Cutting tools with high length-to-diameter ratios used in internal turning often experience chatter due to increased compliance. To ensure stable machining, active damping methods using hydraulic-, piezoelectric-, magneto-strictive-, electromagnetic- actuators are explored earlier. Magnetic actuators stand out for their cost-effectiveness, manufacturability, and wide bandwidth. However, their bulky desi (…)
Coil-fed laser cutting is widely used for mass production in various industries. Using metal coils instead of metal sheets can not only streamline the feeding of the stock material into the workspace of laser cutting machines but also allow enlarging the size of the coil fed to the laser cutting machine to a virtually unlimited dimension. Practically, this is achieved by implementing machine designs tha (…)
The machining of titanium alloys is associated with high temperature levels which result in rapid tool wear and poor surface integrity. To overcome this issue, cooling the cutting zone has emerged as a solution. This study evaluates the impact of different cooling/lubrication techniques on tool life, tool wear, and surface integrity during the milling of Ti-6Al-4V. The results show that using LCO2 and M (…)
The prediction of milled surface morphology in CAM software typically overlooks the interactions between the workpiece and tool, resulting in an approximate prediction of surface morphology. This study intends to enhance the prediction accuracy by simulating the actual cutting edge motion in 5-axis ball-end milling to overcome the limitations for applications requiring accurate surface morphology predic (…)
Monitoring grinding wheel wear is crucial for optimising dressing intervals and workpiece surface integrity. Grindability tests were conducted on a through-hardened, micro-alloyed C38 steel, using a multi-sensor approach to analyse forces and acoustic emission (AE) under varying grinding aggressiveness and wheel micro-topographies. The acquired data enabled the identification of features sensitive to wh (…)
In recent years, advanced manufacturing has gained traction, particularly in the microscale industries, to enhance material properties. The creation of micro-textures and achieving precise accuracy at the microscale are crucial for the performance of modern devices. In this paper, a method of facilitating these measures will be presented with the integration of Artificial Neural Networks (ANNs) to find (…)
Improving robotic milling efficiency enhances productivity and reduces costs. While feed rate and spindle speed critically influence efficiency, chatter instability complicates their optimization. Existing stability constraints ignore state-dependent regenerative mechanisms, while the nonlinear effects of feed further complicate optimization. Although adjusting the robotic configuration improves stabili (…)
To improve aerostructures assembly processes, aircraft manufacturers want to implement a One-Way Assembly strategy that eliminates the disassembly, cleaning and deburring phases currently required. Implementing this innovative strategy represents major technical challenges, including the management of burr formation at stack interfaces, as they have a negative impact on the assemblies’ fatigue strength. (…)
Cutting chatter is a common phenomenon during metal cutting operations, which can severely impair the surface integrity of machined components and reduce overall production efficiency. Therefore, the precise detection of chatter during the cutting process is of critical importance. In recent years, the widespread integration of artificial intelligence (AI) techniques into chatter detection has led to sa (…)
This study investigates the effect of cutting-edge radius on surface integrity during dry broaching of Inconel 718 at 20 m/min. Experiments and simulations were used to analyse the effect of cutting radius and rise per tooth (RPT) on residual stresses using X-ray diffraction (EDX) and hole drilling, supplemented by Vickers microhardness and SEM. The results show that radii greater than 15µm produce a cr (…)
The increasing demand for work pieces made out of difficult-to-machine materials and for high performance machining parameters, as well as stricter environmental requirements, are driving the machining industry's needs for alternative cooling lubrication strategies. Cryogenic cooling is therefore an innovative approach to improve process performance and sustainability. For example, liquid carbon dioxide (…)
Carbon dioxide (CO2) based cryogenic minimum quantity lubrication (cMQL) is an alternative approach to facilitate cooling lubrication of cutting processes. While it offers greater sustainability than conventional metalworking fluids (MWF), its precise, process-specific dosing can be challenging. This is due to the physical properties of the pressurized CO2, as it already develops its cooling effect in t (…)
A current trend towards sustainable machining can be found in the gradual substitution of lubricants by cryogenic media in the form of liquid carbon dioxide. This strategy has been proven to reduce the tool wear and increase productivity and energy efficiency in milling processes of titanium alloys. While various adjustments to the CO2 supply system such as pre-cooling or pressurization are viable, it r (…)
Eliminating tool eccentricity is critical for longer tool-life and high-quality surface finish. This paper presents an on-machine eccentricity cancellation strategy using machine tool feed drives. Circular motion at the spindle frequency is commanded to the feed axes to introduce an artificial eccentricity vector in tool coordinates. Cutting forces are monitored to extract the components induced by ecce (…)
Milling is a well-established manufacturing process thanks to its accuracy and surface finishing, yet tool vibrations limit these qualities. At the core of many approaches dealing with vibrations the tool-tip frequency response function (FRF) is found allowing the computation of the appropriate cutting conditions for accuracy and stability. The evaluation of the tooltip FRF is often based on experimenta (…)
This study evaluates the measurement system capability of a three-axis vertical milling center under three machine conditions with varying positioning accuracy. Using a laser interferometer, probe, and calibrated KOBA artifact, length measurements were taken and corrected for thermal expansion. Results show that while none of the machine states achieved full capability for the given 0.015 mm tolerance, (…)
This study proposes a method to estimate the surface hardness and residual stress of carbon steel in turning by using analytical information of the cutting process. The machined surface properties depend on the strain, strain rate, stress and temperature fields generated during cutting. Therefore, these state conditions are estimated from the cutting force using a three-dimensional cutting model, and th (…)
Identification of the appropriate model parameters in the cutting process is essential to achieve highly accurate cutting simulations that are effective for the process optimization. During end milling, tool damage deteriorates not only the side cutting edge geometry but also the corner cutting edge as the cutting distance increases. The conventional model does not consider the effect of local corner ed (…)
This study investigates the harmonic response of acoustically functional geometries fabricated via additive manufacturing, with the aim of replicating the vibrational characteristics of natural wood. Utilizing Finite Element Modelling (FEM), various complex structures were designed and analyzed to determine their dynamic behavior under harmonic excitation. The materials under investigation include Nylon (…)
The article presents the design and implementation of a low-level control system for a multi-agent system (MAS) intended for mobile robots participating in robotic soccer. The robot was developed in accordance with the specifications of the FIRA MiroSot category and currently serves as an educational platform for demonstrating multi-agent system concepts. The paper includes the complete design of a new (…)
This study examined the influence of pyrolysis temperature on the properties of biochar produced from coconut fiber, a waste product from mattress manufacturing. Coconut fiber was pyrolyzed in a muffle furnace at 300–700 °C to evaluate its suitability for biochar production and to analyze how temperature affects yield and physicochemical characteristics. The yield decreased from 67.1% at 300 °C to 15.8% (…)
The article discusses the design and testing of a wireless sensor network utilizing multiple communication technologies to achieve low power consumption and extended transfer distances. The sensorial nodes gather data and send it to a central module, which provides a monitoring window. The sensor nodes are designed for educational purposes, enabling students to conduct training experiments focused on cr (…)
Collaborative robotics is a dynamically developing field that combines technical innovations with the principles of human-machine interaction. However, for the successful integration of collaborative robots, it is crucial to provide intuitive and user-friendly work instructions. The aim of the presented study was to design, create and validate standardized visualized work instructions for the basic oper (…)
The article presents a methodology for using augmented reality in the design of a manufacturing system layout. It describes the software and hardware tools Autodesk Factory Design Utilities with AutoCAD Architecture, Inventor Professional, and 3ds Max, as well as HoloLens 2 and the workflow from selecting 3D assets, through converting 2D models to 3D representations, to optimizing polygonal geometry for (…)
The purpose of the research is to solve the problem of adaptive control of operation life of cutting tool in turning of hard-to-machine materials. Adaptive control was performed in real time mode using the results of active diagnostic monitoring of tool cutting edge condition with the guarantee of proper precision and quality, for parts made of hard-to-machine materials, for the case of GX120Mn-13 steel (…)
Annotation. A brushless DC (BLDC) motors diagnostics system based on the model approach in the state space is developed. A digital twin representing a model of BLDC motor and working in parallel with a real BLDC motor is designed. The BLDC motor are analyses using electric current and angular velocity sensors signals and the output signals of the digital twin. Based on the magnitude of the residual, the (…)
The article deals with the analysis of the design of technical information flows and the assessment of the reliability of Airport Information Systems (AIS). It presents mathematical approaches to modelling time differences, failure probabilities and the efficiency of airport processes. The approach is based on identifying connections between individual subsystems and assessing their impact on overall re (…)
The machined surface quality during turning is influenced by the type and geometry of cutting tool used and the selected technological machining parameters, as well as the presence of cutting fluid. The choice of the cutting insert type depends on the machined material and turning operation performed. The contribution compares two carbide-coated cutting inserts types, VCGT and VCMT, for turning AlSi 30 (…)
Noise is a significant environmental factor that must be eliminated by appropriate means. This study investigates the acoustic insulation properties of 3D-printed porous materials with an octet-truss lattice structure, fabricated using fused filament fabrication (FFF) technology. The sound insulation performance of the tested materials was evaluated based on the frequency dependent sound absorption coef (…)
Augmented reality (AR) is rapidly emerging as a crucial real-time interface for data visualisation and decision-making in additive manufacturing (AM). This systematic review screened 71 Web of Science records, analysing 15 empirical studies (2021–2025) on AR-enhanced 3D-printing workflows. Reported prototypes, most frequently based on Microsoft HoloLens and MQTT-enabled data streams, demonstrate signifi (…)
The article describes the original state of the discharge valve design in terms of geometry and flow conditions. Through the simulations performed, it shows in detail the velocity and pressure fields in the valve in individual time steps of the liquid discharge process. By combining numerical and analytical calculations, it determines the total liquid flow through the valve during a specified time inter (…)
Information technology is changing the way medicines are developed and used. Developers, manufacturers, regulators, academic groups and other stakeholders are working to develop a common understanding of where and how specific innovations, such as artificial intelligence and machine learning, can best be used in the drug development process. The assessment procedure is the main tool for planning process (…)
The technology of abrasive water jet is one of the methods of division and cutting materials with the lowest impact on the environment, since water is the cutting tool, in our case with the addition of an abrasive. The experiments were carried out on one kind of material - steel HARDOX 500 with a thickness of 10 mm. The impact of the change of the technological head’s feed rate on the size of the vibrat (…)
The aim of the experiment is to conduct drilling tests on stainless steel, process the measured data, and subsequently evaluate CZ005 drills. The drills have a different cutting-edge geometries two types of coating. For two drills, the cooling grooves on the flank were ground. Based on the evaluation, the order of the tools with the best characteristics was determined, focusing primarily on: • accuracy (…)
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