Advances in Manufacturing II (eBook)

Preface 6
Organization 8
Steering Committee 8
General Chair 8
Chairs 8
Scientific Committee 8
Program Committee 9
Special Sessions 10
Collaborative Manufacturing and Management in the Context of Industry 4.0 10
Sec8 10
Intelligent Manufacturing Systems 10
Sec10 10
Tooling and Fixtures: Design, Optimization, Verification 10
Sec12 10
Advanced Manufacturing Technologies 10
Sec14 10
The Changing Face of Production Engineering and Management in a Contemporary Business Landscape 11
Sec16 11
Enabling Tools and Education for Industry 4.0 11
Sec18 11
Staff for the Industry of the Future 11
Sec20 11
Advances in Manufacturing, Properties, and Surface Integrity of Construction Materials 11
Sec22 11
Materials Engineering 12
Sec24 12
Advanced Mechanics of Systems, Materials and Structures 12
Sec26 12
Virtual and Augmented Reality in Manufacturing 12
Sec28 12
Contents 13
Construction 19
Parametric Modeling of Gear Cutting Tools 20
Abstract 20
1 Introduction 20
2 Research Problem 22
3 Results 22
4 Discussion 25
5 Conclusions 27
References 27
Verification of Machine Tool Set-Up Stability Using a Simplified Wolfram Language-Based Model 29
Abstract 29
1 Introduction 29
2 Impact of Structural Set-Up on the Possibility of Machine Tool Damage 30
3 Theoretical Model 32
4 Experimental Studies 37
5 Conclusions 40
References 40
Balancing of a Wire Rope Hoist Using a Cam Mechanism 42
Abstract 42
1 Introduction 42
2 The Concept of the Mechanical System 43
3 Numerical Analysis and Discussion 46
4 Conclusions 51
Acknowledgments 51
References 51
The Influence of Imperfections on the Strength and Stability of Cold-Formed Sigma Channels with Corrugated Flanges 53
Abstract 53
1 Introduction 53
2 Beams 54
3 Numerical Model 57
4 Results of Numerical Simulations 59
5 Conclusions 64
Acknowledgments 65
References 65
Fatigue Life of Auxetic Re-entrant Honeycomb Structure 67
Abstract 67
1 Introduction 67
2 Fatigue of Material 68
3 Numerical Results 70
4 Conclusions 75
Acknowledgments 75
References 76
Experimental Investigations of Steel Welded Machine Tool Bodies Filled with Composite Material 78
Abstract 78
1 Introduction 78
2 Test Objects 79
3 Experimental Investigations 80
4 Results 82
5 Conclusions 85
Acknowledgments 85
References 85
Loader Crane Modal Analysis Using Simplified Hydraulic Actuator Model 87
Abstract 87
1 Introduction 87
2 Research Problem 88
3 Modelling the Mechanic and Hydraulic System 89
3.1 Numerical Results 90
3.2 Experimental Results 93
4 Discussion 95
5 Conclusions 96
Acknowledgments 96
References 96
Temperature Distribution in Workpiece During Flowdrill - Numerical Experiment Based on Meshless Methods 98
Abstract 98
1 Introduction 98
2 Problem Description 101
2.1 Mathematical Model 102
2.2 Numerical Algorithm 103
3 Numerical Results 108
4 Conclusions 110
References 111
Injection Moulding Simulation and Validation of Thin Wall Components for Precision Applications 113
Abstract 113
1 Introduction 113
2 State-of-the-Art and Need for This Research 114
3 Materials and Methods 116
3.1 Cavity Pressure Measurement System 117
3.2 Injection Molding Process Parameters 118
3.3 Simulation Experiment 118
4 Results and Discussion 119
4.1 Paragraphs and Indents Effects of the Factors Influencing the Accuracy of the Simulation 121
5 Conclusion 123
References 124
Problems of Flaking in Strengthening Shaft Burnishing 125
Abstract 125
1 Introduction 125
2 Problems of Strengthening Burnishing 126
3 Experimental Details 128
4 Researching Results and Discussion 130
5 Conclusion Remarks 137
References 137
Parametric Modeling of Transverse Layout for Machine Tool Gearboxes 139
Abstract 139
1 Introduction 139
2 Methods 141
2.1 Formulation of the Problem 141
2.2 Construction of the Parametric Model and Investigation of the Gearbox Transverse Layout 142
3 Results 144
4 Conclusion 146
References 146
Technology 148
Increasing of Lathe Equipment Efficiency by Application of Gang-Tool Holder 149
Abstract 149
1 Introduction 149
2 Literature Review 150
3 Research Methodology 151
4 Results 154
4.1 Description of the Results of Theoretical and Numerical Researchers 154
4.2 Description of the Results Full-Scale Experiment Researchers of Gang-Tool 156
5 Conclusions 159
References 159
Fabrication of Biodegradable Mg Alloy Bone Scaffold Through Electrical Discharge µ-Drilling Route 161
Abstract 161
1 Introduction 161
2 Materials and Experimental Method 163
3 Fabrication of Scaffold 165
4 Immersion Test 167
4.1 Apatite Formation 167
4.2 Weight Gain and Loss of Load Bearing Capacity 168
5 Conclusions 168
Acknowledgement 169
References 169
Possibility of Block Grouping of Magnetic Inspection Operations for Iron Impurities in Oils and Cutting Fluids 172
Abstract 172
1 Introduction 172
2 Findings and Analysis 175
3 Conclusion 178
Acknowledgements 178
References 179
Construction of the Facility for Aluminium Alloys Electromagnetic Stirring During Casting 180
Abstract 180
1 Introduction 180
1.1 Fe-Rich Intermetallic Phases in AlSi Alloys 181
2 Methodology 183
3 Results 184
4 Discussion 186
5 Conclusions 189
Acknowledgments 190
References 190
The Influence of Technological Parameters on Cutting Force Components in Milling of Magnesium Alloys with PCD Tools and Prediction with Artificial Neural Networks 192
Abstract 192
1 Introduction 192
2 State of the Art - Research Problem 193
3 Test and Simulation Methodology 195
4 Results of Magnesium Alloy Milling Test and Simulation 197
4.1 Analysis of Results 197
4.2 Simulation Results 199
5 Summary and Conclusions 202
References 203
Investigations of Electronic Controller for Electrohydraulic Valve with DC and Stepper Motor 205
Abstract 205
1 Introduction 205
1.1 Motivation 205
1.2 Literature Overview 206
2 Valve Structure 207
2.1 Mechanical Construction 207
3 Theoretical Model of the Valve 208
3.1 Control Unit 210
3.2 32-Bits Microcontroller 211
3.3 Control Algorithm 212
4 Experimental Research 212
5 Conclusion 215
Acknowledgments 215
References 215
Evaluation of Castings Surface Quality Made in 3D Printed Sand Moulds Using 3DP Technology 217
Abstract 217
1 Introduction 217
2 Materials and Methods 218
3 Research 219
4 Results and Discussion 223
5 Conclusions 227
References 228
Impedance-Based PZT Transducer and Fuzzy Logic to Detect Damage in Multi-point Dressers 229
Abstract 229
1 Introduction 229
2 Experimental Setup 231
2.1 Experimental Test and Data Acquisition System 231
2.2 Proposed Fuzzy Logic System 233
3 Results and Discussions 235
4 Conclusion 236
Acknowledgments 237
References 237
Hybrid Numerical-Analytical Approach for Force Prediction in End Milling of 42CrMo4 Steel 239
Abstract 239
1 Introduction 239
2 FEA Model of Chip Formation 240
3 Constitutive Model and Material Properties 242
4 Mechanistic Model for End Milling 243
5 Experimental Setup for Model Validation 243
6 Results and Discussion 245
7 Conclusions 247
References 247
Analysis of the Pulsating Water Jet Maximum Erosive Effect on Stainless Steel 249
Abstract 249
1 Introduction 249
2 Experimental Procedure 251
3 Results 252
3.1 Surface Topography 252
3.2 Metallographic Analysis 253
4 Conclusions 253
Acknowledgments 254
References 254
Comparison of the Weld Quality Created by Metal Active Gas and Shielded Metal Arc Welding 258
Abstract 258
1 Introduction 258
2 Materials and Methods 259
3 Carrying Out of the Experiments 263
4 Evaluation of the Experiments 266
5 Conclusion 271
Acknowledgements 271
References 271
Application of the Motion Capture System in the Biomechanical Analysis of the Injured Knee Joint 273
Abstract 273
1 Introduction 273
2 Methodology 275
3 Results 276
4 Discussion and Conclusions 279
Acknowledgments 280
References 280
Hydrogen Embrittlement After Surface Treatments 282
Abstract 282
1 Introduction 282
2 Hydrogen Embrittlement 283
3 Hydrogen Corrosion 284
4 Diffusion of Hydrogen into Steel 285
5 Choosing the Right Material 286
6 Choosing the Right Material 287
7 Testing of Hydrogen Charging After Surface Treatments 287
8 Hydrogen Charging in the Tumbling Process 289
9 Hydrogen Charging During Pickling 290
10 Conclusions 290
Acknowledgments 290
References 291
Effect of Modification of Mono-crystalline Corundum Grinding Wheel on Cutting Forces in Grinding of Aluminum Alloy 7075 292
Abstract 292
1 Introduction 292
2 Materials and Methods 294
3 Results 296
4 Conclusions 300
References 301
Influence of Processing Parameters on Clamping Force During Injection Molding Process 303
Abstract 303
1 Introduction 303
1.1 Injection Molding Process 304
1.2 Clamping Force 305
2 Experimental Setup 305
3 Results 307
3.1 Injection Phase 307
3.2 Packing Phase 310
4 Conclusions 313
References 315
Prediction of the Microhardness Characteristics, the Removable Material Volume for the Durability Period, Cutting Tools Durability and Processing Productivity Depending on the Grain Size of the Coating or Cutting Tool Base Material 316
Abstract 316
1 Introduction 316
2 Research Problem 317
3 Research Methodology 320
4 Results 321
5 Discussion 326
6 Conclusions 331
References 332
Modelling and Analysis of Cutting Force Components in Turning Process of Commercially Pure Titanium Grade 2 333
Abstract 333
1 Introduction 333
2 Materials and Methods 335
3 Results 338
4 Conclusions 342
References 343
Surface Quality Analysis After Face Grinding of Ceramic Shafts Characterized by Various States of Sintering 345
Abstract 345
1 Introduction 345
2 Research Methodology and Experimental Conditions 347
2.1 The Grinding Process 348
2.2 Measurements of Surface Roughness Parameters 349
3 The Results of the Study 349
4 Discussion 354
5 Conclusion 355
Acknowledgments 355
References 356
Influence of the Most Important Elements of the Prosthesis on Biomechanics of the Human Gait After Amputation of the Lower Limb 358
Abstract 358
1 Introduction 358
2 Elements of the Prosthesis 360
2.1 The Prosthetic Foot 360
2.2 The Knee Joint 360
2.2.1 The C-Leg 2 Knee Joint 360
2.2.2 The Genium Knee Join 361
2.3 The Prosthetic Socket 361
3 Patients 362
4 The Applied Model and Test Conditions 362
5 Reference Data 363
6 Results 364
6.1 Flexion of the Knee Joint 364
6.2 Flexion of the Ankle Joint 365
6.3 Vertical Component of the Ground Reaction Force 367
6.4 Anterior-Posterior Component of the Ground Reaction Force 369
7 Summary and Conclusions 371
Acknowledgments 371
References 371
Potential Studies of Waterjet Cavitation Peening on Surface Treatment, Fatigue and Residual Stress 373
Abstract 373
1 Introduction 373
2 WJP Effects on Surface Treatment 374
3 WJP Effect on Residual Stress 378
4 WJP Effect on Fatigue Performance 382
5 Conclusion 385
References 385
Thermo-Mechanical Phenomena in Aluminum Alloy Casting During Cooling – Experimental Simulation 390
Abstract 390
1 Introduction 390
2 State of Art 392
3 Methodology 393
4 Results and Discussion 396
5 Summary 398
Acknowledgments 399
References 399
Micro-machining and Process Optimization of Electrochemical Discharge Machining (ECDM) Process by GRA Method 400
Abstract 400
1 Introduction 400
2 Methodology and Experimentation 402
3 Results and Discussion 402
3.1 Behaviour of Machining Rate with Process Parameters 402
3.2 Behaviour of Overcut with Process Parameters 403
4 Multi-response Optimization of ECDM Process by Grey Relational Analysis 404
5 Conclusions 406
Acknowledgments 407
Appendix 407
References 407
Analysis of Material Removal Efficiency in Face Milling of Aluminum Alloy 409
Abstract 409
1 Introduction 409
2 Experiments 410
2.1 Aims of the Experiments and Methodology 410
2.2 Conditions of the Experiments 411
3 Results and Discussion 413
4 Summary 418
Acknowledgements 418
References 419
The Examination of Cutting Force as Function of Depth of Cut in Cases with Constant and Changing Chip Cross Section 421
Abstract 421
1 Introduction 421
2 Experimental Conditions 423
3 Results and Discussion 424
4 Conclusions 430
Acknowledgments 430
References 430
Methodology of Determination of Key Casting Process Parameters on DISA MATCH Automatic Moulding Line Affecting the Formation of Alloy-Mould Contact Defects 432
Abstract 432
1 Introduction 432
2 General Characteristic of the Casting Processes Automation 434
3 Research Problem and Methodology 435
4 Data Preparation for Analysis 436
5 Results Analysis 439
5.1 CA-AverageInPar 439
5.2 EDA-RC-AverageInPar 442
5.3 EDA-RC-AllInPar 446
6 Conclusions 447
Acknowledgments 448
References 449
Numerical Modeling of MuCell® Injection Moulding Process 450
Abstract 450
1 Introduction 450
1.1 MuCell® Injection Moulding 451
1.2 Properties of MuCell® Parts 452
2 Simulation of Microcellular Injection Moulding 453
2.1 Preparing the Simulation 453
2.2 Simulation Results 454
3 Microscopical Investigation Results 458
4 Summary and Conclusions 462
Acknowledgments 462
References 463
Materials 464
Comparative Experimental Investigation of Mechanical Properties and Adhesion of Low Temperature PVD Coated TiO2 Thin Films 465
Abstract 465
1 Introduction 465
2 Materials and Methods 466
2.1 Sample Preparation 466
2.2 Coating Deposition 466
2.3 Characterization of the TiO2 Thin Film 467
2.4 Scratch Adhesion Tests 467
2.5 Nano Indentation 468
3 Results and Discussion 469
3.1 TiO2 Thin Film Surface Characterization 469
3.2 Adhesion Strength of the TiO2 Film 470
3.3 Nano Mechanical Properties of TiO2 Thin Film 472
4 Conclusion 473
Acknowledgments 473
References 473
Frictional Properties of ?-Nucleated Polypropylene-Based Composites Filled with Wood Flour 475
Abstract 475
1 Introduction 475
2 Experimental Procedure 476
2.1 Materials 476
2.2 Methods and Equipment 477
3 Results and Discussion 477
3.1 Hardness 477
3.2 Friction 479
3.3 Surface Topography 480
4 Conclusion 483
Acknowledgments 483
References 484
Preparation and Characterization of the Injection Molded Polymer Composites Based on Natural/Synthetic Fiber Reinforcement 487
Abstract 487
1 Introduction 487
2 Experimental 489
2.1 Materials 489
2.2 Sample Preparation 489
2.3 Materials Characterization 489
3 Results and Discussion 491
3.1 Thermal Properties, Phase Transitions - DSC Measurements 491
3.2 Thermo-Mechanical Properties - DMTA Analysis 492
3.3 Mechanical Properties - Tensile and Impact Measurements 492
3.4 Structure Observations - SEM Analysis 494
4 Conclusions 496
Acknowledgments 496
References 496
Innovative Natural Yarn Manufactured from Waste 499
Abstract 499
1 Introduction 499
1.1 The Formary 500
1.2 Fibres and Traditional Processing 500
1.3 Environmental Impact 500
1.4 “Does Use Matter? 501
2 Research Problem 501
3 Results 502
3.1 Conversion of Waste Stream Fibre to Yarn and Cloth 503
4 Discussion 504
4.1 Further Development in Europe and China 506
5 Conclusions 506
Acknowledgments 506
References 507
Mechanical and Thermal Properties of Rotational Molded PE/Flax and PE/Hemp Composites 509
Abstract 509
1 Introduction 509
2 Experimental 510
2.1 Materials 510
2.2 Samples Preparation 511
2.3 Materials Characterization 511
3 Results and Discussion 513
3.1 Mechanical Properties – Tensile Test 513
3.2 Thermal Properties – DSC Measurements, Vicat Temperature 514
3.3 Flammability Test – UL 94 HB 515
3.4 Structure Observations - SEM Analysis 517
4 Conclusions 519
Acknowledgments 519
References 519
Clay/EVA Copolymer Nanocomposite - Processing and Properties 521
Abstract 521
1 Introduction 521
2 Experimental 524
2.1 Nanofillers 524
2.2 Evaluation of the Samples Prepared 524
3 Results 525
3.1 XRD 525
3.2 TEM 527
3.3 DMA 528
4 Conclusion 530
References 530
References for the discussion part 531
Synthesis and Characterization of Bioceramic Oxide Coating on Zr-Ti-Cu-Ni-Be BMG by Electro Discharge Process 532
Abstract 532
1 Introduction 533
2 Experimentation 534
2.1 Materials 534
2.2 Electro Discharge Coating Preparation 535
2.3 Characterizations 536
3 Results and Discussions 536
3.1 Surface Morphology 536
3.2 Formation of Bioceramic Oxides and Carbides Phases on the BMG Surface 538
3.3 HA-EDC Thickness 540
3.4 Material Deposition Rate 541
4 Conclusion 542
Acknowledgments 542
References 543
Investigation of Alloy Composition and Sintering Parameters on the Corrosion Resistance and Microhardness of 316L Stainless Steel Alloy 546
Abstract 546
1 Introduction 547
2 Materials and Methods 548
3 Results and Discussion 549
3.1 Green and Sintered Density 549
3.2 Micro Hardness 550
3.3 Nitriding During Sintering 550
3.4 Microstructure 551
3.5 XRD Analysis 552
3.6 Corrosion Resistance 553
4 Conclusion 554
Acknowledgments 554
References 554
The Impact of Long-Term Environmental Conditions on the Lifetime Prediction (S-N) of Biomaterial Used in Dentistry 556
Abstract 556
1 Introduction 556
2 Materials and Method 558
3 Results and Analysis 560
4 Summary 563
References 564
Influence of Residual Stress Induced in Steel Material on Eddy Currents Response Parameters 565
Abstract 565
1 Introduction 565
2 Experiment 567
3 The Results of the Experiment 571
4 Conclusions 572
Acknowledgments 572
References 572
Determination of Dynamic Properties of a Steel Hollow Section Filled with Composite Mineral Casting 575
Abstract 575
1 Introduction 575
2 Concept of the Solution 577
3 Research Samples 578
4 Static Test Results 579
5 Dynamic Test Results 580
6 Discussion and Conclusions 583
Acknowledgments 585
References 585
Corrosion Resistance of Alternative Chemical Pre-treatments of Hot-Dip Galvanized Zinc Surface 586
Abstract 586
1 Introduction 586
2 Modern Chemical Surface Pre-treatments 587
2.1 Chemical Pre-treatment of the Surface Based on Ti-Zr 587
2.2 Chemical Pre-treatment of the Surface Based on Organosilanes 587
3 Experimental Part 589
3.1 Condensation Chamber Test According to ?SN EN ISO 6270-1 and Salt Fog According to ?SN EN ISO 9227 591
4 Conclusion 594
Acknowledgments 594
References 595
The Influence of Mixing Method and Mixing Parameters in Process of Preparation of Anti-static Coating Materials Containing Nanoparticles 596
Abstract 596
1 Introduction 596
1.1 Antistatic Coatings 597
2 Experimental 597
2.1 Concentration of the MWCNT Filler 598
2.2 Influence of Mixing Process 599
2.3 Final Coatings 600
3 Conclusion 602
Acknowledgments 603
References 603
Cleaning of Internal Surfaces 605
Abstract 605
1 Introduction 605
2 Impurities 605
3 Fouling of Internal Surfaces 607
4 Methods for Cleaning Internal Surfaces 608
5 Experiments 609
5.1 Chemical Cleaning of the Heat Exchanger from Corrosion Products 610
5.2 Chemical Cleaning of the Heat Exchanger from Mineral Deposits 610
5.3 Neutralization of Cleaning Detergent 611
6 Conclusion and Discussion 612
Acknowledgments 613
References 613
Mechanical Properties and Structure of Reactive Rotationally Molded Polyurethane - Basalt Powder Composites 615
Abstract 615
1 Introduction 615
2 Experimental 616
2.1 Materials 616
2.2 Sample Preparation 617
2.3 Sample Preparation 618
3 Results and Discussion 618
4 Conclusions 621
Acknowledgments 621
References 621
Manufacturing and Properties of Biodegradable Composites Based on Thermoplastic Starch/Polyethylene-Vinyl Alcohol and Silver Particles 624
Abstract 624
1 Introduction 624
2 Experimental and Methods 625
2.1 Materials 625
2.2 Processing and Sample Preparation 626
2.3 Morphology and Silver Particles Dispersion 626
2.4 Mechanical Properties 626
2.5 Thermal Properties 627
2.6 Antibacterial Properties 627
3 Results and Discussion 628
3.1 Morphological Characterization 628
3.2 Mechanical Properties 628
3.3 Thermal Properties 630
3.4 Antibacterial Properties 633
4 Conclusion 636
Acknowledgements 637
References 637
Manufacturing and Properties of Recycled Polyethylene Films with an Inorganic Filler by the Extrusion Blow Moulding Method 639
Abstract 639
1 Introduction 639
2 Experimental and Methods 641
2.1 Materials and Films Preparation 641
2.2 Processing Parameters 641
2.3 Film Properties Measurement Techniques 643
3 Result and Discussion 645
3.1 Mechanical Properties 645
3.2 Puncture Test 646
3.3 Thermal Properties 647
3.4 Infrared Spectroscopy Analysis 648
3.5 Processing Properties 649
4 Conclusions 650
Acknowledgments 651
References 651
Hybrid Epoxy Composites Reinforced with Flax Fiber and Basalt Fiber 653
Abstract 653
1 Introduction 653
2 Experimental 654
2.1 Materials 654
2.2 Sample Preparation 654
3 Methods 655
3.1 Dynamic Mechanical Thermal Analysis (DMTA) 655
3.2 Tensile Mechanical Properties 655
3.3 Charpy Impact Strength 655
3.4 Hardness 655
3.5 Thermogravimetry (TGA) 655
4 Results and Discussion 657
4.1 Dynamic Mechanical Thermal Properties 657
4.2 Mechanical Properties 658
4.3 Thermal Stability of the Composites 661
5 Conclusions 663
Acknowledgments 663
References 663
Author Index 665