FEM/AI Models for the Simulation of Precision Grinding

MANUFACTURING TECHNOLOGY

April 2016, Vol. 16, No. 2

Advisory Board

Prof. hab. Dr. Stanislav Adamczak, MSc.Politechnika Kielce, Poland

Prof. Dana Bolibruchová, MSc. PhD.UZ in Zilina, Slovakia

Prof. Milan Brožek, MSc., Ph.D.CULS in Prague, Czech

Prof. Dr. M. Numan DurakbasaVienna University of Technology, Austria

Prof. Dr. František Holešovský, MSc.president, JEPU in Usti n. Labem

Prof. Ji í Hrubý, MSc., Ph.D.VSB TU in Ostrava

Prof. Karel Jande ka, MSc., Ph.D.UWB in Pilsen, Czech

Prof. h. c. Stanislaw Legutko, MSc., Sc.D. Politechnika Pozna ska, Poland

Prof. Karel Kocman, MSc., Sc.D. TBU in Zlin, Czech

Prof. Pavel Kovac, MSc., Ph.D.University of Novi Sad, Serbia

Prof. Dr. János Kundrák, MSc., Sc.D.University of Miskolc, Hungary

Prof. Ivan Kuric, MSc., Ph.D.UZ in Zilina, Slovakia

Prof. Jan Mádl, MSc., Ph.D.CTU in Prague, Czech

Prof. Ioan D. Marinescu, Ph.D.University of Toledo, USA

Prof. Dr. Ivan Mrkvica, MSc.VSB TU in Ostrava, Czech

Prof. Iva Nová, MSc., Ph.D.TU in Liberec, Czech

Prof. Dr. Hitoshi Ohmori, MSc.RIKEN, Japan

Prof. Ing. ubomír Šooš, PhD.SUT in Bratislava, Slovakia

Prof. Dr. Dalibor Vojt ch, MSc.ICHT in Prague, Czech

Col. Assoc. Prof. Milan Chalupa, Ph.D.FMT, University of Defence, Czech

Assoc. Prof. Jan Jersák, MSc., Ph.D.TU in Liberec, Czech

Assoc. Prof. Daniela Kalincova, MSc., PhD.TU in Zvolen, Slovakia

Assoc. Prof. Štefan Michna, MSc., PhD.JEPU in Usti n. Labem, Czech

Assoc. Prof. Pavel Novák, MSc., Ph.D.ICHT in Prague, Czech

Assoc. Prof. Iveta Vaskova, MSc., PhD.FM, TU in Kosice, Slovakia

Dr. Michael N. MorganJohn Moores University, Great Britain

Dr. Thomas PearceUWE Bristol, Great Britain

Editor-in-chief

Assoc. Prof. Martin Novak, Eng. MSc., Ph.D.

Editor

Radek Lattner, MSc.

Editorial Office Address

J. E. Purkyne University in Usti n. LabemFVTM, Campus UJEP, Building H

Pasteurova 3334/7, 400 01 Usti n. LabemCzech Republic

Tel.: +420 475 285 534e-mail: [email protected]

Print

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J. E. Purkyne University in Usti n. LabemPasteurova 1, 400 96 Usti n. Labem

Czech RepublicVAT: CZ44555601

Published 6 p. a., 300 pcs.published in April 2016,

162 pages

Permission: MK CR E 20470

ISSN 1213–2489

indexed on: http://www.scopus.com

Content

317 – 323 Possibilities of Using Al-Si-Mg Alloys with Higher Fe Content for Demanding Castings

Dana Bolibruchová, Lukáš Richtárech 323 – 327

Hot Tearing Evaluation of Al – Based Alloys

Marek Bruna, Augustín Sládek327 – 334

Impact of Silica Sand Granulometry on Bending Strength of Cores Produced by ASK Inotec

Process

Martin Conev, Iveta Vasková, Martina Hrubov áková, Peter Hajdúch 334 – 338

Influence of Finishing Operations and Melt Flow Index on Surface Quality of Injection Molded

Parts

Ji í op, Ladislav Fojtl, Ond ej Bílek, Vladimír Pata 338 – 342

Influence of Morphology of Carbide Phase in Chromium Cast Iron on Wear Resistance

Malwina Dojka, Andrzej Studnicki 343 – 348

Ultrasonic Identification of Weld Defects Made by Butt Welding with Hot Plate on Plastic

Pipelines

Martin Faturík, Miloš Mi ian, Radoslav Ko ár 348 – 354

Material Analysis of Nickel Superalloy for Military Technology

Petr Jonšta, Irena Vl ková, Zden k Jonšta

354 – 360 Measurement of Noise during the Process of Cutting Materials by Water Jet

Jan Kmec, Daniel Kucerka, Miroslav Gombar, Monika Karkova, Alena Vagaska 360 – 365

Finite Element Modeling and Numerical Simulation of Welding at the Repair of Gas Pipelines

with Steel Sleeve

Radoslav Konar, Milos Mician, Marek Patek, Dalibor Kadas 365 – 371

Prediction of Hardness and Residual Stresses of Dissimilar Weld Joint

Radoslav Konar, Marek Patek

371 – 375 Digital Factory Simulation Tools

Ji í Kyncl 375 – 380

Reparation by Hard Facing of the Damaged Secondary Stone Crushers

Vuki Lazi , Dušan Arsi , Ružica Nikoli , Milan Mutavdži , Jozef Meško

380 – 384 Analysis of Heat Transfer Conditions in the Sand and Metal Moulds and Their Effect on the

Solidification of the Casting

Jiri Machuta, Iva Nova 384 – 390

FEM/AI Models for the Simulation of Precision Grinding

Angelos P. Markopoulos, János Kundrák 390 – 396

Determination of Stiffness of Triple Spring Built in a Bogie of a Rail Vehicle

Mária Ma urová, Andrej Suchánek 396 – 401

Evaluation of MRR after WEDM Depending on the Resulting Surface

Katerina Mouralova, Josef Bednar, Jiri Kovar, Jindrich Mach

402 – 406 Laser Cutting of Non-Metallic Material - PMMA

Rastislav Nigrovi , Jozef Meško 406 – 409

Fatigue Durability of Ductile Iron in Very-High-Cycle Region

František Nový, Peter Kopas, Otakar Bok vka, Adriana Savin

410 – 416 Influence of High-Pressure Die-Casting Second Stage Parameter on Structure Of AlSi9Cu3(Fe)

Alloy

ukasz Pa yga, Mateusz Stachowicz, Kazimierz Granat 406 – 409


František Nový, Peter Kopas, Otakar Bok vka, Adriana Savin

410 – 416Influence of High-Pressure Die-Casting Second Stage Parameter on Structure Of AlSi9Cu3(Fe)

Alloy

ukasz Pa yga, Mateusz Stachowicz, Kazimierz Granat

MANUFACTURING TECHNOLOGY

April 2016, Vol. 16, No. 2

Content

417 – 420 The Heat Flux at the Crystallization Under Pressure

Richard Pastir ák, Ján Moravec, Eva Kuchar íková 421 – 425

Design and Testing of the Novel Split Sleeve for Branch Connection Repairs Based on Internal Pressure

Marek Patek, Augustín Sládek, Miloš Mi ian 425 – 431

Tool Geometry Influence on Surface Integrity of Machined Austenite Stainless Steel

Zden k Pitrmuc, Ji í apek, Kamil Kola ík, Libor Beránek, Jan Urban431 – 436

Appliciation of Heat Treatment for Elimination of Iron in Secondary Al-Si Alloy

Lukáš Richtárech, Dana Bolibruchová, Eva Kuchar íková436 – 444

Development and Production of Prototype Model of Axial Fan

Josef Sedlak, Jiri Malasek, Martin Ondra, Ales Polzer444 – 448

Ausferrite Flake Graphite Cast Iron at the Thermal Fatigue

B etislav Skrbek, Ji í Hampl449 – 453

Electro-Erosive Wire Cutting of Aluminum Foam

František Špalek, Jana Petr , Tomáš Zlámal, Ivan Mrkvica, Robert ep, Ji í Kratochvíl454 – 460

Effect of Pre-Wetting of High-Silica Sand on Parameters of Dried Moulding Sands Bonded with Selected Grades of Water-Glass

Mateusz Stachowicz, Kazimierz Granat, ukasz Pa yga, Micha Kami ski461 – 467

Influence of Cutting Conditions on Profile Milling of INCONEL 738LC Alloy

Jan Tomí ek, Alexey Molotovnik 468 – 471

Improvements in Material Characteristics Core Centrifugally Cast Rolls

Tomáš Válek, Ji í Hampl, Jakub Rušaj 471 – 475

Evaluation of Vanadium Influence in AlSi10MgMn Alloy with Increased Iron Level

Maria Zihalova, Dana Bolibruchova

APRIL 2016, Vol. 16, No. 2 – INTERNATIONAL REVIEWERS AND EDITORS LIST

Technology and Assembly Material Engineering and Design

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Possibilities of Using Al-Si-Mg Alloys with Higher Fe Content for Demanding Castings

Dana Bolibruchová, Luká� Richtárech Department of Technological Engineering, Faculty of Mechanical Engineering, University of �ilina, Univerzitná 1, 010 26, Slovak Republic, Email: [email protected]

The present article describes the effect of adding iron into melt, and its impact on the microstructure, chemical

composition and mechanical properties of AlSi7Mg0.3 alloy. Higher iron content is typical of the so-called secon-

dary alloy, which becomes increasingly used by a growing number of manufacturers in the production process of

high-quality castings. The behaviour of AlSi7Mg0.3 alloy with high Fe content has not been scientifically investi-

gated and sufficiently described, therefore working with secondary alloy is very problematic when focusing on

high-sophistication castings for the automotive industry. In general, iron is unwanted in aluminium alloys, and its

content should be kept as low as possible. The only exception is the process of pressure die casting where we can

tolerate iron content up to 1 wt. %. In gravity casting of Al-Si-based alloys, the critical iron content changes mainly

depending on the silicon content. The experimental part of this article investigates the impact of gradual addition

of iron into AlSi7Mg0.3 alloy on the content of the main alloying elements such as, in particular, Si and Mg. In

order to eliminate the negative effect of iron in the alloy, we used in the experiment the correctors Ni and Cr in

the form of AlNi20 and AlCr20 master alloys.

Keywords: AlSiMg alloy, iron, correctors

References

TAYLOR, J.A. (2012). Iron-containing intermetallic phases in Al-Si based casting alloys. In: Procedia Materials Science, Vol. 1, pp. 19 � 33.TAYLOR, J.A. (2004). The effect of iron in Al-Si casting alloys. In: 35th Australian Foundry Institute National Conference, pp. 148 � 157, Adelaide, South Australia. DINNIS, C.M., TAYLOR, J.A., DAHLE, A.K. (2005). As-cast morphology of iron-intermetallics in Al-Si foun-dry alloys. In: Scripta Materialia, Vol. 53, pp. 955 � 958. CAO, X., CAMPBELL, J. (2006). Morphology of Al5FeSi phase in Al-Si cast alloys. In: Materials Transactions, Vol. 47, No. 5, pp. 1303 -1312. KUMARI, S.S.S., PILLAI, R.M., RAJAN, T.P.D., PAI, B.C. (2007). Effects of individual and combined additi-ons of Be, Mn, Ca and Sr on the solidification behaviour, structure and mechanical properties of Al-7Si-0.3Mg-0.8Fe alloy. In: Material Science and Engineering A, Vol. 460-461 BOLIBRUCHOVÁ, D., RICHTÁRECH, L. (2013): Effect of adding iron to the AlSi7Mg0.3 (EN AC 42 100, A356) alloy. In: Manufacturing Technology, Vol. 13, No. 3, pp. 276�281. ISSN 1213-2489 TILLOVA, E., CHALUPOVA, M. (2009). Structural analysis of Al-Si cast alloys, pp. 191. EDIS, �ilina. BOLIBRUCHOVA, D., ZIHALOVA, M. (2013). Possibilities of iron elimination in aluminium alloys by vana-dium. In: Manufacturing technology, Vol. 13, No. 3, pp. 289 -296. ISSN 1213-2489 BOLIBRUCHOVÁ, D., BR�NA, M. (2014): Influencing the crystallization of secondary alloy AlSi6Cu4 with strontium. In: Manufacturing Technology, Vol. 13, No. 1, ISSN 1213-2489 PASTIR�ÁK, R. (2015): Effect of low pressure application during solidification on microstructure of AlSi alloys. In: Manufacturing Technology, ISSN 1213-2489. - Vol. 14, no. 3 (2014), s. 397-402. PETRIK, J., HORVATH, J. (2011). The iron correctors in Al-Si alloys. In: Annals of faculty engineering Hune-doara, Vol. 9, No. 3, pp. 401 � 405. MONDOLFO, L.F. (1943). Metallography of Aluminium Alloys. pp. 351. USA. ZHANG J, FAN Z, WANG Y Q, ZHOU B. Microstrucral refinement in Al-Mg2Si in situ composites [J]. Journal of Materials Science Letters, 1999, 18(10): 783!784. SEIFEDDINE, S. (2007). The influence of Fe on the microstructure and mechanical properties of cast Al-Si alloys: Literature review, Vilmer project. Jönköping University. MOUSTAFA, M.A. (2009). Effect of iron content on the formation of �-Al5FeSi and porosity in Al�Si eutectic alloys, Journal of Materials Processing Technology, 209(1), 605�610, DOI 10.1016/j.jmatprotec.2008.02.073 TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., BONEK, M., DOBRZANSKI, L.A, (2011). Structural analysis of heat treated automotive cast alloy, Journal of Achievements in Materials and Manufacturing Engine-ering/JAMME, 47(1), 19�25

Paper number: M201664

Copyright © 2016. Published by Manufacturing Technology. All rights reserved.


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Hot Tearing Evaluation of Al � Based Alloys

Marek Bruna, Augustín Sládek Department of technological engineering, University of �ilina. Univerzitná 8215/1, 010 26 �ilina, Slovak republic. E-mail: [email protected], [email protected]

Hot tearing during solidification of aluminium alloys castings can be a serious problem. This phenomenon is well

known but still insufficiently investigated. Hot tearing occurs in form of irregular cracks in metal castings that

develop during solidification and cooling (typically while the casting is still inside the mold or die cavity). The cause

of hot tearing is generally attributed to the development of thermally induced tensile stresses and strains in a

casting as the molten metal contracts during solidification and solid state shrinkage. Submited paper consists of

two parts. The first part introduces the reader to the phenomenon of hot tearing. The second part describes newly

developed method for assessing hot tearing susceptibility of aluminium alloys, and also gives the results on hot

tearing for various aluminium alloys.

Keywords: Hot tearing, Al alloys, Freezing range, Chemical composition

References

ESKIN, D. G., KATGERMAN. L. (2007). A Quest for a New Hot Tearing Criterion. In: Metallurgical and Mate-rials Transactions A, 38, 1511-1514.

KNEISSL, C., PABEL, T., DAMBAUER, G., SCHUMACHER, P. (2009). Formenkonzept und Ergebnisse gießtechnologischer Versuche zur Legierungsentwicklung im Niederdruckkokillenguss, Giesserei-Rundschau, 56, 120-125.

PASTIR�ÁK, R., KRIVO�, E. (2013). Effect of opening material granularity on the mould properties and the quality of casting made by patternless process technology. In Manufacturing Technology: Journal for science re-search and production. Vol.13, no. 1, pp. 92-97, ISSN 1213-2489.

ME�KO, J., ZRAK, A., MULCZYK, K., TOFIL, S. (2014). Microstructure analysis of welded joints after laser welding, In: Manufacturing Technology: journal for science, research and production, Vol. 14, No. 3 (2014), s. 355� 359. ISSN 1213-2489, Kód: ADM.

PASTIR�ÁK, R. (2014). Effect of low pressure application during solidification on microstructure of AlSi alloys. In: Manufacturing Technology. ISSN 1213-2489. Vol. 14, No. 3 (2014), p. 397-402.

BOLIBRUCHOVÁ, D., �IHALOVÁ, M. (2013). Possibilities of iron elimination in aluminium alloys by vana-dium. In: Manufacturing technology. Vol. 13, No. 3, pp. 289 -296.

�MINDÁK, M., ME�KO, J., PELAGIC, Z., ZRAK, A. (2014). Finite element analysis of crack growth in pipeli-nes. In: Manufacturing Technology. 2014, Vol. 14, No. 1, pp. 116�122. JEPU in Usti nad Labem. Czech Republic

BOLIBRUCHOVÁ, D., RICHTÁRECH, L. 2013. Effect of adding iron to the AlSi7Mg0.3 (EN AC 42 100, A356) alloy. In: Manufacturing Technology. ISSN 1213-2489. Vol. 13, No. 3, p. 276-281.





Impact of Silica Sand Granulometry on Bending Strength of Cores Produced by ASK Inotec

Process

Martin Conev1, Iveta Vasková1, Martina Hrubov�áková1, Peter Hajdúch2

1Institute of Metallurgy, Faculty of Metallurgy, Technical University in Ko�ice, Slovakia, E-mail: [email protected], [email protected], [email protected] Slovakia s.r.o., �iar nad Hronom, E-mail: [email protected]

Nowadays, constant pressure on enviromental aspects in the foundry industry is calling for an improvement in

casting production. The almost not used inorganic binders are coming back to the fore. Into this group, among

others, belong binders based on alcali silicate solutions, known as water glass. The new hot-curing binder systems

were introduced by different binder manufacturers. In order to compensate dissadvantages of alkalic silicate bin-

der, the systems and processes are working with additives and adjuvants which are contained in a binder itself or

added in liquid or powder form to the sand mixture. This paper presents the ASK Inotec process and impact of

silica sand granulometry on achieved core mixture strength, which is important from a core production and also

from a decoring ability point of view. Experiment was performed in laboratory terms using standard equipment

and conditions.

Keywords: Silica sand, Granulometry, Inorganic binder, ASK Inotec process, Bending strength

References

WALLENHORST, C. (2010). Chemical Background of Inorganic Binder systems - Focus on Core Production at the Molecular Level. In: Giesserei Rundschau. Vol. 57, No. 3/4, pp. 50 - 52. VÖG, Austria

PETR�ELA, L. (1947). Zp�sob výroby formovaných útvar� z písku nebo z jiného prá�kovitého, zrnitého, ka�ovi-tého nebo tekutého materiálu. Patent Nr. 81931. Filling date 12. Dec. 1947.

POLZIN, H. (2014). Inorganic binders for mould and core production in the foundry. pp. 115 - 117. Schiele & Schön GmbH, Berlin.

BOUNDLESS CHEMISTRY (2015). Condensation reactions. Retrieved on 12. Feb. 2016. May be accessed at: www.boundless.com/chemistry/textbooks/boundless-chemistry-textbook/polymers-24/synthetic-organic-poly-mers-173/condensation-reactions-657-5664

ASK Chemicals GmbH (2015). INOTEC The Inorganic Binder System. Presentation

ASK Chemicals GmbH (2016). Inotec process. Retrieved on 2. Feb. 2016. May be accessed at: www.ask-chemi-cals.com/foundry-products/products/inotec-binder-system/inotec-process.html

MAJOR-GABRY�, K., DOBOSZ, S.M., JAKUBSKI, J. (2013). Modified hydrated sodium silicate as a modern binder for ecological moulding sands. In: Manufacturing Technology. Vol. 13, No. 1, pp. 68 - 73. UJEP. Czech republic

RUSÍN, K., BRYCHTA, R. (2005). Co ur�uje cenu jádrových sm�sí s k�emennými ost�ivy? In: Mouldding mate-rials and cost reductions for casting. 8th International conference almanac, pp. 37 - 52. CFS, Czech republic

YEKINNI, A.A., BELLO, S.K. (2013). Investigation and Comparative Analysis of Clay Content, Grain Size and Grain Size Distribution of Foundry Moulding Sands. In: International Journal for Managment Science And Tech-nology. Vol. 1, Issue 7, paper 1. IJMST

PASTIR�ÁK, R., KRIVO�, E. (2013). Effect of opening material granularity on the mould properties and the quality of castings made by patternless process technology. In: Manufacturing Technology. Vol. 13, No. 1, pp. 92 - 97. UJEP. Czech republic

IS 1918 (1966). Methods of physical tests for foundry sands. Indian standards. Bureau of Indian standards, India

JELÍNEK, P. (1970). Teorie slévárenské formy �ást I. Slévárenské formovací sm�si. pp. 14 - 21. V�B, Czech republic





Influence of Finishing Operations and Melt Flow Index on Surface Quality of Injection Mol-

ded Parts

Ji�í �op1, Ladislav Fojtl1,2, Ond�ej Bílek1, Vladimír Pata1 1Department of Production Engineering, Faculty of Technology, Tomas Bata University in Zlín. Vavre�kova 275, 760 01 Zlín. Czech Republic. E-mail: [email protected], [email protected], [email protected], [email protected] 2Centre of Polymer Systems, Tomas Bata University in Zlín, Trida Tomase Bati 5678, 760 01 Zlín, Czech Republic

In the production of polymer parts, great emphasis is placed on the quality of polymer product in terms of dimen-

sional accuracy and optimally surface quality. Achievement of high surface quality of injection molded products

correlate to the high surface quality of core or cavity in injection molds. This surface is copied during injection of

polymer material. The kind of polymer material and its rheological properties can strongly influence this surface

copying. Production of cores and cavities takes in the manufacturing process a considerable part of time, where

some finishing technologies are more economically and time consuming than other processes. Thus, it is necessary

to choose an appropriate finishing operations considering cost of injection mold, which is reflected in future price

of polymer product. This paper experimentally examines the influence of the surface quality of mold cavities and

rheological properties of polymer on the surface quality of injection molded product.

Keywords: Surface quality, Injection molding, Melt flow index, Finishing operations, Polymer, Mold Cavity

Acknowledgement

This study was supported by the internal grant of TBU in Zlín No. IGA/FT/2016/002 funded from the resources of specific university research.

References

BUMBÁLEK, B. (2015). Integrita povrchu a její význam pro posouzení vhodnosti dané plochy pro její funkci. [online]. [cit. 2015-11-1]. http://gps.fme.vutbr.cz/STAH_INFO/2512_Bumbalek.pdfBUMBÁLEK, L., PERNIKÁ�, J., PATA, V. (2009). Kontrola a m��ení. Informatorium. Praha. NOVAK, M. (2012). Surfaces with high precision of roughness after grinding. In: Manufacturing Technology,Vol. 12, pp. 66�70. JEPU in Ústí nad Labem, Czech Republic. GADELMAWLA, E. S., KOURA, M. M., MAKSOUD, T.M.A., ELEWA, I. M., SOLIMAN, H. H. (2002). Roughness parameters. In: Journals of Materials Processing Technology. Vol. 123, pp. 133-145. GROOVER, M. P. (2012) Fundamentals of Modern Manufacturing - Materials, Processes and Systems. 5th ed. USAGRZESIK., W. (2008). Advanced Machining Process of Metallic Materials. 1st ed. TU of Opole, Poland.HOLE�OVSKÝ, F., NOVÁK, M., MICHNA, �. (2007). Studium zm�n brou�ené povrchové vrstvy p�i dynamic-kém zat��ování. In: Strojírenská technologie. pp. 73-76. JEPU in Ústí nad Labem, Czech Republic. KUNDRÁK, J. (2011). Alternative machining procedures of hardened steels. Manufacturing technology. vol. 11, no. 11., pp. 32-39, JEPU in Ústí nad Labem, Czech Republic. NOVÁK, M., HOLE�OVSKÝ, F. (2008) Studium integrity brou�eného povrchu, In: Manufacturing and In-dustrial Engineering. pp. 11-13. Pre�ov. Slovakia.MADL, J., HOLE�OVSKY, F. (2008) Integrita obrobených povrchu z hlediska funk�ních vlastností. (M. Slama., (Ed.)) 1. vyd. Ústi nad Labem : UJEP, FVTM Ústi n. Labem. Czech Republic.STANEK, M., MANAS, D., MANAS, M., SUBA. O. (2011) Optimization of Injection Molding Process. In: In-ternational Journal of Mathematics and Computers Simulation. Vol.5. Issue 5. pp.413-421.BÍLEK, O., LUKOVICS, I. (2014). Výrobní in�enýrství a technologie. 1. vyd. Zlín: Univerzita Tomá�e Bati ve Zlín�. Czech Republic �ILLIKOVÁ, M., MI�ÚCH, M., NESLU�AN M., MI�IETOVÁ, A. (2013). Nondestructive micromagnetic eval-uation of surface damage after grinding. In: Manufacturing Technology. Vol. 13, No. 2, pp. 152�157. JEPU in Ústí nad Labem, Czech Republic. LEGUTKO, S., KROLCZYK. G., KROLCZYK, J. (2014). Quality evaluation of surface layer in highly accurate manufacturing. In: Manufacturing Technology,Vol. 14, No. 1, pp. 50�56. JEPU in Ústí nad Labem, Czech Repub-lic.





Influence of Morphology of Carbide Phase in Chromium Cast Iron on Wear Resistance

Malwina Dojka, Andrzej Studnicki Silesian University of Technology, Foundry Department, Towarowa 7, 44-100 Gliwice, Poland. E-mail: [email protected], [email protected]

The article presents results of M7C3 carbides stereological parameters measurement and wear tests of chromium

cast irons. There are two types of material were compared: not inoculated chromium cast iron and the same ma-

terial about 4% addition of titanium by weight. The samples for studies were taken from casting formed by pou-

ring into ATD-Is tester mould. Then they were properly prepared for testing. Stereological analysis was conducted

in ImageJ software, where the following parameters of carbides was measured: area, width, length, perimeter, and

circularity. Wear test was executed using pin-on-disk method on Tribotester 3-POD. Results of research shown

that Ti addition results in formation of TiC carbide, which is an underlay for crystallization of M7C3 carbides. The

effect of this was the finer grain of M7C3 and the lower weight losses during abrasion.

Keywords: Chromium Cast Iron, M7C3 Carbide, Stereological Parameters, Wear

References

STUDNICKI, A. (2013). Role of selected inoculants in crystallization of wear resistant high chromium cast iron. PAN. Katowice � Gliwice.

GROMCZYK, M., KONDRACKI, M., STUDNICKI, A., SZAJNAR, J. (2015). Stereological Analysis of Car-bides in Hypoeutectic Chromium Cast Iron. In: Archives of Foundry Engineering, Vol. 15, Issue 2, pp. 17 � 22. PAN. Katowice � Gliwice.

STUDNICKI, A., JEZIERSKI J. (2012). Stereological parameters of carbides in modified wear resistant Fe-C-Cr alloys. International Conference on Metallurgy and Materials 23 � 25 May 2012. Brno, Czech Republic, EU.

STUDNICKI, A., DOJKA, R., GROMCZYK, M., KONDRACKI, M. (2016). Influence of Titanium on Crystalli-zation and Wear Resistance of High Chromium Cast Iron. In: Archives of Foundry Engineering, Vol. 16, Issue 1, pp. 117 � 123. PAN. Katowice � Gliwice.

NÁPRSTKOVÁ, N., CAIS, J., STAN�EKOVÁ, D. (2014). Influence of Alsi7Mg0.3 Alloy Modification by Sb on the Tool Wear. In: Manufacturing Technology, Vol. 14, No. 1, pp. 75 � 79.

KOPYCISKI, D., GUZIK, E., SIEKANIEC, D., SZCZSNY, A. (2015). The Effect of Addition of Titanium on The Structure and Properties of High Chromium Cast Iron. In: Archives of Foundry Engineering, Vol. 15, Issue 3, pp. 35 � 38. PAN. Katowice � Gliwice.

MIRZAEE, M., MOMENI, A., KESHMIRI, H., RAZAVINEJAD, R. (2014). Effect of Titanium and Niobium on Modifying the Microstructureof Cast K100 Tool Steel. The Minerals, Metals & Materials Society and ASM In-ternational 2014.

ZHANG, Q., LIU, Q., SHIBATA, H., WANG, Q., JÖNSSON, P., HE, J., NAKAJIMA, K. (2014). Partial Equi-librium Prediction of Solidification and Carbide Precipitation in Ti-added High Cr Cast Irons. In: ISIJ Internatio-nal, Vol. 54 (2014), No. 2.





Ultrasonic Identification of Weld Defects Made by Butt Welding with Hot Plate on Plastic Pi-

pelines

Martin Faturík, Milo� Mi�ian, Radoslav Ko�ár University of �ilina, Univerzitná 1, Department of Mechanical Engineering Technologies; E-mail: [email protected], [email protected], [email protected]

This article describes usage of ultrasonic method TOFD for testing of welds on plastic pipelines welded with butt

fusion with hot plate. As an artificial defects were selected cold fusion and inclusion in the weld area, by using

metallic tape and wire as a mentioned defects. To test defects was necessary to use wedges with water as a bonding

agent. Results of testing are proof of usefulness of this method. It can severely reduce risks of accidents caused by

unidentified defects, which can occur in welded joints. Since plastic pipelines are used even in nuclear industry as

a replacement for metal pipelines for its resistance against radiaton decay, it is necessary to implement similar

testing regulations to avoid fatal incidents and method like TOFD and Phased Array ultrasonic testing can prevent

such failures.

Keywords: ultrasonic defectoscopy, TOFD, plastic pipelines, gas industry

Acknowledgement

Article was created within project solution VEGA: 1/0836/13, KEGA: 034ZU-4/2015 a KEGA: 014ZU-4/2015.

References

KOVÁ�IK, M., HY�A, R. (2013). Ultrazvuková skú�ka �asti obvodového zvaru �pavkovej tlakovej nádoby technikami Phased Array a TOFD. [Online] 2013. [Date: 21. 04 2013.] http://www.ssndt.sk/files/od-borne/PA%20a%20TOFD%20na%20cpavku.pdf.

KOVÁ�IK, M. (2010). Skú�anie materiálov ultrazvukom. Bratislava : s.n., 2010.

MARTAN�ÍK, B. (2012). Výskum diagnostiky defektov pomocou nových ultrazvukových metód TOFD a Phased Array a vplyv na �ivotnos� zváraných kon�trukcií. Bratislava : Slovenská technická unverzita v Bratislave, 2012. s. 151, dizerta�ná práca.

OBRAZ, J. (1989). Zkou�ení materiálu ultrazvukem. Praha : SNTL Nakladatelství technické literatury, 1989. s. 464. ISBN 80-03-00097-1.

OLYMPUS. (2004). Introduction to Phased Array Ultrasonic Technology Applications. Waltham, MA : Olym-pus NDT, 2004. s. 351. ISBN 0-9735933-0-X.

OLYMPUS. (2012). Phased Array Testing Basic Theory for Industrial Applications. 2nd ed. Waltham, MA : Olympus NDT, 2012. s. 113. DMTA-20003-01EN.

LOYDA, M., �PONER, V., ONDRÁ�EK, L a kol. (2001). Sva�ování termoplast�. Praha. Uno, 2001. ISBN 80-223-6603-6

MORAVEC, J., BRADÁ�, J., BERAN, D., NOVÁKOVÁ, I. (2014). The Impact of Thermal Cycles of Superhe-ated Steam on Pipes Material of By-Pass of Steam and Gas-Steam. In: 23rd International Conference on Me-tallurgy and Materials, Metal 2014, Brno, 2014. ISBN 978-80-87294-52-9.

SEJ�, P. BIELAK, R. - �VEC, P. - RO�KO, M. (2006). Computer simulation of heat affected zone during MIG brazing of zinc-coated steel sheets. In Kovové materiály. Metallic materials. Ro�. 44, �. 4 (2006), s.225-234. ISSN 0023-432X.

ME�KO, J. � Zrak, A. � MULCZYK, K. � SZYMON, T. (2014). Microstructure analysis of welded joints after laser welding. In: Manufacturing technology : journal for science, research and production. - ISSN 1213-2489. - Vol. 14, no. 3 (2014), s. 355-359.

NORBERT, R. - ME�KO, J. � ZRAK, A. (2014). Technology of laser forming. In: Manufacturing technology: journal for science, research and production. - ISSN 1213-2489. - Vol. 14, no. 3 (2014), s. 428-431.





Material Analysis of Nickel Superalloy for Military Technology

Petr Jon�ta1, Irena Vl�ková2, Zden�k Jon�ta3

1VÍTKOVICE HEAVY MACHINERY a.s., Ruská 2887/101, Vítkovice, 703 00 Ostrava, Czech Republic, E-mail: [email protected] 2RMTSC, MATERIAL & METALLURGICAL RESEARCH Ltd., Ostrava, remote site VÚH� a.s., 739 51 Dobrá, Czech Republic, E-mail: [email protected] 3Technical University of Ostrava, Faculty of Metallurgy and Materials Engineering, 17. listopadu 15/2172, 708 33 Os-trava-Poruba, Czech Republic, E-mail: [email protected]

In the aerospace industry, the nickel-based superalloys are often used due to their ability to withstand extreme

conditions. They find their use particularly as turbine blades in jet engines. An important example of this type of

superalloy is INCONEL. This construction material must meet a wide range of complex requirements with regard

to its properties and technological and operational characteristics that are required by the heavy duty in extreme

conditions.

The INCONEL Superalloys represent multicomponent and multiphase materials with their complex alloying base

and structure with distinct dendritic segregations. Their long life and reliability in operation are directly related

to the microstructure, or to its stability in a long-term operational application, respectively.

The presented work deals with the evaluation of microstructural parameters at two variants of cast superalloy

INCONEL 713LC, applying the light microscopy and electron microscopy, including the fractographic analysis.

Keywords: Nickel superalloy, as cast condition, structural phase analysis, fractography

Acknowledgments

This work was created during the implementation of the project no. LO1203 "Regional Materials Technology Centre-sustainability program" funded by the Ministry of Education, Youth and Sports of the Czech Republic.

References

High Temp. Alloys for Gas Turbines and Other Appl., Proc. Int. Conf. Liege (1976, 1986, 1990, 1994, 1998).

SCHUBERT, F. (1978). Hochtemperaturwerkstoffe fur den Receiver des Solar Systems, Studie fur die DFVLR.

SIENIAWSKI, J. (1995). Kryteria i sposoby oceny materia!ów na elementy silników turbinowych, Politechnika Rzeszowska.

SIMS, C. T., STOLAFF, N. S., HAGEL, W. C. (1998) Superalloys II. Wiley & Sons, New York (1987).

KOIZUMI, Y., KOBAYASHI, T. et al. (1998) In: High Temp. Mat. for Power Eng., P.II, Liege´98.

HERNAS, A., JON�TA, Z., et. al. (2009). �árupevné oceli a slitiny, ES V�B-TU Ostrava, 392 p.

BELAN, J., HURTALOVÁ, L., VA�KO, A., TILLOVÁ, E. (2014). Metallography Evaluation of IN 718 after Applied Heat Treatment. Manufacturing Technology. Vol. 14, No. 3. ISSN 1213-2489.

DONACHIE, M., J., DONACHIE, S., J. (2002) Superalloys: a technical guide, USA, 439 p.

STRANG, A. (1998). High Temp. Mat. for Power Eng. and Other Appl., Liege´98.

CRANE, F. A., CHARLES, J. A. (1986). Selection and Use of Engineering Materials, Butterworths, London-Wellington.

BELAN, J., KUCHARIKOVÁ, L., TILLOVÁ, E., UHRI�ÍK, M. (2015). The Overview of Intermetallic Phases Presented in Nickel Base Superalloys after Precipitation Hardening. Manufacturing Technology. Vol. 15, No. 4. ISSN 1213-2489.

JON�TA, Z., JON�TA, P., VODÁREK, V., MAZANEC, K. (2007) Physical-Metallurgical Characteristics of Nickel Super Alloys of INCONEL Type. Acta Met.Slovaca, 13, (4).

VILAMOVÁ, �., JANOVSKÁ, K., KOZEL, R.,VOZ�ÁKOVÁ, I., �VECOVÁ, E. (2012). New Trends in the Management within the Metallurgy Firms. International Conference on Metallurgy and Materials Metal 2012. Ostrava: Tanger, pp. 1897-1903.





Measurement of Noise during the Process of Cutting Materials by Water Jet

Jan Kmec1, Daniel Kucerka1, Miroslav Gombar1, Monika Karkova1, Alena Vagaska2, 1The Institute of Technology and Business in �eské Bud�jovice, Czech Republic, E-mail: [email protected], [email protected], [email protected], [email protected], 2Technical University of Kosice, Faculty of Manufacturing Technologies, Slovak Republic, E-mail: [email protected]

Water jet technology material cutting is analyzed from the point of view of environment, namely of an impact of

noise to production process working conditions. Except noise, vibrations also influence working environment but

this problem in this text is not dealt with. Measuring of noise level was focused on one working shift at a production

workplace of a firm WATING Pre�ov. Two workers were chosen for this puprouse - operators who operate two

cutting desks during a common working shift. In accordance of given methodics, measuring microphones were

placed on the operators and on selected places of the workplace. The recorded results of measuring were evaluated

and consequently steps for noise elimination during water jet cutting process were accepted.

Keywords: Noise at production process, Water jet material cutting, Noise measuring, Noise impact to working environ-ment

References

BADIDA, M., KMEC, J., SOBOTOVÁ, L., BI�EJOVÁ, ., GOMBÁR, M. (2013). Hydroerosion and Environ-ment. Edition first, Lüdenscheid, Germany : RAM-Verlag. p. 131. -ISBN 978-3-942303-20-0. KMEC, J., KU�ERKA, D., GOMBÁR, M., BI�EJOVÁ, .,SOBOTOVÁ, L., OPEKÁROVÁ, L., STRAKOVÁ, J., VAGASKÁ, A., HRMO, R. (2014). Water Jet for Practice. Edition second, Lüdenscheid, Germany : RAM- Verlag. p. 150. -ISBN 978-3-942303-27-9, BI�EJOVÁ, . (2013). Abrasive kind and granularity changes affects to water jet technology head vibration during cutting HARDOX material thickness alternation process. In: Applied Mechanics and Materials. Vol. 308, p. 75-79. - ISSN 1660-9336. FABIAN, S., BI�EJOVÁ, . (2014). Technological head tilt angle influence analysis to generation of vibration during ceramics material machining by means of AWJ. In: Applied Mechanics and Materials. Vol. 616, p. 175-182. - ISSN 1660-9336. BI�EJOVÁ, ., FABIAN, S. (2014). Analysis of technological head working pressure, tilt angle and shift impact to its vibrations using AWJ. In: Applied Mechanics and Materials. Vol. 616, p. 159-166. - ISSN 1660-9336. PAVLENKO, S., HA KO, J., MA��ENIK, J., NOVÁKOVÁ, M. (2008). Machine Parts Design with PC Sup-port. - 1. vyd - Pre�ov : FVT TU, 347 s. - ISBN 978-80-553-0166-2. MA��ENIK, J., GA�PÁR, �. (2011). Experimental Assessment of Roughness Changes in the Cutting Surface and Microhardness Changes of the Material S 355 J2 G3 after Being Cut by Non-Conventional Technologies In: Advanced Materials Research. Vol. 314-316, p. 1944-1947. - ISSN 1022-6680. KRENICKÝ, T. (2011). Implementation of Virtual Instrumentation for Machinery Monitoring, in: Scientific Pa-pers: Operation and Diagnostics of Machines and Production Systems Operational States 4, Lüdenscheid, RAM-Verlag, p. 5-8. HA KO, J., PAVLENKO, S. (2013). Design strenght calculation of cycloidal lantern gear. In: BarSU Herald Scientific and practical journal : Physical and Mathematical Sciences : Engineering Sciences. No. 1, p. 58-65. - ISSN 2309-1339. KRENICKÝ, T., JACKO, P. (2009). Simultaneous temperature monitoring using virtualization, in: Scientific Pa-pers: Operation and diagnostics of machines and production systems operational states. Lüdenscheid: RAM-Verlag, p. 58-62. KUNDRÁK, J. (2011). Alternative machining procedures of hardened steels, in: Manufacturing Technology, XI/2011, ISSN 1213-2489, p. 32 � 39. MULLER M., VALÁ�EK P.: Interaction of steel surface treatment by means of abrasive cloth and adhesive bond strength. In.: Manufactruing Technology. 2011. pp. 49 � 57. ISSN 1213-2489 KOCMAN, K. Application of magnetic correlation analysis on the choice and correction of cutting parameters for automated manufacturing systems. Manufacturing Technology, vol.XI, 2011, pp. 28-32 SÝKOROVá, L., Malachová, M. (2012). Laser Machining and Temperature Field Simulation Using COSMOS / M Software. Manufacturing Technology. Nr. 12. ISSN 12132489, s. 113-117





Finite Element Modeling and Numerical Simulation of Welding at the Repair of Gas Pipelines

with Steel Sleeve

Radoslav Konar1, Milos Mician1, Marek Patek1, Dalibor Kadas2

1Department of Technological Engineering, Faculty of Mechanical Engineering, University of Zilina, Univerzitna 8215/1, 010 26 Zilina. Slovak Republic. E-mail: [email protected], [email protected], [email protected] 2INA Kysuce, spol. s r. o., Dr. G. Schaefflera 1, 024 01 Kysucke Nove Mesto, Slovak Republic. E-mail: [email protected]

This article deals with simulations of the welding process for applications of practice using SYSWELD software.

Simulation of welding at the repair of high-pressure gas pipeline with steel sleeve with composite filling is presented

in this paper. Two welds connecting the distance ring and gas pipe were simulated. Structure of programme

SYSWELD and repair of high pressure gas pipeline with steel sleeve is described in theoretical part of article.

Preparation of boundary conditions for numerical simulation on real sample and numerical simulation of welding

is in experimental part. Thermal fields, residual stresses and hardness were simulated. The results of the numerical

model, which are listed in article except for residual stresses are compared to real experiments. This article mainly

describes the numerical simulation capabilities in welding simulation programme SYSWELD.

Keywords: Sysweld, Steel L360NB, Numerical simulations, Repair of gas pipeline

Acknowledgement

This work has been supported by the Scientific Grant Agency of the Ministry of Education of the Slovak Republic, grant VEGA: 1/0836/13, KEGA: 034ZU-4/2015.

References

JOSEPH, A. et al. (2005) Evaluation of residual stresses in dissimilar weld joints. In: International Journal of Pressure Vessels and Piping, Vol. 82, pp. 700 - 705. TOTTEN, G., HOWES, M., INOUE, T. (2002). Handbook of Residual Stress and Deformation of Steel. AMS International, USA, ISBN 0-87170-729-2 MORAVEC, J. (2011). Influence of Welding Parameters on Weld Pool�s Geometry in Shielding Gas Welding. Pollypress, Liberec DENG, D., MURAKAWA, H. (2006). Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements. In: Computational Materials Science, Vol. 37, pp. 269 - 277. WANG, Y. et al. (2013). Simulation and analysis of temperature field for in-service multi-pass welding of a sleeve fillet weld. In: Computational Materials Science, Vol. 68, pp. 198 - 205. ZMINDAK, M., MESKO, J., PELAGIC, Z., ZRAK, A. (2014). Finite Element Analysis of Crack Growth in Pi-pelines. In: Manufacturing Technology, Vol. 14, No. 1, pp. 116 - 122. MESKO, J., ZRAK, A., MULCZYK, K., TOFIL, S. (2014). Microstructure analysis of welded joints after laser welding. In: Manufacturing technology, Vol. 14, No. 3, pp. 355-359. J.E. Purkyne University, Ústi nad Labem. MORAVEC, J., NOVAKOVA, I., BRADAC, J. (2016). Effect of Age Hardening Conditions on Mechanical Pro-perities of AW 6082 Alloy Welds. In: Manufacturing technology, Vol. 16, No. 1, pp. 192-198. J.E. Purkyne Uni-versity, Usti nad Labem. NOVAK, P., MESKO, J., ZMINDAK, M. (2013). Finite element implementation of Multi-pass Fillet Weld with Phase Changes. In: Manufacturing Technology, Vol. 13, No. 1, pp. 79 - 85. MICIAN, M., PATEK, M., SLADEK, G. (2014). Concept of Reapiring Branch Pipes on High-pressure Pipelines by Using split Sleeve. In: Manufacturing technology, Vol. 14, No. 3, pp. 60-66. J.E. Purkyne University, Ústi nad Labem. BRUNA, M., KUCHARCIK, L., SLADEK, A. (2013). Complex evaluation of porosity in A356 alluminium alloy using advanced porosity module. In: Manufacturing technology, Vol. 13, No. 1, pp. 26-30. J.E. Purkyne Uni-versity, Usti nad Labem.





Prediction of Hardness and Residual Stresses of Dissimilar Weld Joint

Radoslav Konar, Marek Patek University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Univerzitna 8215/1, 010 26 Zilina, Slovakia. E-mail: [email protected], [email protected]

Welding of the dissimilar weld joints is allied with some technological difficulties that might affect the operational

time of the construction. Between the main problems belong presence of residual stresses and inappropriate

microstructure of the heat affected zone on the side of ferritic steel resulting to increased hardness. These factors

are significantly influenced by heat input during welding, its appropriate control and welding sequence. Optimi-

sation of the heat input and welding sequence requires large amount of experimental work. Recently, numerical

analysis of welding based on finite element models became a successfull tool for prediction of material behaviour

during the process. This article deals with numerical analysis of austenitic X5CrNi18-10 and ferritic S355J2H steel

welding.

Keywords: Finite element analysis, SYSWELD software, Residual stress, Temperature distribution, Welding

Acknowledgement

This work has been supported by Scientific Grant Agency of Ministry of Education of the Slovak Republic, grant KEGA 034�U-4/2015. Authors acknowledge the grant agency for support.

References

DENG, D. et al. (2009). Prediction of residual stresses in a dissimilar metal welded pipe with considering cladding, buttering and post weld heat treatment. In: Computational Materials Science, Vol. 47, pp. 398 � 408. JOSEPH, A. et al. (2005). Evaluation of residual stresses in dissimilar weld joints. In: International Journal of Pressure Vessels and Piping, Vol. 82, pp. 700 - 705. DENG, D., MURAKAWA, H. (2006). Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements. In: Computational Materials Science, Vol. 37, pp. 269 - 277. DURANTON, P. et al. (2004). 3D modelling of multipass welding of a 316L stainless steel pipe. In: Journal of Materials Processing Technology, Vol. 153-154, pp. 457 - 463. BRUNA, M., KUCHARCIK, L., SLADEK, A. (2013). Complex evaluation of porosity in A356 alluminium alloy using advanced porosity module. In: Manufacturing technology, Vol. 13, No. 1, pp. 26-30. J.E. Purkyne Uni-versity, Usti nad Labem. WANG, Y. et al. (2013). Simulation and analysis of temperature field for in-service multi-pass welding of a sleeve fillet weld. In: Computational Materials Science, Vol. 68, pp. 198 - 205. ZMINDAK, M.; MESKO, J.; PELAGIC, Z.; ZRAK, A. (2014). Finite Element Analysis of Crack Growth in Pi-pelines. In: Manufacturing Technology, Vol. 14, No. 1, pp. 116 - 122. MESKO, J., ZRAK, A., MULCZYK, K., TOFIL, S. (2014). Microstructure analysis of welded joints after laser welding. In: Manufacturing technology, Vol. 14, No. 3, pp. 355-359. J.E. Purkyne University, Ústi nad Labem. MORAVEC, J. (2011). Influence of Welding Parameters on Weld Pool�s Geometry in Shielding Gas Welding. Pollypress, Liberec. NOVÁK, P., ME�KO, J., �MINDÁK, M. (2013). Finite element implementation of Multi-pass Fillet Weld with Phase Changes. In: Manufacturing Technology, Vol. 13, No. 1, pp. 79 - 85. AKBARI, D., SATTARI-FAR, I. (2009). Effect of the welding heat input on residual stresses in butt-welds of dissimilar pipe joints. In: International Journal of Pressure Vessels and Piping, Vol. 86, pp. 769 - 776. LEE, CH.-H., CHANG, K.-H. (2014). Comparative study on girth weld-induced residual stresses between auste-nitic and duplex stainless steel pipe welds. In: Applied Thermal Engineering, Vol. 63, pp. 140 - 150. ASL, H. M., VATANI, A. (2013). Numerical analysis of the burn-through at in-service welding of 316 stainless steel pipeline. In: International Journal of Pressure Vessels and Piping, Vol. 105-106, pp. 49 - 59. SYSWELD Engineering Guide of Training and Toolbox (2006). ESI Group, France. RADEK, N., BARTKOWIAK, K. (2012). Laser Treatment of Electro-Spark Coatings Deposited in the Carbon Steel Substrate with using Nanostructured WC-Cu Electrodes. In: Physics Procedia, Vol. 39, pp. 295 - 301. TRZASKA, J. (2013). Calculation of the steel hardness after continuous cooling. In: Archives of Materials Science and Engineering, Vol. 61, No. 2, pp. 87 - 92.





Digital Factory Simulation Tools

Ji�í Kyncl Department of Machining, Process Planning and Metrology, Faculty of Mechanical Engineering, Czech Technical Uni-versity in Prague, Technická 4, 166 07 Praha 6, E-mail: [email protected]

The article deals with the use of Siemens digital factory concept for production capacity planning. In the increasing

competitive environment of globalized world economy, pressure to grow effciency of production pro-cesses and

systems greatly increases. In addition the increasing cmplexity of product requires appropriate as well as-sembly

and logistic processes as production process planning and control. These requirements in the production process

planning and cotrol may be due to its complexity filled only with appropriate instruments provided by comprehe-

sive concept of the digital factory, which allow effective use of information on production, promote collaboration

between departments and provide relevant data to anyone who needs it. This paper describes implementation of

digital factory simulation tools for the production process planning and control at our industrial partner. This

approach to production capacity planning using the digital factory concept is unique in the Czech Republic.

Keywords: Digital factory; simulation; optimization; production process control; production process planning

Acknowledgement

This work was supported by the governmental funding of Technological Agency of Czech Republic � project number TA04020658.

References

BERANEK, L.; VOLF, L. & MIKES, P.: Coordinate Metrology Education Using Virtual CMM, Annals of DAAAM for 2011 & Proceedings of the 22nd International DAAAM Symposium, ISBN 978-3-901509-83-4, ISSN 1726-9679, pp 1323-1324, Editor B[ranko] Katalinic, Published by DAAAM International, Vienna, Austria 2011.

KOSTURIAK, J., GREGOR, M., MI�IETKA, B., MATUZSEK, J.: Projektovanie výrobných systémov pre 21. storo�í, �ilinská univerzita, 2000, pp. 397, ISBN 80-7100-553-3

VL�EK, R.: Management hodnotových inovací. Praha, Management Press, 2008, ISBN 978-80-7261-164-5

ZELENKA, A.: Projektování výrobních proces� a systém�. �VUT v Praze, 2007, pp 136, ISBN 978-80-01-03912-0

ALUKAL, G., MANOS, A.: Lean Kaizen. Quality Press, Milwaukee, USA, 2006, pp. 174, ISBN 978-0-87389-689-4

FIALA, P.: Projektové �ízení, modely, metody, analýzy. Professional Publishing, 2004, pp. 276, ISBN 80-86419-24-X

GÜNTHER, H.-O., TEMPELMEIER, H.: Übungsbuch Produktion ung Logistik. Springer, 2006, pp. 248, ISBN 3-540-25704-7

STASIAK-BETLEJEWSKA, R. (2010). Construction Product Quality Improvement with Applying Production Problems Analysis. In Manufacturing Technology. Vol. 15, No. 5, ISSN 1213-2489

BORKOWSKI, S., STASIAK-BETLEJEWSKA, R. (2010). Analysis of anti-corrosion coating process on steel constructions. In Manufacturing Technology. Vol. 10, No. 10, pp.27 � 29. ISSN 1213-2489





Reparation by Hard Facing of the Damaged Secondary Stone Crushers

Vuki� Lazi�1, Du�an Arsi�1,*, Ru�ica Nikoli�1,2, Milan Mutavd�i�3, Jozef Me�ko4

1Faculty of Engineering, University of Kragujevac, Sestre Janji� 6, Str., 34000 Kragujevac, Serbia, E-mails: [email protected]; [email protected] (corresponding author); 2Research center, University in �ili na, Univerzitna 8215/1, 010 26 �ilina, Slovakia; E-mail: [email protected] 3High Technical School, 24. November bb, 38218 Leposavi�, Serbia; E-mail: [email protected] 4Faculty of Mechanical Engineering, University in �ilina, Univerzitna 8215/1, 010 26 �ilina, Slovakia; E-mail: [email protected]

The possibilities for reparation by hard facing of the damaged working parts � the hammers of the secondary

stones crusher are investigated in this paper. The analyzed crusher is stationary and it belongs into a group of the

process equipment aimed for producing the crushed stone. The produced stone is later used for manufacturing

various construction materials like asphalt, concrete, etc. Wear of the crusher's working parts occurs during the

exploitation due to operation with very hard materials. That wear is usually abrasive and of high intensity what

causes failure of the working parts and consequently the machine's downtimes and appearance of various types of

losses, primarily financial ones. To prevent that, and to reduce the downtimes as well, one uses reparation tech-

nologies, one of which is hard facing. The analysis of the mass losses of the hard faced parts, after certain number

of hours of the crusher's field operation, is performed in this paper.

Keywords: Reparation, Hard facing, Hammer, Secondary crusher

Acknowledgement

This research was partially financially supported by European regional development fund and Slovak state budget by the project "Research Centre of the University of �ilina" - ITMS 26220220183 and by the Ministry of Education, Science and Technological Development of Republic of Serbia through grants: ON174004, TR32036, TR35024 and TR33015 and VEGA � project no. 1/0836/13 �Technological aspects of the laser cutting process, numerical modeling and simulation in terms of optimalization, improve the quality and efficiency of production processes.� Responsible investigator: prof. Jozef Me�ko, MSc., Ph.D.

References

NEDELJKOVI�, B., BABI�, M., MUTAVD�I�, M., RATKOVI�, N., ALEKSANDROVI�, S., NIKOLI�, R., LAZI�, V. (2008). Reparatory hard facing of the rotational device knives for terrain leveling. Journal of the Balkan Tribological Association, Vol. 16, No. 1, pp. 46-57. Bulgaria.

LAZI�, V., JOVANOVI�, M., MILOSAVLJEVI�, D., MUTAVD�I�, M., �UKI�, R. (2008). Choosing of the most suitable technology of hard facing of mixer blades used in asphalt bases. Tribology in industry, Vol. 30, No. 1&2, pp 3-10. Serbia.

MARKOVI�, S., MILOVI�, LJ., MARINKOVI�, A., LAZOVI�, T. (2011). Tribological aspect of selecting filler metal for repair surfacing of gears by hard facing. Structural Integrity and Life, Vol. 11, No. 2, pp. 127-130. Serbia.

LAZI�, V., SEDMAK, A., ALEKSANDROVI�, S., MILOSAVLJEVI�, D., �UKI�, R., GRABULOV, V. (2009). Reparation of damaged mallet for hammer forging by hard facing and weld cladding. Tehni�ki Vjesnik � Technical Gazette, Vol. 16, No. 4, pp. 107-113. Croatia.

HAWRYLUK, M., MARCINIAK, M., MISIUN, G. (2014). Possibilities of investigating abrasive wear in con-ditions close to those prevailing in industrial forging processes. Eksploatacja i Niezawodnosc � Maintenance and Reliability, Vol. 16, No. 4, pp. 600-607. Poland.

ARSI�, M., BURZI�, M., KARI�, R. M., VISTA�, B., SAVI�, Z. (2014). Methodology for repairing defects on internal surfaces of cranks of guide vane apparatus in hydroelectric generating set at hydropower plant Djerdap 1. Structural Integrity and Life, Vol. 14, No.2, pp. 121-124. Serbia.

KANG, S., CHEEMAA, G.S., SINGLA, S. (2014). Wear behavior of hard facings on rotary tiller blades. Procedia Engineering, Vol. 97, pp. 1442-1451. The Netherlands.

LAZI�, V., MUTAVD�I�, M., MILOSAVLJEVI�, D., ALEKSANDROVI�, S., NEDELJKOVI�, B., MARINKOVI�, P., �UKI�, R. (2011). Selection of the most appropriate technology of reparatory hard facing of working parts on universal construction machinery. Tribology in industry, Vol. 33, No. 1, pp. 18-27. Serbia.



LAZI�, V., SEDMAK, A., NIKOLI�, R., MUTAVDZI�, M., ALEKSANDROVI� S., KRSTI� B., MILOSAVLJEVI� D. (2015). Selection of the most appropriate welding technology for hard facing of bucket teeth. Materiali in Tehnologije, Vol. 49, No. 1, pp. 165-172. Slovenia.

ARSI�, D., LAZI�, V., MITROVI�, S., D�UNI�, D., ALEKSANDROVI�, S., NEDELJKOVI�, B., DJORDJEVI�, M. (2016). Tribological behavior of four types of filler metals for hard facing under dry conditions. Industrial Lubrication and Tribology, Vol. 68, (accepted paper). United Kingdom.

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Analysis of Heat Transfer Conditions in the Sand and Metal Moulds and Their Effect on the

Solidification of the Casting

Jiri Machuta, Iva Nova Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 2, 461 17 Liberec 1, Czech Republic. E-mail: [email protected], [email protected],

The article deals with heat transfer in the casting - mould system. There are characteristics of sand and metal

mould. The sand mould is a dispersion system, respectively - a capillary-porous body. In sand mould are heat

transfers shared by all three ways: conduction, convection and radiation. These individual elementary processes

of heat transfer are only theoretical significance, as very often processes are taking place simultaneously in diffe-

rent intensities or interact. The maximum effects of these processes are in a certain temperature range. From

temperature 200 °C dominates conduction heat transfer. Between of temperatures 200 to 600 ° C is the effective

convection heat transfere. At higher temperatures above 600 ° C prevails radiation heat transfer. This is the con-

sequence, why the sand mould has a lower value thermal accumulation than a metal mould. The metal mould as a

result of its character and compactness has a high heat accumulation value. Therefore, in the metal mould cast

solidifies faster than the in sand mould. Based on the Newton´s and Fourier´s laws, there were indicative calculated

times of solidification cast of shape plate in the sand and metal moulds. Concurently were made simulations calcu-

lations performed solidification of shaped plate through simulation software MAGMA 5. To obtain the correspon-

ding results of simulation calculations, it is important to use the respective temperature-dependent of the thermo-

physical variables, including temperature dependence heat transfer coefficient.

Keywords: Sand mould, Metal mould, Solidification, Heat transfer, Thermo-physical quantities.

Acknowledgement

This article is financially supported by Ministry of Education Youth and Sports of Czech Republic through the project SGS.

References

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FEM/AI Models for the Simulation of Precision Grinding

Angelos P. Markopoulos1, János Kundrák2

1Section of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, Heroon Polytechniou 9, 15780 Athens, Greece E-mail: [email protected] of Manufacturing Science, University of Miskolc, Egyetemváros H-3515 Miskolc, Hungary E-mail: [email protected]

Simulation of grinding is a topic of great interest due to the wide application of the process in contemporary in-

dustry. Up to date, several modelling methods have been utilized in order to accurately describe the complex phe-

nomena taking place during grinding, the most common being the finite element method and artificial intelligence

techniques, e.g. soft computing methods. The present paper proposes a new hybrid model for precision grinding,

more specifically the combination of finite elements with neural networks. The model possesses the advantages of

both the aforementioned methods, for the prediction of several grinding features that define the outcome of the

process and the quality of the final product.

Keywords: Grinding, Modelling and Simulation, Finite Element Method, Neural Networks

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Determination of Stiffness of Triple Spring Built in a Bogie of a Rail Vehicle

Mária Ma�urová, Andrej Suchánek Faculty of Mechanical Engineering, Department of Transport and Handling Machines. University of Zilina. Univerzitná 8215/1, 010 26 �ilina. Slovak Republic. E-mail: [email protected], [email protected]

The article deals with the calculation of stiffness of a secondary suspension spring built in a bogie of a rail vehicle

with a tilting car body. The vertical stiffness of the springs was calculated using the ANSYS program. The results

were compared with calculated values afterwards. The lateral stiffness was evaluated in a similar manner. Ana-

lytical method by Gross, Wahl, Budrick, Timoshenko and Ponomarev was used for comparison with numerical

values. The ANSYS simulation was performed for calculating the vertical stiffness of the triple springs. The most

suitable analytical method is a method by Timoshenko and Ponomarev, where the percentage difference was the

smallest. The obtained data will be used as an input for the design of coil springs which will be implemented in a

model of a vehicle with a tilting car body, for which the comfort values during transition in curve will eventually

be determined.

Keywords: Secondary Suspension, Spring, Bogie, Stiffness

Acknowledgement

The work was supported by the Scientific Grant Agency of the Ministry of Education of the Slovak Republic and the Slovak Academy of Sciences in project No. 1/0347/12: �Railway wheel tread profile wear research under the rail vehicle in operation conditions simulation on the test bench�, project No. 1/0383/12: �The rail vehicle running prop-erties research with the help of a computer simulation.� and the project No. APVV-0842-11: �Equivalent railway operation load simulator on the roller rig�.

Research-Educational Center of Rail Vehicles (VVCKV).

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Evaluation of MRR after WEDM Depending on the Resulting Surface

Katerina Mouralova, Josef Bednar, Jiri Kovar, Jindrich Mach Faculty of Mechanical Engineering, Brno University of Technology. Technicka 2896/2, 616 69 Brno. Czech Republic. E-mail: [email protected], [email protected], [email protected], [email protected]

The aim of this article is to evaluate the material removal rate (MRR) after wire electrical discharge machining

(WEDM) and subsequent characteristics of the machined surface. For efficient processing, the aim is to achieve

the highest MRR values but with regard to the preserving of required quality and functional characteristics of the

surface. During the electrical discharge of material removal craters occur on the workpiece surface and due to

diffusion process here premixed and melted material of fodder and wire electrodes cling. As a result of melting

and fast cooling down of the workpiece material microcracks may occur on its surface.

Keywords: WEDM, Electrical Discharge Machining, Design of Experiment, SEM, Aluminium alloy

Acknowledgement

This work is an output of research and scientific activities of NETME Centre, supported through project NETME CENTRE PLUS (LO1202) by financial means from the Ministry of Education, Youth and Sports under the �National Sustainability Programme I�. This part of work was carried out with the support of core facilities of CEITEC - Central European Institute of Tech-nology under CEITEC - open access project, ID number LM2011020, funded by Ministry of Education, Youth and Sports of the Czech Republic under the activity Projects of major infrastructures for research, development and inno-vations.

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Laser Cutting of Non-Metallic Material - PMMA

Rastislav Nigrovi�, Jozef Me�ko University of �ilina, Univerzitná 1, Department of Technological Engineering; [email protected], [email protected]

The presented article describes and characterizes laser cutting of PMMA, the impact of the laser beam on the

PMMA material and compares it with a conventionally using cutting of plastic material - milling. In the experi-

mental part is compare sample shown in Fig. 4 which was cutting by using a laser beam, milling and the sample

which has been cut by laser but was modified by drying, which change properties of the material after cutting.

Keywords: laser cutting, milling, plastic materials, PMMA

Acknowledgement

Research presented in this paper was partially financially supported through realization of projects VEGA no. 1/0186/09 - ( V � 13 � 013 � 00 ) - � Technological aspects of the laser cutting process, numerical modeling and simulation in terms of optimalization, improve the quality and efficiency of production processes �. Responsible inves-tigator : prof. Jozef Me�ko, MSc., Ph.D.

References

SILVFAST, W. T. (2004). Laser Fundamentals, Cambridge University Press, 666p. ISBN 0-521-83345-0. CARISTAN, L. C. (2004). Laser cutting guide for manufacturing. Dearborn, Michigan, USA: Society of Manu-facturing Engineers, 452p. ISBN 0-87263-686-0. �MINDÁK, M., ME�KO, J., PELAGI�, Z., ZRAK, A. (2014). Finite element analysis of crack growth in pipeli-nes. In: Manufacturing Technology: journal for science, research and production, Vol. 14, No. 1, s. 116-122. ISSN 1213-2489. SEJC, P., BIELAK, R., SVEC, P., ROSKO, M. (2006). Computer simulation of heat affected zone during MIG brazing of zinc-coated steel sheets. In: Kovové materiály. Metallic materials. Vol. 44, No. 4, pp.225-234. ISSN 0023-432X. KONAR, R., MICIAN, M., HLAVATY, I. (2014). Defect detection in pipelines during operation using Magnetic Flux Leakage and Phased Array ultrasonic method. In: Manufacturing technology, Vol. 14, No. 3, pp. 337-341. J.E. Purkyne University, Ústi nad Labem. ISSN 1213-2489. KONAR, R., MICIAN, M. (2014). Non-destructive testing of welds in gas pipelines repairs with Phased Array ultrasonic technique. In: Manufacturing technology, Vol. 14, No. 1, pp. 42-47. J.E. Purkyne University, Ústi nad Labem. ISSN 1213-2489. MESKO, J., ZRAK, A., MULCZYK, K., TOFIL, S. (2014). Microstructure analysis of welded joints after laser welding. In: Manufacturing technology, Vol. 14. No. 3, pp. 355-359. 341. J.E. Purkyne University, Ústi nad La-bem. ISSN 1213-2489. RADEK, N., MESKO, J., ZRAK, A. (2014). Technology of laser forming. In: Manufacturing technology, Vol. 14, No. 3, pp. 428-431. J.E. Purkyne University, Ústi nad Labem. ISSN 1213-2489. VRZGULA, P., FATURIK, M., MICIAN, M. (2014). New inspection technologies for identification of failure in the material and welded joints for area gas industry. In: Manufacturing technology, Vol. 14, No. 3, pp. 487-492. J.E. Purkyne University, Ústi nad Labem. ISSN 1213-2489. PATEK, M., KONAR, R., SLADEK, A., RADEK, N. (2014). Non-destructive testing of split sleeve welds by the ultrasonic TOFD method. In: Manufacturing technology, Vol. 14, No. 3, pp. 403-407. J.E. Purkyne University, Ústi nad Labem. ISSN 1213-2489. LAGO, J., BOKUVKA, O., NOVY, F. (2015). The weld toe improvement of Domex 700 by laser remelting. In: 32nd Danubia-Adria symposium on advances in experimental mechanics, pp. 142-143. University of �ilina, �i-lina. ISBN 978-80-554-1094-4. HUANG, Y., LIU, S., Yang, W., YU, Ch. (2010). Surface roughness analysis and improvement of PMMA-based microfluidic chip chambers by CO2 laser cutting. In: Applied surface science Vol. 256, pp. 1675�1678. Elsevier. ISSN 01694332. VAN KREVELEN, D.W. (2009). Properties of polymers, ISBN-9780080548197. EUROLASER.(2015).[online].2016,[cit.2016-02-01]. �http://www.eurolaser.com/cz/products/laser-systems-for-acrylic/xl-1200-acrylic/ >.






Franti�ek Nový1, Peter Kopas1, Otakar Bok�vka1, Adriana Savin2

1Faculty of Mechanical Engineering, University of �ilina, Univerzitná 1, 010 26 �ilina, Slovak Republic. E-mail: [email protected], [email protected], [email protected] 2National Institute of R&D for Technical Physics, Mangeron Boulevard 47, 700050 Iasi, Romania. E-mail: [email protected]

In this work there are published results about fatigue resistance of ductile iron with various types of matrix obta-

ined at cyclic loading in very-high-cycle region. The results show continuous decrease of the stress amplitude with

increasing of cycles number to the failure. The tensile strength increase is not accompanied with corresponding

increase of fatigue properties. The fatigue durability decreases while the tensile strength increases.

Keywords: Ductile iron, austempered ductile iron, fatigue durability

Acknowledgement

This research has been partially supported by Scientific Grand Agency of Ministry of Education of Slovak Republic and Slovak Academy of Sciences, grants VEGA No. 1/0123/15 and 1/0683. A part of research was solved also in the frame of the European Regional Development Fund and Slovak State Budge project APVV-14-0096. This support is gratefully acknowledged.

References

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V�CHET, S., KOHOUT, J., HANZLÍKOVÁ, K. (2005). Influence of isothermal transformation dwell on tensile and fatigue properties of austempered ductile cast iron. In: Materials Science Forum, Vol. 482, p. 371-374.



VA�KO, A., TR�KO, L., KONE�NÁ, R. (2015). Fatigue behaviour of synthetic noduar cast irons. In: Meta-lurgija, Vol. 54, No. 1, p. 19-22.

NOVÝ, F., BOK�VKA, O., KOPAS, P., CHALUPOVÁ, M. (2007). Fatigue endurance of nodular cast iron in gigacycle region. In: Proceedings of the Improvement of quality regarding processes and materials (S. Borkowski (Ed.)), ORGMASZ Warszawa, p. 71-74.

ULEWICZ, R., BORKOWSKI, S. (2004). Fatigue crack in ferrite-pearlite nodular cast iron at loading with very high frequencies. In: Proceedings of the Letná �kola únavy materiálov 2004 (O. Bok�vka (Ed.)), Vol. 7, EDIS �U, �ilina, p. 203-206.

KOPAS, P., NOVÝ, F. (2005). Ductile iron and austempered ductile iron in engineering praxis. In: Proceedingsof the Jako�� w in�ynierii materia!owej i us!ugach (S. Borkowski (Ed.)), ORGMASZ Warszawa, p. 14-17.

HURTÁLOVÁ, L., TILLOVÁ, E., BELAN, J., UHRI�ÍK. M., VA�KO, A., CHALUPOVÁ, M. (2015). Influence of microshrinkage defects on the fatigue properties in AlSi9Cu3 casts. In: Proceedings of the International confe-rence on innovative technologies IN-TECH 2015 (Z. Car and J. Kudlá�ek (Eds.)), Faculty of Engineering Uni-versity of Rijeka, Dubrovnik, p. 69-72.





Influence of High-Pressure Die-Casting Second Stage Parameter on Structure Of

AlSi9Cu3(Fe) Alloy

"ukasz Pa!yga, Mateusz Stachowicz, Kazimierz GranatDepartment of Foundry Engineering, Plastics and Automation, Wroc!aw University of Technology, Wybr-ze�e Wyspia�skiego 25, 50-370 Wroc!aw, Poland. E-mail: [email protected]

In the paper, results of a research on influence of piston stroke rate on structures of AlSi9Cu3(Fe) (EN AB-46000

group) castings manufactured at constant intensification pressure of 290 bar are presented. Relation between pis-

ton speed (0.3- 2.3 m/s) and casting structure was evaluated after a series of trial high-pressure castings. The ex-

aminations were carried-out on properly prepared samples taken from the castings in places with the largest cross-

section area. The effect of pouring rate was evaluated on the grounds of metallographic observations on a light

microscope and a scanning electron microscope. It was found that larger grains of the very hard phase solidify at

low piston speed between 0.3 and 0.75 m/s. Higher piston speed results in finer casting structure and in refinement

of particles of intermetallic Fe-Mn phase, which is beneficial for usable properties of the castings.

Keywords: pressure die casting, structure, silumin, SEM, 2nd injection stage

References

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TSOUKALAS, V. D. (2008). Optimization of porosity formation in AlSi9Cu3 pressure die castings using genetic algorithm analysis. In: Materials and Design 29, pp. 2027-2033.

POLOCZEK, "., DYBOWSKI, B., "USZCZAK, M., KIE"BUS, A. (2015). The microstructure of AlSi9iu3 Al-loy after Different Stage of Liquid Metal Preparation. In: Archives of Foundry Engineering, Vol. 15, Special No. 1, pp. 89-92, Poland,

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PA"YGA, "., STACHOWICZ M., GRANAT, K. (2015). Effect of Selected Parameters of Pressure Die Casting on Quality of AlSi9Cu3 Castings. In: Archives of Foundry Engineering, Vol 15, No. 2, pp. 85�90, Poland.

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PA"YGA, "., STACHOWICZ, M., GRANAT, K. (2015). Evaluation of 2D and 3D surface roughness of die casting from alloy AlSi9Cu3. In: Archives of Foundry Engineering, Vol. 15, Special No. 1, pp. 75-80, Poland.

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HWANG, J.Y., DOTY, H.W., KAUFMAN, M.J. (2008). The effects of Mn addition on the microstructure and mechanical properities of Al-Si-Cu casting alloys. In: Materials Science and Engineering: A, Vol. 488, No. 1�2, pp. 496�504.

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KUCHARIKOVÁ, L., TILLOVÁ, E., BELAN, J., UHRÍ�IK, M. (2015). The Effect of Casting Technology on Fe Intermetallic Phases in Al-Si Cast Alloys. In: Manufacturing Technology, Vol. 15, No. 4, pp. 567 � 571.

TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., �URINÍKOVÁ, E., (2011). Quality control of micro-structure in recycled Al-Si cast alloys. In: Manufacturing Technology, Vol. 11, No. 11, pp. 70 � 76.

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http://www.limatherm.com/img/fck/8910041/limatherm/File/Technical%20information/Aluminium%20specifi-cation.pdf.





The Heat Flux at the Crystallization Under Pressure

Richard Pastir�ák, Ján Moravec, Eva Kuchar�íková Department of technological engineering. Faculty of Mechanical Engineering, University of �ilina, Univerzitná 1, 01026 �ilina, Slovak Republic. E-mail: [email protected], [email protected], [email protected]

This article deals with the influence of different specific pressures on the heat flux from the casting into the mould.

The determination of the heat flux at different crystallization conditions will be the basis for the simulation calcu-

lation of the solidification with the crystallization under pressure.

The article presents the results of the measured temperatures inside of the mold and casting by influencing of the

crystallization pressure of 100 MPa. For comparison, results are also presented in gravity cast specimens. Also are

presented pictures of microstructure that were observed near the surface of the casting. On the basis of the meas-

ured temperatures inside of the mold are calculated as a value of the heat flow from casting into the casting mold.

The results of heat flow correspond with the evaluation result of the microstructure.

Keywords: squeeze casting, heat flux, pressure, alloy AlSi7Mg0.3

Acknowledgements

This work was created within the solution of the grant project VEGA no. 1/0551/14. The authors thank the Grant Agency for support.

References

JACOB O. AWEDA, MICHAEL B. ADEYEMI. (2012). Experimental Determination of Heat Transfer Coeffi-cients During Squeeze Casting of Aluminium, An Overview of Heat Transfer Phenomena, Dr M. Salim Newaz Kazi (Ed.), ISBN: 978-953-51-0827-6, InTech, DOI: 10.5772/52038.

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NOVÁ, I., NOVÁKOVÁ, I., MACHUTA, J. (2011). Aluminium alloys squeeze casting. In.: Slévárenství. ISSN 1213-2489, Vol. LIX, No. 9-10(2011), p. 304-308.

MICHNA, �., NOVÁ, I. (2008). Technológia a spracovanie kovových materiálov. Adin, s.r.o. Pre�ov. ISBN 978 � 80 � 89244 � 38 � 6. 336 pp.

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BOLIBRUCHOVÁ, D., RICHTÁRECH, L. (2013). Effect of adding iron to the AlSi7Mg0.3 (EN AC 42 100, A356) alloy In: Manufacturing Technology. ISSN 1213-2489. Vol. 13, No. 3, p. 276-281.

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BR�NA, M., KUCHAR�ÍK, L. (2013). Prediction of the Porosity of Al Alloys. In: Manufacturing Technology. ISSN 1213-2489. Vol. 13, No. 3, p. 296-302.





Design and Testing of the Novel Split Sleeve for Branch Connection Repairs Based on Inter-

nal Pressure

Marek Patek, Augustín Sládek, Milo� Mi�ian University of �ilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Univerzitná 8215/1, 010 26 �ilina, Slovakia. E-mail: [email protected], [email protected], [email protected]

Presented article deals with designing of the novel technology for repairing of the defects in branch connections of

the gas pipelines. Until now, defects of the branch connections could be repaired mainly by replacing of the da-

maged area, especially those allied with gas leakage. The most important requirement of new type of repairing

technology is maximal allowable operational pressure, which has to be the same as for repaired pipeline. Dimen-

sions of the split sleeve should be thus designed according to required pressure value. In the case of split sleeve for

branch connections, dimensions were determined by the static analysis in ANSYS software. Designed sleeve was

after manufacturing process subjected to pressure testing by standardised test to confirm requirements of the

standards. Pressure test to destruction was performed in order to determine the weakest place of construction.

Proposed repairing solution might lead to reducing of the costs for performing of the branch connections repairs.

Keywords: Pipeline repair, Branch connection defects, Finite element analysis, Internal Pressure

Acknowledgement

Research has been supported by Scientific Grant Agency of Ministry of Education of the Slovak Republic, grant KEGA 034�U-4/2015. Authors acknowledge the grant agency for support.

References

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GAJDO�, . (2000). Spolehlivost plynovodních potrubí, pp. 217. �VUT, Praha, Czech Republic. (in Czech)

BATISSE R. (2007). Review of gas transmission pipeline repair methods. In: Safety, Reliability and Risks Asso-ciated with Water, Oil and Gas Pipelines, pp. 335-348. Springer, Dordrecht.

MI�IAN M., PATEK M., SLÁDEK, A. (2014). Concept of repairing branch pipes on high-pressure pipelines by using split sleeve. In: Manufacturing Technology, Vol. 14, No. 1, pp. 60-66.

�MINDÁK, M., ME�KO, J., PELAGI�, Z., ZRAK, A. (2014). Finite element analysis of crack growth in pipeli-nes. In: Manufacturing Technology, Vol. 14, No. 1, pp. 116-122.

BEER F.P. et al. (2011). Statics and Mechanics of Materials, pp. 714. McGraw-Hill, New York.

ZRAK, A., KO�ÁR, R., JANKEJECH, P. (2015). Influence of chemical composition in steel on laser cutting stability. In: Manufacturing Technology, Vol. 15, No. 4, pp. 748-752.

ME�KO J., FABIAN P., HOPKO A., KO�ÁR R. (2011). Shape of heat source in simulation program SYSWELD using different types of gases and welding methods. In: Strojírenská technologie, Vol. 16, No. 5, pp. 6-11.

EN 13480-3 Metallic industrial piping. Part 3: Design and calculations, 2012.

EN 12 327 Gas infrastructure. Pressure testing, commissioning and decommissioning procedures. Functional requirements, 2012.

TPP 702 11 Repairs of high-pressure steel pipelines with maximal allowable operational pressure 40 bar inclu-ding, 2011. (in Slovak)





Tool Geometry Influence on Surface Integrity of Machined Austenite Stainless Steel

Zden�k Pitrmuc1, Ji�í �apek2, Kamil Kola�ík2, Libor Beránek1, Jan Urban1

1Department of Machining, Process Planning and Metrology, Faculty of Mechanical Engineering, Czech Technical Uni-versity in Prague. E-mail: [email protected], [email protected] 2Department of Solid State Engineering, Faculty of Nuclear Sciences and Physical Engineering, Czech Technical Uni-versity in Prague. E-mail: [email protected], [email protected]

The goal of this contribution was to describe the microstructure and properties changes of difficult to cut materials

after turning. Surface residual stresses, roughness, microstructure of AISI 304 type stainless steel were studied as

a function of side rake angle �o. Residual stresses and phase composition of surface and sub-surface layers were

determined using X-ray diffraction techniques. The presence of strain-induced martensite was investigated using

Barkhausen noise, optical microscope, and microhardness measurement.

Keywords: Austenite Stainless Steel, Strain-induced Martensite, Tool Geometry, Residual Stresses, Roughness

Acknowledgement

This work was supported by the governmental funding of Technological Agency of Czech Republic � project number TA04020658.

References

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HAUSILD, P., KOLARIK, K., KARLIK, M. (2013). Characterization of strain-induced martensitic transformation in A301 stainless steel by Barkhausen noise measurement. In: Materials & Design, Vol. 44, pp. 548 � 554.

CHEN, H. T., YAN, M. F., FU, S. S. (2014). Martensite transformation induced by plasma nitrocarburizing on AISI304 austenitic stainless steel. In: Vacuum, Vol. 105, pp. 33 � 38.

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SAGLAM, H., UNSACAR, F., YALDIZ, S. (2006). Investigation of the effect of rake angle and approaching angle on main cutting force and tool tip temperature. In: International Journal of Machine Tools and Manufacture, Vol. 46, No. 2, pp. 132 � 141.

VASILKO, K. (2009). Teória a prax trieskového obrábania, pp. 35 � 82. COFIN, Pre�ov.

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GUPTA, M., KUMAR, S. (2015). Investigation of surface roughness and MRR for turning of UD-GFRP using PCA and Taguchi method. In: Engineering Science and Technology, an International Journal, Vol. 18, No. 1, pp. 70 � 81.





Appliciation of Heat Treatment for Elimination of Iron in Secondary Al-Si Alloy

Luká� Richtárech, Dana Bolibruchová, Eva Kuchar�íková Department of Technological Engineering, Faculty of Mechanical Engineering, University of �ilina, Univerzitná 1, 010 26, Slovak Republic, Email: [email protected]

This paper deals with possibility of changing of shape of iron based phases in the secondary alloy AlSi7Mg0.3

microstructure by heat treatment. The Al-Si alloy usually has some other coexisting elements such as copper,

magnesium, manganese, zinc, and iron. The solubility of these elements in aluminum usually increases with increasing

temperature. This decrease from high concentrations at elevated temperatures to relatively low concentrations during

solidification and heat treatment results in the formation of secondary intermetallic phases. For instance, the

precipitation of Si, Mn, and Fe forms an Al12(Fe,Mn)3Si phase. The wide variety of intermetallic phases in aluminum

alloys occur because aluminum is highly electronegative and trivalent. The main attention of this research is paid on

possibility of changing the shape of iron based particles with heat treatment and on using heat treatment together with

iron corrector. Realization of experiments and results shows new view on effect of heat treatment on iron based

phases in castings with higher iron content.

Keywords: secondary AlSi7Mg0.3 alloys, intermetallic phases, heat treatment

Acknowledgment

This work was created in framework of the grant project VEGA �. 1/0363/13. The authors would like to thank the Grant Agency for support.

References

HURTALOVÁ, L., TILLOVÁ, E. (2013). Elimination of the negative effect of Fe-rich intermetallicphases in secondary (recycled) aluminium cast alloy. In Manufacturing Technology, Vol. 13, No. 1, p. 44-50, ISSN 1213-2489 BOLIBRUCHOVA, D., ZIHALOVA, M. (2013). Possibilities of iron elimination in aluminium alloys by vanadium. In: Manufacturing technology, Vol. 13, No. 3, pp. 289-296, ISSN 1213-2489 BOLIBRUCHOVA, D., RICHTARECH, L. (2014). Effect of selected elements on the microstructure of secondary Al-Si alloys In: Manufacturing technology, Vol. 14, No. 3, pp. 431-437, ISSN 1213-2489 DINNIS, C. M. � TAYLOR, J. A. � DAHLE, A. K. 2005. As-cast morphology of iron-intermetallics in Al�Si foundry alloys. In Scripta Materialia 53, 2005, p. 955 - 958 MICHALCOVÁ, A., VOJT�CH, D. (2012). Structure of rapidly solidified aluminium alloys. In Manufacturing Technology. ISSN 1213-2489. vol. 12, p.166-169 TAYLOR, J. A. 2004. The effect of iron in Al-Si casting alloys. In 35th Australian Foundry Institute National Conference, Adelaide, South Australia, 2004, p. 148 � 157. PASTIR�ÁK, R., KRIVO�, E. (2013). Effect of opening material granularity on the mould properties and the quality of casting made by patternless process technology. In Manufacturing technology. Vol.13, no.1 (2013), p. 92-97, ISSN 1213-2489 BR�NA, M., KUCHAR�ÍK, L. (2013). Prediction of the porosity of Al alloys. In Manufacturing technology. Vol. 13, no. 3 (2013), p. 296-302, ISSN 1213-2489

Moderné vzdelávanie pre vedomostnú spolo�nos�/Projekt je spolufinancovaný zo zdrojov EÚ Podpora kvality vzdelávania a rozvoj �udských zdrojov v oblasti technického výskumu a vývoja v priestore

modernej vedomostnej spole�nosti

ITMS 26110230117





Development and Production of Prototype Model of Axial Fan

Josef Sedlak1, Jiri Malasek2, Martin Ondra2, Ales Polzer1

1Department of Machining Technology, Institute of Manufacturing Technology, Faculty of Mechanical Engineering, Brno University of Technology, Technická 2896/2, Brno 616 69, Czech Republic. E-mail: [email protected], [email protected] 2Department of Handling and Building Machines, Institute of Automotive Engineering, Faculty of Mechanical Engineer-ing, Brno University of Technology, Technická 2896/2, Brno 616 69, Czech Republic. E-mail: [email protected], [email protected]

Additive technologies belong to modern trends in production of prototype components. They include e.g. sintering

of powders with a various chemical composition, granularity, physical, chemical and other usable qualities. There

belong to additive technologies especially a technology of Rapid Prototyping that use various principles to make

components. According to the used technology photopolymers, thermoplastics, a specially modified paper or metal

powders are used in a Rapid Prototyping machinery.

An article deals with a characteristic, concept, calculation and production of a prototype model of an axial fan that

enables quick build-up time of fan turbine speed. Production of the axial fan is realized by an additive technology

of Rapid Prototyping using a method of Fused Deposition Modelling � a 3D printer Fortus 360mc. The article

describes individual development stages from the concept to production itself including a final visualization of the

prototype model of an 11-blade axial fan.

Keywords: Axial Fan, Additive Technology, Rapid Prototyping, Fused Deposition Modeling, 3D Printer

Acknowledgement

The research was supported and co-financed from the project called �TA CR GAMA PP1 TG01010054 - VUT SANCE�.

References

©2015 VYTOZ-EKO spol. s.r.o. Ventilacni turbiny ZLT. All rights reserved. [Online]. [Seen 27th May 2015]. Available at: http://www.vytozeko.cz/ventilacni-turbiny-zlt/.

©2015 H-tech group s.r.o. Ventilacni turbiny a vetraci ventilatory. All rights reserved. [Online]. [Seen 27th May 2015]. Available at: http://www.vetrani.com/index.php/cs/vv-ventilacni-turbiny.

©2015 Haze s r.o. Lomanco ventilacni turbina. [Online]. [Seen 27th May 2015]. Available at: http://www.haze.cz/stresni-vetraci-systemy/lomanco-ventilacni-turbina/.

©2015 MOBILAND TRADE s.r.o., Edmonds. Neco o ventilaci. [Online]. [Seen 27th May 2015]. Available at: http://www.ventilacniturbiny.cz/neco-o-ventilaci.

ONDRA, M. (2015). Vyvoj a regulace ventilacnich turbin. Brno. Master Thesis. Brno University of Technology, Faculty of Mechanical Engineering, Institute of Automotive Engineering. 84 p., 15 appendices. Advisor doc. Ing. Jiri Malasek, Ph.D.

Edmonds. In: Hurricane Brochure. [Online]. [Seen 18th April 2015]. Available at: http://www.ed-monds.com.au/Edmonds/UploadedFiles/40/400d36aa-8717-47d7-adc8-b5cf04f32686.pdf.

Edmonds. In: Technicke specifikace windmaster, superwhirly. [Online]. [Seen 18th May 2015]. Available at: http://www.ventilacniturbiny.cz/technicke-dokumenty/superwhirly/superwhirly-tech-specifikace.pdf.

Edmonds. In: Technicke specifikace supavent, turbobeam. [Online]. [Seen 18th May 2015]. Available at: http://www.ventilacniturbiny.cz/technicke-dokumenty/turbobeam/turbobeam-tech-specifikace.pdf.

Edmonds. In: Technicke specifikace turbo ventura, sewer vent. [Online]. [Seen 18th May 2015]. Available at: http://www.ventilacniturbiny.cz/technicke-dokumenty/sewervent/sewervent-tech-specifikace.pdf.

Insight 10.2®. ©2015 Stratasys Ltd. All rights reserved. [Online]. [Seen. 21st September 2015]. Available at: http://www.dimensionprinting.com/applications/rapid-prototyping.aspx.

CHUA, C. K., LEONG, K. F., LIM, C. S. (2010). Rapid Prototyping: Principles and Applications. 3rd Ed. New Jersey: World Scientific, 512 p. ISBN 978-981-277-897-0.

GEBHARDT, A. (2003). Rapid Prototyping. CARL HANSER VERLAG, 377 p. ISBN 3-446-21259-0.



SEDLAK, J., PTACKOVA, M., NEJEDLY, J., MADAJ, M., DVORACEK, J., ZOUHAR, J., CHARVAT, O., PISKA, M. (2013). Material Analysis of Titanium Alloy Produced by Direct Metal Laser Sintering. Interna-tional Journal of Metalcasting, Vol. 7, No. 2, p. 43-50. ISSN 1939-5981.

MARCINCIN, J. N., JANAK, M., MARCINCINOVA, L. N. (2012). Increasing of Product Quality Produced by Rapid Prototyping Technology. Manufacturing Technology, June, Vol. 12, No. 12, p. 71-75. ISSN 1213-2489.

SEDLAK, J., RICAN, D., PISKA, M. (2015). Study of Materials Produced by Powder Metallurgy Using Classi-cal and Modern Additive Laser Technology. Procedia Engineering, Vol. 2015, No. 1, p. 1232-1241. ISSN 1877-7058.

SEDLAK, J., SEKERKA, V., SLANY, M., KOURIL, K., ZEMCIK, O., CHLADIL, J., ROZKOSNY, L. (2015). Production of Prototype Parts Using Direct Metal Laser Sintering Technology. Acta Polytechnica, 2015, Vol. 55, No. 4, p. 260-266. ISSN 1210-2709.

SEDLAK, J., SLANY, M., FIALA, Z., JAROS, A. (2015). Production Method of Implant Prototype of Knee-Joint Femoral Component. Manufacturing Technology, 2015, Vol. 15, No. 2, p. 195-204. ISSN 1213-2489.

SHIGLEY, J. E., MISCHKE, Ch. R., BUDYNAS, R. G. (2010). Konstruovani strojnich soucasti. Brno: VUTIUM, 1186 p. ISBN 978-80-214-2629-0.

LEINVEBER, J., VAVRA, P. (2011). Strojnicke tabulky. 5th Ed. Uvaly: ALBRA, 927 p. ISBN 978-80-7361-081-4.





Ausferrite Flake Graphite Cast Iron at the Thermal Fatigue

B�etislav Skrbek1, Ji�í Hampl2

1KMT SF TU Liberec, Studentská 2, 461 17, Liberec, E-mail: [email protected] 2V�B TU FMME, 17. listopadu 15, 708 33 Ostrava Poruba, E-mail: [email protected],

The automotive brake (clutch) disks are produced almost exclusively from flake graphite cast iron. These disks

must fullfil a variety of strictly controlled parameters - high wear resistance, hardness, resistance against thermal

fatigue and good thermal conductivity. The microstructure is created by the IA graphite in pearlite matrix. The

isothermal hardening to ausferrite structure (AGI) was made in order to improve standard flake graphite cast

iron properties. New methods and procedures of non-destructive structuroscopy, magnetoinductive, ultrasound

and magnetic spot methods were used to compare material properties of flake graphite cast iron and ADI. By these

methods, elasticity modulus, strength and hardness were evaluated. The resistance against thermal fatigue was

evaluated by the Eichelberg factor. In this contribution, Material parameters of standard flake graphite cast iron

and AGI are compared. The heat treatment of brake disk matrix from AGI can considerably improve their mate-

rial parameters, especially durability.

Keywords: Non-destructive testing, thermal fatigue, brake disks, austempered cast irons

References

EN 1564 - 2012. Founding - Ausferitic spheroidal graphite cast iron. Standard.

�EZÁ�, Z. (2007). Pevnost p�epá�ek válc� motoru z r�zných období. M.Sc. thesis, TU of Liberec.

SKRBEK, B. NOSEK, V. (2005). Materiál sedel ventil�. In: Proceedings of METAL 2005 � 14th Int. Conf. Me-talurgy and Materials, Ostrava : Tanger, Ltd., 2005, Paper no.2, p.1-5, ISBN 80-7849-972-5.

SKRBEK, B. (2006). Slitiny �eleza na výfuková potrubí spalovacích motoru - trendy. In: Proceedings of METAL 2006 � 15th Int. Conf. Metalurgy and Materials, Ostrava: Tanger, Ltd.,. Paper 114. pp.5, ISBN 80-86840-18-2.

SKRBEK, B. (2006). NDT diagnostika strukturních zm�n austenitických ventilových ocelí. In: Proceedings of Provozní degradace austenitických ventilových ocelí, Liberec, TU SF KMT, p. 58-62, ISBN 80-7372-113-9.

DO�EKAL, J., SKRBEK, B. (2007). Non-destructive structuroscopy of brake and clech disks. In: Proceedings of15 World Wheelset Congress, Prague Congress Centre, September 23-27, [CD ROM].

ANDR�OVÁ, Z. (2014). Nedestruktivní strukturoskopie izotermicky kalených litin. Ph.D. Thesis, TU of Liberec,

PREMUS, M. (2015). Technologické zkou�ky litinových brzdových kotou��. M.Sc. Thesis, V�B-TU Ostrava,

ANDR�OVÁ, Z., SKRBEK, B. (2012). The use of magnetic and ultrasonic structuroscopy for inspection of ADI/AGI castings. (2012). Sample Journal Manufacturing Technology, Volume 12, p. 93-97, ISSN 1213-2489.

NOVA, I., MACHUTA, J. (2014). Monitoring Methods the Properties and Structure of Grey Iron Castings. Sample Journal, Manufacturing Technology, Volume 14, p. 223-228, ISSN 1213�2489.

ULEWICZ, R. (2014). Practical Application of Quality Tools in the Cast Iron Foundry. Sample Journal, Manu-facturing Technology, Volume 14, p. 104-111, ISSN 1213�2489.





Electro-Erosive Wire Cutting of Aluminum Foam

Franti�ek �palek, Jana Petr�, Tomá� Zlámal, Ivan Mrkvica, Robert �ep, Ji�í Kratochvíl Faculty of Mechanical Engineering, V�B � Technical University of Ostrava. 17. Listopadu 15/2172, Ostrava. The Czech Republic, E-mail: [email protected], [email protected], [email protected], [email protected], [email protected], [email protected]

This contribution deals with experimental cutting of samples made of special Alporas aluminum foam. This foam

has been made by a powder metallurgy method and the foam resulting structure features very diverse material

porosity. Test cuts through the aluminum foil were done using an non-conventional WEDM wire electro-erosive

cutting technology. Monitoring and analysis of effects of proposed processing parameters on the resulting cut

quality was done as a follow-up. Achieved accurracy of individual samples and its repeatability was also evaluated.

At the end of the contribution wire cutting of aluminum foam technology findings are summarized and possible

recommendations for practice are presented.

Key words: wire cutting, aluminium foam, powder metallurgy, non-conventional technology

Acknowledgments

This paper was created in the project No. LO1203 �Regional Materials Science and Technology Centre � Feasibility Program" funded by Ministry of Education, Youth and Sports. This work was supported by the European Regional Development Fund in the IT4Innovations Centre of Excellence project CZ.1.05/1.1.00/02.0070 and by Education for Competitiveness Operational Programme financed by Structural Founds of Europe Union in project Integrita CZ.1.07/2.3.00/20.0037 and by Student Grant Competitions SP2015/116 and SP2015/129 financed by the Ministry of Education, Youth and Sports and Faculty of Mechanical Engineering V�B-Technical University of Ostrava.

References

�PALEK, F. (2015). Technology Wire Electrical Discharge Machining: Master Thesis. Ostrava: V�B � Technical University of Ostrava, Faculty of Mechanical Engineering, Department of Machining, assembly and engineering metrology 2015, 87 p. HOCHENG, Hong, Hung-Yin TSAI. (2013). Advanced analysis of nontraditional machining. New York: Sprin-ger, vii, 500 s. ISBN 978-1-4614-4053-6. SOMMER, C. (2009). Non-traditional machining handbook. 2nd ed. Houston: Advance Publishing, 391 s. ISBN 978-1-57537-325-6. MI�IETOVÁ, A., MA�KOVÁ, I., VELÍ�EK, K. (2007). Top trendy v obrábaní. �ilina: Media/ST, 2007, 232 s. ISBN 978-80-968954-7-2. SAMI YILBAS, B., AKHTAR, S. S., KELES, O. (2013). Laser Cutting of Aluminum Foam: Experimental and Model Studies. POOLE, Austin Lane. Journal of Manufacturing Science and Engineering: 1087-1216. 2. ed. Ox-ford: Clarendon press, 135(5): 051018-. Oxford history of England, III. DOI: 10.1115/1.4025009. ISSN 1087-1357. Available from: http://manufacturingscience.asmedigitalcollection.asme.org/ar-ticle.aspx?doi=10.1115/1.4025009. YILBAS, B. S., AKHTAR, S. S., KELES., O. (2015). Laser cutting of small diameter hole in aluminum foam. The International Journal of Advanced Manufacturing Technology. 2015, 79(1-4): 101-111. DOI: 10.1007/s00170-015-6789-8. ISSN 0268-3768. Available from: http://link.springer.com/10.1007/s00170-015-6789-8. HERGHELEGIU, E., RADU, C., SCHNAKOVSZKY, C., CRISTEA, I. (2013). High Pressure Water Jet Cutting of the Al 6061 T651 Aluminum Alloy: Thermal stress analysis and morphology.Applied Mechanics and Materials. 2013, 371(1): 245-249. DOI: 10.4028/www.scientific.net/AMM.371.245. ISSN 1662-7482. Available from: http://www.scientific.net/AMM.371.245. RAO, Thella Babu and A. Gopala KRISHNA. (2014). Selection of optimal process parameters in WEDM while machining Al7075/SiCp metal matrix composites. The International Journal of Advanced Manufacturing Techno-logy. 2014, 73(1-4): 299-314. DOI: 10.1007/s00170-014-5780-0. ISSN 0268-3768. Available from: http://link.springer.com/10.1007/s00170-014-5780-0 . BEDNÁ�OVÁ, V., LICHÝ, P., ELBEL, T., LÁNA, I. (2013). Production and properties of metal foams from non-ferrous metals alloys. Manufacturing Technology, Vol. 13, No. 3, pp. 262-265. ISSN 1213-2489 BANHART, J. (2001). Manufacture, characterisation and application of cellular metals and metal foams, In: Pro-gress in Materials Science, Vol. 46, No. 6, pp. 559-632. NOVÁ, I., MACHUTA, J. (2007) Product from aluminium foam. MM Industrial Spectrum, Vol. 11, No.12 pp. 58-59. ISSN 1212-2572





Effect of Pre-Wetting of High-Silica Sand on Parameters of Dried Moulding Sands Bonded

with Selected Grades of Water-Glass

Mateusz Stachowicz, Kazimierz Granat, !ukasz Pa"yga, Micha" Kami�ski Department of Foundry Engineering, Plastics and Automation, Wroc"aw University of Technology, Wybr-ze�e Wyspia�skiego 25, 50-370 Wroc"aw, Poland. E-mail: [email protected]

Within the research, an attempt was made to determine influence of preliminary wetting of high-silica based eco-

friendly moulding sands containing sodium water-glass on effectiveness of their hardening by traditional drying.

Effectiveness of adding water to the base during stirring was evaluated by comparing mechanical and technologi-

cal parameters after traditional drying at 100 °C. Medium high-silica sand and two grades of hydrated sodium

silicate 149 and 150 were used in the examinations. It was found that modification of preparation procedure by

adding a proper quantity of water to high-silica base before adding binder (1.5 wt%) favourably affects mechanical

and technological parameters of hardened sandmix. Results of the measurements are correlated with SEM obser-

vations of links between base grains. On the grounds of complex evaluation of moulding sands hardened by tra-

ditional drying, a positive effect of water addition was found, especially in the sandmixes containing binder with

higher viscosity, i.e. grade 149. Optimum quantity of water addition should be determined for each specific grade

of binder.

Keywords: foundry sands, drying technology, water-glass, wetting, strength

References

GRANAT, K., NOWAK, D., PIGIEL, M., STACHOWICZ, M., WIKIERA, R. (2007). The influence of hardening method on basic properties of water glass molding sands. In: Visnik Chmel'nickogo Nacional'nogo Universitetu, Vol. 4, No. 1, pp. 98 � 104.

GRANAT, K., NOWAK, D., PIGIEL, M., STACHOWICZ, M., WIKIERA, R. (2008). The influence of micro-wave heating and water glass kind on the properties of molding sands. In: Archives of Foundry Engineering, Vol. 8, Special No. 1, pp. 119-122.

JINA, W., ZITIAN, F., XIAOLEI, Z., DI, P. (2009). Properties of sodium silicate bonded sand hardened by mi-crowave heating. In: China Foundry, Vol. 6, No. 3, pp. 191-196.

BALISKI, A. (2002). Residual strength of molding a hydrated sodium silicate curing ethylene glycol diacetate in the light of the phase transition temperature and the resulting silica gel. In: Archiwum Technologii Maszyn i Automatyzacji, Vol. 22, No.1, pp. 11-22.

STACHOWICZ, M., GRANAT, K., PA!YGA, !. (2016). Effect of sand wetting on physically hardened moulding sands containing a selected inorganic binder. Part 1. In: Archives of Foundry Engineering, Vol. 16, No. 1, pp. 73-78.

STACHOWICZ, M., GRANAT, K., PA!YGA, !. (2016). Effect of sand wetting on physically hardened moulding sands containing a selected inorganic binder. Part 2. In: Archives of Foundry Engineering, Vol. 16, No. 1, pp. 79-84.

STACHOWICZ, M., GRANAT, K., NOWAK, D. (2010). Studies on the possibility of more effective use of water glass thanks to application of selected methods of hardening. In: Archives of Foundry Engineering, Vol. 10, Special No. 2, pp. 135-140.

STACHOWICZ, M., GRANAT, K., NOWAK, D., HAIMANN, K. (2013). Effect of hardening methods of mould-ing sands with water glass on structure of bonding bridges. In: Archives of Foundry Engineering, Vol. 10, No. 3, pp. 123-128.

GRANAT, K., NOWAK, D., PIGIEL, M., STACHOWICZ, M., WIKIERA, R. (2009). Determination of applica-tion possibilities of microwave heating in the curing process of water glass molding sands with fluid esters. Pt. 1. In: Archives of Foundry Engineering. Vol. 9, No. 1, pp. 45-50.

MAJOR-GABRY�, K., DOBOSZ, S.M., JAKUBSKI J. (2013). Modified hydrated sodium silicate as a modern binder for ecological moulding sands. In: Manufacturing Technology, Vol. 13, No. 1, pp. 68 � 73.

STACHOWICZ, M., GRANAT, K. (2014). Possibilities of reclamation microwave-hardened molding sands with water glass. In: Archives of Metallurgy and Materials, Vol. 59, No. 2, pp. 757-760.



STACHOWICZ, M., GRANAT, K. (2015). Influence of melt temperature on strength parameters of cyclically activated used-up sandmixes containing water-glass, hardened with microwaves, In: Archives Of Civil And Me-chanical Engineering, 2015, Vol. 15, No. 4, pp. 831-835.

HUTERA, B., SMYKSY, K., DRO�YSKI, D. (2007). Influence of lowered temperature on wettability of quartz grains by binders used in moulding sands. In: Archives of Mechanical Technology and Automation, Vol. 27, No. 1, pp. 47-55.

DOBOSZ, S.,M. (2006). Water in moulding and core sands, pp. 9 � 19, 123 - 136. Akapit Science Publisher, Kraków.

BOBROWSKI, A., KMITA, A., STAROWICZ, M., STYPU!A, B., HUTERA, B. (2012). Effect of Magnesium Oxide Nanoparticles on Water Glass Structure. In: Archives of Foundry Engineering, Vol. 12, No. 3, pp. 9 � 12.





Influence of Cutting Conditions on Profile Milling of INCONEL 738LC Alloy

Jan Tomí�ek, Alexey Molotovnik Department of machining, process planning and metrology, Faculty of mechanical engineering, CTU in Prague. Tech-nicka 4, 166 07 Praha 6 Dejvice. Czech Republic. E-mail: [email protected]

This article presents particular results from a long term research focused on machining of INCONEL alloys. As a

representative of this group of material INCONEL 738LC is selected and the article presents results of different

experiments conducted. The behavior of material under different conditions was evaluated with focus to define

cutting condition that can be recommended as suitable cutting conditions for profile milling of material. Basic

problems of profile milling are exposed with focus to the respective material. Several machining experiments are

explained and archived results are discussed. Effect of tool geometry and geometrical constraints and relations

during profile milling is defined. Tool wear and cutting forces were measured and evaluated. The final conclusion

is a recommendation for successful machining of given material.

Keywords: Inconel 738LC, profile milling, CAM, cutting force, tool wear

Acknowledgement

This experiment was conducted under the scientific research included in the project TA02011031 � Surface integrity after application of new progressive technologies for milling on 4 and 5 axis machining centers.

References

MALÝ, J. (2006). Obráb�ní te�koobrobitelných materiál� se zam��ením na trvanlivost b�itu nástroje a velikost sil p�i obráb�ní, �eské vysoké u�ení technické v Praze, fakulta strojní, VÝZKUMNÉ CENTRUM PRO STROJÍRENSKOU VÝROBNÍ TECHNIKU A TECHNOLOGII, Praha. AUTHORS COLLECTIVE, (2012). Hodnocení metalografických vzork�, [Online]. Available: http://ime.fme.vutbr.cz/files/Studijni%20opory/PHMV/ni_i738.php. [Accessed 01 11 2012]. ALL METALS & FORGE GROUP, (2012). Alloy Information Report for Inconel� 738, [Online]. Available: http://www.steelforge.com/forgings/alloys/inconel738report.php. AUTHORS COLLECTIVE, (2012). Nickel development institute - Machining Nickel Alloys handbook, [Online]. Available: http://www.nickelinstitute.org/~/Media/Files/TechnicalLiterature/MachiningNickelAl-loys_11008_.pdf. [Accessed 05 07 2012]. UHLÁ�, V. (2008). Problematika prvního záb�ru b�itu nástroje p�i frézování (doctoral thesis), V�B-TUO, Fakulta strojní, Ostrava ALAUDDIN, M., MAZID, M.A.,EL BARADI, M.A., HASHMI, M.S.J. (1998) Cutting Forces In The End Milling Of Inconel 718, Journal of Materials Processing Technology, vol. 77, pp 153-159, Elsevier, GUHRING at al. (2012) Guhring / Tool catalogue 2012 [Online]. Available: http://www.gueh-ring.cz/data/produkty/cz_64.pdf. [Accessed 15 09 2014]. VYSKO�IL, Z. (2013) Odborná zpráva o postupu prací a dosa�ených výsledích za rok 2012 projektu Výzkum integrity povrchu pro zavedení nových progresivních technologií výroby na 4- a 5-ti osých obráb�cích centrech, PBS Velká bíte�, Velká Bíte�. VRABEC, M., TOMÍ�EK, J. (2007). Surface Quality after 5-Axis Milling, In: Funk�né povrchy v strojárstve2007, pp. 187-192, ISSN 1336-9199. ISBN 978-80-8075-217-0, Tren�ianska univerzita, Fakulta �peciálnej tech-niky, Tren�ín. KYNCL, J., BERÁNEK, L., KOLA�ÍK, K., PALA, Z. (2014). The Research of the Surface Profile after Profiling of Inconel 738LC, Procedia Engineering, vol. 2014, no. 69, pp. 974-979, ISSN 1877-7058 KOLA�ÍK, K., PALA, Z., �APEK, J., BERÁNEK, L. VYSKO�IL, Z. (2014). Non-Destructive Inspection of Surface Integrity in Milled Turbine Blades of Inconel 738LC, In: Applied Mechanics and Materials, pp. 9-15, ISSN 1660-9336. ISBN 978-3-03785-977-3, Trans Tech Publications, Uetikon-Zurich GANEV, N., KOLA�ÍK, K., BERÁNEK, L., MIKE�, P. (2014). X-Ray Diffraction Analysis Of Residual Stersses After Milling Of Super-Alloys, in: International Conference on Technics, Technologies and Education ICTTE2014, Faculty of Technics and Technologies, Trakia University, 2014, p. 49-54. ISSN 1314-9474, Yambol.





Improvements in Material Characteristics Core Centrifugally Cast Rolls

Tomá� Válek1, Ji�í Hampl2, Jakub Ru�aj2

1Vítkovické Slévárny, spol. s r.o., Halasova 2904, 706 02 Ostrava � Vítkovice, Czech Republic. E-mail: [email protected] 2V�B-Technical Univesity of Ostrava, Ostrava, Czech Republic, [email protected]

The paper describes the influence of metallurgical processing on the microstructural characteristics of spheroidal

graphite cast iron. The iron is used for casting the core of double layer centrifugally cast rolls. Low carbon content

in the core spheroidal graphite cast iron supporting metastable solidification was eliminated by managing of me-

tallurgical processing of spheroidal graphite cast iron. The metallurgical quality of the cast iron was controlled by

using thermal analysis during all time i.e. melting furnace, through modification and inoculation. The metallurgi-

cal quality is documented by metallographic analysis, determination of surface proportion and amount of graphite

on surface etched specimen. Test rolls were cast in operating conditions in roll foundry Vítkovické foundries, spol.

s r.o. Evaluation of melts and microstructures were made in the laboratories of the VSB-TU Ostrava.

Keywords: Centrifugally cast rolls, metallurgical quality, spheroidal graphite cast iron, inoculation

Acknowledgement

This paper was made with the support of TA CR within the project ev. no. TA04010223.

References

VALEK, T., HAMPL, J. (2011). Prediction of Metallurgic Quality of ICDP Material before Tapping, Physics Procedia Volume 22 (2011), Pages 191�196, 2011 International Conference on Physics Science and Technology, doi:10.1016/j.phpro.2011.11.030

HAMPL, J., VALEK, T., LICHY, P., ELBEL, T.(2014). Control of the metallurgical processing of ICDP cast irons, Materiali in tehnologije / Materials and technology 48 (2014) 5, 685�688, ISSN 1580-2949

VALEK, T., �IMON, P., STRILKOVA, L. (2012) The Comparison of Selected Methods of Cast Iron Spheroidi-sation in Industrial Conditions, A R C H I V E S Of F O U N D R Y E N G I N E E R I N G, ISSN (1897 3310) Volume 12 Issue 2/2012

HAMPL, J., ELBEL, T., VALEK, T. (2015) Application of thermodynamic calculation in the research of cast irons structure. Metalurgija, vol 54, No 2, pp. 323-327, 2015

HAMPL, J., ELBEL, T (2009). Influence of Al and Ti on microstructure and quality of compacted graphite iron castings. Metalurgija, vol 48, No 4, pp. 243-249, 2009

LICHÝ, P., BE�O, J., CAGALA, M. (2013) Inoculant Addition Effect on Thermomechanical and Thermophysical Properties of Mg-Sr Magnesium Alloy. Manufacturing Technology, vol. 13, No 201313, pp. 64-67, ISSN 1213-2489, 2013

VASKOVA, I. �EBEK, P., MULLI, I.(2013) Hardness of Ductile Cast Iron Castings and its Control in Praxis, Manufacturing Technology, vol. 13, No 201323, pp. 120-122, ISSN 1213-2489, 2013





Evaluation of Vanadium Influence in AlSi10MgMn Alloy with Increased Iron Level

Maria Zihalova, Dana Bolibruchova Department of Technological Engineering, Faculty of Mechanical Engineering, University of Zilina, Univerzitna 8215/1, 010 26 Zilina. Slovak Republic. E-mail: [email protected], [email protected]

Final properties of castings made of aluminium alloys strongly depend on amount of impurities. Production of

high quality parts thus requires strict control of impurity level or elimination of detrimental effects caused by

presence of impurities. Such requirements are even more important in case of castings made of recycled materials.

In Al-Si based alloys is very important awareness of the problems with the presence of iron as an impurity. Nega-

tive iron effect is expressive even in low amounts, and with higher level becomes more harmful. Elimination of its

effects can be performed by several techniques, from which no one have general implementation. One of the pos-

sible ways is addition of so called iron correctors to the alloys. Influence of vanadium as iron corrector is still not

precisely examined. In this article, influence of vanadium to AlSi10MgMn alloy with 1.0 wt. % of iron is analysed

by tensile and hardness testing together with microstructural evaluation.

Keywords: AlSi10MgMn alloy, Intermetallic phase, Correctors of iron, Vanadium

Acknowledgements

This work was created in the framework of the grant project VEGA N° 1/0363/13. The authors acknowledge the grant agency for support.

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