Chatter undermines surface quality, tool life, and productivity, and most available indicators react only after vibration is fully developed. We introduce a real-time monitoring framework for turning that runs short time-domain simulations, extracts a single energy-trend indicator from the tool’s phase-space spiral area, and triggers threshold-based decisions. The indicator crosses its zero threshold se (…)
This study presents a simulation-based approach for analyzing tool wear progression in Ti6Al4V machining using an in-house developed hybrid Smoothed Particle Hydrodynamics–Finite Element Method (SPH-FEM) solver. Cutting experiments are used to examine key wear indicators including crater depth and flank wear land width along with SEM analysis to understand underlying wear mechanisms. Despite the dominan (…)
Due to rising costs and the need for a more sustainable use of resources, there is an increasing focus on energy use in industrial production. As a result, energy-related data, for example from machine tools, is increasingly being collected. In addition to information for the energy evaluation of individual systems and processes, load profiles of machine tools offer further opportunities for process mon (…)
To manufacture components with a certain pre-defined surface integrity, it is important to understand how tool wear affects the machined workpiece. In this work, an approach is proposed to simulate the effect of tool wear based on measured geometries of worn turning tools on process forces for different feeds. In orthogonal cutting simulations utilizing the Coupled Eulerian-Lagrangian (CEL) finite eleme (…)
Titanium alloys are widely employed in several industrial applications, including medical sector thanks to their biocompatibility, and are useful when high strength-to-weight ratio, high temperature and corrosion resistance are desirable. Since titanium alloys have considerably low thermal conductivity and high hardness, thus being difficult to machine, abrasive water-jet machining (AWJM) represents an (…)
Tool wear represents a central challenge for manufacturing companies. The resulting workpiece rejects and machine downtimes cause significant costs. One difficulty lies in predicting the optimal tool change timing. In practice, two suboptimal scenarios occur: Either tools are changed too early, not fully utilizing their service life, or too late, which can result in quality losses or tool breakage. In t (…)
Hybrid manufacturing approaches, combining additive with subtractive manufacturing technologies, offer superior material efficiency compared to traditional subtractive manufacturing techniques. However, metal powder-based additive manufacturing methods reduce this advantage due to unavoidable powder loss. Additionally, most additive manufacturing processes necessitate the use of support structures to fa (…)
The manufacturing sector is undergoing a data-driven revolution, with standards such as ISO 10303 (STEP) enabling a seamless digital thread – enhancing productivity, sustainability, and regulatory compliance. As the complexity of manufacturing operations grows, so does the demand for end-to-end certifiable processes via interoperable, standards-based digital workflows to maintain traceability and trust (…)
This study investigates the wear mechanisms for two different cemented carbide grades during intermittent turning of nodular cast iron. Turning tests with in-situ force measurements were performed on workpieces with axially oriented grooves. An in-depth analysis of tools and the workpiece material was conducted utilising scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). (…)
Friction and wear significantly degrade cutting tools and surface quality of machined parts in high-speed machining. This study examines the Ti‑6Al‑4V/WC‑Co contacts under a range of PV (pressure × velocity) of (160-4000 MPa.m/s) with contacting pressures of 64,110,200 and 320 MPa and sliding speeds of 0.5,1,10 and 20 m/s. These contact conditions are representative of the tool-workpiece and tool-chip c (…)
The rising share of variable renewable electricity in Germany has increased price volatility, emphasizing the need for demand response. This study introduces an execution service within Energy-Aware Production Scheduling (EAPS), using OPC UA for automated schedule implementation. Based on real industrial data, machine states and energy use are modeled, enabling a cyber-physical system to optimize makesp (…)
In a context of safer, more cost-effective, and environmentally friendly machining processes, supercritical carbon dioxide (sCO2) emerges as a promising alternative to conventional cutting fluids. However, a consolidated understanding of the optimal sCO2 jet parameters for machining and its impact on the tool and the material remains unavailable. This work intends to address the behavior of a free and i (…)
The purpose of this work is to present a quick method for designing the divergent section of planar Laval micro-nozzles in order to predict the properties of the CO2 jet at the nozzle and better control the cooling effect in the context of cryogenic machining with supercritical CO2 (ScCO2). The Method of Characteristics (MOC) and a real gas model have been implemented to obtain 2D nozzles divergent part (…)
Tool geometry assessment is essential in machining processes to ensure the accuracy of manufactured parts. Tool presetters such as laser beam interruption systems and camera-based systems are optical systems used to determine the tool geometry and are considered a prerequisite for machining operations. Tool geometry can be measured both on- and off-machine; however, on-machine tool presetting is preferr (…)
Although manufacturing becomes increasingly data-driven, sensor data is typically available only locally, with limited integration across systems or organizations. This lack of available, heterogeneous data prevents the development of robust AI models to predict key machining outcomes such as tool wear and surface roughness. To overcome this challenge, a cooperative approach that leverages Dataspaces an (…)
Continuous fiber reinforced metal matrix composites (CFMMCs) show great potential in aerospace industry due to their high specific strength, excellent high-temperature resistance, improved fatigue performance, and lightweight properties. Grinding plays a pivotal role in machining difficult-to-cut materials, including ceramic composites and metal matrix composites. However, the process often results in s (…)
Carbon Fibre Reinforced Polymers (CFRP) are favoured for their high strength to weight ratio, excellent directional mechanical and thermal properties, and the ability to be optimized in the direction of stress or heat flow. These properties make it ideal for power transmission applications. Heating of the machined surface during grinding can lead to reduced workpiece quality, particularly if the glass t (…)
Large-format additive manufacturing is a production technology that enables production of large-scale parts made from fibre-filled thermoplastic pellets. A kinematic structure, such a robot or a CNC portal machine, carries the extruder that plasticizes polymer granulates and extrudes material layer by layer (Pellet Extrusion Modelling - PEM). The technology is usually used in tooling manufacturing proce (…)
In an era where industries are increasingly prioritizing sustainability and efficiency, optimizing manufacturing processes is mandatory. Among these processes, lathe operations are widely used in industry and consume significant amount of energy. This research investigates the monitoring of a turning process, focusing on real-time data analysis with the final aim of achieving a more sustainable and ener (…)
The machining industry aims to boost productivity and sustainability through advanced machining strategies like conical taper barrel milling. These tools, with large contact radii, enhance surface quality, efficiency, and material removal on freeform surfaces. However, industry uptake is limited by challenges in programming varying tilt angles leading to uneven tool wear. Unlike lathes using G96 to main (…)
Process digital twins are developed for predictive checks and optimisation of machining processes and for post-process checks of workpiece quality based on machining data. Although there are significant advantages to applying both of these concepts, practical implementation is difficult and hindered by various barriers. This study presents a use case of mould milling on a medium-sized machining centre s (…)
This study examines how Fused Filament Fabrication (FFF) process parameters affect the mechanical properties of sintered 17-4PH stainless steel. Test specimens were printed from BASF Ultrafuse 17-4PH filament on an IDEX system and processed by industrial debinding and sintering. The effects of layer height, printing speed and infill angle were evaluated through tensile testing. The highest tensile stren (…)
Direct Metal Laser Sintering (DMLS) technology is gaining ground in the automotive industry, especially in areas where a high strength-to-weight ratio is of paramount importance, such as racing cars and limited production supercars. It has the advantage of being able to create complex, weight-reduced components. In this research, we present a scanning electron microscopy study of a powder feedstock of a (…)
As lightweight materials with enhanced mechanical and tribological properties, aluminum metal matrix composites, or AMMCs, are attracting more and more attention. This work used the stir-casting process to reinforce Al 6063 alloy with rare earth oxide (LaO₃) and alumina (AlO₃) to create a hybrid AMMC. A consistent distribution of reinforcements inside the matrix was verified by SEM and EDS investigati (…)
Selective Laser Melting (SLM) is a sophisticated form of additive manufacturing that allows the straightforward creation of complex, high-precision metal parts with a digital design. The paper will provide an in-depth examination of the SLM processing of various metals and alloys, including steels, titanium, aluminium, nickel, and metal matrix alloys and composites, in their applications and their suita (…)
This paper focuses on designing and optimizing production layouts in manufacturing enterprises, using Ehlebracht Slowakei, Ltd. as a case study. Effective spatial planning is shown to be essential for improving efficiency, productivity, and competitiveness. The Michalovce plant initially suffered from capacity limitations that restricted flexibility and hindered modernization. A systematic approach was (…)
Annotation. A model of a brushless direct current (BLDC) motor in the form of differential equations has been developed, taking into account the influence of external factors and defects. The measurement of the output parameters of the BLDC motor takes place in the process of acceleration at constant acceleration. For practical tasks it is proposed to use a correcting link, which allows minimising the c (…)
Kinematic compatibility is crucial in wearable walking assistive devices. We aim to design wearable walking assistive devices with high degree of kinematic compatibility by focusing on tensegrity structure, regarded as the basis of the body structure. In this paper, we examined the factors required to design the tensegrity knee joint for wearable walking assistive devices. To support the mobility and st (…)
The purpose of this study is to determine the material parameters of platinum-cured silicone using uniaxial tensile testing combined with hyperelastic material models to simulate material deformation via the finite element method (FEM). Experimental data from uniaxial tensile tests were used to estimate and capture the material behavior based on selected hyperelastic models. Matlab software was employed (…)
Due to the requirements of energy efficiency as well as the increasing importance of energy savings and efficiency improvements, it is essential to focus on the optimization of lighting in buildings. Lighting represents a significant part of energy consumption and therefore it is important to implement solutions that minimize its energy intensity. The use of daylight through efficient window and light p (…)
The article deals with the design of an educational model of an automated workplace controlled by a programmable logic controller. Controllers are commonly taught without didactic models, and many students do not have practical experience and skills with controllers, sensors, actuators and other peripherals. Such models should contribute to better preparation of students.
This paper examines condition-based maintenance (CBM) of complex technical systems using aircraft engines as an example. CBM requires continuous vibration monitoring to predict the optimal moment for scheduled maintenance. At any given moment, an engine may exist in multiple possible states, only one of which is realized. This set of possible states represents the physical potential of the system. To de (…)
The article deals with the prediction of pressability results (distribution of residual stress or plastic strain in the workpiece, thickness distribution in the workpiece, etc.) of deep-drawing (DC 04, DC 05) and chrome-nickel (DIN 1.4301) sheets. For the needs of computer numerical simulation, material parameters for individual sheets were calculated using Matlab software, and the simulation itself was (…)
Gears are very common machine components that enable precise transmission of rotational motion and power transmission from shaft to shaft. High demands are placed on the function of gears in operation. They must enable precise, uniform transmission, must not cause noise, often have to transmit large forces, etc. Gears are manufactured from a variety of materials and with different performance specificat (…)
This study examines the problems of the district heating systems current state. The causes of extreme operating conditions of district heating systems in Ukraine and in the Eastern European region have been analyzed. Considered are the main factors influencing the district heating systems stability in extreme conditions. Promising approaches are proposed to increase the reliability of district heating s (…)
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