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Abstrakt

The paper presents the production problems related to casting using precision casting methods. The essential adverse effect of the casting

process is the presence of burrs understood as oversize material necessary to remove the next finishing operations. In addition, the surfaces

of the cast often characterized by a porous structure. One of the methods to improve the smoothness of the area proposed by the authors is

the use of vibro-abrasive finishing. This type of treatment is widely used in the treatment of finishing small objects as well as complex

shapes. Objects in the form of casting in the first step was treated with aggressive deburring polyester matrix abrasive media. The second

stage was polishing, with using smoothing porcelain media. The study evaluated the effect of vibro-abrasive machining typical cast on the

basic parameters of the geometric structure of the surface. Observations using optical microscope Nicon Eclipse MA 200 compared

changes in surface microstructure and the effect of deburring. Clearly we can say that vibro-abrasive machining an effective way

of reducing the size of burrs, smoothing and lightening the surface of objects made by casting.

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Autorzy i Afiliacje

D. Bańkowski
S. Spadło

Abstrakt

The article presents an example of finishing treatment for aluminum alloys with the use of vibration machining, with loose abrasive media in a closed tumbler. For the analysis of selected properties of the surface layer prepared flat samples of aluminum alloy PA6/2017 in the state after recrystallization. The samples in the first stage were subjected to a treatment of deburring using ceramic media. In a second step polishing process performed with a strengthening metal media. In addition, for comparative purposes was considered. only the case of metal polishing. The prepared samples were subjected to hardness tests and a tangential tensile test. As a result of finishing with vibratory machining, it was possible to remove burrs, flash, rounding sharp edges, smoothing and lightening the surface of objects made. The basic parameters of the surface geometry were obtained using the Talysurf CCI Lite - Taylor Hobson optical profiler. As a result of the tests it can be stated that the greatest reduction of surface roughness and mass loss occurs in the first minutes of the process. Mechanical tests have shown that the most advantageous high values of tensile strength and hardness are obtained with two-stage vibration treatment, - combination of deburring and polishing. Moreover the use of metal media resulted in the strengthening of the surface by pressure deburring with metal media.

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Autorzy i Afiliacje

D. Bańkowski
S. Spadło

Abstrakt

The paper presents an example of the application of vibratory machining for castings based on the results of visual testing. The purpose of the work is to popularize non-destructive testing and vibratory machining as finishing process, especially in the case of cast objects. Visual testing is one of the obligatory non-destructive tests used for castings and welded joints. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The tested castings, which had characteristic traces of the casting process, were subjected to vibratory machining. The machining with loose abrasive media in vibrating containers is aimed at smoothing the surface and reducing or completely removing flashes. To complement the visual testing were also conducted research on the contact profilometer Taylor Hobson PGI 1200. Particular attention was focused on measuring the height of flashes and changes in the surface of smoothed details based on BNIF No. 359 touch-visual patterns. Based on the work, it can be concluded that vibratory machining allows for removal flashes and smoothing of the surface of aluminum alloy cast objects.

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Autorzy i Afiliacje

D. Bańkowski
ORCID: ORCID
P. Młynarczyk
ORCID: ORCID

Abstrakt

This article proposes these of vibratory machining to Ti-6Al-4V titanium alloy as finishing treatment. Titanium alloy was used in the aerospace industry, military, metallurgical, automotive and medical processes, extreme sports and other. The three-level three-factor Box-Behnken experiment examined the influence of machining time of vibratory machining, the type of mass finishing media used and the initial state of the surface layer on the mass loss, geometric structure of the surface, micro hardness and the optimal process parameters were determined. Considerations were given the surfaces after milling, after cutting with a band saw and after the sanding process. The experiment used three types of mass finishing media: polyester, porcelain and metal. Duration of vibratory machining treatment was assumed to be 20, 40, 60 minutes. The form profiles before and after vibratory machining were determined with the Talysurf CCI Lite - Taylor Hobson optical profiler. Future tests should concern research to carry out tests using abrasive pastes with a larger granulation of abrasive grains, to carry out tests for longer processing times and to determine the time after which the parameters of geometrical structure of the surface change is unnoticeable.

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Autorzy i Afiliacje

D. Bańkowski
ORCID: ORCID
S. Spadło
ORCID: ORCID

Abstrakt

The article presents the results of research on the finishing of M63 Z4 brass by vibratory machining. Brass alloy was used for the research due to the common use of ammunition elements, cartridge case and good cold forming properties on the construction. Until now, the authors have not met with the results of research to determine the impact of abrasive pastes in container processing. It was found that the additive for container abrasive treatment of abrasive paste causes larger mass losses and faster surface smoothing effects. The treatment was carried out in two stages: in the first stage, the workpieces were deburred and then polished. Considerations were given to the impact of mass of workpieces, machining time and its type on mass loss and changes in the geometric structure of the surface. The surface roughness of machining samples was measured with the Talysurf CCI Lite optical profiler. The suggestions for future research may be to carry out tests using abrasive pastes with a larger granulation of abrasive grains, and to carry out tests for longer processing times and to determine the time after which the parameters of SGP change is unnoticeable.

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Autorzy i Afiliacje

D. Bańkowski
ORCID: ORCID
S. Spadło
ORCID: ORCID
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Abstrakt

The aim of the article was to determine the impact of crushed condition (work hardening) on the effectiveness of the vibratory machining. The vibratory machining processing was carried out in two steps. The first step consisted of mechanical abrasion and remove oxides from the surface of the workpieces with abrasive media. While in the second step, smoothing - polishing with metal media was performed. Vibratory polishing also strengthened the treated surfaces. The test results were compared for samples in the crushed state (work hardening, plastic processing) and samples subjected to recrystallization annealing heat treatment. Mass losses, changes in the geometric structure of the surface and changes in the hardness of the machining surfaces were analyzed. Samples subjected to recrystallization, as compared to the samples in the state after work hardening-plastic working, are characterized by a slightly higher arithmetic mean surface roughness and lower surface hardness than for analogous processes for samples not subjected to heat treatment. Heat treatment of annealing allows to remove the effects of crushing and thus it is possible to obtain larger mass losses. Smaller burrs dimensions were obtained for samples after the heat treatment – annealing than after work hardening.
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Bibliografia

[1] Stal Centrum (2021). M63 - Material properties, Application. Retrieved April 1, 2021, from http://www.stal-Centrum.com.pl/index.php/pomoc-techniczna/charakterystyka-gatunkow/mosiadz/m63cuzn37 (in Polish).
[2] Bańkowski, D., & Spadło, S. (2017). Investigations of influence of vibration smoothing conditions of geometrical structure on machined surfaces. IOP Conference Series: Materials Science and Engineering. 179 (1), 012002). DOI.: 10.1088/1757-899X/179/1/012002
[3] Ciampini, D., Papini, M. & Spelt, J.K. (2007). Impact velocity measurement of media in a vibratory finisher. Journal of Materials Processing Technology. 183(2-3), 347-357. DOI.: 1016/j.jmatprotec.2006.10.024.
[4] Borovets, V., Lanets, O., Korendiy, V., Dmyterko, P. (2021). Volumetric vibration treatment of machine parts fixed in rotary devices. In: Tonkonogyi, V., et al., Advanced Manufacturing Processes II (pp.373-383). Springer, Cham. DOI.: 10.1007/978-3-030-68014-5_37.
[5] Mediratta, R., Ahluwalia, K. & Yeo, S.H. (2016). State-of-the-art on vibratory finishing in the aviation industry: An industrial and academic perspective. The International Journal of Advanced Manufacturing Technology. 85, 415-429. DOI.: 10.1007/s00170-015-7942-0.
[6] Grigoriev, S.N., Metel, A.S., Tarasova, T.V., Filatova, A.A., Sundukov, S.K., Volosova, M.A., Okunkova, A.A., Melnik, Y.A. & Podrabinnik, P.A. (2020). Effect of cavitation erosion wear, vibration tumbling, and heat treatment on additively manufactured surface quality and properties. Metals. 10(11), 1540, 1-27. DOI.: 10.3390/met10111540.
[7] Canals, L., Badreddine, J., McGillivray, B., Miao, H.Y., Levesque, M. (2019). Effect of vibratory peening on the sub-surface layer of aerospace materials Ti-6Al-4V and E-16NiCrMo13. Journal of Materials Processing Technology. 264, 91-106. DOI.: 10.1016/j.jmatprotec.2018.08.023.
[8] Uhlmann, E., Eulitz, A. (2018). Influence of ceramic media composition on material removal in vibratory finishing. Procedia CIRP. 72, 1445-1450. https://doi.org/10.1016/ j.procir.2018.03.285
[9] Bańkowski, D., Spadło, S. (2017). Vibratory tumbling of elements made of Hardox400 steel. In 26th International Conference on Metallurgy and Materials, 24-26 May 2017 (pp. 725-730). Brno, Czech Republic.
[10] Bankowski, D., Spadlo, S. (2018). Influence of ceramic media on the effects of tumbler treatment. In 27th International Conference on Metallurgy and Materials, 23-25 May 2018, (pp. 1062-1066). Brno, Czech Republic.
[11] Metel, A.S., Grigoriev, S.N., Tarasova, T.V., Filatova, A.A., Sundukov, S.K., Volosova, M.A., Okunkova, A.A., Melnik, Y.A. & Podrabinnik, P.A. (2020). Influence of postprocessing on wear resistance of aerospace steel parts produced by laser powder bed fusion. Technologies. 8(4), 73. DOI.: 10.3390/technologies8040073.
[12] Glvan, D.O. et al. (2018). Study on the influence of supplying compressed air channels and evicting channels on pneumatical oscillation systems for vibromooshing. In IOP Conference Series: Materials Science and Engineering, 10-12 May 2017 (pp. 012069). Hunedoara, Romania. DOI.: 10.1088/1757-899X/294/1/012069.
[13] Bańkowski, D. & Spadło, S. (2020). Research on the influence of vibratory machining on titanium alloys properties. Archives of Foundry Engineering. ‏20(3), ‏47-52. DOI: 10.24425/afe.2020.133329.
[14] Woźniak, K. (2017). Surface treatment in container smoothing machines. Warszawa: WNT (in Polish).
[15] Micallef, C., Zhuk, Y. & Aria, A.I. (2020). Recent progress in precision machining and surface finishing of tungsten carbide hard composite coatings. Coatings. 10(8), 731, 1-35. DOI.: 10.3390/coatings10080731.
[16] Domblesky, J., Evans, R. & Cariapa, V. (2004). Material removal model for vibratory finishing. International Journal of Production Research. 42(5). 1029-1041. https://doi.org/10.1080/00207540310001619641.
[17] Bańkowski, D. & Spadło, S., (2019). The influence of abrasive paste on the effects of vibratory machining of brass. Archives of Foundry Engineering. 19(4), 5-10. DOI.: 10.24425/afe.2019.129622.
[18] Janecki, D., Stępień, K. & Adamczak, S. (2010). Problems of measurement of barrel- and saddle-shaped elements using the radial method. Measurement. 43(5), 659-663. DOI.: 10.1016/j.measurement.2010.01.015.
[19] Marciniak, M., Stefko, A., Szyrle W. (1983). Basics of processing in container smoothing machines. Warszawa: WNT. (in Polish).
[20] Hashimoto, F. & Debra, D.B. (1996). Modelling and optimization of vibratory finishing process. CIRP Annals. 45(1), 303-306. DOI.: 10.1016/S0007-8506(07)63068-6.
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Autorzy i Afiliacje

D. Bańkowski
1
ORCID: ORCID
S. Spadło
1
ORCID: ORCID

  1. Kielce University of Technology, Poland

Abstrakt

This article deals with the effects of electrical discharge machining (EDM) on the chemical composition and microstructure of cast Alnico alloys, i.e., iron-based alloys composed of aluminum, nickel and cobalt. The experiments focused on determining the chemical composition of the surface layer before and after the EDM process. The microstructure of the material altered by the EDM was also examined. The study included measurement of the thickness of the white layer characteristic of EDM. It is evident that low values of the surface roughness parameters can be obtained by correctly selecting the EDM process parameters. The average surface roughness reported in the experiments was 1 μm. The surface roughness measurements were conducted with a Talysurf CCI lite non-contact profiler. The metrological results also indicate that lower surface roughness can be obtained at small discharge energies.
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Autorzy i Afiliacje

D. Bańkowski
1
ORCID: ORCID
P. Młynarczyk
1
ORCID: ORCID
B. Szwed
1
ORCID: ORCID

  1. Kielce University of Technology, Poland

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