This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.
Results of a study investigating a skew rolling process for elongated axisymmetric parts are presented. Despite the fact that the skew rolling technique for producing such parts was developed and implemented in the mid-twentieth century, there are no studies on this problem. The first part of this paper presents the results of FEM modelling of skew rolling stepped axles and shafts (solid and hollow). The FEM analysis was performed using the MSC Simufact Forming software. The numerical simulation involved the determination of metal flow patterns, the analysis of thermal parameters of the material during rolling, and the prediction of cracking by the Cockcroft-Latham ductile fracture criterion. Force parameters of rolling solid and hollow parts were also determined. The aim of the FEM analysis was to determine initial design assumptions and parameters for the development of the skew rolling mill. Later on in the paper, a design solution of a CNC skew rolling mill for rolling parts based on their envelope profile is proposed. FEM strength test results of a mill stand, obtained with MSC. NASTRAN, are presented. Finally, the performance test results of the constructed rolling mill are presented. The experiments involved rolling real stepped shafts that were modelled numerically. Obtained results show that the proposed skew rolling method has considerable potential. The designed and constructed rolling mill can be used to perform the rolling process according to the proposed method, with the tool and material kinematics being controlled based on the set parameters of a workpiece envelope.
This paper presents a pilot scale version of the new construction of filter to remove pollution from the gas. The construction of the filter is based on the bifilar windings. The filter is designed for the removal dielectric dust particles from the air. A new chassis of bifilar winding is introduced recently. The most recent results of the filtering efficiency are presented in this paper. Streszczenie. W artykule zaprezentowano półprzemysłową wersję filtru nowej konstrukcji do usuwania zanieczyszczeń z gazu. Konstrukcja filtru oparta jest na uzwojeniach bifilarnych. Filtr zaprojektowano w celu usuwania cząstek zanieczyszczeń dielektrycznych z powietrza. W ostatnich testach wprowadzono nową ramę uzwojenia bifilarnego. W pracy zamieszczono najnowsze wyniki skuteczności odpylania zmodyfikowanego filtru. (Wpływ konstrukcji uzwojenia bifilarnego na skuteczność elektrostatycznego odpylacza bifilarnego).
Rolling machines are often used for forming flat elements or pipes. Problems occur when used to produce cylindrical elements other than pipes, or when experimental materials are used. It is required to introduce flexible control of the rolling process parameters in such cases. It is necessary to monitor the device operating parameters. When a rolling machine works with experimental materials, there are no typical control and acquisition data systems available. The article presents the concept and capabilities of the control and computer data acquisition system supporting the rolling process. The main task of software system is acquisition of force and kinetic parameters related to the analysed process of the compression during rolling. This system allows current recording and analysis of five physical values. The acquisition data application is developed in National Instruments LabVIEW environment. The software algorithm is based on the state machine. The article contains a detailed description of hardware and software implementation of the functions mentioned.
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