Thin-walled elements are widely used in the aerospace industry, where the aim is to reduce the process time and the weight of the structure while ensuring the sufficient quality of the finished product. Quality is determined by geometric structure parameters and dimensional and shape accuracy. The main problem encountered during the milling of thin-walled elements is the deformation of the product. Despite the various methods available for measuring deformation, more are still being developed. This paper presents selected surface topography parameters and deformation of vertical thin-walled elements during an experiment under controlled cutting conditions for samples from titanium alloy Ti6Al4V. Constant parameters of feed (f), cutting speed (Vc,) and tool diameter (D) were used. Samples were milled using a tool for general-purpose and a tool for high-performance machining, as well as two different machining approaches: with greater involvement of face milling, and cylindrical milling with a constant material removal rate (MRR). For samples with vertical thin walls, the parameters of waviness (Wa, Wz,) and roughness (Ra, Rz) were measured using a contact profilometer in the selected areas on both processed sides. Deformations were determined in selected cross-sections perpendicular and parallel to the bottom of the sample using GOM measurement (GOM—Global Optical Measurement). The experiment showed the possibility of measuring deformations and deflection arrows of thin-walled elements proceeded from titanium alloy using GOM measurement. Differences in selected surface topography parameters and deformations were observed for the machining methods used with an increased cross-section of the cut layer. A sample with a deviation of 0.08 mm from the assumed shape was obtained.
This paper discusses the pull-out laboratory tests and the monitoring of expansion-shell bolts with a length of 1.82 m. The bolts comprised the KE-3W expansion shell, a rod with a diameter of 0.0183 m and a profiled, circular plate with a diameter of 0.14 m, and a gauge of 0.006 m. The bolts were installed in a concrete block with a compressive strength of 75 MPa. The tests were conducted on a state-of-the-art test stand owned by the Department of Underground Mining of the AGH University of Science and Technology. The test stand can be used to test roof bolts on a geometric scale of 1:1 under static and rapidly varying loads. Also, the stand is suitable for testing rods measuring 5.5 m in length. The stand has a special feature of providing the ongoing monitoring of bolt load, displacement and deformation. The primary aim of the study was to compare the results recorded by two different measurement systems with the innovative Self-Excited Acoustic System (SAS) for measuring stress variations in roof bolts. In order to use the SAS, a special handle equipped with an accelerometer and exciter mounted to the nut or the upset end of the rod was designed at the Faculties of Mining and Geoengineering and Mechanical Engineering and Robotics of the AGH University of Science and Technology. The SAS can be used for nondestructive evaluation of performance of bolts around mining workings and in tunnels. Through laboratory calibration tests, roof bolt loads can be assessed using the in-situ non-destructive method.
The article presents a novel yielding mechanism, especially designed for the rock bolt support. Mechanical rock bolts with an expansion head and equipped with one, two, four and six dome bearing plates were tested in the laboratory conditions. Furthermore, in the Phase2D numerical program, five room and pillar widths were modeled. The main aim of numerical modeling was to determine the maximal range of the rock damage area and the total displacements in the expanded room. The models were made for a room and pillar method with a roof sag for copper ore deposits in the Legnica-Głogów Copper District in Poland. Additionally, in the article a load model of the rock bolt support as a result of a geomechanical seismic event is presented. Based on the results of laboratory tests (load–displacement characteristics), the strain energy of the bolt support equipped with the yielding device in the form of dome bearing plates was determined and compared with the impact energy caused by predicted falling rock layers. Based on the laboratory tests, numerical modeling and mathematical dynamic model of rock bolt support, the dependence of the drop height and the corresponding impact energy for the expanded room was determined.
This paper presents the results of laboratory tensile testing of segmentally-installed glue-in roof bolting. We studied roof bolting of the type Olkusz-16A (Boltech Sp. z o.o., ZGH Bolesław S.A., Bukowno, Poland), additionally equipped with a steel rod coil, which was mounted in steel cylinders filled with a concrete mixture using multi-part resin cartridges with a diameter of 0.024 m and length of 0.045 m. The mounting depths were 0.1 m and 0.2 m, respectively. Our main purpose was to determine the effect of the bolt hole diameter, which assumed the values 0.028 m, 0.032 m, 0.035 m, and 0.037 m, respectively, on the load-bearing capacity of the roof bolting in relation to the mounting depth. We found that the mounting depth of 0.2 m was sufficient for the roof bolting to exhibit its full load and displacement properties for all four diameters of the bolt hole. To determine whether the roof bolting was capable of transferring the load in situ, we presented the results of the predicted load on the roof bolting applied in a room and pillar mining method in an underground mine of zinc and lead ore deposits. Our objective was to determine the influence of the room and pillar mining method geometry on the range of the fault zone of rocks around pits. We designed the deposit excavation model using the Examine3D numerical modeling software, which is based on the boundary element method. We created three-dimensional models for three variants of working space opening widths: featuring two, three, and four rows of rooms. The geometry of rooms and pillars corresponded to the mine conditions; the width, height, and length parameters were all 5 m. We determined the strength, strain, and structural parameters of the rock mass on the basis of laboratory studies of the drill core and rock forms collected from the room longwall. We used the strength factor to specify the maximum range of the fault zone of rocks around pits. In the last stage of research, we compared the load value obtained based on numerical testing with the maximum load obtained in the tensile strength tests of the roof bolting and determined the safety factor of the segmentally-installed roof bolting.
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