwed Bartłomiej

Archives of Foundry Engineering

|

2023

|

Vol. 23, iss. 2

106--111

EN

This article deals with the effects of electrical discharge machining (EDM) on the chemical composition and microstructure of cast Alnico alloys, i.e., iron-based alloys composed of aluminum, nickel and cobalt. The experiments focused on determining the chemical composition of the surface layer before and after the EDM process. The microstructure of the material altered by the EDM was also examined. The study included measurement of the thickness of the white layer characteristic of EDM. It is evident that low values of the surface roughness parameters can be obtained by correctly selecting the EDM process parameters. The average surface roughness reported in the experiments was 1 μm. The surface roughness measurements were conducted with a Talysurf CCI lite non-contact profiler. The metrological results also indicate that lower surface roughness can be obtained at small discharge energies.

4

Initial assessment of the quality of road surfaces

Szczucka-Lasota Bożena, Waligóra Kamil, Węgrzyn Tomasz, Wszołek Łukasz

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

|

2022

|

z. 157

571--578

EN

Purpose: The aim of the article is to check the quality of the road and classify the selected road on a four-level scale. Design/methodology/approach: The paper outlines the impact of comprehensive road surface quality management on the safety of vehicles and road users. The basic types of road damage were presented, as well as preliminary diagnostics of a randomly selected national road was carried out. Visual tests were carried out to determine: the type and geometry of the pavement damage, the number of damage, the area covered by the damage. In the article the damage indicators were calculated. The results allowed for the assessment of the quality of the tested pavement and its classification on a four-point scale. Findings: The quality of the road surface was assessed and classified as level C. Research limitations/implications: In the future, it can be suggested to change the methodology of investigate the road. It is proposal to using drone with the application. Practical implications: The research indicates the need to plan the renovation of the road surface and suggests changing the surface material from construction asphalt to the new modified asphalt. Originality/value: The article indicates the need to amend the documents and the current methodology of the procedure.

5

Zgrzewanie oporowe w praktyce inżynierskiej

Lonkwic Paweł, Usydus Ireneusz

Obróbka Metalu

|

2022

|

nr 2

47--53

PL

Zgrzewanie oporowe, zarówno punktowe jak i liniowe wykorzystywane jest w wielu branżach. Z uwagi na krótki czas operacji obserwuje się szybki wzrostu liczby produkowanych detali tą technologią łączenia. Można ją stosować do łączenia materiałów, tzw. jednoimiennych oraz dwuimiennych (blach o różnych grubościach). W artykule przedstawiono analizę informacji literaturowych oraz rezultaty badań eksperymentalnych z tego zakresu, na podstawie których wskazano czynniki determinujące jakość połączeń wykonanych tą technologią.

EN

Point and linear resistance welding are used in many industries. Due to the short operating time, a rapid increase in the number of parts can be observed with this connection technology. It can be used to connect so-called one-name and two-name materials (sheets with different thicknesses).In this paper analyses literature information and experimental investigations on this domain were consisted. On the basis of experiments factors determining the quality of connections with this technology were identified. resistance welding, surface quality, connection strength.

6

Czynniki determinujące jakość powierzchni po frezotoczeniu

Słomion Małgorzata, Wojciechowski Andrzej, Matuszewski Maciej, Polishchuk Oleg

Obróbka Metalu

|

2022

|

nr 3

40--44

PL

W artykule przedstawiono technologię frezotoczenia. W szczególności scharakteryzowano uwarunkowania technologiczne determinujące jakość powierzchni po obróbce. Uwypuklono najważniejsze zalety i wady frezotoczenia.

EN

In this paper the technology of turn-milling is presented. In particular, the technological conditions determining the quality of the surface after treatment were characterized. The most important advantages and disadvantages of turn-milling are described too.

7

Finishing processes of additively manufactured metallic parts

Grzesik Wit, Rech Joël

Mechanik

|

2022

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R. 95, nr 10

33--37

EN

This review paper highlights some important finishing processes used in fabricating additively manufactured metalic parts, mainly using SLM (selective laser melting). In practice, there are applied hybrid processes which integrate additive and subtractive componential processes (AM + SM type) or additional finishing processes, mainly based on the electrochemical polishing such as ECP (electrochemical cavitation polishing) and PEMEC (electrochemical-mechanical polishing) ones. For conformal cooling (CC) channels AFM (abrasive flow machining) is predominantly recommended. Some conclusions and future trends in the implementation of hybrid processes are outlined.

PL

W artykule dokonano przeglądu procesów wykańczającego kształtowania złożonych wyrobów metalowych wytwarzanych techniką przyrostową, głównie poprzez selektywne topienie laserowe (SLM). W praktyce stosuje się kombinację kształtowania przyrostowego i ubytkowego (AM + SM) lub dodatkową obróbkę wykańczającą złożonych geometrycznie wyrobów z użyciem procesów konwencjonalnych i hybrydowych w celu uzyskania żądanych jakości powierzchni i właściwości użytkowych, m.in. przetłaczanie ścierne (AFM) do wykańczania powierzchni zewnętrznych oraz polerowanie elektrochemiczne wspomagane ultradźwiękami (ECP) i polerowanie elektrochemiczno-mechaniczne (PEMEC) do wykańczania konforemnych układów chłodzących.

8

Technological methods of ensuring the reliability of lock connections in marine gas turbines

Dvirna Olha, Zembrzuska Natasza

Journal of KONBiN

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2022

|

Vol. 52, iss. 3

149--163

EN

The article presents the test results of the surface quality parameters after broaching of heat-resistant steels of grades: 1.7335 (13CrMo4-5) and 1.4841 (X15CrNiSi25-20). The aim of the work is to determine the technological methods of obtaining the lowest treated surface roughness, surface layer hardening and the elimination of surface defects after broaching. To investigate the influence of cutting conditions (cutting speed, tool geometry and feed) on surface roughness and hardness, the physical modeling method of the broaching was used. As a result of the research, recommendations for improvement of the main parameters of the surface layer quality when broaching samples from selected grades of heat-resistant steels.

PL

W artykule przedstawiono wyniki badań parametrów jakości powierzchni po przeciąganiu stali żaroodpornych gatunków: 1.7335 (13CrMo4-5) i 1.4841 (X15CrNiSi25-20). Celem pracy jest określenie technologicznych sposobów uzyskania najmniejszej chropowatości obrobionej powierzchni, korzystnego poziomu umocnienia warstwy wierzchniej i eliminacji defektów powierzchniowych po obróbce skrawaniem. Aby zbadać wpływ warunków skrawania (prędkości skrawania, geometrii narzędzia i prędkości posuwu) na chropowatość i umocnienia powierzchni, zastosowana została metoda modelowania fizycznego procesu przeciągania. W wyniku badań opracowane zostały rekomendacje dotyczące podniesienia głównych parametrów jakości warstwy wierzchniej podczas przeciągania próbek z wybranych gatunków materiałów żaroodpornych.

9

Ocena jakości ściany wykonanej w technologii druku 3D za pomocą systemu analizy obrazu

Skibicki Szymon

Inżynieria i Budownictwo

|

2022

|

R. 78, nr 3-4

124--127

PL

W artykule przedstawiono pilotażowe badania dotyczące zastosowania systemu analizy obrazu do oceny jakości struktur wykonanych w technologii druku 3D kompozytów cementowych. Zaproponowany algorytm w sposób prawidłowy ocenia jakość powierzchni wydrukowanych elementów. Analiza nieciągłości mieszanki tą metodą może być przydatna nie tylko w ocenie estetyki wykonanych elementów, ale także możliwe jest jej powiązanie z właściwościami mechanicznymi, skurczem oraz trwałością drukowanej struktury.

EN

The paper presents a pilot study on the use of an image analysis system to assess the quality of structures made in the 3D printing technology of cementitious composites. The proposed algorithm correctly evaluated the surface quality of the printed elements. Analysis of the path discontinuity with this method can be useful not only in the assessment of the aesthetics of the manufactured elements, but also it is possible to link it with the mechanical properties, shrinkage and durability of the printed structure.

10

Analysis of surface quality after oxygen cutting

Krawczyk Ryszard, Słania Jacek

Biuletyn Instytutu Spawalnictwa w Gliwicach

|

2022

|

Vol. 66, No. 2

33--41

EN

The article discusses tests concerning surface quality after the oxygen cutting of steel plates of various thicknesses. The study involved visual tests, macro and microscopic metallographic tests as well as hardness measurements and the identification of hardness distribution in the cut zone and in the heat affected zone.

PL

Przedstawiono badania jakości powierzchni po cięciu tlenowym blach stalowych o różnej grubości. Przeprowadzono ocenę wizualną powierzchni próbek po cięciu tlenowym oraz wykonano badania makro- i mikroskopowe zgładów poprzecznych pobranych z próbek. Wykonano pomiary twardości i przedstawiono ich rozkład w strefie cięcia, a także w strefie wpływu ciepła.

11

The Effect of Reclaim Primary Quality on Moulding Sand Parameters and Quality of Ductile Iron Casting Surface Layer

Kamińska Jadwiga, Angrecki M., Puzio S., Stachowicz M.

Archives of Foundry Engineering

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2022

|

Vol. 22, iss. 2

83--88

EN

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.

12

Surface texture analysis of the X5CrNi18-10 steel after cutting with abrasive water jet and photon beam (laser)

Romanowski Marcin, Nadolny Krzysztof

Journal of Mechanical and Energy Engineering

|

2020

|

Vol. 4, No 4

365--374

EN

The article presents an analysis of the geometric structure of the surface of X5CrNi18-10 steel sheet after cutting with a abrasive water-jet (AWJ) and a photon beam (laser). Both methods and the workpiece material were also described. Using the laser triangulation method, the cut surface texture was measured by opto-digital microscopy. Additionally, microscopic images of the cut surface were made using the Dino-Lite Edge AM7915MZT microscope by ANMO Electronics Co. The analysis of changes in the value of the Sa parameter for the surface after laser cutting and abrasive water-jet showed that the thickness of the cut material has the most significant influence on the obtained measurement results.

13

Effect of cutting parameters and machining environments on the chips characteristics and surface quality of commercial high-conductive materials

Kaiser Mohammad Salim, Rahman Khandaker Tawshif, Ahmed Sheikh Reaz

Journal of Mechanical and Energy Engineering

|

2020

|

Vol. 4, No 4

325--334

EN

The present paper is on the physical and mechanical characterization of machined chips of commercially available highly conductive materials, namely aluminium and copper under different machining environments. More specifically, geometry and hardness of chips as well as the chips removal effect on the machined surfaces are investigated in a quantitative fashion as a function of machining fluid and cutting parameter. The machining is carried out using a horizontal shaper machine with a V-shaped HSS tool under three different machining fluids, where the feed rate is kept constant, while the cutting speed and depth of cut are varied. Results show that chips attain the lower hardness in dry machining conditions than those of under kerosene and soluble oil as a phenomenon alike to hot rolling. Discontinuous chips are formed at low depth of cut for Al and higher depth of cut for Cu in dry condition. Cutting fluid offer improved surface quality through less friction and built up edge formation. Cu generates more heat than Al since copper is harder than aluminum and cutting speed is more effective than depth of cut.

14

Simulation of the contact temperature in the cylindrical plunge grinding process

Syzyi Yurii, Ushakov Oleksandr, Slipchenko Serhii, Basova Yevheniia, Ivanova Maryna

Diagnostyka

|

2020

|

Vol. 21, No. 2

77--86

EN

The intensifying of the manufacturing process and increasing the efficiency of production planning of parts are the first-priority task in modern manufacturing. The use of various methods for controlling the cutting force and temperature in cutting zone under cylindrical infeed grinding and studying its impact on the quality and accuracy of parts machining can improve machining efficiency. The peculiarity of the work is to the proposal to consider a fast-moving source like a heat source in the plunge grinding process. Based on the Peclet analysis, the further development of the method for calculating the allowance removed at each workpiece revolution by optimizing the cylindrical plunge grinding cycle parameters has been justified. The methodology for determining the optimal parameters of a cylindrical plunge grinding cycle, which based on a simulation of the dynamics of such a process represented by a three-mass model of a 3M151 circular grinding machine has been used in research. The practical value of the study lies in studying the ways of improving the grinding performance of the parts by intensifying cutting modes and optimizing the structure of machining cycles.

15

The cutting of steels using various methods

Pocica Anna, Kochanek Dawid

Biuletyn Instytutu Spawalnictwa w Gliwicach

|

2020

|

Vol. 64, No. 3

77--81

EN

The article describes tests of steel subjected to cutting with laser, plasma and abrasive waterjet. The research discussed in the article also involved microstructure observation and changes in hardness after cutting are as well as the assessment of surface quality based on measurements of surface parameters.

16

Sustainable manufacturing: re-contouring of laser cladding restored parts by machining method with cutting energy management

Zhang Peirong, Du Jin, Zhou Tingting, Su Guosheng, Huang Weimin, Liu Zhanqiang

Archives of Civil and Mechanical Engineering

|

2020

|

Vol. 20, no. 2

167--176

EN

Laser cladding has been commonly utilized for restoring high value-added parts. However, the poor surface quality becomes key technological barrier which restricts its widespread applications. In the paper, re-contouring strategies by machining method are explored for minimal energy consumption as well as required surface roughness. Firstly, the effect of structural characteristics of the laser-cladded workpiece on specific cutting energy was explored by means of layer-by-layer turning and orthogonal cutting. Results indicated that the specific cutting energy increased, and the machining chatter/vibration exacerbated with decreasing coating thickness under fixed cutting parameters. The reason can be summarized as a result of the effect of elastoplastic deformation behavior across the interface. Then, the influences of depth of cut and feed on specific cutting energy in finish turning were addressed. Results indicated that the specific cutting energy reduced with increasing depth of cut and feed in the form of power functions. In addition, energy efficiency decreased with an increase in uncut chip thickness and cutting speed. On basis of this work, large feed and low cutting speed with the adoption of wiper inserts were recommended for minimizing energy consumption within surface roughness requirement.

17

Comparison of composite laminates machining methods and its influence on process temperature and edge quality

Jaśkiewicz Robert

Transactions on Aerospace Research

|

2019

|

Nr 4 (257)

46--54

EN

The article presents the description of technological trials and the results of three methods of machining carbon fiber reinforced composites panels. It also reviews the literature concerned heat affected zone in composites and its influence on material properties. As a part of the research, the cutting method using diamond coated saw was tested, as well as the milling method with two different types of carbide milling cutters. The processing of the panels was done using 4-axis CNC machine with special adapter for cutting discs in Composite Testing Laboratory (Center for Composite Technologies, Warsaw Institute of Aviation). The methods were compared in terms of machined edge quality and panel temperature during the processes. For this purpose, thermocouples were mounted into panels. Records from thermocouples were included. Edge quality and surface roughness have been checked by microscopic observation. Additionally, samples machined by each evaluated processing method were tested using differential scanning calorimetry (DSC). The method was used to determine the glass transition temperature of the tested material. The article conclusions contain a comparison of three processing methods in terms of cutting quality, process temperature, processing method productivity as well as DSC tests results.

PL

W niniejszym artykule zawarto opis i rezultaty trzech metod obróbki materiałów kompozytowych wzmocnionych włóknami węglowymi. Artykuł zawiera przegląd literaturowy tematu wpływu ciepła podczas obróbki na właściwości obrabianych materiałów kompozytowych. W ramach wykonanych prób użyto tarczy z nasypem diamentowym i dwóch różnych frezów węglikowych. Testy zostały wykonane z użyciem 4-osiowego plotera frezującego z agregatem do tarcz tnącym w warsztacie Laboratorium Badań Kompozytowych w Instytucie Lotnictwa w Warszawie. Metody obróbki zostały porównane pod względem uzyskiwanej jakości krawędzi cięcia i temperatury podczas procesu. W artykule zawarto wykresy zapisów temperatury z termopar umieszczonych w panelach testowych. Jakość i chropowatość uzyskiwanych podczas cięcia powierzchni zostały porównane podczas obserwacji mikroskopowych. Dodatkowo wykonano testy sprawdzenia temperatury zeszklenia próbek z obrabianych obszarów z użyciem kalorymetru różnicowego. Wniosku artykułu podsumowują testy z uwzględniając rezultaty przeprowadzonych testów obróbki, wyniki DSC i możliwości produkcyjne.

18

Wpływ reaktywnego trawienia jonowego wspomaganego plazmą BCl3 na jakość powierzchni węglika krzemu 4H-SiC

Stonio Bartłomiej, Kwietniewski Norbert, Firek Piotr, Słowikowski Mateusz, Pavłov Krystian, Caban Piotr, Sochacki Mariusz, Szmidt Jan

Przegląd Elektrotechniczny

|

2019

|

R. 95, nr 9

175--177

PL

Jakość powierzchni materiałów po wykonaniu procesów technologicznych jest ważnym zagadnieniem niezbędnym do zoptymalizowania przy próbie wykonania dobrej jakości przyrzadów półprzewodnikowych. W zależnosci od parametrów procesu, jakość powierzchni się zmienia. W niniejszej pracy zaprezentowano wpływ parametrów suchego trawienia RIE (ang. reactive ion etching) wspomaganego plazmą BCl₃ na jakość powierzchni węglika krzemu 4H-SiC. Podczas prac modyfikowano moc dostarczaną do reaktora, ciśnienie w reaktorze stosunek gazów roboczyhc oraz czas trawania procesu. Powierzchnia materiału po trawieniu została zobrazowana za pomocą wysokorozdzielczego skaningowego mikroskopu elektronowego SEM (ang. scanning electron microscope). Chropowatość została zmierzona za pomocą mikroskopu sił atomowych AFM (ang. atomic force microscope).

EN

The quality of material surface after technological process is one of the most important issue, during semiconductors device manufacturing. The quality of the surface is changing depending on parameters of process that was realized. This paper presents influence of the RIE (reactive ion etching) parameters using BCl3 plasma on the 4H-SiC surface quality. After the process, the SiC surface using high resolution SEM (scanning electron microscope) was investigated. The roughness of the surface was measured using AFM (atomic force microscopy).

19

The effect of an active force while slide diamond burnishing of wooden shafts upon process quality

Dobrzyński Michał, Jaworek Lubomir, Orłowski Kazimierz, Przybylski Włodzimierz

Journal of Machine Construction and Maintenance - Problemy Eksploatacji

|

2019

|

no. 1

7--15

EN

The quality of the surface of wooden elements that have been turned and burnished has got a crucial meaning in the whole production process flow, since the obtained effects affect the quality of the wooden surface after finishing (coating, painting). In the paper, selected results of the investigation of the effect of the burnishing process on the surface quality of the elements after turning are presented. Research experiments were conducted on a lathe with a slide diamond burnisher and active (loading) forces: 30 N, 50 N, and 70 N. The elements under treatment were of great maple (Acer pseudoplatanus L.). The following report presents measuring results of the surface layer condition as well as some profile samples, and dimensional and geometrical deviations analysis.

PL

Jakość powierzchni elementów drewnianych, które zostały toczone i nagniatane, ma decydujące znaczenie w całym procesie produkcji, ponieważ uzyskane efekty wpływają na jakość drewnianych powierzchni po obróbce finalnej (powlekaniu, malowaniu). W artykule przedstawiono wybrane wyniki badań wpływu procesu nagniatania na jakość powierzchni elementów po toczeniu. Eksperymenty badawcze przeprowadzono na tokarce diamentowym narzędziem nagniatającym dla sił: 30 N; 50 N i 70 N. Obrabiane elementy wykonane były z drewna jaworowego (Acer pseudoplatanus L.). Poniższy raport przedstawia wyniki pomiarów stanu warstwy wierzchniej, a także analizy wybranych profili, odchyłek wymiarowych i geometrycznych.

20

The Use of Floster S Technology in Modified Ablation Casting of Aluminum Alloys

Kamińska J., Angrecki M., Puzio S., Hosadyna-Kondracka M., Major-Gabryś K.

Archives of Foundry Engineering

|

2019

|

iss. 4

81--86

EN

Ablation casting is a technological process in which the increased cooling rate causes microstructure refinement, resulting in improved mechanical properties of the final product. This technology is particularly suitable for the manufacture of castings with intricate shapes and thin walls. Currently, the ablation casting process is not used in the Polish industry. This article presents the results of strength tests carried out on moulding sands based on hydrated sodium silicate hardened in the Floster S technology, intended for ablation casting of the AlSi7Mg (AK7) aluminium alloy. When testing the bending and tensile strengths of sands, parameters such as binder and hardener content were taken into account. The sand mixtures were tested after 24h hardening at room temperature. The next stage of the study describes the course of the ablation casting process, starting with the manufacture of foundry mould from the selected moulding mixture and ending in tests carried out on the ready casting to check the surface quality, structure and mechanical properties. The results were compared with the parallel results obtained on a casting gravity poured into the sand mould and solidifying in a traditional way at ambient temperature.