Advances in Manufacturing (eBook)

Preface 6
Organization 8
Steering Committee 8
Scientific Committee 8
Program Committee 10
Contents 13
Production Engineering 22
1 Analysis of the Conditions for Effective Use of Numerically Controlled Machine Tools 23
Abstract 23
1 Introduction 23
2 Assessment of Effectiveness of Implementation of New Manufacturing Methods 24
3 Analysis of Profitability of Selected Investment at AesculapChifa sp. z o.o. 25
3.1 Premises for Replacing Conventional Machines with CNC Machinery at ACP 26
3.2 Operating and Economic Analysis After 1 Year from Introducing CNC Machines 28
3.3 Preparation to Organizational and Technological Improvement of Production Processes 30
4 Summary 31
Acknowledgements 31
References 31
2 A Simulative Study Approach for Improving the Efficiency of Production Process of Floorboard Middle Layer 33
Abstract 33
1 Introduction 33
2 Object of the Study 35
2.1 Production Process 35
2.2 Statistical Input Data 37
3 Model and Experimentation 38
4 Summary 41
Acknowledgements 41
References 41
3 A Methodology of Improvement of Manufacturing Productivity Through Increasing Operational Efficiency of the Production Process 43
Abstract 43
1 Introduction 43
2 Methodology of Improvement of Manufacturing Productivity 44
3 Case Study 47
4 Conclusion 50
Acknowledgements 50
References 50
4 The Impact of Buffer Allocation in Assembly-Line Manufacturing Systems on the Effectiveness of Production Processes 53
Abstract 53
1 Introduction 53
2 A Model for Discrete Assembly-Line Manufacturing Systems 55
2.1 The Buffer Allocation Problem (BAP) 55
2.2 A Model for Assembly-Line Manufacturing Systems 57
3 Results of the Simulation Experiments 59
4 Conclusions 62
References 63
5 Overall Equipment Effectiveness: Analysis of Different Ways of Calculations and Improvements 64
Abstract 64
1 Introduction 64
2 OEE Origin and Calculations 65
3 Production Disturbances and Other Wastes Influencing OEE 67
4 The OEE Method Application in Companies—Case Studies 68
4.1 The Research Methodology 68
4.2 First Company: OEE Calculations and OEE Improvement After TPM Implementation 69
4.3 The Other Company: OEE Calculations According to the Standard and Improved Method 70
5 Discussion and a Proposal for OEE Calculation Improvement 73
6 Conclusions 73
References 74
6 Verification of the Method for Assessing Productivity, Taking into Account Logistical Processes in Manufacturing Companies 75
Abstract 75
1 Introduction 75
2 Productivity in Manufacturing Enterprises 76
3 Short Description of the Methodology 76
4 Verification of Methodology in Enterprise 79
5 Conclusions 83
References 84
7 The Impact of Task Balancing and Sequencing on Production Efficiency 85
Abstract 85
1 Introduction 85
2 Description of the Analysed Assembly Line 87
3 Improving Operation of the Assembly Line 88
3.1 Separating Product Families 88
3.2 Analysis of Product Assembly Labour Intensity 89
3.3 Assembly-Line Balancing 90
3.4 Rules of Scheduling Production Task Performance 91
4 Evaluation of the Implemented Solutions 92
5 Summary 92
Acknowledgements 94
References 94
8 Formal Description of Integrated Process and Assembly System Planning 96
Abstract 96
1 Introduction 96
2 Defining of the Product in the Live Cycle Context 97
3 Formal Description of the Assembly Process 98
4 Integrated Process and Assembly Systems Development 99
4.1 Conceptual Process Planning Stage 100
4.2 Conceptual Production Organization Planning Stage 102
4.3 Detailed Process Planning Stage 103
4.4 Detailed Production Organization Planning Stage 104
5 Verification and Conclusions 104
References 105
9 The Operational Validation of a Planning Process Integration Model in a Manufacturing Company 107
Abstract 107
1 Introduction 107
1.1 Planning Process Integration 107
1.2 Validation of Models 108
2 Planning Process Integration Model 109
3 Operational Validation of the Model 111
3.1 Operational Validation Methodology 111
3.2 Operational Validation of the Planning Process Integration Model 111
4 Summary 114
Acknowledgements 115
References 115
10 Job Scheduling Problem in a Flow Shop System with Simulated Hardening Algorithm 117
Abstract 117
1 Introduction 117
2 Problem Description 118
3 Simulated Hardening Algorithm 119
4 Results 122
5 Conclusion 124
References 124
11 A Study of Priority Rules for a Levelled Production Plan 126
Abstract 126
1 Introduction 127
2 Levelled Production Implementation Methodology 128
3 Selected Priority Rules 129
4 Research Methodology 130
4.1 Research Results 131
5 Summary 133
Acknowledgements 134
References 134
12 Production Process Analysis in Conditions of Short-Term Raw Materials Expiration Dates and Long Setup Times Using Simulation Method 136
Abstract 136
1 Introduction 136
2 Production Process of Liquid Soap 137
3 Simulation Model and Its Verification 138
4 Simulation Experiments 139
5 Discussion of Results 143
References 144
13 Development of an Intelligent and Automated System for Lean Industrial Production, Adding  Maximum Productivity and Efficiency in the Production Process 146
Abstract 146
1 Introduction 147
2 Review of Literature 148
3 Description of the Problem 149
3.1 Proposed System 152
3.2 Criteria Adopted for the Memory of Calculation 152
4 Conclusion 153
Acknowledgements 154
References 154
14 The Use of Virtual Design to Accommodate a Workplace for a Hearing-Impaired Worker 156
Abstract 156
1 Introduction 156
2 Description of a Workplace Operated by a Hearing-Impaired Worker 158
3 Workplace Analysis 161
4 Proposed Accommodation of the Existing Workplace 161
5 Conclusions 163
References 163
15 Intelligent Platform for Supervision and Production Activity Control in Real Time 166
Abstract 166
1 Introduction 166
2 Proposed Platform 167
2.1 Platform General Architecture 167
2.2 Platform’s Main Functionalities 168
2.3 Platform Usage Scenario for the Allocation of Operations to Operators 169
3 Conclusions 173
Acknowledgements 174
References 174
16 Definition of Smart Retrofitting: First Steps for a Company to Deploy Aspects of Industry 4.0 175
Abstract 175
1 Introduction 176
2 Related Work 177
3 Definition of Smart Retrofitting 178
4 Case Study 181
5 Conclusion 183
Acknowledgements 184
References 184
17 Additive Manufacturing Technologies Cost Calculation as a Crucial Factor in Industry 4.0 185
Abstract 185
1 Introduction 185
2 Importance of Cost Calculation in Additive Manufacturing 186
3 Cost Factors in Different Approaches 187
4 Analysis of Approaches to Cost Calculation in AM 188
5 Discussion 193
6 Summary 193
References 196
18 Fulfilling Individual Requirements of Customers in Smart Factory Model 198
Abstract 198
1 Introduction 198
2 Model of Smart Manufacturing System 199
3 Defining the Configuration of Products 200
4 Defining Technological Processes 202
4.1 Technological Capabilities of the Production System 202
4.2 Generating Technological Processes 203
5 Production Planning 204
6 Summary 205
Acknowledgements 205
References 206
19 Model of Competency Management in the Network of Production Enterprises in Industry 4.0—Assumptions 208
Abstract 208
1 Introduction 209
2 Methodology of Research 210
3 Results of the Research 211
4 Assumptions for Creating a Model of Managing Competencies in the Network of Production Enterprises in Industry 4.0 214
5 Discussion and Conclusions 216
References 216
20 The Benefits of Using Computer Simulation Models to Support Decision-Making 218
Abstract 218
1 Introduction 219
2 Research Problem 219
3 Results 223
4 Discussion 224
5 Conclusion 226
References 227
21 Cyclic Steady-State Approach to Modelling of Multimodal Processes Flow Levelling 228
Abstract 228
1 Introduction 228
2 Cyclic Steady Flows Modelling 230
3 Problem Statement 233
4 Multimodal Processes Flow Levelling 234
5 Concluding Remarks 237
Acknowledgements 237
References 237
22 Symbolic Representation of Production Knowledge in the Development of Knowledge Management Systems 239
Abstract 239
1 Introduction 239
2 Analysis of Decision Problems in the Technological Preparation of Production 240
3 Elaboration of the Method of Knowledge Representation About Structure of Machine Parts 241
4 Method of the Knowledge Representation About the Structure of the Technological Process 243
5 The Use of the Decision-Making Rules in the Designing of Technological Processes 245
6 The Construction of a Framework Representation of the Technological Knowledge 247
7 Conclusion 248
References 248
23 Methodology of KBE System Development for Automated Design of Multivariant Products 250
Abstract 250
1 Introduction 250
2 MDAVP Methodology 252
3 Case Studies 255
3.1 SAVPD System for Bent Copper Pipes 255
3.2 SAVPD System for Forged Couplings 257
4 Conclusions 258
References 259
24 Interacting Manufacturing Features in CAPP Systems 260
Abstract 260
1 Introduction 260
2 Review of the Works on Feature Recognition 261
3 Algorithm 264
4 Example of Processing 266
5 Conclusions 268
References 269
25 Case Studies of the Process-Oriented Approach to Technology Management 270
Abstract 270
1 Introduction 270
2 Technology Management Models 271
3 The Business Process 272
4 Research Methods 273
5 Case Study of a Company Producing Machines and Technical Devices 274
6 Case Study of a Company Producing Farm Machinery 276
7 Conclusions 278
Acknowledgements 278
References 278
26 Technical Product-Service Systems—A Business Opportunity for Machine Industry 280
Abstract 280
1 Introduction 280
2 Product-Service Systems and Servicization 281
2.1 Definitions 281
2.2 Types of Product-Service Systems 282
2.3 Methodologies and Tools of Products Servicization and Selected Examples of PSS 283
3 Technical Product-Service Systems—A Case of Foundry Moulds 285
4 Conclusions 287
References 288
27 Development of a Speech System Using BCI Based on ERD/ERS for Patients Suffering from Amyotrophic Lateral Sclerosis 290
Abstract 290
1 Introduction 290
1.1 Literature Overview 291
2 System Structure 292
2.1 ERD/ERS Method 292
2.2 Algorithm 293
3 Results and Discussion 295
4 Conclusion 298
Acknowledgements 298
References 298
28 GPenSIM for Performance Evaluation of Event Graphs 300
Abstract 300
1 Introduction 300
2 Event Graphs: Definition and Properties 301
2.1 Definitions [1, 2] 301
2.2 Properties of Strongly Connected Event Graphs 302
3 GPenSIM 302
3.1 Modeling Timed Petri Nets in GPenSIM 303
3.2 The Functions for Performance Evaluation of Event Graphs 303
4 Application Example 304
4.1 The Petri Net Model 306
4.2 GPenSIM Code for Simulation 306
4.3 The Simulation Results 308
5 Discussion 309
Acknowledgements 309
References 310
29 Analysis of the Environmental Costs in Manufacturing Companies in the SME Sector in Poland 311
Abstract 311
1 Introduction 311
2 Typical Environmental Aspects of Manufacturing Companies 312
3 Classification of Environmental Protection Costs in Companies 314
4 Analysis of Environmental Costs in the Manufacturing Company 316
5 Summary and Conclusions 319
Acknowledgements 319
References 319
30 Product Variants Recycling Cost Estimation with the Use of Multi-agent Support System 321
Abstract 321
1 Introduction 321
2 A System for Recycling-Oriented Product Assessment 322
3 Recycling-Oriented Assessment of a Selected Product 324
4 Research Conclusions and Summary 326
Acknowledgements 329
References 329
31 The Use of Machine Learning Method in Concurrent Ecodesign of Products and Technological Processes 331
Abstract 331
1 Introduction 331
2 Literature Review 332
3 Methods 333
3.1 The Principle of Integrating Product Ecodesign and Technology Engineering 333
3.2 Decision Tree Induction Method 335
3.3 The Method of Material and Connection Selection for Ecodesign 335
3.3.1 General Description 335
3.3.2 Selection of Materials According to Their Compatibility 336
3.3.3 Selecting Additional Material with Regard to Compatibility 336
3.3.4 Choosing Material Connections 337
4 Expert System Supporting Ecodesign with the Use of the CE Approach 337
5 Conclusion and Future Research 338
References 339
Design, Building and Research of Machines and Devices 341
32 Intelligent Materials Application in Mechatronic Devices 342
Abstract 342
1 Introduction 342
2 Piezo Actuators Control Electronics 344
3 Piezo Actuators Hysteresis Modelling and Compensation 346
4 Magnetic Shape Memory Actuators Investigations 349
5 Gear with Magnetorheological Fluid 351
6 Summary 351
Acknowledgements 352
References 352
33 Development of Force Feedback Controller For the Loader Crane 354
Abstract 354
1 Introduction 354
1.1 State of the Art 355
2 Modeling 356
3 Electronic Components 357
4 Experimental Verification 360
4.1 Test Stand 360
4.2 Experimental Tests 360
5 Conclusion 363
Acknowledgements 363
References 363
34 Analysing and Optimizing 2.5D Circular Pocket Machining Strategies 364
Abstract 364
1 Introduction 365
1.1 Technological Challenges at Pocket Milling Task 365
2 The Pocket Milling Strategy Evaluation Aspects and Experimental Methods 366
2.1 Simulation Inspection and Metal Cutting Experiments 366
3 The Strategies Used During the Circular Pocket Milling 367
3.1 NC Cycles for Circular Pocket Milling 367
3.2 CAM Systems for Circular Pocket Milling 369
3.3 Evaluation 370
4 Suggested Circular Pocket Milling Strategies 370
4.1 Advanced Spiral-like Strategy I 371
4.2 Advanced Spiral-like Strategy II 371
5 Summary 372
Acknowledgements 373
References 373
35 Study on Mechanical Characteristics in Electromechanical Disengaging Damper 374
Abstract 374
1 Introduction 375
2 Electromechanical Semi-active Disengaging Damper 376
3 Experimental Studies 376
3.1 Measurement Results 379
4 Discussion 380
5 Conclusions 381
Acknowledgements 382
References 382
36 Modeling and 3D Simulation of an Electro-hydraulic Manipulator Controlled by Vision System with Kalman Filter 384
Abstract 384
1 Introduction 384
2 The Test Bed 385
3 Mathematical Background 386
4 Implementation of Kalman Filter 389
5 The Experiment 390
6 Conclusion 392
Acknowledgements 392
References 393
37 Trends in the Development of Rotary Tables with Different Types of Gears 394
Abstract 394
1 Introduction 394
2 Requirements for Rotary Tables and Precision Gearboxes 395
3 Rotary Tables with Spiroid Gears Duplex Type 397
4 Rotary Tables with Hybrid Gearbox 397
5 Rotary Tables with Cylindrical Helical Gears and Flat Face Gears 398
6 Rotary Tables with Conical Helical Gears and Conical Face Gears 399
7 Summary 400
References 402
38 Survey on Design and Development of Hexapod Walking Robot, Automated Guided Vehicle and Drone 404
Abstract 404
1 Introduction 405
1.1 Line Follower Design and Development 405
1.2 Drone Design and Development 407
2 Hexapod 407
3 Summary and Discussion 412
References 413
39 Development of Conical Face Gear Technology Cooperation with Conical Worm in Spiroid Gear Drive 414
Abstract 414
1 Introduction 414
2 Technology of Forming of a Conical Face Gear with an Involute Gear Line 415
3 Examples of Cutting Conical Face Gears with an Involute Gear Line 420
4 Conclusions 422
References 423
40 Unilateral Hydraulic Telemanipulation System for Operation in Machining Work Area 424
Abstract 424
1 Introduction 424
2 Problem Statement 426
3 The Prediction Block 428
4 The Experiment 429
5 Conclusions 431
Acknowledgements 432
References 432
41 Effect of Different Electrolytes on Material Removal Rate, Diameter of Hole, and Spark in Electrochemical Discharge Machining 435
Abstract 435
1 Introduction 435
2 Experimentation 436
2.1 Experimental Setup 437
2.2 Selection of the Process Parameter and Machining Conditions 438
3 Result and Discussion 438
3.1 Effect of Electrolytes on Material Removal Rate 438
3.2 Effect of Electrolytes on Entrance and Exit Diameter of Hole 443
3.3 Spark Color and Spark Stability 443
4 Conclusion 444
References 445
42 ExoArm 7-DOF (Interactive 7-DOF Motion Controller of the Operator Arm) Master Device for Control of Loading Crane 446
Abstract 446
1 Introduction 446
2 The Mechanical Design 447
2.1 The Closed Loop Bowden Cable Conduit System 448
2.2 The 3 DOF Shoulder Joint 450
2.3 The 1 DOF Elbow Joint 450
2.4 The 3 DOF Wrist Joint 451
3 The Prototype 452
4 Dynamic Loads of Closed Loop Bowden Cable Conduit System 452
5 Conclusions 455
Acknowledgements 456
References 456
43 Influence of Selected Factors on Static Friction for Combination of Expanded Graphite-Steel 457
Abstract 457
1 Introduction 457
2 Test Subject 458
3 Motion Tests of the Combination 459
3.1 Test Conditions 459
3.2 Test Results 459
4 Summary and Conclusions 461
References 462
44 Development of Experimental Design for Hydraulic Active Heave Compensation Systems 463
Abstract 463
1 Introduction 463
2 Design of Heave Compensation System 464
2.1 Experimental Test Stand 464
2.2 Control Design 465
3 Experimental Results 467
4 Conclusion 468
Acknowledgements 470
References 470
45 Loader Crane Working Area Monitoring System Based on LIDAR Scanner 471
Abstract 471
1 Introduction 472
2 Related Work 473
3 LIDAR Scanner 474
4 Ground Filtration and Segmentation Algorithm 476
5 Conclusions 478
Acknowledgements 479
References 479
46 Optimization of the Movement Trajectory of Mobile Crane Working Elements 481
Abstract 481
1 Introduction 481
2 Methodology of the Optimization of the Handling Assignment 482
3 Model of the Handling Crane 482
4 Kinematic Model of the Handling System 484
5 Optimization of Cargo Displacement Trajectory 484
5.1 Criteria and Limitations of Optimization 484
5.2 Optimization Assignment 486
5.3 Simulation Testing Results 487
6 Conclusion 489
Acknowledgements 489
References 490
47 Design, Manufacture, and Application of Chamber for the Magnetohydrodynamic Deposition Made of PP 491
Abstract 491
1 Introduction 491
2 Design 492
3 Manufacture 493
4 Experimental Details 497
5 Results and Discussion 497
6 Summary 500
References 501
48 Testing of Tight Crimped Joint Made on a Prototype Stand 503
Abstract 503
1 Introduction 503
2 Materials and Method 504
3 The Stand Concept 505
4 Methodology of the Experiment 507
5 Results and Discussion 508
6 Conclusions 512
References 512
Cutting Machining & Technological and Assembly Processes
49 Computer Simulation of the Process of Regenerating the Adsorbent Using Microwave Radiation in Compressed Air Dryers 515
Abstract 515
1 Introduction 515
2 Research Problem 516
3 Results and Discussion 517
4 Conclusions 523
Acknowledgements 523
References 523
50 Spatial Adjusting of the Industrial Robot Program with Matrix Codes 524
Abstract 524
1 Introduction 524
2 Related Work 525
3 Approach 525
4 Detection of Matrix Codes 526
5 System Calibration 527
6 Dynamic Adjusting of the Program 530
7 Experimental Verification 532
8 Conclusions 532
Acknowledgements 533
References 533
51 Topology Optimisation Aimed at Additive—SLM Manufacturing of Metal Parts of ExoArm 7-DOF 535
Abstract 535
1 Introduction 535
2 Research Objective 536
3 Research Methodology 537
4 Post Processing—Application of Lightweight Lattice Structures 541
5 Summary 542
Acknowledgements 543
References 543
52 Applications of Optomechatronic Technologies in Innovative Industry 544
Abstract 544
1 Introduction 544
2 The Area of Research and Main Directions for the Development of Optomechatronic Technologies for Industry 545
3 Examples of Applications of Optomechatronic Technologies in Innovative Industry 549
3.1 System for Visual Inspection and Qualitative Selection of Shafts 550
3.2 Hybrid System for Monitoring the Plastic Forming Processes 550
4 Conclusion 552
References 553
53 Case Study of Thermal Stress Distribution Within Coating Applied on Aluminum Plain Clutch Plate by Thermal Spray Coating Technique 555
Abstract 555
1 Introduction 555
2 Research Problem 557
2.1 Simulation Model Preparation 558
3 Results 559
4 Discussion 560
5 Conclusions 561
Acknowledgements 562
References 562
54 Augmented Reality in Training of Fused Deposition Modelling Process 564
Abstract 564
1 Introduction 564
2 Materials and Methods 565
2.1 Fused Deposition Modelling Technology 565
2.2 Operating Procedure of MakerBot Replicator 2X 566
2.3 Augmented Reality Application 567
2.4 Research Outline 569
3 Results and Discussion 570
4 Summary 571
References 572
55 Complex Control Method of Degreasing Process 574
Abstract 574
1 Introduction 574
2 Degreasing Quality Control 575
2.1 Grease Detection on Product Surface 575
2.2 Sequential Scanning of Objects 576
2.3 Inspection of Internal Surfaces of the Tubes 577
3 Selecting a Degreasing Agent 578
4 Detection of Contamination of Liquids 580
5 Conclusion 583
Acknowledgements 583
References 584
56 Hybrid Processing by Turning and Burnishing of Machine Components 585
Abstract 585
1 Introduction 585
2 Roughness Deformations in Rolling Burnishing Process 586
3 Hybrid Machining and Burnishing Process 589
4 Conclusion 594
References 595
57 Virtual Reality and CAD Systems Integration for Quick Product Variant Design 597
Abstract 597
1 Introduction 597
2 Product Variant Design Using VR and CAD Systems 598
3 Virtual Design Studio for City Buses Configuration 599
4 Generative CAD Model of Bus Interior 603
5 Conclusions 604
References 605
58 An Approach to Modeling and Simulation of a Complex Conveyor System Using Delmia Quest—A Case Study 607
Abstract 607
1 Introduction 607
2 Description of the Production Line 609
2.1 Transportation Subsystem Description 609
2.2 Pallets Movement Analysis 610
3 Conveyors Modeling with Delmia Quest 611
3.1 Model Building of a Complex Conveyor System 611
3.2 Additional Decision Points 612
3.3 Model of Production Lines 614
4 Simulation Experiment and Results 615
5 Conclusions 616
References 616
59 Prediction of HPDC Casting Properties Made of AlSi9Cu3 Alloy 618
Abstract 618
1 Introduction 618
2 State of the Art 619
3 Methodology of Studies 623
4 Results and Discussion 624
5 Summary 626
Acknowledgements 627
References 627
60 Internal Stresses Analysis in the Shrink-Fitted Joints of the Assembled Crankshafts 629
Abstract 629
1 Introduction 629
2 Experimental Conditions 630
3 Results and Discussion 631
4 Conclusions 635
Acknowledgements 635
References 635
61 The Influence of Composition Chemical of Nanofluids on Hardness and Wear Resistance of Laser-Treated C20 Steel 637
Abstract 637
1 Introduction 638
2 Methods of Research 639
3 Results of Research 641
4 Summary 645
Acknowledgements 645
References 646
62 Application of Correlation Function for Analysis of Surface Structure Shaping by Hybrid Manufacturing Technology 647
Abstract 647
1 Introduction 647
2 Burnishing of Complex Spatial Surfaces After Milling 648
3 Materials and Methods 649
3.1 Sample Preparation 649
3.2 Surface Measurements 650
3.3 Data Processing—Normalized Cross Correlation 651
4 Results 653
5 Summary and Conclusions 653
References 655
63 Investigation of Heat Distribution in Coated Indexable Tool Inserts 656
Abstract 656
1 Introduction 656
2 Theoretical Background 657
3 Materials and Method 660
4 Results and Discussion 661
5 Conclusions 664
References 665
64 Assessment of the Accuracy of High-Speed Machining of Thin-Walled EN AW-2024 Aluminium Alloy Elements Using Carbide Milling Cutter and with PCD Blades 666
Abstract 666
1 Introduction 666
2 Methodology 667
3 Results 669
4 Conclusion 673
Acknowledgements 674
References 674
65 Effect of Heat Treatment on Mechanical Properties of Inconel 625/Steel P355NH Bimetal Clad Plate Manufactured by Explosive Welding 676
Abstract 676
1 Introduction 676
2 Results of the Research 677
2.1 Tensile Test 678
2.2 Charpy Impact Test 678
2.3 Shear Test and Bend Test 679
3 Discussion 679
4 Conclusions 680
Acknowledgements 680
References 680
66 Alternative Methods of Chemical Pre-Treatment on Hot-Dip Galvanization Surface for Adhesion Organic Coatings 682
Abstract 682
1 Introduction 683
2 Conversion Layers 683
2.1 Phosphating 683
2.2 Chromating 683
2.3 Alternative Technologies for the Ferrous Phosphating and Chromating 684
3 Experimental Part 686
3.1 Verification Physico-Mechanical Properties of the Coating Systems 687
3.2 Comparison of Various Pre-Treatments 688
4 Experimental Part 688
Acknowledgements 690
References 690
67 Influence of Machining Conditions on the Energy Consumption and Productivity in Finish Hard Turning 691
Abstract 691
1 Introduction 691
2 Experimental Details 692
2.1 Workpiece Materials and Machining Conditions 692
2.2 Measurements of Cutting Forces and Cutting Energy 693
2.3 Computations of the Cutting and Specific Cutting Energy 694
3 Experimental Results and Discussion 694
3.1 Cutting Forces and Their Relationships 694
3.2 Changes of Cutting Energy Resulting from Variable Machining Conditions 696
3.3 Relationship Between Cutting Energy and Machinability Rate 697
4 Conclusions 698
References 699
68 Application of Principal Component Analysis and Decision Trees in Diagnostics of Cylindrical Plunge Grinding Process 700
Abstract 700
1 Introduction 700
2 Hardware Setup and Conditions of Experimental Research 701
3 Discrete Time Series Analysis Methods 702
4 Feature Selection and Data Modeling Methods 705
5 Conclusions 708
References 709
69 Assessment of Deformation Characteristics on CW004A Copper Influenced by Acoustically Enhanced Water Jet 710
Abstract 710
1 Introduction 710
2 Experimental Conditions 712
2.1 Experimental Material 712
2.2 Experimental Investigation 712
3 Results 714
4 Conclusions 715
Acknowledgements 716
References 716
Measurement Systems and Quality Engineering 718
70 Measuring the Punching Profile of a Punch And Bind Machine 719
Abstract 719
1 Introduction 719
2 Experimental Procedures 721
3 Results and Discussion 721
4 Conclusions 723
Acknowledgements 723
References 724
71 Influence of the Inlet Nozzle Diameter on the Air Gauge Dynamics 725
Abstract 725
1 Introduction 725
2 Dynamic Mass Flow and Back-Pressure in the Air Gauge 726
3 Experimental Apparatus 728
4 Measurement Results and Discussions 731
5 Conclusions 733
References 734
72 Accuracy of Hysteresis Modeling in Smart Actuator with MSMA 735
Abstract 735
1 Introduction 735
1.1 Magnetic Shape Memory Alloys—MSMAs 736
2 Hysteresis Modeling 737
2.1 Generalized Prandtl-Ishlinskii Model 737
3 Actuator and Test Stand 739
4 Hysteresis Models and Results 740
5 Conclusions and Discussion 743
Acknowledgements 743
References 743
73 Application of Scanning Techniques in the Analysis of the Wear Forging Tools 745
Abstract 745
1 Introduction 746
1.1 Goal and Scope of the Paper 747
2 Measuring Method and Description of the Measuring Station 747
3 Scanning of Forging Tools 748
4 Development of Reverse 3D Scanning Methods 750
5 Comparison of the Wear Curve Determined on the Basis of Scanned Tools and Reverse 3D Scanning 753
6 Summary 754
Acknowledgements 755
References 755
74 Comparison of Geometrical Accuracy of a Component Manufactured Using Additive and Conventional Methods 757
Abstract 757
1 Introduction 757
2 Materials and Methods 758
3 Results 763
4 Conclusions 766
References 767
75 Studies of Geometric Accuracy of Polygons Machined by Polygonal Turning Technique 769
Abstract 769
1 Introduction 769
2 Research Problem 772
3 Results 772
4 Discussion 776
5 Conclusions 777
Acknowledgements 778
References 778
76 Ensuring the Reliability of the Car Body Controls by Controlling the Current Inspection of Measuring Machines 779
Abstract 779
1 Introduction 779
2 Aspects of Current Inspections 780
3 Artifacts Applied to Research 781
4 Coordinate Measuring Machines 782
5 Measurements 784
6 Results 784
7 Conclusions 785
References 787
77 Application of Industrial Robot as a Measuring System 788
Abstract 788
1 Introduction 788
2 The Object of the Research 789
3 Modules of the Measurement System 790
4 Execution of Verifying Measurement 792
5 Conclusion 794
Acknowledgements 794
References 794
78 Surface Roughness of Graphite and Aluminium Alloy After Hydro-abrasive Machining 796
Abstract 796
1 Introduction 796
2 State of the Art 797
3 Experiment 799
4 Measurement and Results 800
5 Conclusions 802
Acknowledgements 803
References 803
79 Measurement of Surface Topography Using Computed Tomography 805
Abstract 805
1 Introduction 805
2 Computed Tomography 806
3 Equipment Used During the Test 808
4 Studied Objects 809
5 Conclusions 812
Acknowledgements 813
References 813
80 Cylindricity Measurement on a Coordinate Measuring Machine 815
Abstract 815
1 Introduction 815
2 Cylindricity Measuring Strategies 817
3 Experimental Setup 818
4 Results 821
5 Conclusions 823
References 824
81 Improvement of Acceptance Sampling Inspection for the Operation of Sealing Packages 826
Abstract 826
1 Introduction 826
2 Research Problem 828
3 Research Methodology and Analysis of Results 829
3.1 Analysis of Results for “Small” Packages 830
3.2 Analysis of Results for “Big” Packages 832
4 Conclusions and Recommendations 834
Acknowledgements 834
References 834
82 I Spy, with My Little Eye: Quality Standards of Different Target Groups 836
Abstract 836
1 Introduction 836
2 Objectives and Research Question of the Feasibility Study 837
3 Methodology 838
4 Data Analysis and Implications 839
4.1 Influence of the Target Group Type on Defect Detection (H0a) 840
4.2 Influence of Viewing Areas on Defect Detection (H0b) 841
4.3 Influence of the Target Group Type on the Evaluation of Defect Relevance Compared to the Standard (H0c) 842
5 Discussion 843
6 Conclusion 844
References 844
83 Reduction of Errors of the Conformity Assessment During the Visual Inspection of Electrical Devices 846
Abstract 846
1 Introduction 846
2 Research Problem 847
3 Results and Discussion 849
4 Conclusion 854
References 855
84 Possibilities and Limitations of Passive Experiments Conducted in Industrial Conditions 857
Abstract 857
1 Introduction 857
2 Comparison of Active and Passive Experiments Results on Example of Industrial Studies 859
2.1 Experiment 1—Conducted with Passive Approach 861
2.2 Experiment 2—Conducted with Active Approach 864
3 Summary of the Passive and Active Experiments 865
References 866
85 A Study of Raters Agreement in Quality Inspection with the Participation of Hearing Disabled Employees 868
Abstract 868
1 Introduction 868
2 Research Problem 870
3 Results 872
4 Discussion 873
5 Conclusions 874
Acknowledgements 874
References 874
86 Assessment of Quality Management System Maturity 876
Abstract 876
1 Introduction 876
2 Maturity of Quality Management System 877
3 Quality Costs in the Context of Company Operation—ACO 879
4 Technique to Evaluate QMS Maturity 881
5 Conclusion 884
Acknowledgements 884
References 885
87 Organization of Visual Inspection and Its Impact on the Effectiveness of Inspection 886
Abstract 886
1 Introduction 886
2 Methodology of the Study 888
3 Results (Case Study) 889
3.1 Stage 1: Description of the Process 889
3.2 Stage 2: Study Plan 891
3.3 Stage 3: Analysis of Results 891
4 Discussion and Summary 893
Acknowledgements 895
References 895
Materials Engineering 897
88 On the Formation Features and Some Material Properties of the Coating Formed by Laser Cladding of a NiCrBSi Self-fluxing Alloy 898
Abstract 898
1 Introduction 898
2 Experimental Procedure 899
3 Results and Discussion 901
3.1 Powder Flow When Passing Through the Nozzle 901
3.2 Microstructure and Phase Composition of Single-Layer Coating 902
3.3 The Distribution of Elements Over the Depth of a Single-Layer Coating 903
3.4 Microhardness of the Coating 904
4 Conclusions 906
References 906
89 Fracture Toughness of Plasma Paste-Borided Layers Produced on Nickel-Based Alloys 908
Abstract 908
1 Introduction 909
2 Experimental Procedure 909
3 Results and Discussion 911
4 Summary and Conclusions 915
Acknowledgements 916
References 916
90 Effect of Residual Stresses in Surface Layer of Nickel-Based Alloy—Inconel 718 on the Safety Factor of Construction 918
Abstract 918
1 Introduction 918
2 The Characteristics of the Surface Layer Formed in the Cutting Process 919
3 Impact of Cutting Conditions on Stress State in the Surface Layer of Inconel 718 920
4 Safety Factor in Terms of Construction Reliability 921
5 Conclusions 924
References 925
91 Influence of Preparation Conditions on Final Dielectric Properties of Pure and Ca-Doped BaTiO3 Ceramics 926
Abstract 926
1 Introduction 927
2 Experimental Procedure 928
3 Results and Discussion 928
3.1 X-Ray Diffraction 928
3.2 Hot-Pressing Conditions 930
3.3 Microstructure of the Powders and Ceramic Samples 930
3.4 Dielectric Properties 932
4 Conclusions 934
Acknowledgements 934
References 935
92 Wear of Solid Carbide Ball Nose End Mill 936
Abstract 936
1 Introduction 936
2 Cutting Tool Wear 937
3 Nose Tool Life Under Variable Machine Cutting Conditions 938
4 Mill Tool Life and Wear with Alternating Variable Cutting Parameters 940
5 Measurement Results 941
6 Summary and Conclusions 943
References 945
Author Index 947