MANUFACTURING ENGINEERING AND MANAGEMENTProceedings of 2nd International Conference on MANUFACTURING ENGINEERING & MANAGEMENT 2012 Organised by: Faculty of Manufacturing Technologies with a seat in Prešov, Technical University of Košice, Slovakia Mechanical Engineering Faculty in Slavonski Brod, J.J. Strossmayer University of Osijek, Croatia Industrial Engineering Department, Faculty of Engineering, Marmara University Istanbul, Turkey Participants states |ALB|CZ|DEN|EE|ESP|HR|IN|IR|IT|KOR|PL|RO|SK|SLO|SRB|TR|UA| December 5 - 7, 2012 Prešov Slovak Republic Manufacturing Engineering and Management Sergej Hloch Jozef Husár Lucia Knapčíková Ivan Lazár Editors Prešov, 5‐7 December 2012 I This book contains the papers suggested by the reviewers for publishing and presentation at the Second International MANUFACTURING ENGINEERING & MANAGEMENT 2012 to be held during 5th – 7th December 2012 in Prešov, Slovak Republic, European Union. Note This publication was reproduced from the manuscripts supplied by authors and co‐authors. The layout, the figures and tables of some papers did not conform exactly to the standard requirements. In some cases was the layout of the manuscripts rebuild. The editors are not responsible either for the statements made or for the opinion expressed in that papers, published in the proceedings of MANUFACTURING ENGINEERING & MANAGEMENT 2012. Editors: HLOCH Sergej HUSÁR Jozef KNAPČÍKOVÁ Lucia LAZÁR Ivan Layout and Design: HLOCH Sergej Cover Design: HUSÁR Jozef Publisher: Faculty of Manufacturing Technologies Technical University of Košice with a seat in Prešov All Rights Reserved © 2012 FVT TU in Košice with a seat in Prešov No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written permission from the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work. ISBN 978‐80‐553‐1216‐3 II Brief Contents Forewords ........................................................................................................... V Chairman Foreword ............................................................................................ V Foreword of the Mayor of the City of Prešov ..................................................... VII General information ............................................................................................ VIII Programme Committee ...................................................................................... IX Proceedings contents .......................................................................................... X Keynote Lectures ................................................................................................ 1 Papers ................................................................................................................. 44 Keynote Lecture .................................................................................................. 210 Advertising .......................................................................................................... 217 III “My desire, sir, is to escape from trade which I find vicious and selfish and to become a servant of science which I imagine makes its pursuers amiable and liberal.” Michael Faraday IV E. Concern for the man himself and his fate must always form the chief interest of all technical endeavours. In fact.e. Lucia Knapčíková. Specifically. We are thankful for the generous donation by WELDEX. breakthroughs.. wrote me in one e‐mail “Democracy lies on the conscious individuals who are living for innovations in science. science. For running a conference of this magnitude. and Vice‐rector of University of Prof.G. included among the strongest forces helping get the ideas dressed into reality which change the way of life.. Jozef Novák – Marcinčin. Colleagues. milestones of human life commence. In addition to the contributed papers.“ Yes. Dear friends. PhD. ICMEM conference is arranged under the patronage Dean of the Faculty of the Manufacturing Technologies Technical University of Košice with a seat in Prešov Prof. Dr. financial support is essential. To what extent is reality accessible? The question should be raised other way. ICMEM Organizing Committee received more than 64 submissions which authors and co‐authors and participants are from 20 different countries of the world. Jointly they are V . prominent researches were invited to give keynote lectures in their respective fields of competence. technology and management surprisingly bring new inventions. Olcnava. applications and permeate in other spheres of human life. Pavel Hagyari. Bratislava. Ing. 1st Presov tool making company. Management means how to organize. Slovak Republic. Many times the reason rests in waving the advances or inventions aside or in becoming frightened of them. Pavol Hreha. Dear my great friend Prof. is not partial to “mess“. I would like to thank all those who 2012 helped in organization of the ICMEM conference especially our colleagues from Department of Manufacturing Management. Ing. Following pages deal with the issues of our ancestors and consequently with the ones is having occurred in the course of experimental work. Pursuant to the article published in Scientific American each person disposes of different limited field of vision exceeding the borders of imagination and fantasy of the world.” Thank you my But as Albert Einstein said: “It is not enough that you should understand about applied science in order that your work may increase man’s blessings. fantasy. Slovak Republic. kind of “battery“(or light) in the space of unknown matters is exploration magnifying notional radius of cognition. Prešov. Slovak Republic.. For the present the only working means. Technologies mean knowing how to do.. certain space exists between the borders of cognition and fantasy.. Ltd. Ltd. Reviewers and Members of the Program committee and their recommendations used for a selection of carefully reviewed all submissions. your work. Slovak Republic. When examining the world around – either at home or work. Ing. Smooth running of the conference can be hardly imagined without the devoted presence of Ing. The content of the words in this proceeding is not focused solely on knowledge having been acquired through arduous and challenging research but it is a desired metamorphosis of ideas having occurred in your mind earlier to become familiar with other so far unknown “miracles”. Ltd. Human mind. This year.S. DRC. Prešov. Ivan Samardžić and Mayor of the Prešov Town JUDr. technologies represent processes which through the explicit or implicit research and development stage. A.. With respect to the pace of the scientific and technical progress a man often fails to understand the innovations of which they possess no adequate experience. Sc. VIA MAGNA. This conference bears all the hall marks of success. This book includes the proceeding of the Second International Scientific Conference on Manufacturing Engineering and Management 2012 organized by Manufacturing Management Department Faculty of Manufacturing Technologies. This is due to the great team work. PhD. Inter alia. by application of scientific knowledge not only do allow commercial production of goods and services.. Slovak Republic. Husár. Technologies and engineering are overcoming distances yet absence of certain closeness to the man and chiefly among people is apparent.. i. Slovak Republic. Prešov. AVON. PhD. fortunately. where the latest findings in science and engineering concerned with the 2012 technology systems operation are reported. Science. Slovak Republic. Friend for your big words.. Chairman Foreword Dear Participants. Prešov.. when travelling and entertaining oneself or working – results of the work of anonymous scientists and engineers are being used.. science means studying and knowing (learning). Why? Because reality includes both objects and events occurring beyond the human cognition. It is the space for ideas within the frame of which the most significant moments. Ing. Dražan Kozak.. without the unsolved issues and issues not being solved one would possess nothing. However. imagination. PhD. research and related reshaping of natural or artificial substance‐material through technologies significantly affect society development. Those are exactly the words used to express degree of unawareness of causal chain of reasons and consequences that correlates with the correctness of evaluation of the particular action having occurred in time and space. SPINEA – Solution for Precision. According their advices were accepted 47 papers. perception. Technical University of Košice with a seat in Prešov. Prešov. In point of causality it is the area of undefined reasons and interactions many times vaguely described by terms of fate or accident. especially in gaining new experience based on experiments. Ltd. habits and view over the world of every society inclusive of ours as well.. Ltd. who left us forever. Thanks belong to the reviewers for their diligence and expert reviewing. At last I would like to say big THANK YOU. VI . Last but not least are the authors who deserve big thank you. We wish you warm welcome 2012 and hope that your participation in ICMEM will be enjoyable and also professionally rewarding and we are hoping that the proceedings will be helpful to all scientists and engineers. PhD. their research and development efforts are recorded in those proceedings. to my friend prof. We never forget. Peter Fečko. Ing. Assoc. this year. Hloch Sergej... Vincent Peržel and Jozef Chomanič the owner of Via Magna.. Prof. SALT MINES and GOLDEN MINES together under the open‐air mine's museum and to create a great place to visit. We are pleased by the attention of foreign visitors. The relationship with industrial parks will improve the level of the high education not only at this particular Faculty but also it is good opportunity for the other educational institutions in our city. JUDr. Pavel Hagyari Mayor of the City of Presov VII . The City of Prešov has an ambitious aim to be a leader in the Eastern Slovakia region. officials and representatives of the authorities of the European Union that we regularly welcome at our City Hall. The city has an ambition to establish an environment that can offer opportunities for high‐class education and also for students’ employment. It needs people who will not leave the city but people who will stay in the city that can care of them. educational institutions and industrial parks. Prešov is on the best way to become modern and dynamic city that is interesting for its inhabitants as well as it is attractive for tourists. We would like to utilize the other alternative energy sources like solar energy and biomass. One of the major aims of the city on this successful way is to help students to resolve the problem with an accommodation by building up of new flats. Their connection is an important element for the experience of the graduates and for students. One of the ideas of the cooperation between the city of Prešov and the Faculty of Manufacturing Technologies is to make suitable environment for students in our city. The message of this Conference would be to bring together Faculty and the City and thus enable Prešov to become the ecological and technological city. It is also one of the solutions for students to gain experience in the field of their studies and it is the opportunity I wish we will meet again on the further Conference in 2014. Ladies and Gentlemen. The connection of the city and the University will secure not only opportunity for graduates. Our plan is to connect OPAL MINES. We expect that the University graduates will fulfil the requirements and expectations of the growing city and new coming investors. Prešov is a seat of the University of Prešov. The Municipality has further ambition to build up wellness centres for students and for inhabitants of Prešov. but also opportunity for students to practice during their studies and see how the technologies are used in industry. The students from all parts of Slovakia are studying at the University. Our main objective is especially the utilization of geothermal energy for heating and also using of the energy for development of tourism and for production of electricity. Energie‐Cités is the association of European local authorities for the promotion of local sustainable energy policies. We look forward to our cooperation with Technical University in Kosice through its Faculty of Manufacturing Technologies with seat in Prešov. The unique sources of the geothermal energy are opening big opportunities for our citizens how to cut down energy costs and for its further usage. That is the reason why there must be connection between the city. The city needs educated and ambitious people in order to become a prominent European centre. After discussion in Energy‐Cites Prešov has been selected as a pilot city for the IMAGINE Campaign. Education will remain one of the priorities of the city’s development. To become a professional. the City of Prešov makes an effort to belong to these fast growing cities that will be able to respond to solving such a big challenge as the climate changes and global warming are. Presov has the great potential of the utilizable natural energy. There are also other faculties in the city and one of them is the Faculty of Manufacturing Technologies. The citizens of Prešov do understand the need to cut down energy usage and the importance of combat against climate changes. I am delighted to attend today the second International Scientific Conference on Manufacturing Engineering and Management 2012. At the present time. Dear Ladies and Gentlemen. Foreword of the Mayor of the City of Prešov for the university to get feedback on their education programs directly from the practice. The cooperation of the City and the Faculty is a significant step forwards by reason that they lived independently until this time. Municipality of Prešov has clear priorities to achieve concrete results for which the connection between the Faculty and the City will be beneficial. Clean and healthy environment belongs to the main priorities when we are talking about the City of Prešov. This Conference has encouraged us to see the future of the city and the faculty as a one entity on its way to become a modern and prospering ecological city that uses the advanced technologies. I hope that our collaboration will help us to establish a strong base for the graduates and their potential employers. one has to be educated and have a good experience in the field of his study program. There are also OPAL MINES in our region that are very attractive touristic attraction with its unique "nobel opal". Technical University of Kosice. I believe that this conference will be beneficial not only for the participants but also for the development of cooperation between University and the City of Presov. the International Scientific Conference Manufacturing Engineering and Management „ICMEM“ is a biennial event organized by Department of Manufacturing Management with the aims of serving as a platform for reviewing and exchanging ideas and experience in modern industrial training. Slovak Republic TOPVAR Brewery – Šariš Brewery. Organised by: ‐ Department of Manufacturing Management. Ltd.sk) (http://www.sk) DRC. and to promote the importance of intellectually challenging.sk/) (http://www. Slovak Republic (http://www. Turkey. Strossmayer University of Osijek. Olcnava.J. Slovak Republic (http://www. Slovakia. relevant industrial training as an integral part of higher education. J.sk) A..weldex. Slovak Republic VIII . Prešov. Faculty of Manufacturing Technologies with a seat in Prešov. Prešov. Bratislava.. Ltd. Slovak Republic (http.G. Marmara University Istanbul.sk) AVON. Ltd.//www. ‐ Industrial Engineering Department. Faculty of Engineering.avon.. ICMEM2012 2ND International Scientific Conference MANUFACTURING ENGINEERING & MANAGEMENT Inaugurated in 2010. Slovak Republic VIA MAGNA. Prešov. Prešov. Technical University of Košice.sk/) SPINEA – Solution for Precision. Ltd.. Croatia.agesmetal. Slovak Republic WELDEX.1pn.S.spinea. Slovak Republic (http://www.sk) (http://www. Ltd. Prešov. ‐ Mechanical Engineering Faculty in Slavonski Brod. In cooperation Slavonski Brod Town (Croatia) Institute of Geonics AS CR District Authority of Prešov Prešov Town Financially supported by (in alphabetical order): 1st Presov tool making company.E..drc. Veľký Šariš.topvar. Scientific Committee | in alphabetical order AL HELALAT OMAR AL MOMANI MUFADI AL‐NIMR M A. DAEJUN UT POZNAŇ CALIFORNIA STATE UNIVERSITY UNIVERSITY OF PETROSANI UNIVERSITY OF RIJEKA UNIVERSITY OF ECONOMICS. MARIANA MAN MIKAC TONČI MLÁDKOVÁ LUDMILA MODRÁK VLADIMÍR OHLÍDAL MILOSLAV PETROPOULOS GEORGE PIŠTORA JAROMÍR RAJAKARUNAKARAN S. MESRA VALAHIA UNIVERSITY OF TARGOVISTE J. DESIGN AND DEV. STROSSMAYER UNIVERSITY OF OSIJEK KALASALINGAM UNIVERSITY TALLINN UNIVERSITY OF TECHNOLOGY J. STROSSMAYER UNIVERSITY OF OSIJEK NEW YORK INSTITUTE OF TECHNOLOGY UNIVERSITY OF BELGRADE MARMARA UNIVERSITY.J. ISTANBUL SHARIF UNIVERSITY OF TECHNOLOGY BIRLA INSTITUTE OF TECHNOLOGY. SEMNAN BRANCH AL‐HUSON COLLEGE UNIVERSITY UNIVERSITY OF MONTENEGRO POLITECHNICA UNIVERSITY BUCHAREST KOREA AEROSPACE RESEARCH INSTITUTE. YURCI MEHMENT EMIN ZAMAN ABEDULLAH NEW YORK INSTITUTE OF TECHNOLOGY APPLIED UNIVERSITY OF JORDAN UNIVERSITY OF SCIENCE AND TECHNOLOGY VALAHIA UNIVERSITY OF TARGOVISTE VALAHIA UNIVERSITY OF TARGOVISTE VIENNA UNIVERSITY OF TECHNOLOGY VŠB –TU OSTRAVA INSTITUTE OF GEONICS AS CR CZESTOCHOWA UNIVERSITY OF TECHNOLOGY UNIVERSITY OF MARIBOR UNIVERSITY OF NOVI SAD INDIAN SCHOOL OF MINES.J. IX UAE J J RO RO A CZ CZ PL SLO RS IN HU SWE IR J MNE RO KR PL US RO HR CZ SK CZ GR CZ IND PL HR BR PL I HR UAE RS TR IR IN RO CRO IND EE CRO TR TR IND TR SWE . R SURZENKOV ANDREI ŠIMUNOVIĆ GORAN TOZAN HAKAN VAYVAY ÖZALP VENKUMAR P. OF INNOVATION. STROSSMAYER UNIVERSITY OF OSIJEK UNIVERSITY OF SAO PAULO. FEČKO PETER FOLDYNA JOZEF GRABARA JANUSZ GUBELJAK NENAD HODOLIČ JANKO CHATTOPADHYAYA SOMNATH ILLÉS BÉLA JACKSON MATS JAVADI YASHAR KHADRAWI A F KRIVOKAPIĆ ZDRAVKO LACATUS ELENA LEE HO‐SUNG LEGUTKO STANISLAW MAHALIK. BADEA LEONARDO DIMA CONSTANTIN IOAN DURAKBASA NUMAN M. N. DHANBAD UNIVERSITY OF MISKOLC MÄLARDALEN UNIVERSITY ISLAMIC AZAD UNIVERSITY. RAJCZYK JAROSLAW RAOS PERO RIBEIRO JOSÉ ROKOSZ KRZYSZTOF RUGGIERO ALESSANDRO SAMARDŽIĆ IVAN SARHAN AHMAD SEDMAK ALEKSANDAR SENNAROĞLU BAHAR SHARIATI AZADED SHARMA VINAY STEGAROIU ION STOIĆ ANTUN SUDHAKARAPANDIAN. PRAGUE TECHNICAL UNIVERZITY OF KOŠICE SF VÚT BRNO UNIVERSITY OF THESSALY VŠB –TU OSTRAVA KALASALINGAM UNIVERSITY CZESTOCHOWA UNIVERSITY OF TECHNOLOGY J.. P. ISTANBUL KALASALINGAM UNIVERSITY TU ISTANBUL DEPT.J. STROSSMAYER UNIVERSITY OF OSIJEK TURKISH NAVAL ACADEMY.BRAZIL KOSZALIN UNIVERSITY OF TECHNOLOGY UNIVERSITY OF SALERNO J. ISTANBUL MARMARA UNIVERSITY.J. ....... 37‐40 Raos P......................................................... Miloš M................ Elasto‐plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates ..... A Man Who Really Loved This World (In Memory of prof.............................. Aykul H... Jojić B....... 41‐43 Regular Section | in alphabetical order Ahn E... Stojšić J............. Baskaran BV... 1‐5 Ghosh A........................... Blagojević Đ.. 15‐18 Sennaroglu B...................... 68‐69 X ........ The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60 ......................................... Chattopadhyaya S............. 6‐14 Mládková L Knowledge workers in manufacturing sector ............. 23‐26 Kumar S........................ 44‐48 Atmaca A....... Kalendova A......... Vallikivi A......................................... Study on polyamide 12/clay nanocomposites by melt‐intercalation process… ... Proceedings Contents Keynote Lectures | in presentation order Samardzic I............................. Viljus M............................ Gabeta A.................. 27‐32 Surzhenkov A................... Orlovsky I..... Chattopadhyaya S Selection of appropriate moving heat source shape of submerged arc welding process .......................... Türkbaş OS............ Sharma V Green supply chain management: A case study from Indian small and medium scale industry ....................... 53‐55 Cucllari F......... Vilgo T.. Maneski T.. Şen S Integrated AHP and TOPSIS approach for supplier selection ... The Impact of Human Resources Management 1 ‐ on the Performance of Small and Medium Enterprises in Albania . Kulu P... Wear Resistant Self‐fluxing Alloy Based TiC‐NiMo and Cr2C3‐Ni Hardmetal Particles… ........................ Chang DS.......... Cini M..................... 33‐36 Sreenivasan M........ Fečko) .............................................. Zrilic M..... Kladaric I.. 64‐67 Fečko P.................................... Simulation based Layout Design… .......................................... Erdin ME................. 49‐52 Celovic S................................. Kozak D............. 56‐58 Davidović N................................. Merinska D......... Vuherer T......................... Magnetically‐Impelled Arc Butt Welding for Manufacture of Automobile Hollow Parts of Mass Production… .............. 19‐22 Ruggiero A........ Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison .......................... Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure ....... Parg SC............................................... Kachinskiy V................................................. Tipsarevic M................. Hloch S Method to determine the analytical approximate description of non‐steady fluid film force in fluid film bearings ............................. Dunđer M Application of weld thermal cycle simulator in manufacturing engineering .................. Hloch S......................... Šercer M........................................................ 59‐63 Duplak J....... Kuchuk‐Yatsenko S.................. Mikli V.. Miloš P....................... Stoić A..... . 132‐136 Podżorny T................... 94‐96 Kushan MC............................................................................. 151‐154 Shankar R..... Rzepka J........ Textile Recovery from Srap Rubber Tires ....... Henc P........ A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts .. Miloš M........... 113‐121 Modrák V............................. Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils ............ Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves .............................................. 100‐106 Mahdi AM.. 85‐88 Kejval J......... Electro‐Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control ....................... Mitrovic N.. Ekinci H........ Bahman A. Duplák J................. Petrovski B........................ Ungureanu N...... Miloš M. Oravec P........... Hatala M......... 80‐84 Kadnár M.......................... Budimir NJ........................ Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes ...................... Manojlovic D. Jarić MS......................... 122‐125 Müller M.......... Tököly P..... 91‐93 Knežević S................................................... Olexa Ľ............................. Duspara M.......................................... Multimedia Support in Subject Material Science ......... Quality Assurance of a Large Welded Penstock Manufacturing by Means of Full‐scale Model Testing ...................... Marton D....... Kušnerová M... Budzyń G................... Manivannan A.................................... Husár J............... 141‐148 Radvanska A...... Chocholouš P......... 107‐108 Milosevic M. Procedure Development for Standardized Tooth Cavity Preparation for in Vitro Research Purposes . Rusnák J............. 126‐131 Nauparac DB....... Bednár S...................... 137‐140 Prakash A...................... 70‐73 Javadi Y... 149‐150 Rakonjac IM... 109‐112 Miloš P................. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles ...... 74‐79 Javadi Y............................ Comparison of Complexity Indicators for Assessing General Process Structures ................. Sedmak A....... Gorvendra S................................................. Budimir SJ........................................... Kormoš M.. Verification of Sequential Patterns in Production Using Information Entropy ........ Vijayakumar D......................... 155‐162 XI .... Tatić US.............................. Blagojević Đ......................... Sigurnjak L...... Pršić DH............ Manufacturing Technologies in Republic of Croatia . Gode E................ Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools .. Laser Feedback System for Accurate Sub‐Micrometer ... High‐Strength Fiber in Polyvinyl Butyral Matrix ............. Miletic V................ 97‐99 Lazár I. Michalik P.................................. Momcilovic N................. Djurdjevic AA............................. Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric .................................................................................. Davidović N...... Sedmak AS.. Müller M............ 89‐90 Knapčíková L... 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design .......... Jojić B........ Chotěborský R............... Valíček J............. Unalir T....... Sedmak SA........................... Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone .. Tribological Features of Journal Bearings Made of Bimetallic Alloy ......... ...................... Dvorský T. Shadrokh Sh.. 176‐177 Tunalioğlu MŞ............. 210‐215 XII ............ 182‐186 Yağimli M.................................. Hloch S................... Tozan H........ Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project ................................................. Ruiz R.. Hloch S....... Shirvani N....................................... Ozyilmaz E........... Developments in High Precision Metrology for Advanced Manufacturing ..... A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series ..................... Bas G......................................................... Experimental and Numerical Stress‐strain Analysis of Composite Beams .. Veg E............ Two and Three Body Abrasion of Polymer‐Particle Composites with Fillers on Basis of Machining Splinters from Hardfacing Alloys ....... Tozan H.... Harničárova M............... 170‐175 Trávníček P.................. Gemalmayan N.. The Investigation of Scoring Resistance on Spur Gears ............ Valíček J...................................... Daxner J.......... 198‐203 Václavík V................ 187‐191 Yanar L......... A Fuzzy Based Decision Support Model for Non‐traditional Machining Process Selection ........................ Recycled Polyurethane Foam as New Filler in Restoration Mortars ............. Sedmak A... Calculation Fire and Explosion Index Value for the Biogas Station . Kušnerová M....... Müller M........................... Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software . Valíček J.............................. 204‐208 Keynote lecture | Requested Durakbasa N............. Cieslar J... Emina D.... Junga P............................... 163‐166 Smiljanic P... 167‐169 Temuçin T............ Vítěz T.... Bauer J.... Tozan H.......... 178‐181 Valášek P................................................... Perishable Product Scheduling on Single Machine with Deadlines ................. Dirner V... 192‐197 Zohrevandi S.... it would not be called research. would it?" Albert Einstein . Keynote Lectures | in presentation order| "If we knew what it was we were doing. . etc. This method is suitable for investigations in different production processes. This approach is often used for acceleration of weldability investigations combined with additional investigations (e.g. which can accelerate process of obtaining WPAR/PQR (Welding Procedure Approval Record / Procedure Qualification Record) and reduce costs of welding process qualification. and scheme of execution unit for simulation of thermal cycle are given below. However.tk Manufacturing Engineering & Management The Proceedings Application of Weld Thermal Cycle Simulator in Manufacturing Engineering Ivan Samardžić1 ‐ Antun Stoić2‐ Dražan Kozak1‐ Ivica Kladaric1 ‐ Marko Dunđer3 1 Mechanical Engineering Faculty in Slavonski Brod. investigations at PQR/WPAR. casting. Croatia 2 University of Applied Sciences in Slavonski Brod.g. etc. (2012). It gives relatively fast information. Slavonski Brod. With weld thermal cycle simulator it is possible to reduce duration and costs of production (e. Croatia ARTICLE INFO: Category : Application Received : 21 August 2012 / Revised: 24 September 2011 / Accepted: 3 October 2012 Keywords: (in causal order) Abstract: PWHT Smitweld TCS 1406 T/P P91 Weld thermal cycle simulation Weldability The paper presents application of weld thermal cycle simulator for investigations and data predictions after welding process and post weld heat treatment of base material. Thermal cycle simulation method is an experimental method developed mostly for weldability investigations. Simulations of thermal cycle of base metal individual point are followed by investigations on specimens. Fig. hot metal forming. e.icmem. 2 Dimensions of thermal cycle specimens according to the Thermorestor‐W method.: Application of weld thermal cycle simulator in manufacturing engineering. 1‐5. hardness and toughness determination. beside application at weldability investigations. There are several laboratory devices for thermal cycle simulation (Smitweld. the most important application of this method is in investigations of base metal weldability at single pass and multi pass welding. Along with basic description of thermal cycle simulator Smitweld TCS 1406 and influence of weld thermal cycle on mechanical properties and micro structure of base metal. hardness and toughness testing. University of Osijek. et al. 1 Thermal cycle simulation method Fig.). the authors provided some practical data obtained on specimens after thermal simulation. detail of setting the probe in simulation device. 2nd International Conference Manufacturing Engineering & Management 2012. it is possible to perform single‐ cycle or multi‐cycle weld thermal cycle simulation and appropriate mechanical testing or other investigations.g.g. a) b) Fig. Figuration and dimensions of probe for thermal cycle. Thermo couple setting by capacitor discharging method on each specimen followed after preparing specimens for thermal simulation (Figure 1). post weld heat treatment. Depending of requirements for weldability investigations.Contents lists available at www. Specimen was inserted in jaw of block for fixation (position 6 on Figure 4) and stationary sensor was set for dilatation measurement (position 4 on Figure 5). Citation: Samardžić I. tensile test and investigations of micro structure. PWHT). Thermorestor). Gleeble.) and other investigations (e. 3 Specimen for thermal cycle simulation by the Gleeble method. p. Description of weld thermal cycle simulation method and presentation of some results after experimental work give opportunity for some other application of this method. micro structure investigation. 1 . in the case of indirect cooling (a) and in the case of indirect and additional direct cooling by water (b). in which thermal cycle at heating and/or cooling has significant influence on product quality. Croatia 3 University of Rijeka. 1 Dimensions of thermal cycle specimens according to Smitweld TCS 1405 method. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Simulation of thermal cycle of base metal individual point is a laboratory method suitable for weldability investigations. b ‐ specimen during thermal cycle simulation). 6 ‐ Jaw block for fixation.I. in the case of which the gas protection unit is set (position 6 on Figure 5). thermocouple and gas protection. 3 ‐ Water flow canal for indirect cooling. during precise dilatation measuring and very sensitive materials on air influence on elevated temperatures). After connecting all sensors (for temperature and dilatation). 2 3 Weld thermal simulation can be performed as single cycle or multi cycle. which is very important in materials science. 4 ‐ Dilatometer porter and temperature sensor. 2 ‐Thermocouple. 2 8 9 7 10 4 5 3 3 2 6 a) 1 Fig. it is possible to monitor the temperature–dilatation relationship. 2 ‐ Pipe connectors for indirect cooling. After thermal simulation. 6 ‐ Gas protection unit. cooling time between 800 and 500 ºC).g. Figure 7a shows an example of single weld thermal cycle simulation and Figure 7b shows double weld thermal cycle simulation. controlled heat input in base material is applied and it is possible to expect very similar effect during real welding in workshop in case of controlled welding parameters (heat input achieved by Fig. Samardžić et al. specimens were prepared for next investigation (e. 1 where 1‐ Base screw with bolt. heating and cooling rate. 9 ‐ Direct cooling block. peak temperature. 7a Single weld thermal cycle simulation. Figure 6a shows Smitweld TCS 1406 before thermal cycle simulation and Figure 6b during rapid heating by electric resistance system. 8 ‐ Pipe connectors for direct cooling. 5 Fig. Besides temperature–time relationship during heating and cooling. 3 ‐ Station dilatometer sensor. 1. 4 Execution unit on simulator of thermal cycle type Smitweld CTS 1405. 4 ‐ Movable dilatometer sensor. 5 ‐ Micrometer screw for dilatometer regulation. 2 2 . temperature‐ time and temperature‐dilatation relationship. Application of Weld Thermal Cycle Simulator in Manufacturing Engineering means of welding current and voltage and welding speed). 7 ‐ Contraction screw for direct cooling application. very rapid heating and cooling follows in controlled conditions (determined start temperature. 5 Position of dilatometer. 10 ‐ Current cable 6 1 4 b) Fig. 5 ‐ Base screw for jaws. In this way. toughness testing. Sometimes there is a need for gas shielding during simulation (e. metalography investigations). where: 1 ‐ Probe. hardness measurement. The thermal simulation process is monitored by a computer and all data are available after simulation for further processing and application. 6 Detail of simulation of test probe on simulator of thermal cycle type Smitweld CTS 1405 (a ‐ specimen before and after thermal simulation.g. .. It is also possible to improve quality of existing documents. J/mm (2) q U I l 4 c t8 / 5 2 2 2 v v 1 1 500 To 800 To E ef2 4 c 2 t8 / 5 1 500 To 2 1 800 To 2 . which is very often used in steam boiler components production. J/(kgK) t . welding speed... For the selected heat input. s v .Application of Weld Thermal Cycle Simulator in Manufacturing Engineering I. 3‐ dimensional model will be used (high speed point energy source on very thick plate). and cooling time (cooling rate) on the other side. the cooling rate is derived at determined temperature for 2‐ and 3‐ dimensional heat flow model. W/(mmC) c . and the weld thermal cycle simulation is cost effective. 7b Double weld thermal cycle simulation. mm . the reliability of weldments will be improved.. the heat input can be determined by equation 4 and 5. time.. Samardžić et al. 7 3 . [3‐6] Eef . 8 Influence of cooling time on mechanical properties of 10CrMo910 steel after austenitisation and cooling at different cooling time. which determine relationship between welding parameters. thermal conductivity. Fig.. At some welding products with increased risk of failure (power plants. W l . showing TTT (Temperature‐Time‐ Transformation) diagram for 10CrMo910 steel. if these data are available to welding engineers. J/mm . physical and geometric variables on the one side. heat flow (q=UIl). oC/s (6) dT w 2 c Eef2 dt T Cooling rate (w) at temperature T for 3‐dimensional heat flow model: T T0 2 .. In that case... 3‐6 Cooling rate (w) at temperature T for 2‐dimensional heat flow model: T T0 3 2 . mm/s q . but it is very valuable for modern materials during weldability investigations and preparation of welding process qualification documents. If the border thickness (gr calculated thickness) is over real thickness at construction. LPG and LNG tanks). 2 The heat input and cooling conditions have crucial influence on micro structure and mechanical properties of base material and welded joint. Based on Fouriers differential equation.. it is possible to calculate border thickness between 2 and 3‐dimensional heat flows at arc fusion welding (equation 1). Otherwise. thickness. There are many mathematical solutions derived from Fouriers differential equation for heat conduction. in that case it is possible to compare cooling time and mechanical properties and microstructure after base metal exposure to thermal cycle simulator under controlled conditions... oC/s dT w 2 Eef dt T (7) where: To .s (3) In case of 3‐dimensional heat flow. ‐ Therefore.. [3‐6] q v 1 1 ( ) 2 c 500 To 800 To gr mm (1) In case of 2‐dimensional heat flow. preheating temperature. 2‐ dimensional heat flow model has to be used (high speed moving line energy source at thin plate). This type of investigation is very expensive and time‐ consuming. contribution to quality and reliability can significantly reduce the failure risk. specific thermal capacity. temperature‐time and temperature‐dilatation relationship. s Eef 1 1 2 500 To 800 To (4) (5) Fig. 3‐6 E ef q U I l v v t8/5 2 t8 / 5 1 1 500 To 800 To . An example of that influence is evident on Figure 8.. oC . the heat input can be determined by equation 2 and 3.arc weld efficiency.. thick material (a). This paper analyzes fine grain HAZ of T/P91 steel. temp. as this HAZ region is the most problematic due to creep in practical application.I. Maximal temperature: Tmax = 975°C.5 s. Investigation on specimens after weld thermal cycle simulation in HAZ 8 HAZ region in welded joint is narrow and materials in the HAZ are heterogeneous. Samardžić et al. T [°C] T [°C] 1400 1200 1000 B T/P91 A A T/P91 T/P91 750 . after PWHT (b).Heating speed: 150°C/s.TIG process 200°C slow cooling till 80 100°C min. while investigating the influence of PWHT at that temperature. Holding time on maximal temperature: 0. Many different microstructures arise in HAZ under the influence of weld thermal cycle. slow cooling till room temp. Fig. a) b) (b) 0 B . Fig. 11 Basics of welding technology of T/P91 to T/P91. Start of transformation of austenite into martensite (MS) is 405 °C and finish (MF) is 325°C. 1 h PWHT preheat interpass temp. before PWHT 4 200°C preheat interpass temp.770°C 600 max. 300°C 400 (a) 0 B . Cooling time between 800 and 500 °C: t8/5 = 20 s. 9 TTT diagram of P91 steel with chemical compositions Influence of weld thermal cycle and dilatation curve is shown in Figure 10b. martensite start and martensite finish temperature are determined after heating and cooling under controlled conditions. it was necessary to perform PWHT at 750 ‐770C (Figure 11).TIG process . Application of Weld Thermal Cycle Simulator in Manufacturing Engineering After welding of T/P P91 steel.770°C 600 max.SMAW or SAW process T/P91 800 200 A . Figure 12 shows micro structure of base material and Figure 13 shows microstructure of fine grain HAZ before PWHT (a). After weld thermal cycle simulation of P91 steel (Figure 9). temp. 10 Weld thermal cycle (a) and dilatation (b) of steel T/P P91 in order to determine martensite start and finish temperature. The following input data were used for weld thermal cycle simulation (Figure 10a): Preheating temperature: T0 = 200 °C. A . 300°C 400 200 PWHT Fig. T [°C] T [°C] 1400 1200 1000 B T/P91 A T/P91 A T/P91 750 . 13a Microstructure of fine grain HAZ (light microscope 1000). 12 Microstructure of base material (light microscope 1000) Fig. thin material (b).SMAW or SAW process T/P91 800 Fig. Duration of the simulation: tfinish =300 s. within the regime shown on Figure 10a. Slavonski Brod. (Croatia) [6] Samardžić. (Croatia) [7] Seyffarth‐Mayer‐Schaff.. 5 . A. Lj. Galović. Ispitivanje ovisnosti tvrdoće i radnje loma o vremenu hlađenja t8/5 nakon simulacije jednoprolaznog zavarivanja. M. I. Milović. Časopis Zavarivanje 36(1993)1/2.V. [2] Dunđer. Galović. 14 Results of Vickers’ hardness measurement before and after PWHT. [8] Vuherer. Martensite start and martensite finish temperature for fine grade zone in HAZ and investigation of influence PWHT in fine grade HAZ of modern steam boiler steel T/P 91 are determined as an example of application of weld thermal cycle method... Instruction of welding and review of steels for power plant equipment and possibility of using haz simulation in order improve weld joint quality.Application of Weld Thermal Cycle Simulator in Manufacturing Engineering I. Samardžić. I. (Croatia) [5] Lukačević. 211‐217..A. 81‐91. Dunđer. Samardžić. Primjedbe na računanje toplinskog inputa kod REL postupka zavarivanja sitnozrnatih visokočvrstih čelika. Vickers hardness [HV10] 400 350 300 250 200 150 100 50 0 OM BEFORE PWHT OM AFTER PWHT FG HAZ FG HAZ AFTER BEFORE PWHT PWHT Material/condition Fig. The results confirm strong influence of PWHT on hardness. Nestacionarnost temperaturnih polja kod zavarivanja. Disertation: Cooling time influence on hardness and toughness of microalloyed steels. I. 1992. It presents relationship between cooling time at weld thermal cycle simulating parameters and mechanical properties of weld joint in heat affected zone (HAZ). I.. 4th International Conference on Production Engineering (CIM). M.. Stoić. 13b Microstructure of fine grain HAZ (light microscope 1000) after PWHT Hardness results on Figure 15 show the influence of PWHT in fine HAZ after weld thermal cycle simulation. M. Opatija 12/13 VI. Three dimensional temperature field didtribution during welding. REFERENCES [1] Samardžić. Samardžić et al. 255‐258. Gliha. A.. I. 2010. Z. Welding conference. [3] Stahl Eisen Werkstoffblatt 88 /1993.. 1997. (Croatia) Fig. T. Časopis Zavarivanje 31(1988)2. [4] Samardžić. 2004. FSB. Grosser Atlas Schweiss‐ZTU‐ Schaubilder. Dusseldorf. which is very suitable for accelerated investigation of weldability and influence of PWHT on weldment properties. CONCLUSION This paper presents description of Smitweld TCS 1405 weld thermal cycle simulator. Zagreb (Croatia).. DVS. Stoić. Časopis Zavarivanje 36(1993)6. But there are still some limitations of this analytical solution. et al. sufficiently accurate approximate solutions can be obtained by computers using numerical methods.sk Dept of ME & MME. and cannot be solved analytically.An attempt of development of mathematical model of travelling heat source was made more than fifty years ago.19] are still limited to 2D heat source. [31] developed a model of temperature distribution during circumferential arc welding of spherical and cylindrical components using the finite element method and got very good results.y) plane but this solution is felt to find out temperature distribution along Z direction. WB. Study of temperature distribution of welded plates is very essential for designing submerged arc welding joint [14]. Kermanpur et al. Nguyen et al. It was revealed that for heat input of SAW process best suitable heat source shape was oval. wire feed rate. Nguyen et. Berhampore.tk Manufacturing Engineering & Management The Proceedings Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process Aniruddha Ghosh1‐ Sergej Hloch2‐ Somnath Chattopadhyaya3 1 GovtCollegeofEngg&TextileTechnology.These researches [10. This solution was an improved version of estimation temperature distribution near heat source area in (x. Akkus (2009) investigated the effect of sheet thickness.com 2 3 ARTICLE INFO: Category : Original Scientific Paper Received: 10 March 2012 / Revised: 30 October 2012 / Accepted: 11November 2012 Keywords: (in causal order) Gaussian heat distribution Oval heat source shape Submerged Arc Welding Abstract: An attempt is made in this paper to find out the analytical solution of the thermal field induced in a semi infinite body by a moving heat source with Gaussian distribution by selecting appropriate inside volume for submerged arc welding process. To estimate the temperature of the welded joints with deeper weld bead penetration. [26] again described an approximate analytical solution for double ellipsoidal heat source in finite thick plates. In such cases. p.[25] presented an analytical solution of transient temperature distribution of a semi‐infinite body subjected to three dimensional heat density of semi‐ellipsoidal and double ellipsoidal mobile heat source. Maheshwari et al. It is an effective tool for finding thermal stress and microstructure modeling. Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process . it is found thicker sheets have higher temperatures in weld zone. Chandra [9] described the extension of Rosenthal’s method for the estimation of thermal field in a pipe with a mobile heat source. and TUKE with a seat in Prešov. Citation: Ghosh A. India. this solution is valid only for identical radii and heat 6 . [4] investigated temperature distribution in RSW by applying metallographic method. i. voltage. current density on speed of cooling and distribution of temperature in resistance spot welding by experiment. stick out and the like are involved in submerged arc welding.com Faculty of Manufacturing Technologies. Heat generation in welding zone was affected by current density and sheet thickness.ISM.Contents lists available at www. [15] first described 3D double ellipsoidal moving heat source and calculated three‐dimensional temperature distribution through finite element modeling which could overcome the shortcoming of the two dimensional Gaussian model.6‐14.al. ISBN 978‐80‐553‐1216‐3 INTRODUCTION dissipation of rear and front ellipsoid. Then an analytical solution for transient temperature distribution for welded joint based on similar Gaussian heat distribution but different distribution parameters was introduced [19]. In spite of more laborious and time temperature distribution obtained by experiment has some Several critical input variables e. In this work.Dhanbad. Recently this shortcoming has been overcome by considering 3D heat source. current. Employing many simplifying assumptions in the mathematical model. electrode diameter. Email: sergej. 080 01 Prešov. Fachinotti.et al. Slovakia . Initially two dimension surface Gaussian heat source with effective arc radius was adopted to find out temperature distribution on welded plates and weld pool geometry [10].. Many researchers gave importance on experimentations for finding out temperature distribution of welded plates. [23] used thermocouples to measure temperature at different locations of GMA welded plates. 2ndInternational Conference Manufacturing Engineering & Management 2012. [20] investigated experimentally temperature distribution of GTAW process for butt weld. [11] proposed a semi‐analytical solution which was able to overcome the aforesaid limitations. (2012). lots of research works have been continuing on this area.The shape of heat distribution changes with variation of input parameters of SAW process [13].hloch@tuke. Very good agreement between predicted and measured temperature distribution data achieved assuming double ellipsoidal heat source. However this attempt indicated new direction for finding out temperature distribution on welded plates. Email: agmech74@gmail. D. V. Ravichandran et al. so these solutions are felt to describe the effect of penetration. Temperature readings are taken in every 10 seconds interval and temperature profile are generated for GMAW process which may be helpful to optimize the GMAW. [34] measured temperature between electrodes for RSW by applying thermal method and Bentley et al. After that. Their approximate solution can be directly used for simulation of welding of finite thick plate without the need for applying the mirror method as required in a semi‐infinite body. Email: somuismu@gmail. travel speed.India. Temperature distribution during welding depends on these welding process parameters as heat input is function of these parameters[16]. Veenstra et al.g.icmem. Many problems of welding encountered in practice involve complicated geometries with complex boundary conditions or variable properties.e. [27] considered radiative heat transfer.26 5.al. Here convection and radiation effect have been considered.34 3. The job was firmly fixed to a base plate and then the submerged arc welding was finally carried out. Table‐1 depict the weld parameters of SAW considered in present work.Ghosh et. 0. Table‐3 shows the temperature‐ dependent material properties (Mahapatra et. [8] analyzed a numerical model with the aid of the finite element package ANSYS for single pass single sides submerged arc welding of square butt joints and the distortion of welded joint was determined. Gutierrez and Araya [17] conducted the numerical simulation of the temperature distribution generated by mobile heat source by the approach of control volume. From the above.58 6.33]and Klobcar et.Researchers [11.1) except welding line 7 Job No.Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process by infrared thermometers (OMEGA SCOPE OS524E.002 cm. In this analysis. models for both conduction and convection are available.69 8.92 13. The chemical composition of work piece material is described in Table 1. if any. Bianaco et al. 2.[32. The experiments were conducted as per the design matrix randomly to avoid errors due to noise factors. Therefore a three dimensional thermal model was considered to analysis the heat transfer and the resulting temperature distribution. In arc welding. 2 Observed values for bead parameters EXPERIMENTAL METHOD C A.00 30.12 15.retifyer type power source with a 1200‐A capacity was used to join C‐Mn steel plates 30×15×2cm.Temperatures are recorded at different points of the welded plates (as shown in fig.023 0.al. The various material properties of metals in the molten state are also not authentically established.72 6.96 21.90 21. these efforts are still directed towards a proper modeling of convective heat transfer.38 2. reinforcement height are measured using digital venire caliper of least count 0. and viscous stress to find out temperature distribution.Ghosh et al.[12. Sabapathy et. They found that surface heat transfer strongly affected the temperature distributions in the workpiece.94 17. From the literature survey it is clear that the heat transfer mechanism in a molten pool is extremely complex and its physics is not well understood. The samples are prepared by standard metallographic process and the average values of the penetration. these efforts are still directed towards simple cases. P4) where reading of temperature was taken The job is cut at three sections of welded plates when flux has been used.03 0. MEMCO semi automatic welding machine with constant voltage.16 2. Although some progress has recently been made towards a proper modeling of convective heat transfer.1 cm root opening was selected to join the plates in the flat position keeping electrode positive and perpendicular to the plate.00 1. .25 1.90 22. [24] considered specific heat and thermal conductivity values for solid and liquid metal only.027 0. [5.basic fluoride type granular flux used. C‐Mn mils steel has been used.ESAB SA1(E8). 1 Representation of axes and identification of few points (P1. In their study.26] investigated analytical solution of thermal field based on heat conduction. P3. al.25. P2. Biswas. evaporation.01 0.05 The welding parameters were recorded during actual welding to determine their fluctuations. temperature range 2482 . till near about 10% error in prediction of transient temperature distribution was found. Assuming constant thermal properties of material. except for a small volume of metal. resolution 1 .58 0. it is clear that heat transfer mechanism in a molten pool is extremely complex and its physics is not well understood.315cm diameter.al.94 20.04 0.response time 10ms).28 4.0. and Mandal .No.2.76 1.Thermal Modeling: A three dimensional thermal model through approximate analytical solution is developed in the present work to analyze the heat transfer and temperature distribution in submerged arc welding.al[21]attempted to find out thermal field on welded plates for MMA welding process considering flatter and more evenly distributed heat than Gaussian and found excellent comparison with measured data. Fig. advantages. Voltage (V) Current (A) Travel Speed (cm/min) Penetration (mm) Reinforcement Height(mm) Bead Width (mm) 1 2 3 4 5 6 7 8 A1 A2 A3 A4 B1 B2 B3 B4 25 35 25 35 25 35 25 35 350 350 450 450 350 350 450 450 17 17 17 17 30 30 30 30 6. without considering heat lost through convection and radiation. Radiation and convection modes of heat transfer from work piece surfaces as well as variable thermophysical properties are taken into account. [6] investigated transient three‐ dimensional temperature distribution numerically by COMSOL Multiphysics 3. Tab.70 3. In the literature. Ohring and Lugt. The slag was removed and the job was allowed to cool down.6] numerically solved the two and three dimensional models for evaluating transient conductive fields due to moving heat source.18 0.36 1.But their investigation. Two pieces of C‐Mn steel plates were cut and V groove of angle 60o as per the standards were prepared. (2006)) used for the transient heat transfer and HAZ analysis. an attempt is made in this paper to find out the analytical solution of the thermal field induced in a semi infinite body by a moving heat source with Gaussian heat distribution by selecting inside volume of oval shape for submerged arc welding process. But practically the three modes of heat transfer occur in welding process.78 2. Sn Sl.78 2. Mundra et al. Bianco et.06 0. heat lost through natural heat convection is considered.13] investigated heat source shape for submerged arc welding procees.60 7.66 Material Properties: In the present analysis. most portions of work specimen remain in the solid state. accuracy is ±1% rdg or 2 which ever is greater. The measured values of weld dimensions and corresponding welding conditions are described in Tab. 1 Chemical composition of C‐Mn steel work piece (in %) Mn P S Cr Ni Mo Cu Al 0.coper coated electrode in coil from and ESAB brand . Tab. b=semi minor axis. Let us consider a fixed Cartesian reference frame x. has an important effect on the heat distribution pattern in the vicinity of the weld zone. et al. Heat Source Model: The heat source model.33 0. Arc efficiency is taken 0. b.ŋ=welding voltage. (4) V. Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process Temperature ( ) Thermal conductivity (W/mK) Specific heat(J/kgK) Thermal expansion coefficient(10 ‐6 / Young modulus(GPa ) Poisson ratio Tab. z) = A (1) [Where A is Gaussian heat distribution parameter and a. combination of semi ellipsoids is assumed to be an oval shape.2. (2006): 0 100 300 450 550 600 720 800 1450 1510 1580 5000 52 51 46 41 37. wherem=0. For this study. In present study it was found for experiments that shape of weld pool geometry was oval. Initially proposed a oval heat source (as shown in Fig. al. 1) and oval .37 0.28 0. z × Q0 / (2) Oval shape heat distribution equation is: q(x. double central conicoidal.7 29. y.equation of oval weld pool geometry was .3.7 42 450 500 565 630.oval heat source considered and found most suitable heat source shape. For analyzing the heat flow pattern on welded plates. It is in this region where the fusion zone and the heat affected zone are formed. .It can be realized from equation is fig.For job B4 of table‐2. All other thermal properties ware considered as a function of temperature.5 0. . However.Ghosh et. al. z) = / × Q0 (3) Here. The heat density q(x.5 36 31 26 29. an attempt has been made to accommodate the actual welding conditions as far as possible.It was found from . Assumption made in thermal model: In developing the thermal model. it is a 8 √ π . 1shapes. y. 3 Variation of thermo mechanical properties with respect to temperature of C‐Mn Steel (Mahapatra et. the following have been assumed in the thermal model of the welding process.(1988).3). z) at a point(x. Analytical solution: Transient temperature field of oval shape heat source in a semi‐infinite body is based on Fig. 1. then 2Q0 = or A= ∞ ∞ √ π ∞ ∞ ∞ q ∞ x.(1999). y. y. 1 .Q0=I×V×ŋ. In the literature.9 for submerged arc welding process.heat source shape for this study was assumed as an oval shape(as shown in fig.3) whose equation is . z as shown in fig. Semi major axis of one of these ellipsoids was af another was ar as shown in fig.5 773.3 Comparison of ellipse ( .3 1080 931 438 400 735 400 10 11 12 13 14 14 14 14 15 15 15 15.00002 0.5 200 200 200 150 110 88 20 20 2 0. the heat input can be treated as distributed heat source.2 0.3forthisstudy (1) Where af+ar=a= semi major axis. y. Density was remains constant and did not change with temperature change.5 0. These combination of two semi ellipsoidal shapes was called double ellipsoidal heat source configuration. al. many heat source distributions through Gaussian manner of inside volume ellipsoidal.2 Double ellipsoidal heat Source described by Henwood et al.(2011)that most suitable heat source is combination of two semi ellipsoidal shapes. z) with in oval shape is given by the following equation: q(x.5 combination of two semi ellipsoidal (one has major axis af and other ar).al. y. 1.31 0. m are oval heat source parameters] If Q0 is the total heat input.2.3) in which heat is distributed in a Gaussian manner throughout the heat source’s volume. Heat loss due to radiation.5 705. double ellipsoidal.It was found from literature (Nguyen et. Convective heat lost through all surfaces of welded plated. bell (2D). c.37 0.47 0. defining the distribution of the heat input due to the welding arc.I. current and arc efficiency respectively. was described(Ghosh et.Ghosh A. . 1(as shown in fig.00002 0. Fig.5 29. c=another semi‐principal axis of an ellipsoid whose 1 .42 0.34 0. In present work .(2011). experiment that shape of weld pool geometry is oval and equation of weld pool geometry for B4 job (of table‐2) is . So . .36 0.Double Ellipsoidal Heat Source Configuration i.e. It is therefore important to study the effect of heat input distribution on the size and shape of these zones. Iy / / Izdt’ / √ dT= Izdt’(as α / ) (20) / .15×B( experimentally found i. B. through weld pool measurement for submerged arc welding process).i. ρ is the density. Here: solution for the instant point source that satisfied the following differential equation of heat conduction of fixed coordinates (Nguyen et al. due to the linearity of equation (7). t. by assuming the body was initially at the homogeneous temperature T0. c is the heat capacity and k is the thermal conductivity of the plates of welded plates. z) at time t. z‐ ∆T(x.t. b= c= (16) (17) (18) (19) Values A.05 q (0) (11) ′ ′ ′ Q Finally. dz’ (13) ′ ′ x q x’. Then. the temperature increment at point(x. y. t’) applied at (x’. t’ =time. t’ G (x‐x’. temperature. y‐y’.( x’. t) is the temperature at point(x. y. 1999).C=Penetration and A = half of the major axis of oval shape=1. t) = . the temperature increment at any point (x.e. q (A. which is described below. z’. y’. z’. C are applied to find out the values temperature distribution of equation No‐16.t‐t’) = ′ ′ = (5) ′ ∞ ∞ Iz= Induced Temperature Field: Heat conduction in a homogeneous solid is governed by the linear partial differential equation k 2T + q = c A. z. the increase of temperature during this time is equivalent to the sum of all the contributions of the moving heat source during the travelling time as: (7) / ′ ′ ∞ q ∞ ′ ′ x ′ ∞ ∞ [ If we assume that the heat has been continuously generated from t’=0 throughout an infinite medium. y.r. 2005). y. specific heats of material are changed with change of temperature. y’. Mathematical expression of oval heat source is q(x. z) at time t is ∞ ∞ ′ ′ ′ x ′ ∞ ∞ Ix = ′ ′ = ′ = (6) ′ ′ Iy = Where T = T(x. t’) G (x‐x’. C are the Oval Shape Bead Geometry parameters. assuming the body to be infinite with an initial homogeneous temperature.0) =q(0) =0. t) = . z. B. t) –T0= . t) –T0= x’. ρ=mass density. z. y’. z) and at any instant t takes the form ∆T(x. z’) from t’=0. y. y. y. y’.B=half of the bead width. z’.when Ix =f(x)) I / ′ T(x. t‐t’) ′ ′ ′dt’ (10) Then the temperature induced by the oval heat source defined by equation is √ Ix has been calculated by applying numerical method taking appropriate values of integration upper and lower limit.The fundamental solution of equation (6) is the Green function. y. y. dTt’=transient temperature change dy’ (14) Calculation of Oval Shape Bead Geometry parameters: Let the A. y. t‐t’) Assuming that heat has been continuously generated at point (x’. y‐y’. z) at time t by instantaneous heat source of magnitude q (x’. z. y‐y’. I =f (x‐vt’).From equation No. t’ G (x‐x’.z‐z’. z’. 0. thermal conductivity. It has been literature (Goldak and Akhlaghi.Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process due to the point heat source dQ at time t’ . y’. y. y’. q is the heat source. Experimentally measured values A. B. G (x‐x’. z’) = location of instant point heat source dQ at time t’. z’. ′ (Where. c_p=specific heat.Moving Double Oval Heat Source Problem:Let us consider a heat source located at x = 0 at time t = 0 moves with constant velocity v along the x axis and heat emitted at a point(x.. z’) at instant t’.1 to 10. t‐t’) dt’ (9) ∞ ∞ ′ ′ ′ =[ Where α = k/(ρc) is the thermal diffusivity. z) and at instant t due to an instantaneous unit heat source applied at point (x’. the temperature field is defined by T(x. the temperature variation induced at point(x. z) at an instant t by the oval heat source. y. z. z) = √ π × Q0 / ′ ′ / I I dt’ I I I dt’ √ ′ / / a= ′ ′ dx´ ′ ′ ′ ′ ′ × (x) + ′ ′ ′ ′ ′ ]× (x) x (15) √ / / ′ dt´ Similarly. y’. C can be measured from weld bead geometry.e. it can be written that ρc α Q Q (12) I Q 9 / I √ dT= Iy kα Or Where α=thermal diffusivity. z‐z’. y‐y’. When heat source is moving with constant speed v from time t’=0 to t’=t. Equation (7) gives the temperature increment at point(x. z‐z’. y’. So to get better results again approximate solution of transient temperature distribution has been developed considering variation of thermomechanical properties w.Actually thermal diffusivity.Ghosh et al. z’) at time t’ is (8) q (x’. b. where T0 is initial temperature of base metals.Solution of this equation(equation 22)has been completed with the help of Horner’s method.182 T √ 10 T = 1 Q I Iy Iz dt´ Calculation of a.where T0 is initial temperature of base metals.Putting the mathematical expression in equation 20. Here x axis denotes time and Y axis denotes(T‐T0). RESULTS AND DISCUSION With the help of equation 22 and literature survey (Ghosh et.86 T 0. = (1- .182 T T I Iy Iz dt´ (21) Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (25. 0).Ghosh A.0675 T T 31.2 10 0. Prediction of Penetration Weld bead penetration of a structural steel is the region heated from atmospheric temperature (i. Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process a Or From data of thermo mechanical properties of table 3 and with the help of MATLAB.e. transient temperature was calculated and compared with measured data which are shown in fig.2 has been assumed for this study. 15.210 10 0. et al.1464 ).7 1. 20. 0).9 T 0. 273 ) to the melting point temperature of welded materials (i.86 10 T 31.01 √ = 52 Q / / 0.4. Here x axis denotes time and Y axis denotes (T‐T0). 0. So it can be written that Heat input (Q0) = c Q = (1- So. 2 0). equation can be written in this way when convective lost is assumed 0. Fig.. c have been done with the help of equations 17. 10 .dz=plate thickness=L) Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (25.(2011)). convective heat transfer coefficient h. Here x axis denotes time and Y axis denotes (T‐T0). Value of m is equal to 0. 8 Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source on (0.we get 2.2 10 T 10 0.18. dy.9Q (from table ‐8) d So.4Consideration of convection – Heat input (Q0) =Conductive heat flow ( (neglecting radiation) Let a block of dimension dx.19. .c have been done with the help of equations 17. relations between thermo mechanical properties and temperature have been developed which are described in table 7.0035 I Iy Iz dt´ b Or 0.where T0 is initial temperature of base metals.18.e. = (1- Q0=0. dz. c ) = (1- (as.4 Comparison of measured and estimated temperature distribution through analytical solution with the help of past history considering different types of heat source. Putting these values in the equation (22).It was found that most suitable heat source shape is oval. Calculation of a.b.0675 10 = T T T Q √ / T 0. 5. al.19.Solution of this equation (equation 21)has been completed with the help of Horner’s method. 0 1. .91 1. .723 ) temperature of welded material.No penetration(s) can be calculated at y=0.90 0.01 1.90 17. Tm melting point temperature of welded material. C’ are the oval Shape heat affected zone boundary parameters.90 0.66 24.90 0.58 5.7 20. half of weld bead(s) can be calculated at z=0.0 0.1 1. x=vt’.6 Predicted HAZ width(s) 1.9 0.92 0. = Or. Tab.5 0.2 1. Heat density at the boundary of heat affected zone =ρ×cp×(Thaz–T0).69 7.5 1.33 1.5 8.36 10 3.3 1.9 1..9 22.00 23. Heat density at the boundary of oval Shape Bead Geometry=ρ×cp×(Tmelt – T0).003 1510 0. . Putting these values in the equation (22) HAZ width(s) can be calculated at z=0.210 Regression coefficient R2(%) 52 96 99 0. q (A. 0) =q (0) 0.2 21.01 K data. .002 720 0.003 600 0.7 Mathematical relation of thermo mechanical properties and temperature Sl. where ρ density of welded material.90 0.8 Calculated values of (1‐ Tab. It has been found from literature [Goldak (2005)] that.26 9. where A’.000009 0.09 9.000015 0. Similarly.6 30.described in table‐3 (Thermal Temperature Thermal 2 1/2 ( ) diffusivity(m /sec) diffusivity) 0 0.0035 ) with the help of (1‐ ) 0. ′. 723 ) to the temperature just below the melting point temperature of welded materials (i.73 9.12 22.34 9. after that multiplying by two bead width(s).e. So.003 PREDICTION OF HAZ WIDTH HAZ width of a C‐Mn steel is the region heated from lower critical temperature (i. where Thaz is the lower critical temperature(i.4 1.000004 0.92 34.26 9.90 0.8 15.3 1.90 9. . 11 / Prediction of HAZ widthin alternative way Let. A.9 1.002 1450 0.3 1.90 .e.4 2.000007 0.90 0.9 1 2 3 4 5 6 7 8 1 2 Mathematical Model Tab.56 ∴ a= 2.70 7.1464 ).000010 0.4 α Tab.7 10 1. ′. = .004 100 0.9 6. the results are tabulated in table 5.000006 0.5 Comparison of predicted and experimental values of weld bead width Weld Bead Width Weld Bead Width % error (mm) (mm) (Experimental Values) (Predicted Values) 17.e.1 0.60 7.01 10 13.1 9 6. 1.32 1.08 10 5.28 5. where A.9 1.90 0.72 4. Relation with temperature thermo mechanical property Tab. cp is the specific heat of this material. Putting these values in the equation (22).003 550 0. .90 0.4 2.e.8 7.78 8.4 Comparison of predicted and experimental values of penetration Penetration Penetration % error (mm) (mm) (Experimental Values) (Predicted Values) 6. 1.22 1.Ghosh et al.e.05 0 . 723 ) to the temperature the melting point temperature of welded materials (i.9 21.90 23.2 1.8 4. – ρ ρ – Or. T0 is the atmospheric temperature. 0. B’. – – = . b= .000009 0.55 9.5 1. .2 1. x=vt’. 1464 ). . which are tabulated in table 4. t=t’= travel time of electrode.003 450 0.90 0. x=vt’. t=t’= travel time of electrode which are described in table‐6.91 9.96 19.9 PREDICTION OF WELD BEAD WIDTH Weld bead width of a structural steel is the region heated from atmospheric temperature (i. C are the oval shape bead geometry parameters. t=t’=travel time of electrode.03 9.000013 0.78 9.29 9.00 9. c= Let equation of oval Shape heat affected zone boundary (curve‐2) A’x2+ (B’y2+C’z2) f(x) =1.1 1.002 800 0.94 15.1 1. B. – – = ′ .47 9.000008 0. .12 1.4 1.000004 0.Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process Calculated HAZ width(mm) the help of equation ‐23 Calculated HAZ width(mm) the help of equation ‐22 Measured HAZ width(mm) with the help of hardness variation Value of B(mm) Sl No. equation of an oval Shape Bead Geometry Ax2+ (By2+Cz2) f(x) =1..004 300 0. 6) were carried out.156 cm or 1.84 kJ/mm heat input. It was found by measuring hardness (as shown in fig. Microstructure at the Heat Affected Zone.Ghosh A. a =1.1224 So. But. 0 0. This low hardness and prominent grain growth portion is the heat affected zone (HAZ). in few points. Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process As. Microstructure at the Heat Affected Zone (as shown in fig. So it can be written.1224×B (23) With the help of table‐2 and eqation‐23. This is the Heat Affected Zone.56mm (for the job‐A4. This is the Heat Affected Zone.t welded portion. a Microstructure at the non welded zone (as shown in fig.56 mm in both side at just below the fusion zone the hardness values (as shown in fig.6c) because temperature of this portion exceeded from recrystalisation temperature of the metal for a time.84 kJ/mm heat input.6 Microstructure Variation of welded plates Around 1. et al.5) and analysis of microstructure (as shown in fig. HAZ width is equal to 0. Fig.5c) of 3000 magnifications for 2. measurement of hardness on welded zone and non welded zone (as shown in fig.5b) are comparatively low.5c) of 3000 magnification for 2.1224×B Or.5b. Here more softening portions were found w. HAZ width(s) have been calculated which are also described in table‐6. Above description 12 . These are the softening portion of welded zone. Here more softening portion w. Negligible grain growth portion. HAZ width=0. b Hardness values are recorded at different grid junctions of the welded specimen (distance between two grid points is equal to 2 mm) b Microstructure at the welded zone (as shown in fig. these are the softening portion of welded zone Fringe plot of hard variation of submerged arc welded plates.Thaz = 7230C. prominent grain growth ware found9as shown in fig6b). Few points are prominent grain growth in this microstructure. VALIDATION OF PREDICTED DATA OF HAZ WIDTH To validate predicted HAZ width.5c) of 3000 magnification for 2. ′ the hardness values are low and prominent grain growth (as shown in fig‐6c) was found at just below the fusion zone.05q (0) and assuming atmospheric temperature is equal to 300C. (B’ –B) =0.5 Hardness Variation of welded plates Negligible grain growth portion was found form the analysis of microstructure at the non welded zone(as shown in fig6a) .84 kJ/mm heat input.Here.c) that at just below the fusion zone. C c Identification of different portion of submerged arc welded plates Fig.r.t welded portion (as shown in fig. heat input for the process is 2.84KJ/mm).r. Tmelt =14640C. That is why prominent grain growth ware found. (2011).. O.The similar phenomenon is also revealed in case of hardness. 15‐21.. Zhang.. . 199‐202.Prediction of Weld Bead Penetration. Springer. Press. P. G. A..November.In this study. O. J.Eng. Welding Journal. residual stress calculations and microstructure modeling. P. [8] Biswas.Washington. Brit Weld J. T. O. W.. 48. (1985). Proc. 21‐24. y‐ axis is perpendicular to welding line and z‐axis towards plate thickness. Both numerical and experimental results from this study have showed that the present analytical solution could offer a very good prediction for transient temperatures near the weld pool. 4. Technol. D. N.A.. [2] Ali.Ghosh et al. 7.3rd Int.Prediction of HAZ width has been made with the help of three dimension transient temperature distribution equation.D. Transient Heat Conduction in Solids Irradiated by a Moving Heat Source. (1983). Y. Bibby. IMechE Vol. on Engineering Systems Design and Analysis July 19‐22.al.. S. IMECE2003‐43545.. very good agreement between the calculated and measured temperature data indeed shows the creditability of the newly found solution and potential application for various simulation purposes. [15] Goldak. Transient Temperature Distribution& HAZ width of Submerged Arc Welded Structural Steel Plates. 5. Mech.Proc. P. M.2003 ASME Int.. Manca.pp. 178‐184.. Predominant direction of the grain growth is clearly observed from the photograph of the microstructure.. ESDA2004‐58286 7th Biennial Conf. [9] Chandra..Existence of prominent grain growth provides the confirmatory evidence of the HAZ softening phenomenon. G. CONCLUSION 1. Proc.. Greenwod.224 Part B: J.56 mm for 2. 10. (1963).71‐115. L.. Very good agreement between the calculated and experimental values.. N. A.100) for the heat input of 2. Tsai. 48 2397‐2406. Akhlaghi..Knowlson. In the context of this equation one can say that the hardness of the grain growth portion will also manifest lower values related to higher grain sizes. 2. L.. [12] Ghosh. M.(2006). Y. 94‐98. Thermomechanical Finite Element Analysis and Experimental Investigation of Single –Pass Single – Sided Submerged Arc Welding of C‐Mn Steel Plates’. This grain formation is distinctly revealed in the magnification (50.Heat distribution on welded plate is Oval shape for Submerged Arc Welding process and heat source parameters of this heat source can be measured from the dimension of bead geometry. such as thermal stress.. Zhang. 316‐317. Temperature fields produced by traveling distributed heat sources. Temperature distribution in spot welds’. In the grain growth portion of the welded region longer grains have been found depicting the chances of dislocation. Volumes 284 – 286. G. 627 – 639. 613‐619.. Naso. [16] Gunarajan.Congr. J. Advanced Materials Research. Determination of residual stresses due to girth butt welds in pipes. 2741‐2758. M. In the welded portion.pp 135‐152. Nardini. [14] Goldak. V. 68. 13 A. International Journal of Heat Mass Transfer. 62(12). paper n BN2. R. Nardini. 6. Chakravarti. N. Excerpt from the Proceedings of COMSOL User Conference 2006 Milano. (2009).6) and hardness analysis have been made.. Fig. Relativistic Heat Conduction.84 kJ/mm. Baker. as well as simulate the complicated welding path. [7] Bianco. [17] Gutierrez.Validations of calculated HAZ width through analysis of microstructure changes(comp.Conf.et.. grain refinement occurs in most of the region due to the heating and cooling cycle of SAW method. A. N. Murugan.. (2009) Temperature distribution study in resistance spot welding... [3] Ali. ASME J. Trans. (2004). Fluid Mechanics and Thermodynamics. (2005) Relativistic Heat Source’. low yield strength and low hardness values measured in Rockwell scale B. Ves. P.Transient temperature distribution on welded plate can be calculated with the help of Gaussian Oval shape Heat distribution technique. Very good agreement has also been found for this case.. Defect and Diffusion Forum Vols. analytical solutions for the transient temperature field of a semi infinite body subjected to 3‐ D power density moving heat source (such as oval shape heat source. Araya. REFERENCES [1] Akkus. Cardona. A.. (2005).Engineering Manufacture. . [4] Bentley. [10] Eager. (2011). Two Dimensional Transient Analysis of Temperature Distribution in a Solid Irradiated by a Gaussian Lesser Source’.. 2002. [13] Ghosh. [5] Bianco. A. (2003). IIW Doc.. V. Manca. J.. K.84 kJ/mm heat input in welding process which compares well with the above predicted HAZ width data as given in Table 6.Prediction of Temperature Distribution on Submerged Arc Welded Plates through Gaussian Heat Distribution Technique. It is also new technique which is not previously applied. N.. S. (2005). M.Selection of Appropriate Moving Heat Source Shape of Submerged Arc Welding Process proves that HAZ width 1. Manca. C. Numerical analysis of Transient Temperature Fields in Solids by a Moving Heat Source’.. Temperature Distribution in a finite Solid due to a Moving laser Beam. A.C. The analytical solution for oval shape heat source was used to calculate transient temperatures at selected points on a mild steel plates which are welded by taking x‐ axis along welding line. 1519‐1530. which is first time attempted in this work) were found and experimentally validated. 346‐355. Furthermore.. Hall Petch equation states the strength of the metal is to vary reciprocally with size of subgrain. S. International Journal of Heat Mass Transfer. [6] Bianco.Bead geometry dimensions have been calculated with the help of analytical solution (described in this paper). 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Ganesan.Numerical models of in‐service welding of gas pipelines. 223‐232. B. S.paper 45. Analytical Approximate Solution for Double Ellipsoidal Heat Source in Finite Thick Plate. Knowledge Workers in Manufacturing Sector. Knowledge worker’s 15 . For Robert Reich [19] knowledge worker is the one who engage in non‐ standardised problem solving using a range of analytic tools often abstract in nature. Data driven approaches see knowledge workers as all those who work in particular organisations or in particular sectors or institutions – sometimes under the dubious impression that knowledge workers make up the overwhelming majority of workers in such industries. WHO ARE KNOWLEDGE WORKERS Even though there is no common definition of the term knowledge worker. Knowledge worker. the worker may not know about it or may not understand its importance. This causes problems especially when organisation sees knowledge workers only as people with high degree of formal education and fails to see importance of “ordinary” employees like workers. there are problems with control. generally said. The keys to these workers’ success include creativity and innovation and incorporate occupations ranging from lawyers to bankers to Knowledge workers are people who. organisations in these industries need to deploy a wide range of complementary jobs with varying degrees of intellectual content [4]. Prague 3.tk Manufacturing Engineering & Management The Proceedings Knowledge Workers in Manufacturing Sector Ludmila Mládková1 1 Department of Management. Conceptual approaches explain the term knowledge worker from the complex point of view. Theory is accompanied by examples from manufacturing organizations. It is especially the tacit dimension of knowledge and the ability of knowledge workers to develop and use it that makes the difference between knowledge and non-knowledge workers. but this is not a rule. The first to use the term knowledge worker was Peter Drucker [6]. As for the methodology. he can use the knowledge in work. think for living [5]. Their work and productivity depend on their knowledge and ability to learn. Job content approaches see knowledge workers as people who do a certain type of job. The observer cannot see how a knowledge worker uses knowledge when working [11]. knowledge and knowledge work. Their work and productivity depend on their knowledge and ability to learn. conceptual definitions and approaches. think for living [5]. The process of work of knowledge workers is hidden. Employees’ importance for an organisation. 2nd International Conference Manufacturing Engineering & Management 2012. or experience. Other employees of the organisation have a limited approach to the knowledge. Davenport says that the primary purpose of a knowledge workers’ job involves the creation.cz ARTICLE INFO: Category : Professional Paper Received : 14 September 2012 / Revised: 14 October 2012 / Accepted: 22 October 2012 Keywords: (in causal order) Abstract: Knowledge Knowledge work Knowledge worker Management of knowledge workers Tacit knowledge Knowledge workers are people who. Lowe [13] limits knowledge workers to those with a university degree. even though they work with their hands [27]. Citation: Mládková L. distribution. data (industry) driven approaches. Thomas Davenport [5] sees knowledge workers as people with high degrees of expertise. pictures or other means. of intangible character. knowledge workers often work intellectually. Jack Vinson understands the knowledge worker as every employee who uses his brain more than his hands. Mahdon. and job content approaches [4]. When the worker leaves the organisation. maintenance people who often posses tacit knowledge important for their organisation. He states that a knowledge worker must be able to create and improve his technological knowledge or manage the technological knowledge of co‐workers. W. The paper provides the reader with a review of theoretical literature on knowledge workers and other related topic. Czech Republic. his knowledge is leaving with him. his style of work with knowledge. Fauth. even though they work with their hands [27]. R&D and high tech companies.icmem. 130 00. Brinkley. in practice. Major working tool and asset of knowledge workers is their knowledge. due to its tacit dimension. 16‐18. an engineer or a person who operates sophisticated technology. education. Knowledge is. definitions and approaches to knowledge workers can be classified into 3 different groups. However. notes. Due to the intangibility of tacit knowledge. by Drucker’s definition is a person who has knowledge important for the organisation and is often the only person who has it. Email:
[email protected] lists available at www. Alvesson [2] sees knowledge workers as people who work in knowledge intensive organisations. (2012). They help to explain role and importance of knowledge workers in organizations. Knowledge workers depend on their knowledge and ability to learn. The intangibility of knowledge is responsible for the difficulties managers face when managing knowledge workers. Method of storytelling is used for the example on how knowledge worker may be important in manufacturing organization. or application of knowledge. people in administration. First. Sveiby [20] takes the industry approach and relates knowledge workers with software and advertising firms. Knowledge workers often posses knowledge that is not widely available and even their managers do not have it. ISBN 978‐80‐553‐ 1216‐3 INTRODUCTION knowledge is partly subconscious. By Drucker. University of Economics Prague. p. generally said. Big portion of this knowledge is of tacit dimension and cannot be expressed by words. Theodoropoulou [4] conclude that economists often distinguish knowledge workers based on the investment expenditures in activities such as education and research and development. Churchilla 4. Knowledge is a major working tool and asset of knowledge workers. Alvin Toffler [22] understands the typical knowledge worker as a scientist. knowledge workers are difficult to manage. education and other factors are taken into account. even though they work with their hands [27]. a review of literature on knowledge workers was done by analysis of literature on knowledge workers. For Wiig [29] knowledge is the body of understandings. facts. management and consultancy. Martín de Castro and López Sáez [7] write. Kidd [12] identifies knowledge workers as people who work in design. The tacit dimension is hidden. Turban [24] writes that knowledge is information that is organised and analysed to become legible and usable for problem solution and decision making. thinking processes and meanings. an open system whose elements are different individuals able to create knowledge through time. physicians and accountants. How Knowledge Workers Work with Knowledge While working with knowledge. The quality and success of individual work with knowledge depend on talents and willingness of knowledge workers and on the environment the organisation creates for work with knowledge. All three processes of work with knowledge and the creation of knowledge can happen simultaneously. Knowledge sharing that is important for achieving group and organisational objectives and which may be very tricky in case of when knowledge is in the tacit form and when even a knowledge worker who is willing to share it may fail. through space and time. experiences. This article gives space for mentioning only some of them. of distinct authors stating characteristics Tab. 1 Main characteristics of knowledge workers [30] Knowledge. For example Woolf [28] sees knowledge as organised information used for problem solving. rules. people in technical and professional occupations and associate professionals. and processes and is easily communicated externally through data [25. Tobin [21] understands knowledge as information plus intuition and experience. analogies and models. As García Muina. Tacit knowledge is stored in peoples’ brains as mental models. Nomikos [15] classifies knowledge workers as a group that includes scientists. products. Individual knowledge creation is explained in the SECI model [18]. They are knowledge acquisition. three are crucial. explicit knowledge is combined through reasoning. Group members share their tacit knowledge through metaphors. generalisations. Capturing tacit knowledge and codifying it is one of the biggest challenges of knowledge management [3. attorneys.L. goes on through professional training and continues in the productive age. To be able to understand fully the problematic of knowledge workers. Mládková Knowledge Workers in Manufacturing Sector is information with context that provides the basis for actions and decision making. 1]. advertising. knowledge creation and knowledge sharing. the model of Ba [16] and the model of knowledge assets [17]. documents. knowledge workers are specific group of employees. Veber [26] defines knowledge as a changing system with interactions among experience. The process of knowledge acquisition starts in childhood. or it appears so because the human brain can work very efficiently and quickly. Knowledge creation which is the ability to create new knowledge. subconscious and even an owner of the knowledge may not be aware of it. a knowledge worker must have more knowledge that is actually needed for the creation of that knowledge [14]. marketing. and it is processed by the human brain. But he concludes that knowledge workers are highly qualified and highly educated professionals. drawings. knowledge workers execute and interlink different knowledge processes. caused by relations with other individuals or generally with the nature of the environment. Material and Tool for Knowledge Workers Knowledge is a major tool and source for knowledge workers. Tomlinson [23] identifies them as managers. Nonaka and Takeuchi [18] define knowledge as justified true belief. engineers. and skills and is difficult to communicate externally [25]. the organisational level and the inter‐organisational level. facilities. systems. 1]. it researchers to consultants [4]. Yau [30] collects and summarises ideas of different authors on knowledge workers. The organisational level creates rules and guidelines that influence the level of the group and individual. CHARACTERISTICS OF KNOWLEDGE WORKERS As mentioned in the introduction. finance and research. the term knowledge must be explained. individual knowledge is shaped by personal experiences. Transformation of tacit knowledge to explicit is difficult and often does not lead to good results. Kanter [10] says that knowledge 16 . Among many. dialogue and material sharing [14]. explicit and tacit [18]. Group level develops in the group. broadcasting. skills. professors. and abstractions that we carry with us on a permanent or semi‐permanent basis and apply to interpret and manage the world around us [14]. They happen on different levels: Individual level is a basic level. Knowledge acquisition when knowledge workers must acquire the necessary knowledge before they start to create values for their organisation. Knowledge itself can be defined and understood in many ways. values. The group level captures knowledge from individuals and from higher level systems. 12 2 Profession 8 Application of knowledge New breed/class Continuous development Creating new knowledge Finding exi‐ sting knowledge 7 7 6 6 6 5 5 5 5 3 4 5 6 7 8 Credentials 9 External controls 10 11 Knowledge sharing Social interaction Characteristics stated by Kelloway and Barling Commitment Characteristics stated by Kidd Primary characteristics of knowledge worker 1 Characteristics stated by Collins No/Rating Total no. Explicit knowledge is encoded in organisational formal models. If the organisational level is managed wisely. law. It is said that tacit knowledge creates 90% of knowledge we have. no group or organisation can learn and work with knowledge if its individuals do not learn and work with knowledge. relations. Knowledge can be classified to two groups. services. The tacit dimension of knowledge is responsible for the intangibility of knowledge work and specifics of knowledge workers. The trouble is that those most productive and most important may be invisible till they leave their organisation taking their knowledge with them. the machine did not start. Therefore the hall where the production line was located required to follow special rules for cleaning. Crawled close. During her first shift she turned out to be an excellent cleaner. The intangible character of knowledge leads to specifics of knowledge work. Finally. The new maintenance men did exactly what he saw John doing. The organisation had a group of devoted cleaning ladies who followed the rules rigidly. 17 . the most important part of knowledge work happens in the heads of employees even though the final result of their work has a manual character. Simply said. He repeated the process once again and then the technique was called to help him. they knew which chemicals to use and which were forbidden in this hall. bath or bus) syndrome. When he broke the leg and was hospitalised no one paid it special attention. Everything was shining. Many knowledge workers talk about the BBB (bed. The BBB syndrome means that the best ideas and solutions are often not invented during working hours in the organisation but when an employee finally relaxes [14]. The machine did not start. Mládková positively influences knowledge creation in group and individual levels [14]. CONCLUSIONS As examples show. the disaster later.Knowledge Workers in Manufacturing Sector L. When he returned to work. except of one old worker could do it. They worked so perfectly that organisation got use to it and took it for granted. Many of them make the final control of their product or service themselves [14]. managers. said yes. They met one Saturday in the factory and they were mixing and mixing till what the product of their effort was acceptable. designers. The cleaning lady The organisation in the machinery industry had a very specific production line. listen to the sound of the engine. and repaired it. It is strongly influenced by the cultural. power shifts from managers to subordinates. very sensitive to certain types of chemicals. knowledge employee in formal and position of the Power based on and power employee in power structures of the structures of the organisation organisation Work is Linear Non linear Way the Employee evaluates the employee Based on position situation and decides responds to and task the way to respond to it various situations himself Standards are By others Employee himself developed Control is Work and results of Employee directed to work Performance is Accordance with Employee contribution measured by standards Role of employee Tool Agent How to mix the sub product The organisation in the pharmaceutical industry used a special sub product for one of the drugs they were producing. When knowledge work is involved. ethical and legal background of the region [14]. It cannot be observed and controlled. repaired it and that was all. they had to disconnect two pipes of their production line. measurement and evaluation. Inter‐organisational level resembles the previously described levels. so they produced it only from time to time. Then they had to mix the sub product. Knowledge and not the material element is the major raw material for knowledge work. The maintenance men John was always brilliant in maintaining that huge machine in the middle of the assembly line. I deliberately give examples of people who may not be classified as knowledge workers for the first sight. e. Unfortunately the forbidden chemical was used. They have more knowledge and they often understand what they are doing much more than their managers. including the hall with that production line. EXAMPLES OF IMPORTANCE OF KNOWLEDGE WORKER FROM MANUFACTURING INDUSTRY To demonstrate above theory I decided to give three examples of importance of knowledge workers for manufacturing industry. John retired and the machine broke after some time. said yes. the real perfectionist. BASICS ON KNOWLEDGE WORK Due to its tacit dimension. which was very difficult to achieve. They needed only small amount every day and the sub product did not change in time. knowledge is of an intangible character. the machine started. The specifics of knowledge work are most visible when knowledge work is compared to non‐knowledge work. The results of knowledge work may differ from the short and long term perspective. Nobody. One of cleaners got ill and they hired new one. I did not use examples of employees who are usually perceived as knowledge workers like researches. difficult to do. knowledge workers are important employees who directly influence performance of their organisations. It was fun at the beginning. The same result. Cables and testing devices everywhere but the machine still refused to work. The assembly line stop for 48 hours. It was natural that they always called him to do this unpopular work. To do so. repaired it and nothing. more decision making rights and the right to control their subordinates. effects Links to Results immediate delayed Concentrated in Diffused in the heads of Knowledge the hands of employees managers Position of the Profession. which causes problems with standards. The proportion of drugs in the sub product had to be exact. costs were enormous and then suddenly. listen to the sound of the engine. So he crawled close again.g. As opposed to non‐knowledge work. organisations in manufacturing industry including. listen to the sound of the engine again. put them in the bucket and mix chemicals they contained. Soon the machine looked like a seriously ill patient in the hospital. Managers used to be the people who had more knowledge. said may be. Tab. He just crawl close. The table shows that the differences between knowledge and non‐knowledge work is considerable. they had to visit their colleague in the hospital to try to externalize his strange tacit knowledge. The growing importance of knowledge work changes power relations in organisations. These specifics complicate the management of knowledge work and knowledge workers. four other people were chosen to get training. and it is not linear. Nobody knew why. 2 Differences between knowledge and non‐ knowledge work Characteristics Major Raw Material Process of Work Work Visibility Non‐Knowledge Work Knowledge Work Material elements Knowledge Obvious Hidden High Low Direct and Non direct. Bantam Books. A Report on the New ‘Post‐Modern’World. Knowledge of knowledge workers is often tacit. MAHDON.. Vol. 1995. (1993): Knowledge Management Foundation. UK. pg. (2009): Knowledge Workers and Knowledge Work. K. (2002): The Knowledge – Creation Process: A Critical examination of the SECI model. et al. 7–15. [12] KIDD. Greece... (1954): Landmarks of Tomorrow. 8(2). [24] TURBAN..ac. John Wiley & Sons. Management Press.. O’CONNOR.pdf. R. Maxwell Macmillan. [29] WIIG. difficult to share and express in explicit form.. New York: Vintage Books. E. ANUMBA. [21] TOBIN. Management. Ba and Leadership: a Unified Model of Dynamic Knowledge. [13] LOWE. Vol. THEODOROPOULOU S. In BRINKLEY. N.S. E. E. (2000) SECI. University of York. R. P. Spring.uk/fac/soc/wbs/conf/olkc/a rchive/oklc3/papers/id151. p. California Management Review Vol 40.vinson. 1992. CHI94. SR. Syst. [accessed 15.. (2003): Defining Knowledge Work: a British and Hispanic Cross‐Cultural Study. 1 February 2000. 16 (4). Ch. University of Manchester.> [28] WOLF. I. J. Department of Computer Science. (1999): Knowledge mapping: Getting started with knowledge management. Long Range Planning.L.E. No. 1995.g. A Knowledge Economy Programme Report. Jaromír a kol. ISBN 0‐553‐29215‐3. N. G. Pages 5‐34. W. 516‐524. L. [15] NOMIKOS G. 5 ‐ 6 April 2002. 2010.com/Assets/Docs/Kn owledge%20Workers‐March%202009. p. 16–23. Merriam. CAMARRILLO. FAUTH. základy.. T. In [8] http://www2. [18] NONAKA I. Praha. B. TOYAMA. organisations are advised to work with this group of employees systemically and to find the way how to motivate them to share what they know. THEODOROPOULOU S. M. (2010): Knowledge in Context. (1995): Management of Knowledge Intensive Companies. ISBN 978‐80‐8078‐463‐8. F. 139‐172. M.pdf [9] 20. 1999.. Journal Knowledge Management. J. H. Wealth and Violence at the Edge of the 21st Century. (1997): The New Organisational Wealth: Managing and Measuring Knowledge‐Based Assests.2009. 1997. Iura Edition. KAMARA. (2006): Prototype System for Knowledge Problem Definition. 1999. [23] TOMLINSON M. http://www. KONNO. 16(4). [26] VEBER. globalizace. E. I.3 Spring [17] NONAKA I.. J. (1989): Managing Knowledge Workers for Productivity. Volume 33. F. R. The Third European Conference on Organizational Knowledge. Berrett‐Koehler.warwick. [27] VINSON. NY. Schema Press. 2 (2). 20–27. National Productivity Review. M. OKLC 3. Oxford University Press.theworkfoundation. K.8. I. (1999): The Learning Economy and Embodied Knowledge Flows.. When organisations loose knowledge workers. knowledge they manage to capture is often the fragment of his knowledge. A. (1990): Powershift: Knowledge..2011 14:16. 18 . A Knowledge Economy Programme Report. (2005): Thinking for Living. (1998) The concept of “Ba’: Building foundation for Knowledge Creation. Inf.ISBN 1‐56000‐622‐6. Mládková Knowledge Workers in Manufacturing Sector [14] MLÁDKOVÁ. prosperita. 132. (2000): Management.com. [4] BRINKLEY. [25] VAIL. Iura Edition. Syst. (1992): The Work of Nations. KONNO. [3] BAIR. A M.2009] <www. MAHDON. P. May. SR. De Gruyter. p. J. Transaction Publisher London. and C. Learning and Capabilities. A. Human Factors in Computing Systems. TAKEUCHI. LÓPEZ SÁEZ. To minimise problems with knowledge workers and their knowledge.: Knowledge Workers and Knowledge Work.. (1990): Webster’s New World Dictionary of the American Language. 20. p. G. (1995): The Knowledge Creating Company: How Japanese Companies Create the Dynamics of Innovation. M. [11] KELEMEN J. H. (1992): Expert Systems and Applied Artificial Intelligence. (2012) Management of Knowledge Workers. (2002): Leveraging the skills of Knowledge Workers. 11. G. [22] TOFFLER. Athens. New York. [7] GARCÍA MUINA. P. [30] YAU. 2003. Centre for Research on Innovation and Competition. e. Issue 5. (1998): The state of the product in knowledge management. [16] NONAKA.3. D. F. ISBN 1‐59139‐423‐6.. MARTÍN de CASTRO. Isuma.2011 14:29 [10] KANTER. 1990. E. ISBN 0‐19‐509269. Discussion paper 26. [5] DAVENPORT.7.. (1994): The Marks are on the Knowledge Worker. R. [19] REICH. J. 1989. [2] ALVESSON. REFERENCES [1] AL‐GHASANI. Management. [6] DRUCKER.. (1999): Knowledge management: Practically speaking” Inf. [20] SVEIBY. Issue 1. M. J. (1996): Transformational Learning – Renewing Your Company Through Knowledge and Skills. Vol. ISBN 80‐7261‐029‐5. Boston. HVB School Publishing. FAUTH. H.7. Journal of Construction Engineering & Management. CBR 11%. DEA. employment relations. service. manufacturing capability. management. Agarwal et al. the hierarchy of supplier selection criteria was developed. and case‐ based‐reasoning (CBR) systems as the decision methods for pre‐qualification of suitable suppliers. data envelopment analysis (DEA). Based on an extensive literature survey Bruno et al. Supplier selection problem is a multiple criteria decision making (MCDM) problem typically having conflicting criteria that include both qualitative and quantitative measures. Firstly. service attitude. ISBN 978‐80‐553‐1216‐3 INTRODUCTION programming models 17%. GP. Integrated AHP and TOPSIS Approach for Supplier Selection . Analytic Hierarchy Process (AHP) 15%. and criteria based decision making methods such as ELECTRE and PROMETHEE 7%. equipment and capability. communication system. One of these activities is purchasing. followed by delivery. Istanbul. reputation. procedure legality. [3] present a review of decision methods reported in the literature for supporting the supplier selection process. mathematical programming models.tk Manufacturing Engineering & Management The Proceedings Integrated AHP and TOPSIS Approach for Supplier Selection Bahar Sennaroglu1 ‐ Seda Şen 2 1 Marmara University. Turkey. Based on a literature review of 78 journal articles from 2000 to 2008 on MCDM approaches for supplier evaluation and selection Ho et al. multi‐objective programming. cluster analysis. efficiency. and artificial intelligence‐based models as the decision models for making a final choice among suitable suppliers. guarantee and compensation. Citation: Sennaroglu B. Supply Chain Management (SCM) is a process of organizing the activities from the customer’s order through final delivery for speed. Analytic Network Process (ANP) 5%. The company purchases cap screws from the domestic market which are raw materials for the production of contactors. The integrated AHP and TOPSIS approach employed for supplier selection problem can be applicable to any other selection problem. mixed integer non‐linear programming. finance. They report the distribution of MCDM methods used in these articles by DEA 30%.icmem. historical performance. and safety and environment. price/cost. p.Contents lists available at www. They present linear weighting models. business relations. technical capability. [4] review sixty‐eight articles from 2000 to 2011 to find out the most prominent MCDM methodology followed by the researchers for supplier evaluation and selection. technology. They define pre‐qualification as the process of reducing the set of all suppliers to a smaller set of acceptable suppliers and present categorical methods. previous image. management and organization. There is a need to have strong relationship and integration with its suppliers for a successful Supply Chain Management (SCM) system. maintenance service. simple multi‐attribute rating technique (SMART) 3%.tr 2 ARTICLE INFO: Category : Original Scientific Paper Received : 19 September 2012 / Revised: 24 September 2012 / Accepted: 2 October 2012 Keywords: (in causal order) Abstract: AHP Supplier selection TOPSIS The study was conducted for a company which manufactures low voltage switching devices.edu. the integrated AHP approaches with other techniques include bi‐negotiation. [7] use the fuzzy TOPSIS method for supplier selection problem. (2012). industrial reputation. mutual negotiation. The objective is to select the most suitable supplier among four alternatives for a company manufacturing low voltage switching devices. [5] conclude that AHP‐based models are useful in constructing structured and formalized approaches for supplier evaluation and can be used in combination with many other approaches. and fuzzy set theory. It needs to select its main supplier for purchasing cap screws to work collaboratively in its supply chain. Finally. Email: seda. whereas the most popular integrated approach is AHP–GP (Goal Programming).com. Turkey. flexibility. This study uses a methodology which combines AHP and TOPSIS methods for a supplier selection problem. The company purchases cap screws from the domestic market which are raw materials for the production of contactors. geographic location. Istanbul. They also conclude that the most popular criterion used for evaluating the performance of suppliers is quality. the objective of this study is to rank the four different suppliers of cap screws and select the most suitable one as the main supplier. Then the weights of criteria were determined using the Analytic Hierarchy Process (AHP). previous sales. financial situation. fuzzy set theory 10%. Due to strategic importance of supplier selection process. 2nd International Conference Manufacturing Engineering & Management 2012. De Boer et al. SCM has an increasing importance in today’s competitive business world and companies need to have strong relationships and integrations with their suppliers for a successful SCM system. Therefore. mathematical THE ANALYTIC HIERARCHY PROCESS (AHP) AHP was developed by Thomas Saaty [8]. extensive research has been done on supplier selection criteria and methods. genetic algorithm (GA) 2%. Chen [2] uses DEA technique to screen potential suppliers and then TOPSIS method to rank the candidate suppliers. and quality [1]. the ranking and selection process was carried out by the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). risk. delivery. 19‐ 22. Email: bsennar@marmara. production control ability.tr ING Bank. research and development. Chen [2] summarizes important criteria for supplier selection from the literature as price. DEA and artificial neural network. The AHP weights were used in applying TOPSIS method. total cost of ownership models. statistical models. quality. Şen S. training ability. grey relational analysis. packing ability. [6] conclude that the most prevalent individual approach is DEA. Chen et al.sen@ingbank. AHP decomposes a complex MCDM problem into a system of 19 . relationship. 0 Ci 1 Si Si Step 6. The comparison matrix A is standardized by dividing the elements of each column by the sum of the elements of the same column.1.B.. The separation of each alternative from the positive ideal solution: aij ajk = aik ... 1 Scale used for pairwise comparisons Value (aij) Definition Explanation i and j are equally important i is slightly more important 3 weak importance than j i is strongly more 5 strong importance important than j very strong i is very strongly more 7 importance important than j extreme i is absolutely more 9 importance important than j 2. and k The consistency ratio (CR) is used to test consistency: Si CI RI n n CI max n 1 1.. The value of nmax is calculated from: Ci Si i 1. m ij The separation of each alternative from the negative ideal solution: Si n (v j 1 ij v j )2 i 1. v A min v | j J . The normalized value rij is calculated as: The procedure for the determination of the relative weights is as follows [11]: Assuming that there are n criteria at a given level of the hierarchy. Calculate the relative closeness to the ideal solution: where CI and RI are the consistency index and random consistency index of A.. the relative weights must be established for each factor (alternatives. Its steps are as follows [9]: Step 1.. m v . Letting aij define the element (i. the columns of the normalized matrix N are identical. The weighted normalized value is calculated mxn as vij ( w j )(rij )i 1. 2. respectively. Senaroglu..... 2..….. j 1. Step 3... Step 4.. i 1.. The TOPSIS method evaluates the decision matrix X x hierarchies [9]. m. TOPSIS is a multiple criteria decision making (MCDM) method to identify solutions from a finite set of alternatives. i 1. v . A. v .2. Determine the positive ideal solution (PIS) and negative ideal solution (NIS) A : max v | j J . Tab. 2.98(n 2) RI n CR n (v j 1 v j ) 2 i 1.. using the n‐ dimensional Euclidean distance.. a comparison matrix A is consistent if: Aw nmax w ij which refers to m alternatives which are evaluated in terms of n criteria and denotes the performance measure of the ith alternative in terms of the jth criterion. m v . Otherwise. If the decision maker exhibits perfect consistency in specifying the entries of the comparison matrix A.. The sum of column elements of the resulting normalized matrix N is equal to 1. the procedure establishes an n n pairwise comparison matrix... The preferred alternative should have the shortest distance from the positive ideal solution and the farthest distance from the negative ideal solution. m Step 5. Consistency in judgment requires that aij = k automatically implies that aji = 1/k. 2.. the inconsistency is high and the decision maker is advised to revise the elements aij of A to realize a better consistency. nmax n If CR 0. Once the hierarchy has been structured. 4.. 2. 2. attributes. m..... Mathematically. Calculate the normalized decision matrix R r where m is the number of alternatives and n is . Application of the integrated AHP and TOPSIS approach for supplier selection The hierarchy of supplier selection criteria was determined through interviews with the decision makers 20 mxn the number of criteria. the level of inconsistency in the comparison matrix A is acceptable...n) where all the diagonal elements aii of A must equal 1. 2. . Calculate the separation measures..2..j) of A.. for all i. the pairwise comparison is made such that the criterion in row i (i=1. m.n) is ranked relative to every other criterion in column j (j=1.... Calculate the weighted normalized decision matrix V vij . Şen Integrated AHP and TOPSIS Approach for Supplier Selection The Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) Yoon and Hwang [12] introduced the TOPSIS method based on the idea that the best alternative should have the shortest distance from the positive ideal solution and farthest distance from the negative ideal solution.. v A ij i i ij 1 2 n ij 1 2 n ij i i where J is a set of benefit criteria and J´ is a set of cost criteria. Step 2. or criteria) on a given level with respect to each factor on the level immediately above it by using pairwise comparisons (Table 1) among the factors on the given level [10]....…. The relative weights are computed as the row average of matrix N. n m xij2 i 1 The normalization is done for convenience of comparison by converting different units of criteria to a unified unit. j 1. where a higher Ci would mean higher preference. n where w j is the weight of the jth criterion and n w j 1 j 1 . S. 6. Rank the alternatives with respect to Ci in the descending order. 2. max v | j J .. used when a compromise intermediate values 8 is needed 1 equal importance ij mxn xij rij i 1.. 2.j... min v | j J .. and thus it was selected as the main supplier of the company for purchasing cap screws. In order to determine the relative weights of the sub criteria within their main criterion. According to the preference rank order of the best alternative was Supplier A. B. the number of matrices was reduced from seven to six. When the level of inconsistency was found inacceptable. 4x4. and D) in terms of 21 sub criteria under 7 main criteria. the pairwise comparison matrix (a 7x7 matrix) for the main criteria was prepared by the consensus of the decision makers of the company. in the company (Table 2) and accordingly the hierarchical structure of the problem was developed (Figure 1). and 3x3 matrices) were prepared by the consensus of the decision makers. separately On time payment Abide by payment conditions Type of payment Sub Criteria Label Q1 Q2 Q3 Q4 C1 C2 C3 D1 D2 D3 D4 M1 M2 PC1 PC2 PC3 PC4 HS1 PT1 PT2 PT3 Fig. 3 presents the weights found using AHP method and application steps of the TOPSIS method. The decision problem has 4 alternatives to be evaluated under 7 main criteria and 21 sub criteria. Firstly. delivery. a 2x2 matrix is always consistent. C. 1 Hierarchical structure of the supplier selection problem The composite weights of criteria were determined using AHP. Technology and Flexibility Holding Stock Payment Term Sub Criteria Quality inspection methods Percentage of refused products High quality employee Product performance Discount dependent on purchasing quantity Outsourcing costs Holding costs Delivery speed Just in time delivery Transportation costs Flexibility on delivery time Holding stock on desired quantity Supplier’s adaptation to requested quantity Utilization of the capacity Product variety that can be produced by the supplier Operation amendment tendency Able to respond to changes of quantity Special stock holding for the firm. Since a single sub Fig. The inconsistency of each pairwise comparison matrix was examined by CR except the 2x2 matrix. S. all criteria were benefit criteria. The decision matrix for the TOPSIS method was formed with the decision makers’ evaluations of 4 supplier alternatives (Supplier A. 2x2. six pairwise comparison matrices (4x4. Therefore. The company strategy was to set up strong and long term relationships with one selected supplier to overcome quality.Integrated AHP and TOPSIS Approach for Supplier Selection B. the elements of the related matrix were revised with the decision makers. The computations were carried out using Excel 2010. and cost problems. 2 Hierarchy of supplier selection criteria for the company Main Criteria Quality Cost Delivery Time and Transportation Minimum Order Quantity Production Capacity. Şen criteria existed with respect to holding stock. Tab. As an evaluation scale a 0‐100 scale was used where 100 represented the best value and 0 represented the worst value for an alternative with respect to a criterion. The composite weights of criteria were found by multiplying each sub criterion weight by its related main criterion weight. Fig. 4x4. Since the columns of any 2x2 comparison matrix are dependent. 3x3. 2 Computations for integrated AHP and TOPSIS approach 21 . Senaroglu. . Senaroglu. [5] Bruno. E. S. pp. Şen Integrated AHP and TOPSIS Approach for Supplier Selection [4] Agarwal. 289–301 [8] Saaty. H. Multi‐criteria decision making approaches for supplier evaluation and selection: A literature review.‐L.. A fuzzy approach for supplier evaluation and selection in supply chain management.. 2007. C.. L. X. Singh V. http://dx. New Jersey. [7] Chen. Sahai. Genovese. International Journal of Production Economics. [6] Ho. 22 .‐T..V. Y.‐F. The Analytic Hierarchy Process. REFERENCES [1] Meredith. A Review of Methods Supporting Supplier Selection. 1995. AHP‐ based approaches for supplier evaluation: Problems and perspectives. Project Management: Engineering. European Journal of Operational Research.001.. S. Kluwer Academic Publishers... Hwang. New Jersey. 1980. Prentice Hall. 16–24. Multi‐Criteria Decision Making Methods: A Comparative Study.. pp. Operations Research: An introduction. F. [2] Chen..org/10.. Bard. Esposito. 8e.. 181 (2011). (2012). A.. A. Bag. The proposed methodology can also be applied to any other selection problem involving multiple and conflicting criteria. 1994. Information Sciences. Structured methodology for supplier selection and evaluation in a supply chain. 102 (2006). J. 3e. Sage Publications. Labro.05. The integrated AHP and TOPSIS approach is proposed as an efficient and effective methodology to be used by decision makers on supply chains in terms of its ability to deal with both qualitative and quantitative performance measures. K. [3] De Boer.pursup. Xu.B. Technology and Implementation. 801–810. M. [11] Taha. W. P. 202 (2010). R.. J. 2 (2011). T. California.. John Wiley. Mishra. Journal of Purchasing and Supply Management. Multiple Attribute Decision Making: An Introduction. [10] Shtub. E. 2007.1016/j. International Journal of Industrial Engineering Computations. S. Dey. pp. 1651–1670. C.. [12] Yoon. M. pp. extensive research is being done to cope with this MCDM problem. Globerson. L. New York. companies prefer to work closely with a few suppliers or dependable one supplier in order to achieve and maintain high supply chain performance. [9] Triantaphyllou. C. G. As a result. M.‐T. K. 75–89. P. S. Due to strategic importance of supplier evaluation and selection process. Shafer. pp. A. A review of multi‐criteria decision making techniques for supplier evaluation and selection. P.‐J. Operations Management or MBAs. McGraw Hill. New Jersey. 7 (2001). P.doi. Lin. Huang. European Journal of Purchasing and Supply Management. Dordrecht. This study presents an integrated AHP and TOPSIS approach with an application to supplier selection decision problem of a company.. 2012. Pearson Prentice Hall. Morlacchi. Passaro. 2000. CONCLUSION Managing the links between the suppliers and customers successfully in a supply chain necessitates their active collaboration. R. E. Hloch S. which is assumed to be independent from the axial coordinate. z p L z . Italy. 1 (2) Coshzq Coshq (3) are respectively the Sommerfeld solution for the cavitated infinite long bearing [2] and Warner’s flow correction factor with q and indicated in the following relations: q2 2 dp h 3 L d d L h 3 D p L 2 d Where is calculated from equations [2]: 2 2 cos 1 2 sin 0 2 2 sin 1 2 cos 0 ANALYSIS (4) and pa the pressure for 0 . is: h C (1 cos ) y W e x P assuming the film pressure distribution proposed by Warner [1] : (1) pw . [4]. University of Salerno. The thickness of the oil film. the use of pure numerical transient analysis incurs the computational expense of solving the two‐dimensional Reynolds equation with the numeric methods in order to determine the fluid film force at every time step of the numerical integration procedure of the motion equations. such as the time transient analysis. In the present paper a analytical approximated fluid film force in finite journal bearing is proposed. Citation: Ruggiero A.1 Notations for journal bearing The dimensionless force components fr e ft are obtained by integrating the pressure over the film domain: 23 t . Email: ruggiero@unisa. 23‐26. Email: sergej. ISBN 978‐80‐553‐1216‐3 INTRODUCTION The analytical approach to analysing the behaviour of a system is more effective than a numerical investigation and makes it possible to cover not only the individual case but also the whole class to which the system in question belongs. With reference to the journal bearing in Figure 1 the pair of coordinates . Furthermore the model proposed allow us a quickly analytical determination of the stiffness and damping coefficients.it Faculty of Manufacturing Technologies TUKE with a seat in Prešov. Method to determine the analytical approximate descriptionof non‐steady fluid film force in fluid film bearings .tk Manufacturing Engineering & Management The Proceedings Method to determine the analytical approximate description of nonsteady fluid film force in fluid film bearings Alessandro Ruggiero1 ‐ Sergej Hloch2 1 Department of Industrial Engineering. The analysis is based on the description of the pressure field in the gap using the Warner’s flow correction factor [1]. p.Contents lists available at www. requires an analytical model in order to provide a rapid description of the hydrodynamic force field governing the interaction between journal and bearing.hloch@tuke. The description of the analytical fluid film force proposed allow us the analytical determination of stiffness and damping coefficient and the analysis of the stability of journal’s orbit for values of imbalance assigned [3]. R 1 2 sin cos p L p ( ) p a 6 22 C 2 1 1 2 1 cos 1 cos and: z . The analysis of many aspects of the dynamic behaviour of a rotor on lubricated bearings.icmem. The analysis has been conducted assuming the Warner solution for the pressure field. Slovak Republic. 2nd International Conference Manufacturing Engineering & Management 2012. z identifies the generic point T on the internal surface of the bearing while the intersection point P of the journal axis on the bearing middle plain is identified by the pair of coordinates e.sk 2 ARTICLE INFO: Category : Preliminary Communication Received : 21 October 2012 / Revised: 11 November 2012 / Accepted: 12 November 2012 Keywords: (in causal order) Analytical fluid film force Hydrodynamic lubrication Journal bearing Stiffness and damping coefficients Abstract: A theoretical analysis is carried out to determine the analytical approximate description of the fluid film force of a symmetrical rigid rotor supported on two lubricated journal bearings. In fact. (2012). The analytical approach to analysing the behaviour of a system is more effective than a numerical investigation and makes it possible to cover not only the individual case but also the whole class to which the system in question belongs. where: T r Fig. .A. K xy x . Tan x . Hloch 1 fr f t 1 p L Method to Determine the Analytical Approximate Description of Non-Steady Fluid Film Force in Fluid Film Bearings cos d dz sin (5) On the other hand the differential equation of motion in reference rotating frame can be write in the following form: 1 3 M 2 6 f r . dimensionless pressure.7 and 8 are shown the orbit of the centre of the journal.0 bilt‐in function. f r ( 2 2 4 ) 2 0 (1 2 )3 / 2 (2 ) 1 2 2 (12) x2 y2 Mx f x x. . for various aspect ratios L/D (Constantinescu map [ 2]) Where with S 2 RL R . x y . Stiffness and damping coefficients are required for both synchronous response calculations and linear stability analysis and they are determined as follows: with: . I3 cos 2 d . x. y. y 0 C yx f y x 0 0 4 2 22 4 4 ( 2 4 ) . The orbit have been obtained integrating the differential equations (6) with a Mathematica 4. dimensionless mass.6. . y xy xy f x .5. were: I1 f y f y f x f . x. x 0 where the subscript "0" denotes that they have to be evaluate at an equilibrium position. . The analytical determination of the stationary derivative of the fluid film force components fr . On the other hand we can obtain the dimensionless force components fx and fy whit simple transformation: f x sin f y cos cos f r sin f t f r f 2 2 . I2 sin 2 d . h I6 h2 sin cos h2 d sin cos d h (10) f r 0 Substituting the (10) and (9) in (8) we obtain the analytical expression of fluid film force components fr and ft in explicit form (see Appendix). f r 22 1 2 I 4 I1 I 6 I 3 . M 0 W C p0 2C M0 R p0 6 C 2 In Figures 3. r 2 2 4 0 f t 0 (11) f t . ft 22 STIFFNESS AND CALCULATION (8) 1 1 tanh q ) q (9) C xx I4 sin 2 d .2 Full journal bearing. xx yy C yy and setting: oxy f x . M .7) to get the analytical expression of stiffness and damping coefficients. y 1 My f y x. The dimensionless fluid film force components fr and ft can be write in following form: 1 2 I 6 I 3 I 5 I 2 . . cos S 2 1 3 M 2 6 f t . critical mass versus Sommerfeld number. sin S 2 (6) Fig. ft (the infinitely long bearing model components) and q will make possible with (2. p p . y S 0 (2 2 2 4 ) (4 3 4 6 ) 1 2 f t 0 2 1 2 f t we obtain the differential equation of motion in reference fixed frame: 0 q (13) 24 C xy 2 x2 y2 f y . S. dz 2(1 DAMPING 2 (2 ) 1 2 2 8 4 2 6 4 3 6 4(2 2 2 4 ) 1 2 0 (1 ) 2 2 ( 2 3 2 1 ) 2 2 2 2 2 2 (2 2 ) ( 2 3 2 2 1 2 ) 1 2 . M SW . y 0 2 2 2 .. using the Warner’s flow correction factor. for fixed operating condition indicated in Figure 2. (7) are identified the Sommerfeld number. reference mass and reference pressure.. Ruggiero. K yx x 0 y 0 y 0 x 0 K xx COEFFICIENTS The dynamic system oil film bearing can be modelled by means of stiffness and damping coefficients for small motions about the journal equilibrium position. h I5 h2 cos 2 d . .4. y. K yy . 91. L/D=2 -0.75 -0. S.25 0.25 0.75 1 -0.5 -1 -0.5 0.5 -0. S=0.25 by setting: 0 -0.75 1 0.63.Method to Determine the Analytical Approximate Description of Non-Steady Fluid Film Force in Fluid Film Bearings q A.75 1 0.5 -1 Fig.25 0.25 -1 -0.75 -0.25 -0.5 -0.5 -0.5 (Point E Constantinescu map) (Point B Constantinescu map) 25 .25 -0.75 -0. Hloch 1 And 0. S=0.5 -1 Fig.25 Assuming as parameter of stability m as done by others authors: -1 CM 2 m W 02 0.75 1 0.5 0.5 -1 -0.31.25 0. S=3.3 Orbit of the journal for approximate finite model journal bearing with : M=1.5 (Point D Constantinescu map) 1 (Point A Constantinescu map) 0. S=3.25 0.75 -0.63.25 0.75 -0.5 -0.75 1 -0.75 -1 Fig.5 0.75 -0.5 0.5 0.6 Orbit of the journal for approximate finite model journal bearing with: M=11. L/D=1 -0.4 Orbit of the journal for approximate finite model journal bearing with: M=2.5 -0. L/D=0.5 -0.25 0.25 -0.75.25 0.5 0.75 1 0.25 0. S=0.25 0. L/D=0.5 -0.75 0.5 0 0.75 -1 Fig.25 -0.75 1 -0. Ruggiero.75 0 0.14.55.75.14.75 -0.5 0.25 -0.5 -0.75 K xx C yy K yy C xx K xy C yx K yx C xy C xx C yy -1 K xx 0 K yy 0 K xy K yx Fig.25 -1 -0. L/D=1 C xxC yy C xy C yx the value of m at threshold of instability is: (Point C Constantinescu map) 1 m0 20 0 0.14.75 0.5 Orbit of the journal for approximate finite model journal bearing with: M=8.7 Orbit of the journal for approximate finite model journal bearing with: M=15.25 0. [2] Constantinescu V. ft Load Dynamic viscosity Eccentricity Eccentricity ratio Attitude angle Aspect ratio Journal mass (half of rotor mass) Dimensionless journal mass Coordinates of journal centre in fixed system frame Dimensionless coordinates of journal centre REFERENCE [1] P.5 p 0.N. Allerton Press. Volume II.31.5 -0.. ASME Journal of Tribology. Radial clearance Bearing diameter Eccentricity Components of the fluid film force in rotating system frame Dimensionless components of 26 Dimensionless pressure Bearing radius Sommerfeld number NOMENCLATURE C D=2R e the fluid film force in rotating system frame Oil film thickness Dimensionless oil film thickness Bearing length Pressure Reference pressure . [4] Capone G.e. XIII Congresso Nazionale AIMETA. incompressible and isoviscous flow made in addition to the negligibility of fluid inertia so as to justify the use of the standard form of the Reynolds equation.25 0.116.. [3] V. Hloch Method to Determine the Analytical Approximate Description of Non-Steady Fluid Film Force in Fluid Film Bearings 1 0. L/D=2 -1 e/C = L/D (Point F Constantinescu map) M CONCLUSIONS m M 2C /( SW ) With reference to finite length plain journal bearings.75 p0 6R / C 2 p p / p0 1 R = -0.75 e Fig.75 -0. D. The use of proposed method is recommended in all types of bearing analysis that favour an analytical approach. "A Finite Lenght Plain Journal Bearing Theory". assuming the Warner’s flow factor correction for the pressure field. 648‐653.Guida. D'Agostino V. y x x . S.D'Agostino. A. The present paper represents a “method” applied to a finite journal bearing modelling and.A. June 1963.y y C C Fr. Trans of the ASME. has been determined the approximate analytical fluid film force field. as such. Ft fr.25 S RL -0. Guida D.8 Orbit of the journal for approximate finite model journal bearing with: M=22. pp135‐ 140..28.25 0. C. x. Ruggiero.5 R C 2 W W -0.25 -1 -0.5 0. S=0. is likely to be enhanced to take to account other aspect on lubrication mechanism and/or on the bearing geometry. Journal of Basic Engineering.75 h h h /C L 0. i. in the assumptions of laminar. (1994).Ruggiero: " Sulla Determinazione Analitica Dei Coefficienti Di Rigidezza e Smorzamento Nei Cuscinetti Lubrificati". 1985. Warner: “Static and dynamic properties of partial journal bearings”.. Vol. "Sliding Bearings". in all cases in which the aim is to obtain a better trade‐off between accuracy and computational expense. Contents lists available at www. Citation: Kumar. technical (lead‐free soldering) and performance specifications that its suppliers must meet to be recognized as preferred suppliers. Ranchi. Training is administered to companies that provide not only advice on sustainability issues in purchasing. 27 . the other describing a relative supplier performance in a business perspective were given.The concept covers all the phases of a product’s life cycle. operational performance. India. 2008) [2]. Environmental pollution is the main problem which may lead to the extinction of mankind on earth if not addressed in time. but also to deliver to suppliers to provide them with information on product life cycle through collaboration with suppliers. Brink et al. Chattopadhyaya. Global warming is the result of increasing CO2 (carbon dioxide) concentration in the atmosphere. purchase and personnel from other relevant departments. Organizations have specific criteria and recognized standards (ISO14001). 2008) [2]. stakeholders vendor management etc. Indian School of Mines. eco logistic design.. : Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry.com. Regulations and legislation related to environment and the “green branding” drive has triggered the adaptation and practice of green techniques in supply chain management (Sikhar Barari et al. Email: Sanjeevkg9@gmail. The study of the impact of supply chains on the environment is relatively new and a rapidly growing research area. environmental performance. marketing & communication. Gil et al. who are ready for paying more for green products.com 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 20 September 2012 / Revised: 21 October 2012 / Accepted: 11 November 2012 Keywords: (in causal order) Abstract: Indian Small and Medium Scale Industry Sustainable Supply Chain Environmental Performance Steel Industries Case Study This study aims to investigate the sustainable supply chain management practices likely to be adopted by the manufacturing industry of steel in India. Email: vinay1970@gmail. The approach of the present research includes a literature review.. Dhanbad. The system provides a questionnaire for suppliers to self‐audit their environmental performance and gives them some solutions to improve the environmental profile of their product.com ME&MME Department. can be found in organizations with the advanced strategies for sharing sustainability‐oriented information.icmem. Department. S. Indian School of Mines.Rawat. 2012) [6]. Supplier performances can be enhanced through on‐site third‐ party auditing or periodic self‐assessment by suppliers.R. Dhanbad. Mesra. one showing absolute supplier performances in environmental perspective. economic performance.. India. customer co‐operation. Two different approaches. Sharma.. With global warming being recognised as one of the biggest challenges of this century. in response to the current wave of national & international green issues and also environmental performance of the respective industries. Deans. Organizations provide to their consumers/ suppliers their sustainability procurement policy. Birla Institute of Technology. Wang et al.. Hloch. ISBN 978‐80‐553‐1216‐3 INTRODUCTION (2009) [9] have developed a methodology to identify those customers. in depth interviews and questionnaire surveys. p.K. production and distribution phases to the use of the product by consumers and their eventual disposal of same (Bearing point. (2012). India. S.tk Manufacturing Engineering & Management The Proceedings Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry Sanjeev Kumar 1 ‐ Somnath Chattopadhyaya2 ‐ Vinay Sharma3 1 Mech. V. (1999) [4] indicated that an environmental initiative is on‐going process within the US utilities industry which ensures that environmental Environmental issues have become very important in present times due to their high level of visibility. Production Engg. goals and future targets. (1998) [7] devised a system called ‘ECO‐QUEST’. Department. internal environmental management performance. There is need to cope with the changes in the management system for its survival and sustainability with respect to time (V. Yuang and Kielkiewicz‐Yuang (2001) [11] presented an overview of current practices in managing sustainability issues in supply networks. 2nd International Conference Manufacturing Engineering & Management 2012. 2010) [3]. Organizational management is forced to incorporate environmental management into corporate practices (Chen‐Lung Yang et al. Approaches towards Sustainable Supply Chain Management (SSCM) practice have been identified by various researches. The relationship between sustainable supply chain management practices and environmental performance is studied. eco manufacturing practices. The system functionality is limited since it focuses on suppliers in the electronics industry and the comparison of different suppliers’ performances is not assessed. The results indicate that performance of steel industry regarding eco procurement. LITERATURE REVIEW There are only a few studies related to sustainable supply chain management. Considering the consumers behavior for green products as an important business issue. The green or sustainable supply chain is an approach with attempts to minimize a product or services ecological footprint (Bearing point. from the extraction of raw materials through the design. environment. 2010) [8]. 27‐32. Cross functional teams consisting personnel from sales. (2001) [1] indicated that GSCM has a positive relationship with an organization's economic performance. eco accounting. S. Email: somuismu@gmail. Nature changes with the time. Nagel (2000) [5] developed the tool to evaluate the supplier's environmental performance based on life‐cycle analysis. carbon emissions are increasingly becoming the centre of attention. Engg.Pramod and D. eco product design. they are briefly outlined below. The number of organizations ruminating the integration of environmental practices into their strategic plans and daily operations is continuously increasing. 666 (0. and customers Co‐operation with customers for environmental packaging OBJECTIVE OF THE STUDY Investigate the practice and implementation of sustainable supply chain management in Indian Small and Medium Scale Steel manufacturing industries.222 (0. It tells how likely it is that sample data have responded even if the null hypothesis is true. As per the literature review & experts view. The Competitive Strategies and Best Practices Benchmarking Questionnaire have been developed. 3‐Good/ Partly agree.888 (0. (1997) [10] discuss about the neural network for the supplier selection.2 Performance of Eco Accounting [Factor 2] (Average Mean score: 1. t p 1. Communication regarding environmental procurement criteria/requirements to marketing staff. 5‐ Excellent/Completely agree). finally researcher had arrived at set of 105 dimensions after eliminating the redundant dimensions by submitting the statements/dimensions to respondents and discussing with experts. The model aims to explore possible near future developments in the competitive strategies of the companies by addressing their competitive priorities.444 (0. used linkert scale in this questionnaire.000 (0.DEV.444 (0.527) 8.107 0. “t‐test” and “p” test. Industries performance strategies will depend upon their aggregate score. 14 sustainable supply chain factors with 105 underlying dimensions considered in this study and each dimension has its own importance for effective sustainable supply chain performance.965 0.500) to capital purchases and new technology Generate activity based costing in various department or business 1. The other is the function using the neural network to select suppliers.315 0. who were believed to have knowledge of the subject for fair judgment.555 (0. monitoring and abatement equipment.222 (0.000 “Eco Procurement”.726) function Table: 1 to 14 and Figure: 1 explains about the comparative analysis of effectiveness sustainable supply chain factors with 105 underlying dimensions for Indian steel industries. Wei et al.000 1.000 1. RESULTS AND DISCUSSION DIMENSION MEAN (STD. Consider null (0) hypothesis that no significant differences of green supply chain factors.527) 8. it is concluded that the null hypothesis can be rejected).555 (0.g.444 (0.Kumar et al. where ‘1’ employs below average & ‘5’ employs excellent. Tab. waste disposal etc. 2‐Average/ Rarely agree. Provision of education/assistance to suppliers on environmental matters in order to increase supply chain efficiency.56 (0.444 (0.315 0. Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry considerations are a significant factor in purchasing policy and in the selection process for suppliers. As discussed earlier.000 1.355) COMPARATIVE ANALYSIS OF FACTOR. RESEARCH METHODOLOGY It has been observed that the contribution of steel industries in India and around the world is large in the growth of industrial economy. 4 –Very good/ Rather agree. monitoring and abatement 1. timing.333 (0. the extent to which they perceived their industries implementing each of the dimensions of Sustainable Supply Chain Management practices.222 0.444 (0. which has 5 underlying dimension. Based on review of studies.527) 8. Here “p” is the probability of acceptance (The p‐value is a numerical measure of the statistical significance of a hypothesis test. which has 10 underlying dimension.000 “Eco Accounting”.440) use and disposal of the products Communication of environmental costs to customers and within the 1.222).707) 7. using a five‐point Likert scale (1‐ Below average/Completely disagree. This method incorporates qualitative and quantitative criteria. By t p 6.000 1.854 0.000 1.527) 8. employees.) . The weakness of this method is that it demands software and requires a qualified personnel expert on this subject.000 5.05.000 2.1 Performance of Eco Procurement [Factor 1] (Average Mean score: 1.S.000 8. and costs) and storing the evaluation in a database to provide data sources to neural network. In industry the most important dimension is Environmental costs associated with operations and processes (e.000 1.000 0.) Environmental costs associated with operations and processes (e. The supplier‐selecting system is based on two functions: one is the function measuring and evaluating performance of purchasing (quality.DEV. An alternate hypothesis there is significant differences of sustainable supply chain factors.315 0. if the p‐value is less than 0.566) DIMENSION Provides design specification to suppliers that include environmental requirements for purchased item Co‐operation with suppliers for environmental purchasing Existence of cell for environmental audit for suppliers internal management Procurements mainly from ISO14000 certified suppliers Second‐tier supplier’s environmentally friendly practice evaluation Implementation of eco‐ labeling/eco‐logo of products Work with other business functions to discuss and improve purchasing procedures. convention.424 0.527) 8. Each scale signifies how these factors for an industry for effective sustainable supply chain factors.000 1. For these scores have been calculated the competitive ‘mean score’ with‘t’ and ‘p’ value.071 0.000 0. Dimension analysis was conducted for each of the 105 statements/dimensions through a “mean score”.222 0.000 8. waste disposal 28 MEAN (STD.726) equipment.440) industry in key business functions Assisting in evaluation of environmental cost with respect 1. Neural networks save a lot of time and money for system development when compared to conventional models for decision support system. manufacturing objectives and action plans. In industry the most important dimension is Co‐operation with suppliers for environmental purchasing (2.965 0.000 8. quantity. price.222 (0.) are taken care Accounting the costs to the customers associated with the 1. The questionnaire consists of total 14 factors with 105 underlying dimensions. The target respondents of survey were requested to indicate.500) 12.927) 6.222 0.000) and the least important dimension is Second‐tier supplier’s environmentally friendly practice evaluation (1. stakeholders.g.440) 8.854 0.000 1. Tab.726) 5. 600) t p 9.222 (0.000 0. “Marketing and Communication”.4 Performance of Eco Product Design [Factor 4] (Average Mean score: 1.888 (0.000 1.600) 10.000) and the least important dimension is Application of environmental issues in the design of logistics management (1.111 (0. Tab.095 0.774 0. In industry the most important dimension is assisting customers to improve their environmental performance (1.444 (0.000 0.000 1. which has 5 underlying dimension.Kumar et al.) t p DIMENSION Possibility of product being recyclable.000 2.222 (0. 1.944) DIMENSION Design of products for optimum consumption of material/energy Product designed for reuse. Collection & distribution of products/parts that will be recycled. MEAN (STD.000 2. reusable Avoid or minimize the amount of hazardous material used in product production Are designers using life cycle engineering to improve the environmental performance and production efficiency of the products Measures taken to reduce material.111 (0.222).444 (0.222 (0.333) 19.000 0.527) 2.000 (0.DEV. which has 10 underlying dimension.833) 6.666) and the least important dimension is Environmental requirement and activities of customer concern are monitored (1.440) 8.400 0.000 0.222 (0.) are taken care (1. Tab. which has 5 underlying dimension.000 1.000 1.111 (0.3 Pperformance of Eco Logistics Design [Factor 3] (Average Mean score: 1.000 13.333) 19.000 (0.866) 5.888 (0.119 0.444).500) 12.222 (0.315 0.222).770) 3.777 (0. “Eco Manufacturing”.000).000 2.777 (0.666) and the least important dimension is Waste discharge methodology for reducing cost (2.000 1.222 0.000 1.000 2.000 2.000 1.440) 8.500) 12.222 (0.000 1. MEAN (STD.539 0.) 1.440) .000 17.539 0.666) 5.000 0.726) 5.622) DIMENSION Reverse logistics applied in stock planning Application of environmental issues in the design of logistics management Identification.500) 12.111) and the least important dimension is Products are design & developed for ease in dismantling & Reduced setup time 29 S.500 0.777 (0.440) 8. water & energy used in manufacturing Optimizing the use of energy generated from renewable sources in manufacturing operations Inclusion of recycling program for manufacturing operation Industry has established program to increase the service intensity of the products Determination of environmental impacts and costs of the products throughout their life‐cycle Minimizing toxic/hazardous waste during manufacturing Optimum energy consumption during manufacturing process Integrated environmental & efficiency criteria implementation in process design Minimizing use of natural resources during manufacturing is considered Consideration of environmental issue in the process of production planning and control Environmental issue considered during selection of manufacturing process “Eco Logistics Design”.400 2.000 1.000 etc.000 15.000 Tab.860 0.00 0. In industry the most important dimension is minimizing the use of packaging considered (3.539 0.666 (0. components parts Design consideration of products to avoid or reduce use of hazardous of products Design of products to reduce waste & costs Products are design & develop meet environmental regulation and safety standards Co‐operation & feedback with customer in developing eco‐ design Products are design & developed for ease in dismantling & remanufacturing Application of value engineering/analysis in the design of products Evaluation of product durability Possibility of eliminating secondary processes (polishing/painting etc.315 0.965 0. reused Recollection planning for packaging material Minimizing the use of packaging considered MEAN (STD.440) 12.914 0.222 0.333) t p 10.001 remanufacturing (1.222).000 (0.854 0.555) and the least important dimension is Accounting the costs to the customers associated with the use and disposal of the products (1. In industry the most important dimension is Design of products for optimum consumption of material/energy (2.000 “Eco Product Design”.000 0.000 1.000 0.440) 8.5 Performance of Eco Manufacturing [Factor 5] (Average Mean score: 1.440) 12.000 2.000 0.527) 8.777).444 (0.555 (0.527) 8. In industry the most important dimension is minimizing toxic/hazardous waste during manufacturing (2. which has 5 underlying dimension.440) 8.600) 1. which has 15 underlying dimension.) 2.833) 6. In industry the most important dimension is Reduction in cost of energy consumption (2.315 0.444 (0.888 (0.Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry 1.527) 8.500) 18.000 1.222 (0.) considered.111 (0.444) and the least important dimension is Inclusion of recycling program for manufacturing operation (1.222 (0.600) 10.315 0. recovery of material. recycle. “Economic Performance”.777 (0.430 0.333) 17.DEV.971) 6.095 0.111 (0.000 1.000 (0.000 2.000 1.DEV.000 2.000 1.315 0. 000 5.222 (0.527) material DIMENSION DIMENSION p Co‐operation from customers for eco‐design Co‐operation from customers for cleaner production Co‐operation from customers for green packaging Co‐operation from customers for using less energy during product transportation Co‐operation with customers for environmental procurement 0.666) 2.111).777 (0. Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry Tab.000 15.666) 10. “Stakeholders”. (0.000 0. economic.9 Performance of Customer Co‐operation [Factor 9] (Average Mean score: 2.485 p Tab. which has 5 underlying dimension. “Vendor Management”.440) 1.000 0.422) MEAN t p (STD.10 Performance of Customer Co‐operation [Factor 9] (Average Mean score: 2.000 0.222). Tab.000 (0.222) Waste discharge methodology for reducing cost Reduction in cost for materials purchasing without affecting the quality of the product Reduction in cost of energy consumption Effective waste treatment management for reducing cost Reduction of the fine for environmental accidents 2.777) and the least important dimension is Consultation with environmental experts before using new technology (1.000 0.666 (0. In industry the most important dimension is Co‐operation from customers for cleaner production (2.000 Tab. which has 5 underlying dimension.7 Performance of Economic Performance [Factor 7] (Average Mean score: 2.000 technologies Consultation with environmental experts before using new 1.DEV.000 environmental consciousness Increase supervisor training 1.222 (0.666) and the least important dimension is Co‐operation with customers for environmental procurement (2.500) 2.500) 16.444 (0.900) DIMENSION 2.333 (0.) Improvement in worker safety 2.333).000 MEAN t (STD.440) 2.500) 14.) Assisting customers to improve 1.000 0.854 0.000 8.000 (0.000 0.“Internal Environmental Management Performance”.000 0.965 0.422) Tab.000 0.555 (0.555 (0.444 5. In industry the most important dimension is Environmental awareness among the vendors (1. which has 10 underlying dimension. process performances (1.000) and the least important dimension is Development of a prevention program to identify and eliminate sources of pollution (1.500) 2.315 0.000 (0.440) 1.444 environmental information to 5.6 Performance of Marketing and Communication [Factor 6] (Average Mean score: 1.119 0.527) monitored Awareness regarding 1.965 regarding environment.707) Environmental requirement and 1.222 (0.000 6.000 0. In industry the most important dimension is Amount of goods delivered on time (3.527) 15.000 0.000 p 0.000 0.) 2.666) 1.726) 2.444 (0.546 0.071 their environmental performance (0.539 0.546 0.527) 8.DEV. In industry the most important dimension is Consideration & application of environmental issues because of trade organizations (1.928 0. In industry the most important dimension is Optimization of man power resources in production process (2.666 (0.222 (0.000 2.222 marketing & communications (0.111 (0. Use of environmental information during product 1. DIMENSION MEAN (STD.000 Minimization of air emission Minimization of solid waste Improve production procedure/method for reducing waste/scrap Recovery through sale of scrap and used/rejected material Recovery through sale of excess capital equipment Recovery through sale of old/obsolete equipment Recycling of waste water Optimization of man power resources in production process Reduction of consumption for hazardous materials Reduction in frequency of environmental accidents MEAN t p (STD.333).726) performance.000 8.000 2.222 (0.726) 10. which has 10 underlying dimension.726) new and existing employees Departmental interaction and exchange of information 1.315 technology DIMENSION 10.222 activities of customer concern are (0.222 10.898 Motivate workers for 2.500) 12. which has 10 underlying dimension.DEV.600) 10.000 0.707) 16.444 (0.000 0.000 2.000 8.444 8.666 7.000 “Human and Technological Resources”.555) and the least important dimension is Environmental issues are regularly shared by vendors (1. “Operational Performance”.) 2.222 Use of energy efficient 2.000 0.500) 1.222).440) 8.000 “Environmental Performance”.000 (0.Kumar et al.000 (0. In industry the most important dimension is Promotion of quality circles (2.000 0.000 0.333).000 (0. which has 5 underlying dimension.119 0.555 14.500) 2. 30 2.488) MEAN t (STD.8 Performance of Environmental Performance [Factor 8] (Average Mean score: 1.666) and the least important dimension is Recovery through sale of old/obsolete equipment (1.222 (0.S.000 8.666 (0.000 0.094 0.111) and the least important dimension is Existence of policy related to green supply chain management linking environmental.000 8.000 16.440) 18. which has 5 underlying dimension.DEV.866) 1.222).527) 14.666) t “Customer Co‐operation”.444 8.527) 2.DEV.000 12.333 (0.777 (0. In industry the most important dimension is Improvement in worker safety (2.965 (0. efficiency etc.555) and the least important dimension is Consideration & application of environmental issues because of regulatory concerns (1.) .000 0. 333 (0.777 (0.444 (0.222 0.222 0.000 1.000 8.527) 2.666 environmental management (0. Also it very important that the management of the industry should give special focus on the least mean scored dimensions in their organization.444 (0.000 13.539 0. p 14.527) 8.13 Performance of Stakeholders [Factor 13] (Average Mean score: 1.000 1.424 0.Green Supply Chain Management: A Case Study from Indian Small and Medium Scale Industry of suppliers Consideration & application of 1.500) level managers/executive t p 10. process performances Support for green supply chain 1.000 8.222 0.000 Tab.555 (0.440) environmental.527) 8.Kumar et al.527) environmental issues because 8.500) 8.500) MEAN DIMENSION (STD.444 (0.000 5.500) 0.726) Updating the current and proposed environmental regulations and 1.000 31 MEAN (STD.600) Existance of environmental and 1.914 0. “Vendor Management” “Marketing and communication “ “ Internal Environmental Management Performance” for improving sustainable supply chain factors”.355) followed by “Stakeholders” (1.527) 1.DEV.444). .444) t Consideration & application of 1. economic.333 legislation that may impact on (0.866) Commitment of green supply chain 1.000 8.071 0.000 (0.000 5.666 certification (0.707) Implementation of ISO 14001 1.888 (0.000 0.444 (0.222 0.000 5.965 0.527) 8. 8.000 12.000 Environmental performance is an important criteria in vendor selection Environmental awareness among the vendors Environmental certified vendor is considered Environmental issues are regularly shared by vendors.500) 8.333) 3.DEV.000 7.222 0.000 0.11 Performance of Internal Environmental Management Performance [Factor 11] (Average Mean score: 1.500) managers Awareness about the green supply 1. “Eco Procurement”. “Vendor Management” (1.500) adopted by the competitors Existance of total quality 1.000 26.000 1.987 0.000 1.444 (0.000 DIMENSION S. Feedback on environmental issues for the product supplied.222 of employee concerns Consideration & application of 1.000 environmental issues because of regulatory concerns Consideration & application of 1.000 0.555 (0.000 1.444 environmental management (0.422) followed by “Economic Performance” (2.000 Reduced inventory level Reduction in scrap Promote environmental quality products Optimization of capacity utilization Amount of goods delivered on time Monitoring the environmental and implementation for the improvement within industry Program to promote and track the reduction of waste Waste management program for compliance with all applicable regulations Selection and use of energy efficient equipments and fixture for electrical.527) 8.000 DIMENSION 0.546 0.444 (0.928 0.444) DIMENSION 8.000 (0. Therefore for the management point of view they should give more strength on “Eco Accounting”.000 0.333 management policy by senior (0.726) 5. “stakeholders”.) 2.555 (0. mechanical and lighting application Development of a prevention program to identify and eliminate sources of pollution Tab.1 Comparative analysis of effectiveness of sustainable supply chain factors It is also observed that in all 105 dimensions of sustainable supply chain factors.111 (0.000 RESULT AND DISCUSSION While analyzing the sustainable supply chain factors in steel industry it has been observed that (figure 1) the most important factor is “customer co‐operation” (2.444 (0.500) 8.726) 6.000 2.424 of trade organizations Consideration & application of 1.555 auditing program (0. Tab.000 1.444 (0.000 1.) 0.527) 8.444).000 0.DEV.315 0.) Promotion of quality circles 2.000 1.000 Fig.774 0.440) 2.000 t MEAN (STD.333 (0.965 0. It means that null hypothesis of these dimensions is rejected therefore it can be generalize that there is a significant differences of sustainable supply chain dimension among the industry. the value of‘t’ is more than ‘2’.866) 6.333 management from junior & middle (0.333 chain management measures (0.095 0.000 t p 1.333 (0.444 (0.527) Provision of training in 1.222) and the least important factor perceive is “s Eco Accounting” (1.854 0.000 0. so that industry leads to provide customer satisfaction through sustainable supply chain performance.222 environmental issue because of customer & market pressure Tab.12 Performance of Operational Performance [Factor 12] (Average Mean score: 2.444 (0.000 0.527) 8.726) environmental issues because 6.500) business Existence of policy related to green 1.527) 8.000 0.033) MEAN (STD.14 Performance of Vendor Management [Factor 14] (Average Mean score: 1.222 environmental issues because p 0.) 8.222 supply chain management linking (0.DEV. 4‐35. 39. 2000. pp. A decision framework for the analysis of green supply chain contracts: An evolutionary game approach. the score is not up to the mark. 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Research presents practitioners with a 105 item measurement scale for evaluating the different facets of their sustainable supply chain practices implementation. Kielkiewicz‐Yuang. Vol. REFERENCES [1] A. 8.K. 36.J. It also assesses the relative importance of identified approaches that would affect the sustainable supply chain implementation and the development. M. H. Califomia. The pressures or drives to implement SSCM practices and the relationship between SSCM practices and as well as environmental performance were also studied. Vol. No. M. organizational context and performance of Spanish hotels. 2009... A.C. 2001.C. J. Business Excellence. Eco‐ Manage. pp. International Symposium on Electronics & the Environment. ChwenSheu. Mediated effect of environmental management on manufacturing competitiveness: An empirical study. 1997. Manage. From the survey of the industry. San Francisco. 1. Brink. Sustainable supply network management.R. Environ. No. Jinlong Z. 2001. 2010. Int. pp210–220. No. Importance of approach to sustainable supply chain as presented in table 1 to 14. Diehl. The approach adopted in the present study included a questionnaire. 6. Expert system with Applications. Vol. 20 wt% Ni. ≤ 0. to authors' best knowledge. B12C3 [1. Numerous researchers have reported the enhancement of wear resistance of the self‐fluxing alloy based coatings by the addition of both ceramic.: Wear Resistant Self‐fluxing Alloy Based TiC‐NiMo and Cr2C3‐Ni Hardmetal Particles Reinforced Composite Coatings .8 N). reinforced by the TiC‐NiMo and Cr2C3‐Ni hardmetal particles. B. Vickers surface hardness was measured at the surfaces of the coatings applying the load of 1 kgf (9. Prior to spraying the NiCrSiB powder and related mixtures were dried at 150 ºC for 6 h and the FeCrSiB and related mixtures – at 200 ºC for 6 h. Citation: Surzhenkov A. the specimens were heated by gun flame for 5 seconds to the temperature of about 150 °C to dry the moisture out of the steel surface.% TiC‐NiMo. 0.04 Bal.40 Ni) to the dimensions of 50 × 25 × 10 mm.67 3.10 % Mo.1‐ 1. hardmetal TiC‐NiMo and Cr2C3‐Ni powders were obtained by desintegrator milling at Tallinn University of Technology. 0. Estonia 2 ARTICLE INFO: Category : Original Scientific Paper Received : 14 September 2012 / Revised: 11 November 2012 / Accepted: 12 November 2012 Keywords: (in causal order) Abstract: Abrasive wear Composite coating HVOF Recycled hardmetal In the current article. Si.40 % Cr. The sprayed powders were pure NiCrSiB.Contents lists available at www. 70 vol.) gun. The chemical compositions of the coatings are indicated at Table 1. surface hardness and microhardness and progress of abrasive wear of coatings are studied. produced from hardmetal scrap. As indicated in [5].035 % S. The total duration of the test was 300 seconds. chemical composition. as well as hardmetal tungsten [1. 2. Alloy 1640‐02 6AB Preparation of specimens Specimens were milled from carbon steel C45 (0.% TiC‐NiMo and 75 vol. The parameters of spraying are carried at Table 2. High velocity oxy‐fuel (HVOF) spraying of coatings Two self‐fluxing alloy powders (1640‐02 NiCrSiB and 6AB FeCrSiB.2].32 2. (2012).% TiC‐NiMo/Cr2C3‐Ni were studied.2 times and the abrasive wear resistance of the respective coatings increased 1.0 μm. Tallinn University of Technology.tk Manufacturing Engineering & Management The Proceedings Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni Hardmetal Particles Reinforced Composite Coatings Andrei Surzhenkov1 ‐ Ahto Vallikivi1 ‐ Valdek Mikli2 ‐ Mart Viljus2 ‐ Timo Vilgo1 ‐ Priit Kulu1 1 Department of Materials Engineering. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Self‐fluxing alloys are the alloys of composition Ni‐Cr‐Si‐Fe‐ B.0 ± 1. Instantly before spraying.49 N). vol.. Fe. 19086 Tallinn. whereas Cr2C3‐Ni particles reinforced coatings demonstrated better resistance to wear. 30 wt% Ni S. ASTM standard G65‐ 94 abrasive wear test was carried out in order to estimate the abrasive wear resistance of the coatings. 19086 Tallinn. both from Höganäs AB) and two TiC‐NiMo and Cr2C3‐Ni based hardmetal powders (desintegrator milled at Tallinn University of Technology) were applied.52 1. relatively little attention has so far been paid to the Cr2C3 based hardmetals as a possible reinforcement phase of self‐fluxing alloy based coatings.% FeCrSiB + 30 vol. applied for the improvement of wear resistance together with oxidation or hot corrosion [1] by thermal spraying.05 kgf (0. 0.02 . wt% – 0. C.35 3. milled hardmetal scrap can also be applied for these purposes. Tallinn University of Technology. Cr.25 0. 2nd International Conference Manufacturing Engineering & Management 2012.07 TiC‐ NiMo 70 wt% TiC.45 % C.4 – 0. 65 33 Ni. pure FeCrSiB.4‐6] and chromium [7‐9] carbides based hardmetal particles.2]. 33‐36. wt% wt% wt% wt% wt% wt% wt% Bal. In addition.% NiCrSiB/FeCrSiB + 35 – 25 vol.16 7. et al. Microstructure.1 – 1.6 times in comparison with the unreinforced coatings.icmem. TiC [1. Tab.% NiCrSiB + 35 vol. Ehitajate tee 5. Volumetric wear of the coated specimens was calculated after each 60 seconds of test. 1 Chemical composition of powders and coatings EXPERIMENTAL Coatings were sprayed applying the Tafa JP5000 (Praxair Inc. ≤ 0. high velocity oxy‐fuel (HVOF) sprayed wear resistant coatings of the composition 65 – 75 vol. Distribution of chemical elements in the sprayed coatings was studied by the energy dispersive spectroscopy (EDS). p. Vickers microhardness was measured at the cross‐sections of the coatings applying the load of 0. Estonia Centre for Materials Research.% Cr2C3‐Ni.035 % P. [7] and [9].65 % Mn. such as WC [1‐4].% Cr2C3‐Ni. ≤ 0. Ehitajate tee 5. distribution of chemical elements was studied by EDS. Self‐fluxing NiCrSiB and FeCrSiB powders were supplied from Höganäs AB. etc. Microstructure of the sprayed coatings was investigated by SEM. 10 wt% Mo Cr2C3‐Ni 70 wt% Cr2C3.72 6.% NiCrSiB + 30 vol. 13. no information about the application of TiC based hardmetals for the increase of wear resistance of the self‐fluxing alloy based coatings is available. 70 vol. Particle sizes were in the range of (+10 –45) μm in case of the NiCrSiB and FeCrSiB alloys and of (+20 –63) μm in case of TiC‐NiMo and Cr2C3‐Ni hardmetals.% FeCrSiB + 25 vol. Microstructure studies Cross‐sections of the sprayed specimens were polished and studied by the scanning electron microscope (SEM) EVO MA‐15 (Carl Zeiss). Mn. The current article concentrates on the preliminary comparative study of NiCrSiB and FeCrSiB self‐ fluxing alloy based coatings.7 2 2. However. The results showed that the microhardness of the hardmetal reinforced self‐ fluxing alloy based coatings increased 1. Prior to thermal spraying they were grit blasted with Al2O3 to the surface roughness of Ra = 10. the value of the thermal expansion coefficient of the FeCrSiB self‐fluxing alloy should be close to that of pure iron (12. d – FeCrSiB + Cr2C3‐Ni. applying the standard ASTM G65‐94 block‐on‐ring (rubber wheel) test.20 mm. The appearance of such cracks can be possibly explained by the differences in the values of coefficients of thermal expansion between Ni‐based and Fe‐based self‐ fluxing alloys.3 bar Kerosene flow Combustion pressure Nitrogen pressure a) 0. Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni Hardmetal Particles Reinforced Composite Coatings microcracking. 2 Parameters of HVOF spraying. 1. this hypothesis needs further research. 1. all coatings were grinded to the thicknesses of 0. b – NiCrSiB + Cr2C3‐Ni. Taking into account that the binder in the applied hardmetals is either pure Ni or is based on Ni. The total duration of the test was 300 s for each coating. b) RESULTS AND CONCLUSIONS Microstructure studies The microstructures of the composite self‐fluxing alloy – hardmetal coatings are demonstrated at Fig. Also the FeCrSiB alloy based coatings exhibited a less dense structure. c – FeCrSiB + TiC‐NiMo. Vickers microhardness of the coatings was measured at the polished cross‐sections of the specimens at the load of 0. the speed of rotation was 3.3 mm. The sprayed coatings had an almost pore free structure. while in the NiCrSiB alloy based coatings they were negligible or absent (Fig. The normal load was 130 N. taking into account the relatively large Fe content in the applied material (approximately 72 %). in its turn. 1 c.7 bar Kerosene work pressure 8. Prior to the test. with a slightly bigger porosity in the case of FeCrSiB alloy based coatings. what. however. No data.05 kgf (0. 1 Microstructure of the HVOF sprayed coatings: a – NiCrSiB + TiC‐NiMo.5 bar Oxygen work pressure 9. Hardness measurements Vickers hardness was measured at the diamond paste polished surfaces of the sprayed coatings at the load of 1 kgf (9. with a number of evident horizontal microcracks in the microstructure (Fig. water) and tempered (550 °C. 34 .0 × 10‐6 K‐1). Hardened (850 °C. After each 60 s (200 s‐1) the test was stopped.d). However.A. Oxygen supply pressure 14.8 N) using the Indentec 5030 SKV hardness tester. According to the literature data [10‐12]. could lead to c) d) Fig.49 N) applying the Micromet 2001 microhardness tester.15 – 0.Surzhenkov et al. the abrasive was quarz sand with the particle size 0. The difference in the values of thermal expansion coefficients between self‐ fluxing alloy and hardmetals could induce the appearance of thermal stresses. and volumetric wear was calculated.7 bar Oxygen flow 55224 lpm Kerosene supply pressure 11.3 s‐1.b). concerning the value of the thermal expansion coefficient value of self‐fluxing FeCrSiB alloys could be found. it is quite close to the value of pure Ni (13 ×10‐6 K‐1).5 h) carbon steel C45 was used as reference material.1 bar 5 bar Nitrogen flow 27 lpm Spraying distance 380 mm Abrasive wear test The abrasive wear resistance of coatings was tested. the similarity between the values of thermal expansion coefficients should provide a relatively more favourable stress distribution between self‐fluxing alloy matrix and hardmetal particles.1 – 0. Tab.36 lpm 7. 1 a. the coefficient of thermal expansion of NiCrSiB alloys is in the range of (13 – 14) × 10‐6 K‐1. Näkki. S. 411 – 416. as well as by a less dense structure. The effect of micorhardness’ growth was less pronounced in the case of FeCrSiB alloy based coatings.. as can be seen a Fig.2 times in comparison with the pure self‐fluxing alloy coatings (Fig. This may be caused by the initially lower hardmetal content in the sprayed coatings. P.2 times in comparison with those without the addition of hardmetal particles. . what is in good correspondence with the previously obtained results [7]. 3. S. 3). Nath.R. However. Zimakov. than the those with the TiC‐NiMo hardmetal particles. Kulu. Cr2C3‐Ni hardmetal reinforced self‐fluxing alloy coatings demonstrated better abrasive wear resistance than TiC‐NiMo hardmetal based ones. Materials Science and Technology.05. Wear. Currently it may be suggested that reason is a coarser size of the Cr2C3 grains inside the hardmetal particles in comparison with the TiC grains. Vuoristo. 2003.Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni Hardmetal Particles Reinforced Composite Coatings The hardmetal particles are plastically deformed (elongated) in the direction. S. 2012. 36.6 times in comparison with steel C45.FeCrSiB alloy based coatings were less dense due to microcracking. Tribological study of NiCrSiB coating obtained by different processes.Addition of hardmetal particles allows to increase the microhardness of self‐fluxing alloy coatings by 1. Nowotny. 2. Microstructure and properties of hard and wear resistant MMC coatings deposited by laser cladding. Materials Science (Medžiagotyra).. 3. J.6 times with the addition of hardmetal particles. 350 250 NiCrSiB NiCrSiB+ NiCrSiB+ TiC-NiMo Cr2C3-Ni FeCrSiB FeCrSiB+ FeCrSiB+ TiC-NiMo Cr2C3-Ni C45 Fig. Solid particle erosion of HVOF sprayed WC‐Co/NiCrFeSiB coatings. as well as the NiCrSiB+TiC‐NiMo coating were obviously worn through by the end of the test. 2000.. 1996. the abrasive wear resistance of self‐fluxing alloy based coatings increases by 1. B. Also it should be emphasized that the pure NiCrSiB and FeCrSiB based coatings. V.C. MPa 700 600 500 400 300 NiCrSiB NiCrSiB+ TiC-NiMo NiCrSiB+ Cr2C3-Ni FeCrSiB FeCrSiB+ TiC-NiMo FeCrSiB+ Cr2C3-Ni C45 Fig. 4. Sapra. MPa 850 750 650 550 REFERENCES 450 [1] Ramesh. 2010. despite the fact that TiC‐NiMo hardmetal is harder. HV0. 691 – 696..Hardmetal particles allow to increase the abrasive wear resistance of self‐fluxing alloy sprayed coatings by 1. B. 18 16 14 C 45 NiC rS iB F eC rS iB NiC rS iB +TiC ‐NiMo F eC rS iB +TiC ‐NiMo NiC rS iB +C r2C 3‐Ni F eC rS iB +C r2C 3‐Ni 12 mm3 10 8 6 4 2 0 1 min 2 min 3 min 4 min 5 min Fig. 27. Shen... Vuoristo.K. Maksim Antonov for the help with the wear test. [5] Kulu.TiC‐NiMo and Cr2C3‐Ni hardmetal particles reinforced NiCrSiB and FeCrSiB self‐fluxing alloy coatings were successfully sprayed applying the high velocity oxy‐fuel spraying. J.. P.. P. P. 1992. This work was supported by the Estonian Ministry of Education and Research (target‐financed project SF 01400091s08). than the Cr2C3‐Ni one (1415 HV [13] and 980 HV [14]. 1. editor. 181 – 187. 2.M. 2009. [4] Gassmann. Tribology International. Laser cladding with (WC + W2C)/Co‐ Cr and (WC + WC2)/Ni‐B‐Si composites for enhanced abrasive wear resistance. 1. 34 – 39. on the microscale the addition of hardmetal particles to the self‐fluxing alloy caused an increase in microhardness values of the sprayed coatings by 1. Microhardness of sprayed coatings Abrasive wear resistance.1 – 1.. 3.1 – 1.. The reason for that is not clear and needs further investigations. S. 2..M. The growth of wear resistance in comparison with the reference material (steel C45) is up to 2.1 – 1. As can be seen from Fig. 2).Surzhenkov et al. 12. The Cr2C3‐Ni particles reinforced self‐fluxing alloy based coatings generally demonstrated a higher wear resistance. International Journal of Refractory Metals and Hard Materials. as mentioned above. Surface and Coatings Technology.. [7] Sarjas. Guilemany. respectively). The EDS analysis revealed no dissolution of hardmetal material in the self‐fluxing alloy... Prakash.1 – 1. J.6 times in comparison with the pure self‐fluxing alloy coatings and by up to 2. 197 – 205.6 times.. 4. 900 800 HV1. J. Surface hardness of sprayed coatings 1050 ACKNOWLEDGEMENT 950 Authors thank Dr. Surženkov. H. perpendicular to the spraying direction. Vizcaino.. Abrasive wear resistance of sprayed coatings 35 A. Wear resistant thermal sprayed composite coatings based on iron self‐fluxing alloy and recycled cermet powders. 4. Goljandin.. Laser cladding with a heterogeneous powder mixture of WC/Co and NiCrSiB: European conference on laser treatment of materials (ECLAT’92). Venkataraman. [3] Nurminen. as their wear rates were similar to those of the reference material. [2] Miguel.. Mikli..2 Hardness measurements.. 18. 269.K. induced by the differences in the values of thermal expansion coefficients of the FeCrSiB alloy and hardmetals. P. M. CONCLUSION 1. Dausinger. R. 130. D.. 3.. In: Mordike BL. 8. 3 – 4. 46 – 51. J. F. [6] Grünewald. No significant effect of the hardmetal particles’ addition to the surface hardness of the sprayed coatings was observed (Fig. 472 – 478. Wear resistance of thermal sprayed coatings on the base of recycled hardmetal. 1. A. St... [10] Lille. Surženkov. Three‐ body abrasive wear of TiC‐NiMo cermets. 340 – 346.Surzhenkov et al. Viljus. Tribology International. 185 – 190 (in press). U. [8] Määttä. 1 – 2. Tribology International. [12] Deklaagpoeders voor thermisch spuiten. M. 527. Abrasive wear resistance of recycled hardmetal reinforced thick coating. 8.. R.. J. A. Wear Resistant Self-fluxing Alloy Based TiC-NiMo and Cr2C3-Ni Hardmetal Particles Reinforced Composite Coatings [11] Deloro 50EXV Technical Data. 89 – 93. P.be/showpage.09. available at www..com/Portals/0/pdf/Datasheets/Deloro %2050%20EXV%20DS05‐23108%20(S%20R0808). 43. Journal of Thermal Spray Technology. 1 – 2. Tarbe.. K. 2012. Proceedings of Estonian Academy of Science and Engineering. T. H.2012..2012. 07. H. J. M.. 162 – 173. 20. Sarjas. P... Kulu. Kuningas.. Kõo. 2013..vatis. available at http://stellite.. A. Pihl.asp?iID=74.. [14] Hussainova. 36 . Žikin. 34. [13] Pirso. 3. 2001.. 2... Residual stresses in different thermal sprayed coatings. A. I... 2010. Vuoristo. 07. Structure and tribological characteristics of HVOF coatings sprayed from powder blends of Cr2C3‐25NiCr and NiCrSiB alloy.09. 366 – 371. P. Some aspects of solid particle erosion of cermets.A. 2002. Key Engineering Materials. Kanerva.pdf. [9] Kulu. Juhani. 2 Machine MD101 Fig. such as OD 22 x 2.Paton Electric Welding Institute of the NAS of Ukraine the technology and equipment have been developed for the magnetically‐ impelled arc butt welding (MIAB welding).3 Machine MD1 37 .7 mm pneumatic spring and OD 53 x 1. The MIAB equipment is robust and relatively simple in design. The process does not use filler material and any surface impurities are extruded during the forging phase. et al. specified for the work. Weld ability of compact hollow automobile parts. The works were performed using welding machines MD101. which is widely used in the automobile industry of Ukraine.1 Figure 1. At the E. ISBN 978‐80‐553‐1216‐3 INTRODUCTION MD1. welded by MIAB welding are manufactured at Ukrainian automobile plants [1. Figure 2. and requires low upset pressures compared to processes like Friction welding. Basic requirements. will find a great demand at the automobile plants.Paton Electric Welding Institute of NAS of Ukraine. were to develop the highly‐efficiency process of welding for its application in mass automobile production with mechanical properties of welded joints at the level of characteristics of the part parent metal.tk Manufacturing Engineering & Management The Proceedings Magnetically-Impelled Arc Butt Welding for Manufacture of Automobile Hollow Parts of Mass Production Mohan Sreenivasan1 ‐ Bollu Baskaran2 ‐ Vladimir Kachinskiy3 ‐ Sergey Kuchuk‐Yatsenko3 1 GKM College of Engineering & Technology.O.icmem.2 mm piston rod. (2012). Over the recent years the technology of MIAB welding of the new generation of parts of automobile industry has been developed. During this period more than 4 million of welded joints were made. Fig. Technical characteristics of welding machines are given in Table 1. India The E. Chemical composition of parts is presented in Table 2. 2. Kiev. 3]. Figure 3.O.Contents lists available at www. India. Part of OD 19 x 1. 2nd International Conference Manufacturing Engineering & Management 2012. This rotation results from forces imposed on the arc by an external magnetic field. assuring the quality of parts. was investigated. p. and Fig. High‐efficiency and energy‐saving processes of welding.2 mm shock‐ absorbers and OD 34 x 6 mm torque rod. Chennai. Coimbatore. but seldom utilized in India.com Eta Weld Tech (I) Private Limited. Ukraine 2 3 ARTICLE INFO: Category : Application Received : 14 September 2012 / Revised: 28 October 2012 / Accepted: 3 October 2012 Keywords: (in causal order) Abstract: Magnetically‐impelled arc butt welding Automobile parts Joint formation Technology of welding Magnetically Impelled Arc Butt (MIAB) welding is a forge welding technique which generates uniform heating at the joint through rapid rotation of an arc. 37‐40. Magnetically‐Impelled Arc Butt Welding for Manufacture of Automobile Hollow Parts of Mass Production .8 mm shock‐ absorber. Figure 1. Citation: Sreenivasan M. Email:sreenivasansaim@gmail. The development of new technologies will be challenging for achievement of the higher labor productivity. Since 1994 the pneumatic springs and shock‐absorbers. MIAB welding is used extensively in Europe. OD 40 x 2. 12 ≤0.194 Tube Tube 0. kN Consumed power.05 0.32 Piston rod OD22х2. OD 40 x 2.004 0.4 mm.02 W ‐ 0.010 Torque rod OD34х6mm 0. Figure 4 shows the welded joint made by MIAB welding.7 13.2 mm Fig.2 Time of welding.1 4. . Figures 6. Pilot technology of MIAB welding of pipe with hollow rods has been developed as a result of carried out investigations.2 mm piston rod Welded joints were subjected to rupture and bend tests. Figure 5.004 1. kg Tab.07 0. Method of MIABW welding allows.3 Main technological parameters of welding Piston rod 3.008 0. mm Description of part Main technological parameters of welding the parts of OD 22 x 2.23 0.2 Torque OD rod 34 x 6. Metallographic examinations of welded joints of parts of Fig.8 31 3. producing the height of weld reinforcement up to 0.011 0. MD101 10‐61 1 ‐ 5 60 40 30 230 MD1 18‐61 1 ‐ 6 60 60 45 190 piston rod and shock‐absorber were carried out in device M 400 of “Leco” company at 1N load and 100 m pitch. the fracture occurred on the pipe parent metal at 140 mm distance from the butt that proves the high mechanical strength of the joint.18 0. mm Consumed power.M. Upsetting force. Mechanical tests of welded joints were performed in accordance with procedures accepted at the automobile plants.04 0.1 Technical characteristics of machines for pipe welding.006 0.17 0.004 0.90 1.05 0. Width of heat‐ affected zone was 2.004 0.91 0.175 0.174 Shock‐absorber OD40х2. to which rod hollow parts with 60 mm long thread are welded‐on on both sides.162 0.7 21 2.05 0.55 0.015 0.2 Shock‐ OD absorber 40 x 2. Tab. were manufactured from welded joints of the piston rod part.7 Distribution of metal hardness in the welded joint zone 38 0.08 ≤0.6 Macrosection of welded joint of left piston rod The carried out metallographic examinations of welded joint of the piston rod part showed the following results.7…3. PISTON RODS The part of a piston rod represents a pipe of 300 mm length.05 0. The rupture force was 12900 kg. They include full‐scale rupture tests and also local bending of segments of circumferential welds. s Diameter.2 mm shock‐absorber and OD 34 x 6 mm torque rod are presented in Table 3.02 0.107 0.01 0. et al.152 Tenon 0. mm Wall thickness.1 Fig.01 0. welds/h Upsetting force.2 Fig.07 0.015 0.5 mm.9 6.55 Tube 0. Magnetically-Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production Machine Type Diameter of pipes.012 0. Welded joint does not require auxiliary operations after completion of the welding process and flash removal.2 mm piston rod.5 Part of piston rod after rupture tests Macrosections.02 0.22 0.2 40 7…7.2 mm 0.2. when necessary.011 0. kW OD 22 x 2.080 0.146 0.1….2 Chemical composition of automobile parts Mass fraction of elements. kN Part shortening. To reveal the microstructure of welded joint. Figure 7.22 0.012 0.5 7.04 0. mm Efficiency. The measurement of distribution of metal hardness in the zone of welded joint of the piston rod was performed in the direction from the pipe to the rod part. % C Si Mn S P Cr Ni Cu Composition of part 0.56 Bushing 0.170 0.08 0. kVA Mass.3 6. Sreenivasan.17 0.136 0. the chemical etching by 4% alcoholic solution of nitric acid was used.2‐2.018 0.4 Automobile as‐welded part of OD 22 x 2. Tab.07 0. Bend tests showed high ductile properties of the joint.20 Head Piston 0. The structure of HAZ overheating zone represents a mixture of pearlite.2 mm diameter showed the following results. HV 2210 – 2320 MPa. The width of overheating zone is 550 ‐ 600 m. bainite (HV 3060 – 3110 MPa) and a small amount of ferrite (HV 2540‐ 2610 MPa). Figure 8. Mechanical tensile and bend tests of welded joints of a piston rod and shock‐absorber prove that the strength of joints is equal to that of the parent metal of parts.02 mm thickness. The structure of HAZ overheating area of metal of tail piece part represents a mixture of ferrite HV 2190 – 2210 MPa and pearlite HV 2340‐2390 MPa. The performed full‐ scale mechanical bend and rupture tests of parts of piston rod and shock‐absorber showed that ductile properties of the welded joint are at the level of properties of the parent metal. ferrite (HV 2020 MPa). As a result of carried out investigations the technology of MIAB welding of the shock‐absorber part has been developed.2mm size is given in Table 1. Macrosection. pearlite (HV 2120 – 2370 MPa) with a clearly expressed texture of rolled metal. The part represents a pipe of 300 mm length. The structure of HAZ overheating area of rod part is bainite‐ferrite (HV 2710‐ 3210 MPa).8 Line of welded joint Shock‐absorbers Fig. Figure 11. the amount of a pearlite component is increased. Figure 12. Ferrite of different morphological forms is observed in the structure. Fig. Welded joint does not require auxiliary mechanical operations after completion of the welding process. Defects were not revealed in the joint zone. The rupture force was 12200 kg. bainite (HV 3030 – 3210 MPa) and a small amount of ferrite. Figure 8. Figure 12. The structure of parent metal of bushing rod part is ferrite‐pearlite HV 1990 – 2210 MPa with a great domination of a ferrite component. Figure 8. Figures 13. the amount of bainite is decreased. with of overheating area is 700 m. Measurement of metal hardness distribution in welded joint zone was made in the direction from pipe into part. Figure 9 showed a welded joint made by MIAB welding. The structure of HAZ overheating area of pipe metal consists of pearlite (HV 2570 – 2650 MPa). the inner part of which is coated by chromium of 0.10 Welded joint of shock‐absorber part after rupture tests.9 Welded joint of shock‐absorber Mechanical rupture and bend tests were performed. Measurement of metal hardness distribution in welded joint zone was made in the direction from pipe into part. Fig. Metal hardness on the joint line is HV 2700‐ 2850 MPa.12 Distribution of metal hardness in welded joint zone The ferrite decarbonized band on the line of joint of pipe and torque rod is absent. Width of overheating area is 500 μm. HAZ length is 1200 μm.11 Macrosection of welded joint of shock‐absorber part Metallographic examinations of welded joint of parts of shock‐absorber of 40x2. Bend tests showed the high ductile properties of welded joint. Fig. was manufactured of the shock‐absorber welded joint. Sreenivasan et al. Metal hardness on the joint line is HV 2640 – 2970 MPa. Width of heat‐affected zone was 2200 …2400 m. Bend tests are severe for this type of joints.Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production M. Fig. Width of HAZ is 2200 m. a hollow bushing piece with 60 mm long thread is welded‐on on one side.Magnetically. The structure of rod part parent metal is bainite‐ferrite with hardness (HV 2790‐3090 MPa). Defects in the joint zone were not revealed.2 mm diameter showed the following results. Figure 10. 39 . The pipe parent metal has a ferrite‐ pearlite structure with a clearly expressed texture of rolled metal. Metallographic examinations of welded joint of parts of shock‐absorber of 40x2. Chemical composition of part of shock‐absorber of OD 40 x 2. Further the structure is refined. HAZ length is 2300 μm. The rupture tests showed that joint strength is at the level of characteristics of the parent metal of the tail piece part. The ferrite decarbonized band on the joint line is absent. Width of overheating area is 500 μm. The structure of parent metal of pipe is fine‐grained. heads are of steel 30. et al. Krivenko V. Kachinsky V. The presence of flash.The carried out full‐scale mechanical rupture tests of parts of piston rod and shock‐absorber prove the high mechanical strength of welded joint at the level of main characteristics of the parent metal.13 Line of welded joint It was found as a result of investigations that the welded joints of parts of piston rod and shock‐absorber have no structures.I. Results of tests are given in Table 4.The welded joints have no hazardous hardened structures which decrease the ductility and strength of joints.0 95. Cambridge.2 mm piston rod.7. The components are not rotated so the alignment can be maintained. 1. The bainite‐ferrite structure is dominated in the structure of welded joints. Figure 14.G. An automated process enabling the resulting welds to be highly reproducible.. 12. 6.4 Results of testing the torque rod parts at tension‐ compression symmetric cycle Load. Vickers hardness of welded joint metal is in compliance with hardness of parent metal of parts that proves the high gradient of temperature field in MIAB welding. The torque rod consists of a pipe and 2 heads. This is stipulated by the fact that the fine‐grain structure with high tough properties is observed in the place of an increased concentration of stresses at the boundary of weld reinforcement. causing the concentration of stresses... changing significantly the properties of metal as regards to the parent metal. Can be interfaced with automatic handling systems. 13‐14. 15. Low power consumption. Reduces weld time by up to 90% Torque rod The chemical composition of parts of torque rod is shown in Table 1... The carried out mechanical bend tests of parts of piston rod and shock‐absorber in accordance with procedure accepted at the automobile plant prove the high ductile properties of the joint.Yu. Welds are free from inclusions and impurities. Ignatenko V. [2] Kachinsky V. Great Abington.2 mm shock‐absorber has been developed. The carried out cyclic fatigue tests of torque rod parts showed that the fatigue fracture of samples of the torque rod occurred in parent metal.30‐44. 3. Koval M. UK. 7. 14.94128094 (3/4663) of 20.Yu. Magnetically-Impelled Arc Butt Welding For Manufacture of Automobile Hollow Parts of Mass Production compression were performed using joints with a flash. 5. kN Specific load. “Magnetically‐ impelled arc butt welding of hollow and solid parts”. 9. p. TWI. 4.0 2480100 3027500 4 45 85. 2.0 914000 2 3 60 50 114.09. 1997. Pipe material is steel 20.. Ignatenko V. 8. As a result of carried out investigations the technology of MIAB welding of part of the OD34x6 mm torque rod of trucks has been developed. In head body The same The same Without fracture The fracture of the torque rod part after tension‐ compression tests was in parent metal of a tip.S.94. [3] Kachinsky B. The tests of welded joints at symmetric cycle of tension – 40 . No welding consumables are required. Technology of welding the automobile parts of OD22 x 2.12. 11. No. “Avtomaticheskaya Svarka”. Machine for magnetically‐impelled arc butt welding.M. As‐welded parts of the torque rod were subjected to fatigue tests in a special stand at tension‐compression symmetric cycle. Ignatenko V. 13. et al. “Magnetically impelled arc butt welding of tubular parts (equipment and technology)”.14 Cyclic tests of welded part of torque rod Tab. The developed technology can be used in mass production where the high labor productivity is required. MPa Number of cycles before fracture 1 70 133.S. OD34 x 6 mm torque rod and OD40 x 2. Welds a wide variety of materials including dissimilar combinations.1999.of sample 7 REFERENCES Place of fracture [1] Kuchuk‐Yatsenko S. 10. Exploiting solid state joining. The peculiar feature of structure of welded joints is the absence of a coarse‐grain area. Sreenivasan. Patent of Ukraine No.5 10 No. Fig. CONCLUSIONS Fig. did not decrease the values of cyclic tests. consisting of very thin layers that are usually bound together with counter‐ions. Czech Republic. 41‐43. as shown in Fig.hr. These structures may be formed by annealing layered silicate particles. Polymer layered silicates are an important class of nanocomposite materials. the nanocomposites are materials in which at least one phase is in nanometer dimensions. Study on polyamide 12/clay nanocomposites by melt‐intercalation process.cz. fibre reinforcing filler (carbon nanotubes and nanofibres) and nanoparticles (SiO2 nanometre dimensions particles). The field of nanotechnology is one of the most popular areas for current research and development in basically all technical disciplines. Faculty of Mechanical Engineering and Naval Architecture. uniformly dispersed filler in the polymer matrix with the large interactive matrix‐filler surface that result in improvements of the obtained composite properties. For its characteristic properties nanocomposites are nowadays increasingly being used in technique. with a polymer melt. 1. During intercalation. Faculty of Technology. Polymer/layered silicate nanocomposites Layered silicates used in the synthesis of nanocomposites are natural or synthetic minerals. whereby is achieved higher specific interfacial area. Email: mladen. Zagreb. and in the same time does not lead to thermal degradation of nanocomposite. whose surfaces have been chemically modified to render them organophilic. screw rotation speed and compounding time were investigated too. Mechanical Engineering Faculty in Slavonski Brod. and certainly will take a significant share in materials production in the future. 2nd International Conference Manufacturing Engineering & Management 2012.sercer@fsb. Citation: Raos P.
[email protected] 3 ARTICLE INFO: Category : Original Scientific Paper Received : 13 October 2012 / Revised: 21 October 2012 / Accepted: 13 November 2012 Keywords: (in causal order) Abstract: Polymer nanocomposite Montmorillonite PA 12 Nanocomposites are multiphase materials where at least one of the constituent has one dimension less than 100 nm. jstojsic@sfsb. the clay minerals in the sheet form of nanometer thickness are used as filler during the production of polymer nanocomposites. hectorite and saponite. The structure Fig. scientists are lately more and more dealing with nanocomposites.utb. 41 . today are most commonly used natural clay minerals: montmorillonite.[2] Nanocomposites are materials which study had been started in 90th years of last century. Typical nanofiller / reinforce filler includes: layered filler (with nanometre layer thickness and sheet structure.cz University of Zagreb.1 Structure of a 2:1 layered silicate [2] The thickness of such layer is in the order of magnitude 1 nm and the blank between nearby layers is about 0. For this purpose. p. Montmorillonite is clay mineral which is classified in class of dioctahedral smectite. platelet or fibre modification are in the range of 1–100 nm). et al. so that the oxygen ions of the octahedral sheet also belong to the tetrahedral sheets. consists of two dimensional layers where a central octahedral sheet of alumina is fused to two external silica tetrahedra by the tip. For decades. more 2 than 100 m per gram. The aim of the investigation was to determine the optimum combination of compounding parameters which assure satisfy level of intercalation and uniform distribution of nanofillers. (2012). Zlin. Croatia.icmem. [1] The name of Montmorillonite is derived from the deposit Montmorillon which is in France.Contents lists available at www. which allows. The reason why the clay is used to produce nanocomposites is very high specific layer surface. ISBN 978‐80‐553‐1216‐3 INTRODUCTION of montmorillonite is 2:1 The crystal lattice of 2:1 layered silicates (or 2:1 phyllosilicates). Email: kalendova@ft. We studied several types of modified and unmodified montmorillonite clays in various concentrations. This process is called melt‐intercalation. POLYMER NANOCOMPOSITES Polymer nanocomposites are composed of polymer matrix and nanofiller.3 nm. Seeking for new materials with better properties.utb. Email: pero@raos. Therefore the properties of obtained nanocomposites depend more on interactions at the phase boundary than on the phase itself. By definition. but manufacture of nanoscale materials is at least a 100 year old industry (particles of carbon black as fillers in automotive tyres). The paper deals with preparation of polyamide 12/clay nanocomposites by a melt‐intercalation process.tk Manufacturing Engineering & Management The Proceedings Study on Polyamide 12/clay Nanocomposites by Melt-Intercalation Process Pero Raos1 ‐ Josip Stojšić1 ‐ Alena Kalendova2 ‐ Dagmar Merinska2 ‐ Mladen Šercer3 1 University of Osijek.hr 2 Tomas Bata University in Zlin. together with very small mass ratios (2‐6%). The influence of compounding conditions. Croatia. (dimensions of the particle. polymer molecules leave the bulk melt and enter the galleries between the silicate layers. P. Raos, et al. Study on Polyamide 12/clay Nanocomposites by Melt-Intercalation Process organically modified nanometer scale, layered magnesium aluminum silicate platelets. The silicate platelets that the additives are derived from are 1 nanometer thick and 70 – 150 nanometers across. The platelets are surface modified with an organic chemistry to allow complete dispersion into and provide miscibility with the thermoplastic systems for which they were designed to improve Polymer nanocomposites reinforced with carbon nanotubes Carbon nanotubes (CNTs) are ideal fillers for polymer composites due to their high Young’s modulus combined with their low density (1,3 g/cm3) and good electrical and thermal conductivity. The very high aspect ratio (length/ diameter) of the CNTs makes it likely that the addition of a small amount(≤5 wt%) of CNTs strongly improves the electrical thermal and mechanical properties of the polymer matrix. [3] Unlike other carbon materials such as graphite or diamond, carbon nanotubes (CNT) are one‐ dimensional carbon materials where the ratio L /D is greater than 1000, and its diameter is in nanometer scale. [4] Depending on the manufacturing process, today there are nanotubes with one (SWCNTs) or more walls (MWCNTs) (Fig 2.). Fig.2 Conceptual diagram of single‐walled carbon nanotube (SWCNT) (A) and multiwalled carbon nanotube (MWCNT) [5] Fig.3 Conceptual diagram of single‐walled carbon nanotube (SWCNT) (A) and multiwalled carbon nanotube (MWCNT) [5] PRODUCTION OF POLYMER NANOCOMPOSITES BY MELT INTERCALATION PROCESS Tab.1 Performance of Eco Procurement [Factor 1] (Average Mean score: 1.566) The most common and simple method, particularly useful for thermoplastic polymers is melt intercalation. In melt intercalation, fillers are mechanically dispersed into a polymer matrix using a high temperature and high shear force mixer or compounder. This approach is simple and compatible with current industrial practices. The biggest challenge in getting nanocomposite reinforced with clay layers is the separation and dispersal of an individual layer in the polymer matrix. Unless there is no separation of clay layers, common micro composite is obtained (Figure 3a). Nanocomposites with a few polymer molecules inserted in the interlayer between the clay sheets can occur depending on the strength of interfacial interactions (Figure 3b). In the above mentioned dependence can also occur stratified nanocomposite where the clay layers are completely separated and evenly dispersed in the polymer matrix (Figure 3c). Stratified polymer composite is preferred because it produces the largest matrix‐filler contact area, which leads to the best nanocomposite properties. Value Unit Tensile Modulus Tensile Strength Charpy impact strength (+23°C) Shore D hardness (15s) Melting temperature (10°C/min) Density (lasersintered) 1650 48 MPa MPa Test Standard ISO 527‐1/‐2 ISO 527‐1/‐2 53 kJ/m² ISO 179/1eU 75 ‐ 176 °C 930 kg/m³ ISO 868 ISO 11357‐ 1/‐3 EOS Method Cloisite 10A and Cloisite 30B are a natural montmorillonites modified with a quaternary ammonium salt, Cloisite 93A is a natural montmorillonites modified with a ternary ammonium salt, and Cloisite Na+ is a natural bentonite. All fillers are designed for use as an additive for plastics and rubber to improve various physical properties, such as reinforcement, HDT, CLTE, synergistic flame retardant and barrier. Tab.2 Typical Cloisite properties INFLUENCE OF MIXING PARAMETERS AND MONTMORILLONITE TYPE ON THERMAL DEGRADATION OF PA 12 / CLAY NANOCOMPOSITE Materials Nanofiler Closisite + Na Closisite 10A Closisite 30B Closisite 93A Material used for the nanocomposite matrix is PA12 in the powder form (PA 2200 Balance 1.0 made by Eos Company).This material is used for the production of laser‐ sintered fully functional products, which are replacing typical injection moulding products due to their excellent mechanical properties. The main material properties are given in Table 1. Cloisite 10A, Cloisite 30B, Cloisite 93A and Cloisite Na+ of Southern Clay Products are the nanofillers used in the experiment. Cloisite additives consist of 42 Properties Organic Modifier Modifier concentration ‐‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 2MBHT MT2EtOH M2HT 125 meq/100 g clay 90 meq/100 g clay 95 meq/100 g clay Denisity Color 2,86 3 g/cm 1,90 3 g/cm 1,98 3 g/cm 1,88 3 g/cm Off white Off white Off white Off white Study on Polyamide 12/clay Nanocomposites by Melt-Intercalation Process P. Raos, et al. Tab.3 Typical Dry particle sizes (by volume) [8] Nanofiler + Closisite Na Closisite 10A Closisite 30B Closisite 93A 10% less than: 2 2 2 2 50% less than: 6 6 6 6 Design of experiment Polyamide 12 and nanofiller were melt‐compounded in a HAAKE minilab twin screw extruder. The operating temperature was 200 °C. The screw speed was in range from 11 to 129 min‐1 and mixing time from 3 to 36 min. The amount of nanofiller was calculated to be from 0,95 to 11 wt‐% of Cloisite in the whole mixture. The aim of the investigation was to determine the optimum combination of compounding parameters and the optimal nanofiller which assure satisfy level of intercalation and uniform distribution of nanofillers, and in the same time does not lead to thermal degradation of nanocomposite. 90% less than: 13 13 13 13 Equipment Nanocomposite compounds are made on the laboratory twin‐screw extruder HAAK Minilab that is intended to compound nanocomposites and can be used for rheological investigations. The major advantage of this device is that it works with samples of 5 gram size, so that with the small amount of polymer and expensive nanofiller can be made a lot of different compounds in a short time period and is suitable for initial investigation. The system is based on a conical, twin‐screw compounder with an integrated backflow channel. Due to the channel and a bypass valve, the residence time is well defined. Two pressure transducers are integrated in the backflow channel. They allow the measurement of (relative) melt viscosity. CONCLUSION For its characteristic properties nanocomposites are nowadays increasingly being used in technique, and certainly will take a significant share in materials production in the future. This experiment is only a small part of the main experiment that has the aim to determine changes (improvement) in the PA12 properties reinforced with nano‐clay Cloisite (10A, 30B, 93 A). Also, the experiment has been conducted to detect an optimal choice of parameters (mixing time, mixing speed, amount of nanofiller) in nanocomposite preparation and will be reported in details in papers that follow. REFERENCES [1] M. Ivanković, Polimerni nanokompoziti, Polimeri 28(2007)3, pp. 156‐167 [2] S. Pavlidou; C.D. Papaspyrides, A review on polymer– layered silicate nanocomposites. Progress in Polymer Science 33 (2008), pp.1119–1198 [3] O. Valentino, M. Sarno, N.G. Rainone, M.R. Nobile, P. Ciambelli, H. C. Neitzert, G. P. Simon, Influence of the polymer structure and nanotube concentration on the conductivity and rheological properties of polyethylene/CNT composites, Physica E40 (2008) 2440‐2445. [4] P.‐C. Ma; N.A. Siddiqui; G. Marom; J.‐K. Kim, Dispersion and functionalization of carbon nanotubes for polymer‐basednanocomposites:A review, Composites: Part A 41 (2010), pp.1345–1367 [5] The Journal of Nuclear Medicine, http://jnm.snmjournals.org/content/48/7/1039/F1.e xpansion.html, 25.10.2012. [6] R. Krishnamoorti; K. Yurekli, Rheology of polymer layered silicate nanocomposites. Current Opinion in Colloid & Interface Science 6(2001), pp. 464‐470 [7] EOS GmbH, Electro Optical Systems, München, http://eos.materialdatacenter.com/eo/en, 16.06.2011. [8] Rockwood Additives LTD., Product Bulletins http://www.rockwoodadditives.com/product_bulleti ns.asp Fig.4 HAAKE MiniLab twin‐screw compounder 43 Regular Section | in alphabetical order| "Most people say that it is the intellect which makes a great scientist. They are wrong: it is character." Albert Einstein Contents lists available at www.icmem.tk Manufacturing Engineering & Management The Proceedings Simulation Based Layout Design Euikoog Ahn1 ‐ Dae S. Chang2 ‐ Sang C. Park3 1 Department of Industrial Engineering, Ajou University, San 5, Woncheon‐Dong, Yeongtong‐Gu, Suwon 443‐749, Email:
[email protected] Department of Industrial Engineering, Ajou University, San 5, Woncheon‐Dong, Yeongtong‐Gu, Suwon 443‐749, Korea, Email: webmacome@
[email protected] Department of Industrial Engineering, Ajou University, San 5, Woncheon‐Dong, Yeongtong‐Gu, Suwon 443‐749, Korea, Email:
[email protected] 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 21 February 2012 / Revised: 15 September 2012 / Accepted: 30 October 2012 Keywords: (in causal order) Abstract: Layout design Assembly line Manufacturing system This paper proposes a methodology to design a plant layout by using the simulation technology. In order to describe the proposed methodology, this paper presents layout design process and layout editor. In addition, this paper introduces a recommendable layout method. If users select this option, layout is automatically remodeled. The proposed method for simulation based layout design in this paper allows the layout designer to swiftly generate assembly lines with consideration of key factors. For the implementation of the proposed layout editor, this paper employs Discrete Event Systems Specifications (DEVS) formalism. The layout editor can be modeled and simulated for initial layout. This is recommended the editable layout by each case. Citation: Ahn E, Chang DS, Park SC. Simulation based Layout Design , 2nd International Conference Manufacturing Engineering & Management 2012, (2012), p. 44‐48, ISBN 978‐80‐553‐ 1216‐3 INTRODUCTION method for reconfigurable manufacturing systems. Also, Souilah[8] presented methodology for the manufacturing systems layout design problem using simulated annealing. In the digital manufacturing field, much of the previous studies of simulation modeling for evaluation of exiting factory layout and suggestion of editable layout using commercial software were performed [9, 10]. M. Iqbal et al [2] proposed optimized method for improvement of factory flow and verified the layout using commercial software. Park et al [11] constructed the simulation modeling for evaluation and analysis of material flows in automotive body shop. These studies that are based on commercial simulation tools need much time consumption for high fidelity of production lines. In addition, studies for automotive layout design method were performed. Jhon et al [12] presented the partial implementation of a block‐ based layout editor and the basic research on layout compaction systems. Chris J. et al [13] proposes a generic methodology that provides a systematic way to design an optimal layout for all types of automated facilities. Park et al [14] presented automatic design method of assembly sequence modeling by integrating assembly feature information based on the ontology framework. These studies represent the simple production lines. Hence, the creation of complex layout is greatly restricted. International competition has heightened the need to high quality and low cost products that can complete in the global marketplace. To remain competitive, companies must not only continue to improve their products, but also strive to improve production systems continuously [1]. Factory layout involves the arrangement and selection of machines and material handling path, material handling devices, resulting in reduction in cost and time involved in manufacturing a product [2]. Therefore, layout design is an important factor that affects the performance of manufacturing system [3]. However, effective layout design is very difficult because layout design can be affected by variety factors (number of machines, part routing, product mix, material handling and part sequencing). To cope with the problem, modeling and simulation (M&S) techniques are needed. Simulation is an essential tool for the design and analysis of manufacturing systems that cannot be easily described by analytical or mathematical models [4, 5]. It is useful for calculating utilization statistics, finding bottlenecks, analyzing of factory material flow, and evaluation of factory layout. Those commercial simulation tools including ARENA eM‐ Plant and Auto‐Mod, have been widely accepted in industry; however, they are focused on the representation high fidelity of production systems. Thus, these tools need much effort to master. Therefore layout designers want to create easier and faster simulation tools. The main objective of this study is to devise simulation based layout design method. For implementation, this paper is written using the Microsoft Visual Studio 2010 MFC (Microsoft Foundation Class). The overall structure of the paper is as follows: Section 2 presents the related works, while Section 3 demonstrates the approaches. Section 4 gives a detailed description of the editable layout design method. Section 5 implemented layout editor. Finally, Section 6 concludes the paper and outlines. APPROACH This paper proposed simulation based layout design method which supports the decision making by layout designer based on their experience and know‐how. Figure 1 shows process for layout design of proposed method. Layout designer creates initial layout based on existing layout libraries, and initial layout simulates for performance analysis. If designed layout meets the optimal layout, the designer can make a decision layout. Otherwise, the designer needs to edit layout by recommended layout which considers critical factors. These procedures are repeated until optimal layout is found. Designed layout is saved as layout libraries. This paper employs layout editor, which is a simulation language based on DEVS formalism [15, 16]. The DEVS formalism [15, 16] specifies discrete event models in a RELATED WORKS The research for layout design in the area of manufacturing system is quite extensive. Saifallah et al[6] reviewed of emerging trends in design of next design factory layout. Yoram et al [7] proposed the layout 44 Part becomes finished product by sequence of operation. Part is waiting for buffer node until the connected work node is completed. such as assemble the part. we employed the DEVS formalism. δext: Q * X → S: external transition function Q = {(s. modular form. λ. ta> (1) Where: X: input events set. For the implementation of the model. S. Therefore. DS. Fig. The buffer node means waiting operation of part. part and link. S: sequential states set. machine and so on).1 Layout design process Within the formalism. Chang. Y: output events set. SC. Proposed simulator consider key factor for factory operation. e)| s ∈ S. δint: S → S: internal transition function. Fig. Part means the material for product. an atomic model M is specified by 7‐typle: M = < X. δint. Y. Fig. the sink node means the operation for drain of end product. This paper assumes infinity capacity of transport and buffer node. Formally.Ahn. The source node creates parts according to defined inter arrival time by user. Figure 4 shows the state transition diagram of five nodes. In addition. one must specify the atomic model. 0 ≤ e ≤ ta (s)}: total state of M. Figure 2 shows the example of atomic model [17]. The source node must be connected either transport node or buffer node. transport node. basic models from which larger ones are built. δext. The transport node is the operation which is the moving part. the proposed simulation model consists of five nodes. buffer node. The node means the object for operations (convey. work node. The node consists of five nodes: source node. The work node means the operation. Figure 3 shows the relationship between nodes. Finally.4 Atomic model of five nodes 45 . Fig. ta : S → Real: time advance function The four elements in the 7‐tuple namely δint. sink node. the link means to connect between nodes. layout designer are able to easy and quick modeling of factory layout using layout editor. store.2 The example of state transition diagram The layout editor consists of node. λ and ta are called characteristic functions. Park hierarchical.Simulation Based Layout Design E.3 Node process for suggested layout simulation LAYOUT DESIGN METHOD DEVS atomic model for layout editor As mentioned in the previous section. δext . λ : S → Y: output function. Fig. DS. increase the processing time and set up time Fig. parallel processing of transport node and increase the velocity in transport node. The editable input factor for buffer node is follows.E. the number of connected work node. time of creation connected source node. decrease the number of connected source node. If buffer node state is abnormal. Increase the number of connected transport node. In the case of that the number of accumulated part is over the reasonable part capacity in both transport node and buffer node. The editable output factor is decrease the number in connected buffer node. decrease of work node and increase the processing time and setup time of part in connected work node.Ahn. Chang. addition of work node and decrease the processing time and setup time of part in connected work node. it is case 2. The editable input factor for buffer node is follows. The editable input factor consist of the number of connected source node. The editable output factor is decrease the number in connected buffer node. it is case 3. decrease the creation time of part in connected source node. addition of work node and decrease the processing time and setup time of part in connected work node. increase the creation time of part in connected source node. decrease the processing time and set up time in connected work node. The editable output factor is increased the number in connected buffer node. it should be editing input factor. The editable output factor for buffer node are increase the number of connected work node. If transport node state is abnormal. The editable output factor are the number of connected work node. The editable output factor is decreased the number in connected buffer node.5 Basic layout If capacity of transport and buffer node is infinite. The editable input factor for buffer node is as follows: Decrease the number of connected transport node.8 Editable layout of case 3 The editable input factor for transport node is as follows: Increase the number of connected source node. it is case 4. The editable attribute for transport node are decreased of length. The editable output factor for buffer node are decrease the number of connected work node. The editable attribute are length. The editable attribute for transport node are increase of 46 . Park Simulation Based Layout Design Method of editable layout design In this section we proposed four editable layouts through situation of transport and buffer node. In the case of that the number of accumulated part is below the reasonable part capacity in both transport node and buffer node. the number of connected work node. The editable input factor consist of the number of connected source node. it should be editing input factor and output factor. it represents four kinds of abnormal situation of material flow in the factory. Figure 8 shows editable layout for case 3. unify processing and parallel processing. The editable output factor is decrease the number in connected buffer node. time of creation connected source node. it is case 1. Decrease the number of connected transport node. Fig. decrease the number of connected source node. The editable output factor is the number of connected buffer node. and decrease the creation time of part in connected source node. Fig. Figure 7 describes editable layout for case 2. the number of connected transport node. whereas the number of accumulated part in the buffer node is below the reasonable part capacity. The editable attribute for transport node are increase in length. The editable output factor for buffer node are increased the number of connected work node. increase the processing time and set up time in connected work node. If the number of accumulated part in the transport node is over the reasonable part capacity. Figure 6 describes editable layout for case 1. unification of transport node and decrease the velocity in transport node. SC. processing time connected work node and set up time connected work node. increase the number of connected source node. and increase the creation time of part in connected source node. output factor and attribution of transport node. unification of transport node and decrease the velocity in transport node. whereas the number of accumulated part in the buffer node is over the reasonable part capacity. length. The editable output factor is increased the number in connected buffer node. decrease the creation time of part in connected source node.7 Editable layout of case 2 The editable input factor for transport node is as follows: Decrease the number of connected source node.6 Editable layout of case 1 The editable input factor for transport node is as follows: Increase the number of connected source node. Figure 5 illustrates basic layout. If the number of accumulated part in the transport node is below the reasonable part capacity. and increase the creation time of part in connected source node. processing time connected work node and set up time connected work node. Figure 11 shows the result of initial layout model and simulation. Figure 9 shows editable layout for case 4. Fig. The editable output factor is increase the number in connected buffer node. This advantage provides rapid and reasonable design and modification for layout using the result from the simulation that represents unexpected situation at the initial status. this paper employs Discrete Event Systems Specifications (DEVS) formalism. 13 The result of edited model and simulation 47 .12 Selection of editable layout CONCLUSIONS This paper proposes simulation based layout design method. The editable output factor is increase the number in connected buffer node. Figure 12 shows the selection of editable layout. Moreover. and decrease the creation time of part in connected source node. The layout editor can make model and simulation for initial layout. decrease of work node and increase the processing time and setup time of part in connected work node. Chang. and decrease the processing time and set up time in connected work node.Simulation Based Layout Design E. Fig. this paper presents layout design process and layout editor. Users are able to initial layout modeling and simulation. The layout editor makes modeling and simulation for initial layout.10 Layout editor IMPLEMENTATION We have implemented layout editor using Microsoft Visual Studio 2010 MFC. increase the number of connected source node. Layout editor can be recommended the editable layout by each case. Park in connected work node. In order to describe the proposed methodology. Fig.11 The result of initial layout model and simulation Fig. SC. layout is automatically remodeled. The editable attribute for transport node are decrease of length. This paper introduces recommendable layout to respond each situation of four types. and increase the velocity in transport node. Fig. If users select the option. users can select an option according to each case considering simulation results. parallel processing of transport node. Figure 10 describes layout editor. For the implementation of the proposed layout editor. The proposed method for editable layout design in this paper allows layout designer to swiftly generate assembly lines with consideration of key factors. The editable input factor for buffer node is as follows: Increase the number of connected transport node. If users select the option. The editable output factor for buffer node decrease the number of connected work node.9 Editable layout of case 4 The editable input factor for transport node is as follows: Decrease the number of connected source node.Ahn. The result from the simulation of layout is classified as four types along the states of buffer and transport nodes. layout is automatically remodeled. Figure 13 shows the result of edited model and simulation. increase the creation time of part in connected source node. DS. This is the recommended the editable layout by each case. Nodes of ‘buffer’ and ‘transport’ are set infinite capacity. P. Hashmi. Kyoung Son Jhang. DEVSIM++ v3. pp130‐141. 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Theory of modeling and simulation. 2010 [15] Zeigler. Klingstam. Korean Simulation Association. National IT Industry Promotion Agency. [17] Tag Gon Kim.J. DS. Vol. the Agency for Defense Development (UD080042AD) and Korea Research Foundation (2010‐0021040) REFERENCES [1] Man‐soo Han and Dong‐Jo Park. Sung Won Hong. H. Vol. B. Also it is stated that residual stresses can be used for enhancing mechanical properties. To procure a bond between matrix and fibre hot pressing or epoxy resin is used. 2nd International Conference Manufacturing Engineering & Management 2012. Resiny manufacturing method is simpler than hot pressing method. In the finite element analyses. After the manufacturing of composite plate. In symmetrical laminated plates. Experimental methods are used for obtaining mechanical properties of composite structure Methods: and finite element method is used for elasto‐plastic stress analysis. Initiation of plastic deformation in a composite material is determined by the help of a yield criterion. Thus. A numerical method for Citation: Atmaca A. elasto‐plastic stress values are calculated for (0/90o)2 symmetrical cross reinforced and (15/‐15o)2. Hitit Üni. 49‐52. Mühendislik Fakültesi Çevre Yolu Bulvarı No: 8 19030 Çorum. high affinity of aluminum to oxygen does not engender a disadvantage. (45/‐45o)2 symmetrical angular reinforced laminated aluminum metal matrix composite plates. Mühendislik Fakültesi Yükseliş Sok. This study is constituted from three stages. p.edu. Previous studies about stress analysis of composite plates are examined. a metal matrix composite plate is obtained. elasto‐ plastic finite element based stress analyses are executed using ANSYS computer packaged software. First of all. Sayman investigated the elasto‐ plastic behavior of simply supported stainless steel reinforced aluminum metal matrix laminated composite plates under transverse [4] and in‐plane [5] loads using finite element technique. Residual stresses occur in the material because of the deformations arising from plastic stresses [1. investigated the elasto‐plastic stress‐strain behaviors of metal matrix composite materials using finite element method [3]. Sayman stated that composite structure increases yield strength and rigidity.Contents lists available at www. Hitit Üni. Matrix material of the composite structure is aluminum plate and reinforcement material is steel fibre. Tensile and shear tests are carried out to obtain necessary data for elasto‐plastic stress analysis. Tsai‐Hill Theory is used as yield criteria in the analyses.
[email protected] Manufacturing Engineering & Management The Proceedings Elasto-Plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates Alper Atmaca1 ‐ Osman Selim Türkbaş2 ‐ Muhammed Emin Erdin3 ‐ Halil Aykul4 1 Machines Technical Program. Elasto‐ plastic situation of the material is characterized as the permanent deformations on the material after elastic region is exceeded and a specific stress value is reached. Mühendislik Fakültesi Çevre Yolu Bulvarı No: 8 19030 Çorum.edu. Meslek Yüksekokulu Samsun Cad. It is seen that. Steel fibres are placed on the matrix in only one axis.tr 4 Mechanical Engineering Department. Composite material is manufactured. finite element based elasto‐plastic stress analysis is executed using ANSYS packaged computer software. et al. Composite structure is subjected to heat treatment for an hour in 80 oC for gelling and hardening of epoxy resin. : Elasto‐plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates.tr Mechanical Engineering Department.edu. composite COMPOSITE STRUCTURE Two 5083 series aluminum plates are prepared in the dimensions of standard tensile test sample. new searching about materials became compulsory. Hitit University. Chemical composition and mechanical properties of aluminum is given in Table 1 and Table 2 respectively. Composite plate properties and quality differences are corresponded in terms of manufacturing method. Türkiye. turkbas@gazi. it is understood that has no contribution on the strength of composite material but it is a very good adhesive indeed. 2]. From the performed mechanical tests. To find the plastic behavior manner of the material. eminerdin@hitit. Purpose of this study is to determine plastic behavior of composite materials. Gazi Üni. No: 99 19169 Çorum. 7]. To meet the material requirements of developing technology.. a combined structure is developed which is formed by joining two or more different materials in macro level. (30/‐30o)2. Hitit Üni. Development of technology gained a great acceleration during the last century. simple tensile and shear tests are performed to achieve engineering constants and mechanical properties of the composite structure. tensile strength of composite material increases with the increasing fibre ratio. Types and usage areas of composite materials are increasing day by day. Composite plates with aluminum metal matrix show elasto‐plastic behavior during forming operations.icmem.tr 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 2 November 2012 / Revised: 8 November 2012 / Accepted: 13 November 2012 Keywords: (in causal order) Abstract: Composite Plates Aluminum Matrix Steel Fibre Reinforcement Elasto‐plastic Stress Finite Element Analysis Background: obtaining displacements and stresses in composites is presented. In the final stage.tr Mechanical Engineering Department. Besides. In this method. (2012). halilaykul@hitit. Manufacturing techniques are compared. No: 5 Maltepe/Ankara. 49 . plate is simply supported from all of the sides to prevent them to move in x and y directions. Materials that are procured from nature cannot keep up with this development. Daining et al. Türkiye. Hitit University. Stress distributions for different orientation angles are calculated using finite element Results: analysis. Hitit University. This new structure which is called composite material has the superior properties of the materials which form itself. Türkiye. Türkiye. ISBN 978‐80‐553‐1216‐3 INTRODUCTION material is manufactured using two different methods which are hot pressing method and resiny method. Minimal stresses and yielding regions are Conclusions: specified. Gazi University. Özben and Arslan investigated the elastic and plastic behavior of laminated composite plates under transverse loads using finite element method [6.edu. 65 Ni <0.1 Chemical composition of 5083 series aluminum Element % Mass Element % Mass Cu <0.1 A sample of manufactured composite plate 50 . Tab.10 Thickness of the obtained composite structure is more than 3 mm. at 20 oC 60~100 Overall Hardening Time [week]. et al.5 Mechanical properties of composite material Property X [MPa] Y [MPa] S [MPa] Value 130 104 49 Property k [MPa] n [‐] ν12 [‐] Value 2570 0. A manufactured sample of composite plate is seen in Figure 1. So is initial cross‐sectional area and 5.3 Graphical output of the tensile testing Necessary mechanical properties of composite material for elasto‐plastic stress analysis are obtained from the results of tensile tests as given in Table 5. Fig. resin is hardened and bond is procured between aluminum matrix and steel fibres. at 20 oC 1.3 Epoxy resin composition and properties Component Number 2 (A & B) Massive Mixture Ratio (A/B) 50/50 Volumetric Mixture Ratio (A/B) 50/50 Mixture Density [gr/cm3]. The samples for tensile tests are prepared according to TS 138 EN 10002‐1 standards. A snapshot from the shear testing operation is seen in Figure 2 and graphical output of the tensile testing is seen in Figure 3.18 Ti <0. Lo = 5. Tab. at 23 oC 1 Steel fibres of 150 mm length are placed on resiny aluminum plates. the model is simply supported to prevent motion Fig.4 Mechanical properties of steel fibre Property Value X [MPa] 675 Y [MPa] 675 E [GPa] 200 Fig.65(So)1/2 where Lo is initial gauge length of the sample.2 A snapshot from shear testing operation Ρ [kg/dm3] 7 Some more resin is applied on steel fibres and the other aluminum plate is placed on them. the gauge length is calculated with below equation.5 Mixture Life [min. Resin composition and properties is given in Table 3.A.20 Mg 4. A four laminated plate of 50x50x3.10 Zn <0.05 Mn 0.74 Cr 0. Tests are performed in Hitit University Engineering Faculty Laboratories with 100 kN computer controlled Shimadzu Autograph Universal Testing Machine.65 is a coefficient related with the thickness of the tensile sample. 200 gr. A special apparatus is used in tests for preventing shear between matrix and fibres.8 mm. After heat treatment as mentioned above.08 Tab. Atmaca. Tab.2 Mechanical properties of 5083 series aluminum Property X [MPa] Y [MPa] E [GPa] Value 104 104 70 Property G [GPa] δ5 [%] ρ [kg/dm3] Value 26 30~38 2.].08 Fe 0. EXPERIMENTAL STUDY Tensile and shear tests of composite structure is performed for finding necessary mechanical properties of composite material for elasto‐plastic stress analysis. Mechanical properties of steel fibre are given in Table 4.2 mm dimensions is modeled in which thickness of each plate is 0.62 0. Elasto-plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates Tab. Si 0.33 Property G12 [GPa] E1 [GPa] E2 [GPa] Value 41 110 87 ELASTO‐PLASTIC STRESS ANALYSIS Elasto‐plastic stress analyses are executed in Hitit University Engineering Faculty using ANSYS packaged software.7 Paksoy resin is prepared by mixing components A and B in a container for approximately 3 minutes and applied on the aluminum plate. Thus. Plates are slightly compressed by hand to avoid pores on structure. RESULTS & CONCLUSION Elasto‐plastic stress analyses results for all symmetry and orientation situations in critical nodes (A. D and E which are seen in Figure 5) are given in Table 6. A. et al. is the elasticity modulus and ν.4 Finite element model of the elasto‐plastic stress analysis problem The solution procedure for above mentioned mechanical problem will be described step by step thereinafter.6 Stress variation on composite plate . Fig. 1 0 1 0 1 1 0 0 2 In this equation.B. Atmaca.5 Stress distribution on finite element model Stress variation from the side of composite plate to the center is seen in Figure 6. is the Poissons ratio. Finally. . B. superscript „e“ indicates element and det = ‐ where J is the Jacobean Matrix. C. Then Overall Rigidity Matrix is constituted by combining Element Rigidity Matrices. Stress‐Displacement Matrix (B) is found for all elements. .q In this equation. Direct Stiffness Matrix (D) of all elements and the whole model is found. Fig.q where F indicates forces in nodal points. Displacements are calculated from the equation F = k. stresses are calculated from Ludwig Equation which is given below. stress matrix (σ) is obtained in the form of . Stress distribution on finite element composite model is seen in Figure 5. . The model is divided into elements of finite number. These stresses are replaced in the Tsai‐Hill equivalent stress equation which is given below. If the equivalent stress is more than the yield strength (X). In this equation. Rigidity Matrix is found for all elements. 0 0 0 1 0 0 0 det Fig. 51 .6 Results of the elasto‐plastic stress analyses If the equivalent stress is less than the yield strength (X). where is the yield strength of the material. elasticity limit is not exceeded and plastic analysis is not necessary. E. stress values are calculated from the equation σ = D. K is the strength coefficient and n is the strain hardening exponent.Elasto-plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates in x and y axes. Tab. The model is subjected to a pressure of 10 MPa as shown in Figure 4. In symmetrical orientation. “Finite Elements in Plasticity”. Computers & Structures. temperature strength is limited by the decomposition temperature of the resin which is 250 oC for the Paksoy resin used in this study. “Plasticity Theory and Application”.. 593 (1980). yielding occurred only in the central region In antisymmetric orientation. T. 895‐912 (2009). minimal plastic o region occurred in (0/15 )2 reinforcement angle. oxidation is an important problem. A.. [7] Özben. et al... H. 303‐309 (1996). Arslan. 75 (1).R. T. [6] Özben. 55‐63 (2000). C.. Q. N. 52 .A.J. maximal stress occurred in (15/‐15o)2 reinforcement angle and minimal stress occurred in (0/90o)2 reinforcement angle..K. [2] Owen. F. Akbulut.. thus thickness is more in resiny method than hot pressing method. 6. T. 44 (3). In symmetrical orientation. Arslan. Resiny method is simpler and cheaper than hot pressing method.. 349 (1968). In hot pressing method. In symmetrical orientation.. Elasto-plastic Stress Analysis of Steel Fibre Reinforced Aluminum Metal Matrix Composite Plates Conclusions from the performed analyses are listed below: Resin has no effect on strength of the composite structure. New York. yielding occurred in central region and corners. U. “FEM Analysis Laminated Composite Plate with Rectangular Hole and Various Elastic Modulus under Transverse Loads”. [3] Daining. “Elasto‐plastic Stress Analysis in Stainless Steel Fiber Reinforced Aluminium Metal Matrix Laminated Plates Loaded Transversely”. The Macmillan Company. Hinton.. Atmaca. “Expansion of plastic zone and residual stresses in the thermoplastic‐matrix laminated plates ([0°/θ°]2) with a rectangular hole subjected to transverse uniformly distributed load expansion”. O. Computational Materials Science. In antisymmetric orientation. Composite Structures. Pineridge Press Limited. D.. E. Hang. minimal plastic region occurred in (15/‐15o)2 reinforcement angle. 34 (7).. [4] Sayman. O.. In resiny method. structures of fibre and matrix materials change and their strength values decrease because of high temperatures. maximal stress occurred in (0/90o)2 reinforcement angle and minimal stress occurred in (0/15o)2 reinforcement angle. 43. [5] Sayman. 1746‐1762 (2010). “Elasto‐plastic Stress Analysis of Aluminium Metal Matrix Composite Laminated Plates under In‐plane Loading”. Computational Materials Science. REFERENCES [1] Mendelson. 147‐154 (1998).. Meriç.. “Elastic and Plastic Properties of Metal‐Matrix Composites: Geometrical Effects of Particles”. In hot pressing method. In resiny method fibres do not penetrate into matrix. N. In antisymmetric orientation. Shangdong. Density of resin is low and has no negative effect on weight of the composite structure. Swansea. Applied Mathematical Modeling. 2nd International Conference Manufacturing Engineering & Management 2012. The experiments were executed with the equipment “GOM” and software application “ARAMIS”. Both applications were used for measuring 3D changes of the shape (of an object) and for determining the distribution of deformation due to either static or dynamic loads.4].4]. p. calculate and report the deformation of parts of the structure or entire structure. Long side compression strength are presented on the figure 2 and 3. equally distributed along the side. (2012). This article will show how we can predict experimental results by the means of finite element analysis. 53‐55. Numerical analysis was conducted by the application of finite elements using “KOMIPS” software.tk Manufacturing Engineering & Management The Proceedings Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure Sevket Celovic1 ‐ Tasko Maneski2 ‐ Tomaz Vuherer3 ‐ Milos Tipsarevic4 ‐ Milorad Zrilic5 1 PhD student Faculty of Mechanical Engineering Belgrade Faculty of Mechanical Engineering Belgrade Faculty of Mechanical Engineering Maribor. The equipent typically consited of two mobile optical digital stereo cameras supported by „ARAMIS“ software applications [3]. non‐homogeneous. et al. Slovenia 4 Danfoss. Experimental and numerical analysis results to date have shown high degree of correlation. was 4023 N (400 kg). Denmark 5 Faculty of Technology and Metallurgy Belgrade 2 3 ARTICLE INFO: Category : Preliminary Communication Received : 31 October 2012 / Revised: 15 November 2012 / Accepted: 15 November 2012 Keywords: (in causal order) Abstract: FEM Buckling Numerical Experimental Foldable Plastic Packaging This paper describes the experimental and the numerical methodology for analysis of plastic packaging buckling characteristics that are representative of its strength in the real life. Citation: Celovic S. Here are the fields of application of such measurement equipment: 3D deformation. we find this is a very strong learning tool that would enable designers to improve the structural strength of new products in future.icmem. isotropic and anisotropic materials Creep testing and ageing effects of complex structures NVH testing in car industry and also in an aerodynamic tunnel Calculation. This equated to 1341 kg of linear force acting upon entire length of the top face of the crate. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Numerical analysis was conducted by the application of finite elements using “KOMIPS” software [1. Total compressive load pointing downwards. NUMERICAL FEM ANALYSIS OF PLASTIC FOLDABLE PACKAGING IN BUCKLING Long side FE models include the bottom face simply supported (surface support) and load continually applied to each node of the top face pointing downwards (Figure 1) [1.: Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure . We wanted to point out the advantages of applying modern optical 3D measuruent of deformations in identifying buckling effects generated due to compressive loads. The fundamental of analysis is related to the mechanism of failure of foldable packaging. 53 . movement and vibration detection Measuring of dynamic behavior for up to 25Hz Linear and non‐linear behavior of viscous‐elastic materials Testing of homogeneous.1 Numerical model Modulus of elasticity was E=1200 MPa.Contents lists available at www. „ARAMIS“ can analyse. The fundamental question we wish to answer is related to the mechanism of failure of foldable packaging – does the buckling precedes plasticity or vice versa. visualization and display of the position of measurement points in different phases of test Verification of the FE results Fig. 5 mm Fig.59 < 5 we conclude that buckling would preceede the plastic deformation.S.7 mm. Lateral deformation in horisontal plane of the top edge middle point was 0. Natural frequences and the modes shapes for first three modes are shown on the figure 4.4 First three modes oscilations Buckling force estimate based on static and dynamic analysis are: Static calculation: linear elastic limit to stress is 27 MPa / 5.3 Stress field of long side The based of buckling analysis for the long side are calculated natural frequency and main mode oscilation. First mode.3 mm 54 . Maximum horisontal lateral deformation of the top edge middle point is 6. Dynamic calculation: amplitude in the first mode to deformation due to static force is 3.8 tonnes). Natural frequency: 32. Natural frequency. Experimental verification [2] of the previous numerical analysis was executed with the described equipment for 3D optical deformation measurements on the Instron testing machine.3 mm Fig.7 mm (figure 5). Natural frequency: 61.92 mm. (4. Vertical deformation of top edge was 1 mm. Fig.7 Hz. Buckling was determined by the means of 3D optical measurement equipment.2 Deformation of long side Von Misses Stress [MPa] (Max 5. Estimated buckling force would be Fbuck = 67050 N 3.41 MPa) EXPERIMENTAL ANALYSIS OF PLASTIC FOLDABLE PACKAGING IN BUCKLING Fig.3 mm / 0. The measured vertical deformation was 1.4 hz. Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure Maximum total spatial deformation was 3. The shown analysis of the buckling force and the load carrying capacity was not a finction of the modulus of elasticity.92 mm = 3. Results are shown on the following picture. Celovic et al. 65. This determined the load carrying capacity of the crate in compression. Second mode.9 Hz. As 3. Maximum horisontal lateral deformation of the top edge middle point is 6.59 / 5 = 48142 N.5 Experimental verification Next example are buckling effects which appeared much before the plastic deformation with experimental analysis (figure 6).4 MPa = 5. Maximum horisontal lateral deformation of the top edge middle point is 3. Third mode.59. Germany [4] Software KOMIPS.1:678. Monografy. This type of analysis is applicable to a wide range of structural problems with diverse loading patterns... Faculty of Mechanical Engineering 55 .. Computer modeling and structure. UDK 621.798. The difference is that the previous conventional observations of deformations could only detect the consequence of buckling (structural failure) where the 3D optical equipment enabled us to also understand the root‐ cause. REFERENCES [1] Maneski.6 Experimental buckling analysis CONCLUSIONS The methodology described here showed satisfying results regarding the buckling effects on plastic packaging. GOM. Nestorovic B. Belgrade (1998) [2] Maneski T.5 [3] Software ARAMIS. T. Fig. Celovic et al.Experimental and Numerical Analysis Of Foldable Plastic Packaging Buckling Failure S. Faculty of Mechanical Engeneering. We gained conclusions about the root‐causes of the buckling. The analysis was consistent with all previously conducted observations of container behaviour due to compressive loads. Validation numerical modeling with 3d optical measurement of deformations of foldable plastic packaging buckling failure. SAJ _ 2011 _ 3. 9 per cent of the total number of active enterprises in Albania. In terms of geographical location of enterprises. E‐mail: fcucllari@ymail. This paper was aimed at highlighting the importance of human resources management on the performance of the SMEs sector. (Fig. Other regions with a strong presence of SMEs are the regions of Fier.Contents lists available at www. Vlora and Korce. the region of Tirana‐Durres has a higher concentration of private Fig.8 per cent). Shetitore “Rilindasit”.com 2 3 ARTICLE INFO: Category : Short communication Received : 31 October 2012 / Revised: 2 November 2012 / Accepted: 10 November 2012 Keywords: (in causal order) Abstract: Small and medium enterprises (SMEs) continue to be the backbone of the EU economy. the number of active businesses till the end 2010 reached 100. Albania. Shetitore “Rilindasit”. The sectors of trade and services provide 42. by evoking the experiences and challenges of business environment in Albania.5 per cent of the private sector employment.2 Distribution of SMEs by sector of industry [10]. In section 3 highlights the relationship between the performance of SMEs and human resources management. Against this background. : The impact of human resources management on the performance of small and medium enterprises in Albania . Based on INSTAT (2011) data. SMEs represent 99. 56 . This is demonstrated by the fact that SMEs represent 99. The analysis based on national statistics show that it is very hard for SMEs to sustain the human resources development in order to increase their performance. The SMEs contribution in employment is around 66. In sectoral terms 75 percent are in trade and services. national surveys on SMEs in Albania. ISBN 978‐80‐553‐1216‐3 Albania Human resources management Small and medium enterprises INTRODUCTION enterprises. Diber (2 per cent) and Lezhe (2.com Fan S. Shetitore “Rilindasit”. About 50 per cent enterprises are located in regions of Tirana and Durres. Fig.9 per cent). (Fig. this paper will end up with the conclusion. European Commission and some empirical studies. 62 per cent. Albania.9 per cent [5]. 1). (2012). 2nd International Conference Manufacturing Engineering & Management 2012. 56‐58. et al.9 per cent of the total number of active enterprises in Albania [5]. The SMEs activities in Albania are focused in the local market. About 92 per cent of total enterprises are with 1‐4 employed (services and trades sectors are dominated by micro‐enterprises). Finally. The aim of this paper is to discuss the importance of human resources management on the performance of the SMEs sector in Albania.1 Territorial distribution of SMEs and employment [9]. Citation: Cucllari F. The birth rate of new enterprises for 2010 is 16 per cent higher compared to 2009. Albania.icmem. SMEs represent a crucial sector of the Albanian economy because they provide a significant contribution to economic growth. Innovation. p.tk Manufacturing Engineering & Management The Proceedings The Impact of Human Resources Management on the Performance of Small and Medium Enterprises in Albania Frederik Cucllari1 ‐ Mirela Cini2 ‐ Aida Gabeta3 1 Fan S. The most part. SMES AND ITS ROLE IN ALBANIAN’S ECONOMY Albania’s SME policy is based on the European Charter for Small Enterprises and the country is committed to implementing the Small Business Act for Europe. employment creation.9 per cent of all active enterprises and 73 % of GDP. Albania’s definition of SME is in line with the EU’s as regards the number of employees and autonomous partners and linked enterprise concepts. The lowest percentages of businesses are in the regions of Kukes (0. 7001 Korce. E‐mail: gabetaaida@yahoo. The analysis is based on statistics come mainly from Institute of Statistics (INSTAT). 7001 Korce. Human resource development. the factors influencing the level of development of the SMEs sector in Albania are the following: Financing schemes. which is mainly based on SMEs. SMEs represent 99. but is the condition to succeed. This territorial distribution of SMEs generally reflects the discrepancies in term of region size and economic development level but reveals facts describing the specific conditions of SME sector development.com Fan S. The paper is organized as following: Section 2 provides an overview of the Albanian SMEs and its role in national economy. In Albania. Noli” University. 7001 Korce. have only self‐employer. E‐mail:
[email protected] which show a growth of 1 per cent comparing to 2008. Noli” University. 2). Noli” University. poverty reduction and social development. The small business sector is well represented in Albania and is similar in structure to the EU’s [4]. or ‘best practice’ human resources. The results of this study show that incidence of training increase with size of business: while fewer ten per cent of the smallest businesses provided any type of training. et al. businesses structures. life cycles stages and ownership. Knowledge. Although past research findings are generally positive. selective hiring. The table (Tab.The Impact of Human Resources Management on the Performance of Small and Medium Enterprises in Albania F. skills. as well as encouraging employees through empowerment. and. most studies emphasise enhancing the skill base of employees through selective staffing. delegation with confidence. each with varying content and with different ways of operationalising the individual human resources activities. motivation. training. participative problem solving and teamwork and group based incentives. Tab. and its policies are guided by European standards and practices. employee appraisal. Cucllari. The survey findings indicate that most enterprises regard human resource development as a high priority. CONCLUSION To further support and promote economic growth. argued there is a general agreement that (1) human capital can be a source of competitive advantage. indirectly. production.3 Types of training provided. allowing for a higher degree of innovation and productivity enhancements. But at their heart. Priority has been given 57 . therefore. their willingness to learn and to use what they learned in their work [3]. Tab. The understanding of the value of enterprise’s human resource is less developed among Albanian enterprises. Pfeffer [11] listed seven human resources practices: employment security. and sharing information. but relatively few provided training. (2) that human resources management practices have the most direct influence on the human capital of a firm. The centralization of power and decisions to one person or small management group is an indication of a less development human resource management system. (Fig. by size of the enterprise[1]. Human resources management practices Human resources management outcomes Selection Commitment Training Appraisal Quality Rewards Job design Flexibility Involvement Status and security Behaviour outcomes Performance outcomes Effort / motivation High: Productivity Cooperation Quality Innovation Involvement Low: Absence Organisational Labour turnover citizenship Conflict Customer complaints In the majority of the SMEs in Albania the person with responsibility for human resources development issues is the owner. It signed the European Charter for Small Enterprises. comprehensive training and broad developmental activity. Fig. setting goals for others. The results of the training and development survey made in the year 2010 [1] show a concern limited to the Albanian SME sector for the development of training activities. Albania took a series of measures to support private sector and foster business start‐ups. Appropriate human resources management practices can improve employee motivation and identification with the employer company.1 Best practices in human resources [12] There are several lists for high performance work practices.2 Linking human resources management and performance [3] THE RELATIONSHIP BETWEEN THE PERFORMANCE OF SMES AND THE HUMAN RESOURCES MANAGEMENT. Table 2 illustrates how human resources management practices can influence the behaviour of workers and. Human resources management covers a wide range of activities. The most important reason for training employees appears to be related to providing job performance. which in turn acts as a constraint that negatively affects the overall performance of the enterprise and slows down growth. Delery and Shaw [2]. self‐ managed teams. and (3) that the complex nature of human resources management systems of practice can enhance the inimitability of the system. coaching people and team management are some of the key topics that will create a positive human resource management system within the enterprises. there is still some uncertainty about how certain types of human resources management practices influence business performance outcomes. The impact of human resource management on performance has become the dominant research issue in this field [6]. in terms of its potential impact on business performance. in conjunction with organizational performance objectives. company performance. reduction of status differentials. high compensation contingent on performance. 3). Numerous studies identified the critical contribution of human resources management practices to specific firm outcomes. but only few studies focusing on the link between human resources management practices and SMEs performance. 1) below shows best practices human resources [12]. empowerment. The performance of SMEs in Albania is quantified according to criteria of appreciations of the employees by the entrepreneurs. Generalizations in Albanian SMEs are difficult because of the different characteristics in the size. Trends and future prospects of training and development in Albania.gov. Luxembourg. D. J.. 10. 8..al [11] Pfeffer. SBA Fact Sheet 2012 – Albania. Cucllari. Annual Statistical Bulletin 2010. METE. Structural survey of enterprises. E.. Vol. The Impact of Human Resources Management on the Performance of Small and Medium Enterprises in Albania sized enterprises in the EU. 39. 2010. 1997. 2011.F.europa. 2011/12. The human equation: building profits by putting people first. The strategic management of people in work organizations: review. Snell. J.mete.A. and Gabeta. Albania in figures 2010. Tirane. behaviours and outcomes can be measured in economic and social.. [5] European Commission. Delery. http://www. http://www. A major role in development of SMEs rests with the human resources management. Boston: HBS Press.gov.E.D. but relatively few provided training.al [9] METE.W. Dean. and Lepak. Cucllari. Rotterdam. F. Tirane. in terms of its potential impact on business performance. Human Resource management and performance: a review and research agenda.instat. European Commission. 1996.P. to the development of small and medium businesses. p. J. Tirane. A. Tirane. Annual report on small and medium‐ 58 . and J. INSTAT. manufacturing strategy and firm performance. p. http://ec.. synthesis.al [10] METE. Shaw. and extension. Vol. Research paper No.. REFERENCES [1] [2] [3] [4] Cini. No. 2012. Academy of Management Journal. skills. 2012. available at. 2011.al [8] INSTAT.gov. Issue 3. Transformations in Business & Economics. 836‐866. S. [12] Youndt. 2011. INSTAT.. available at. The impact of vocational education and training on company performance. http://www. 2011:1.137‐150.pdfand [6] Guest. 1998. Strategic programme for innovation and technology development of the SMEs for the period 2011‐2016. M.C. M. paper presented at the Academy of Management Meeting 2001 in Washington D. D. Human resource management. 2011. available at. and relying on a more rational use of local resources. et al. p. 2011. Human resources practices complement pathways by which performance analyzed in terms of knowledge. [7] INSTAT. mainly by supporting the development of extraction and processing industries and non‐food industries. European Centre for the Development of Vocational Training (CEDEFOP). The most Albanian enterprises regard human resource development as a high priority.eu/enterprise/policies/sme/facts‐ figures‐analysis/performance‐review/files/countries‐ sheets/2012/albania_en. A.gov. EU SMEs in 2012: at the crossroads. September 2012. The International Journal of Human Resource Management.instat. 19. 2 (23). 2001. http://www.mete.263‐276. Professor.Jet tab and dome deflector TVC are the members of mechanical systems with fixed nozzles. 59‐63. p. University of Belgrade. 2 International Conference Manufacturing Engineering & Management 2012.: Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison. makes system’s control relatively easy. Serbia 5 PhD Mechanical Engineering. Professor. was developed as a part of the national program for the research and development of the low cost cosmic transportation systems.Dome deflector is similar to a jet tab. Belgrade. The downside of this system is that. presented in the paper. so it has performance that is essentially better than performance of a jet tab system. disrupting the flow. Serbia 4 PhD Mechanical Engineering. to create side force. All of this contributed to the efficiency of control engineers.tk Manufacturing Engineering & Management The Proceedings Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison Nikola Davidović1 ‐ Predrag Miloš2 ‐ Branislav Jojić3 ‐ Đorđe Blagojević4 ‐ Marko Miloš5 1 PhD Mechanical Engineering. because of their simplicity. Faculty for Mechanical Enginering University of Belgrade. at the end of the nozzle that can be rotated in and out of the nozzle. Serbia. Research Engineer. Jet tab and dome deflector thrust vector control (TVC) systems were chosen to be the object of the research. Initial advantages of thrust deflection. Mechanical systems are based on different mechanical obstacles. which are used to modify flow around obstacle and/or in the nozzle and consequently changing pressure distribution.Contents lists available at www. Research in the field was initiated in the Jet Propulsion Laboratory of Mechanical Engineering Faculty University of Belgrade in 1983.davidovic@edepro. The jet tab system involves a plate. such as being proportional to the tab area exposed to the flow. jet tab (spoiler). Several mechanical TVC systems have been developed since: jet vane. which causes not only nozzle walls. Jet tab and dome deflector were selected to be the objects of the research because of their simplicity. axial blocked area in nondisturbed region in nozzle critical exit obstacle front obstacle back relative axial direction lateral direction relative blocked whatever is being done. but also dome itself. in operating principle. EDePro. INTRODUCTION Thrust vector control (TVC) is used in rocket propulsion to control rocket’s flying path. EDePro. Belgrade. The stalled flow causes severe erosion inside the nozzle and also additional losses. Mathematical model was built on the fundamental test data and compared to the real rocket motor test data. since it depends on engineering design and control parameters. Mathematical model. domed deflector and domed segmented deflector. Fig. Serbia.icmem.1. when the tab is in the fluid stream. Serbia 2 3 ARTICLE INFO: Category : Technical Note Received: 2 November 2012 / Revised: 14 November 2012 / Accepted: 15 November 2012 Keywords:(in causal order) Abstract: Thrust vector control Nozzle Jet tab Dome deflector Test Research and accompanying mathematical model were realized within the national program for the low cost cosmic transportation systems development.com PhD Mechanical Engineering. Derived method of TVC performance prediction is in alignment with the measured values and presents a reliable engineering tool. Faculty for Mechanical Enginering University of Belgrade. Faculty of Mechanical Engineering. et al. nd Citation:Davidović N. it is proportional to blocked area.1 Segmented dome deflector at solid rocket motor nozzle (R73 air to air rocket) 59 . comparing to other TVC systems. axial jet deflector.. ISBN 978‐80‐553‐1216‐3 NOMENCLATURE A Cf F Fo h K Ls M P Po rc Xiz αd β θ δ 1 a b c cr e of ob r x y z Area (m2) thrust coeficient force (N) thrust without TVC (N) obstacle height (m) ratio of thrust side to loss force position of shock wave measured from exit (m) Mach number pressure (Pa) total pressure before shock wave (Pa) nozlle radius (m) nozzle wall length from throat to exit (m) nozlle divergence angle (rad) obstacle nozzle angle (rad) thrust vector angle (rad) obstacle relative gap parameters just before the shock wave area in disturbed region in nozzle. emai: milos. but its geometry is 3‐dimensional. internal maneuvering vanes.com PhD Mechanical Engineering. (2012).email: nikola. the flow stalls on the tab. Associate Professor. abundance of previous tests and data. Research Engineer. jetavator. and the fact that Fig.predrag@edepro. after separation point. logically. This important facts we took into account for modeling. 4 laboratory tests with flow visualization. Fig. when testing real solid rocket motor boundary layer is not isothermal. thus allowing for the mass interchange between zones. dome deflector) Three types of tests were performed [1]: wind tunnel tests with measuring pressure distribution and flow visualization. It can. it is important to know the pressure distribution along disturbed zone and obstacle. the flow will turn its direction. Its application is known and widely present in many Russian tactical and long‐range missiles. the flow is accelerating through the expansion waves (8) as in Fig. Davidović. PHYSICAL AND MATHEMATICAL MODEL OF DISTURBED FLOW IN THE NOZZLE WITH JET TAB When an obstacle is present in the nozzle’s exit area. 2 tests with air and rocket propellant gases with measurement of force The main difference from flat plate tests is that Mach number is not constant along the main oblique shock wave causing a curved shape. thus giving possibility to control missile around both perpendicular axes. Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison Type of obstacle (spoiler. Another difference. at distance Ls from the exit cross section. Fig. Fig. but it uses only one segment of the dome. Change in direction is realized through the flow which can be described as following [1]: in divergent part of the nozzle. In the disturbed zone.3 Scheme of physical model [1] In order to calculate forces.Segmented domed deflector is similar to dome deflector.N. et al. In front of (before) the obstacle. Flow interchange with recirculation zone is established through the mixture layer with main stream (2) and with mass losses through the nozzle‐obstacle gap. one recirculation zone exists. 3. At the top of the obstacle. a normal shock wave is formed (9).2 Flow visualization at Jet Propulsion Laboratory Faculty of Mechanical Engineering University of Belgrade [1] Fig. which will cause a change in thrust vector. Boundary layer is becoming thicker with lambda shape (5) before separation point causing compressible (4) and expansion shock waves (3). At point (7) normal shock wave is interacting with wave generated by the flow structure.4 Schlieren photo from wind tunnel tests for β=70° and 90° [5] Fig.5 Model designations in mathematical model 60 . It enables usage of two segmented deflectors. which is forming a so‐called liquid wedge (6) [2]. an oblique shock wave occurs (1). be concluded that flow (and consequently pressure distribution) depends on following parameters (which were varied in tests): Relative blocked area of exit nozzle – Az=Ab/Ae Relative gap between an obstacle and exit nozzle cross section – δ= δa/De Angle between an obstacle and nozzle –β d a Fig. with hot gas or air.8912 Az 3D (2) δ 2D δ 3D π α β 2 In the case of dome deflector we have: Az 2D Az 3D δ 2D δ 3D (3) β 2D β 3D The proposed methodology algorithm is: Calculate position of shock wave Ls: From the analyses.40 Relative pressure 0.05 0.93 M1 (7) while for 3D f(nozzle type)=1. The real 3D nozzle should be transformed to the equivalent 2D nozzle by: π D 2D D 3D 4 Ae Ae 2D 3D Acr Acr α 2D α 3D (1) r 3D r 2D In the case of jet tab: Pa/Po=f(Ls) 0. δ f β.20 0.40 Az 2D Relative pressure 0. Po M 1 0.20 0. according to Fig. Davidović.05 0.00 0 1. (4) o for the nozzle angles αd≥20 . respectively) [6] 61 189.17 1 β f nozzle type 1. cos 0.22 .00 0 1 2 3 4 5 Coordinate along obstacle (cm) Fig. 5 0.30 0.17 Az e Xiz f β. 189.18 e . the following method is being proposed. δ 1 0.20 f β 0.15 0.45 0. otherwise it was: 0. 1 δ .15 0. .35 Az .50 Through the analysis of the results from all performed tests. Calculate the average pressures before and after the obstacle. δ (5) e Calculate average pressure in disturbed region “C”‐ Pp: Pp κ M p 1 0. (6) adjustment for 2D nozzle is 0. C.10 1. Pob/Pe=f(h) 0.45 0.10 Relative pressure N.30 0.22 .47 β 1.30 0.Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison 0.385 0.05 0. with measuring pressure distribution or measuring force.6 Typical pressure distribution from test (area A.25 f δ 0.25 0.17 f β.00 0 1 2 3 4 5 6 7 8 9 10 11 12 Coordinate along nozzle wall (cm) 0.10 0.50 Pc/Po=f(Ls) 0.15 Az . .10 f nozzle type 1 62.05 1 2 3 4 5 6 7 Coordinate along obstacle (cm) 8 0. 1 0.5. with jet tab and domed deflector.2 f δ f β . obstacle front and back.35 0.35 Pof/Po =f(h) 0.35 0. the following correlation was established: Ls 1.15 0. the most suited engineering method for calculation of TVC performances was recognized. according to Fig. et al.853 Az 3D 2. Considering the facts that the tests were performed on 2D or 3D nozzles.6889 Az 3D 2.011 0.00 0 1 2 3 4 5 6 7 8 9 10 11 12 Coordinate along nozzle wall (cm) 0.25 0.20 0.30 Relative pressure 0.385 Az .25 0. They contribute to the general discussion on geometrical effect on TVC system.77 0. are: (15) 1 2 Forces acting on the front side of the obstacle are: (16) Forces acting on the back side of the obstacle: (17) Fig. Thrust loss is also increasing but ratio of forces is better with increasing Beta angle after 10% of blockage.N.5 function ψ is defined as: Ψ 1. in that area boundary layer is of the order of the blockage which can have very strong influence.151 Calculate side and axial force difference Forces acting on divergent part of the nozzle.56375 10 (9) 1.256 2. 1 0.6018 10 0. is calculated as: 1.01721 1. et al. COMMENTS AND COMPARISON OF TEST RESULTS 1. are: (14) Further in the paper.1844 0. Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison Average pressure before the obstacle. With increasing the gap between obstacle and nozzle efficiency of the system is generally decreasing.7 Motor at test stand at EDePro company site Resultant forces are: 62 . Forces acting on divergent part of the nozzle.1424 0. with no obstacles. The well‐known equations for the thrust are: (19) (8) 1 (20) and ratio of side to thrust loss force is calculated as: (21) (11) MATHEMATICAL MODEL.6 2. Smaller values of nozzle divergent angle are increasing the system efficiency but it is usually not design parameter for the TVC system. 8 and 9. Davidović. Fig.15 where function ψ depends on Mach number of parameter z.74 (12) where Beta angle correction is (13) 1 0. Following can be concluded: For the all graph values bellow 5% of blocked area are not confirmed because tests were not performed with such a value. Also. graphs from the mathematical model are being presented. which is defined as: when z≤4.6 1 1 (11) Adjustments for the gap and Beta angle are: 1 (18) Thrust vector angle is calculated as: Ψ Calculate relative forces Relative forces are calculated according to the thrust in a non‐disturbed nozzle. with an obstacle.755 Average pressure after the obstacle is calculated as . Side and thrust vector loss force are increasing almost linearly with blockage area in engineering used region from 5 to 20%.66256 2.9446 (10) Otherwise it is defined as: 2. With increasing Beta angle from 70o (normal to flow) side force and thrust vector angle is increasing (jet tab to dome deflector). Milinović. Its accuracy.25 0.15 0.30 Blocked area Fig.06 0.30 63 N.9% Az=15%.1977.10 0.16 0.25 Fig. Fxr=7. Đ. 1984‐1986.15 0.20 Acknowledgement o Research of this paper is result of the national project financed by Serbian Ministry of Education and Science (TR 35044).9%. [2] G. Fxr=6.18 o =70 0. Fxr=1.Stefanović: Research of fluid flow and pressure distribution in supersonic nozzle in connection with vector thrust control.com). Fyr=15.M.15 0.10) shows excellent result for side force while for thrust loss model is engineering acceptable up to relative blockage of 20% what is also practical area of using TVC.00 0.26 Relative thrust loss 0. is excellent in the area between 5 and 20% of the blockage.30 =1%.25 Relative blocked area Fig. which is preferable for control.00 0.10 Ref.Jojić and others: Research from modern rocket propulsion‐TVC‐physical model. PhD thesis. et al. Fyr=20.25 0.3% Az=10%.20 0. Fyr=10.24 0. Jet Propulsion Laboratory Faculty of Mechanical Engineering University of Belgrade. Fyr=9.Jet Tab and Dome Deflector TVC in Solid Rocket Motor Mathematical Model and Test Comparison Comparison with test data (Fig.6%. when compared against the experimental results. Наука. [5] Z. Fxr=0.08 0.N. 0. Fxr=1.05 0.Blagojević.05 0.22 o =90 0.G. 3 0. .Blagojević: Pressure distribution in rocket nozzle with mechanical system for TVC. [4] B. Z.12 0.1987.5% 0. blocked area for different beta angle 0. 6.20 0.00 0.24 o =110 0.Jojić.20 0. and also control parameter Az which gives this method an engineering character and practical usage.V.26 o =110 Relative side force 0. AIAA Propulsion Conference. Davidović. CONCLUSIONS Developed mathematical model is applicable in both jet tab and domed deflector TVC because all experimental data are transformed to the equivalent 2D nozzle.1976.Đ. Fxr=4.7%.9 Relative thrust loss vs. Fig. Fyr=5.Fotev.4% Az=10%.00 0. Faculty of Mechanical Engineering University of Belgrade.14 0. AFRPL TR‐77‐49.10 0.30 0 =1%. Moscow.14 0.10 0.9%.02 0.9%.Jojić.Marko and others: Rocket propulsion research‐thrust vector control.6%.18 0. 0. M.30 Fyr Test Az=5%. It is very difficult to predict pressure after the obstacle for greater values of blockage which is causing differences between model and test.10 [1] B. [3] R.8 Relative side force vs.08 0.d=20 0.06 0.00 0.edepro.1% Az=20%.04 0. Fyr=19.10 0.04 0.Eatough: Improved jet tab thrust vector control for the BGM‐34C booster. [6] B. Fxr=0. Tests were performed with real rocket motor and six components test stand at EDePro company site (www. Side force shows complete linear behavior.28 0 0.00 0. Fyr=4. San Diego.16 o =70 0.Abramovič: Прикладная газовая динамика.22 =90 0. 1986.30 Blocked area 0.4%.05 0.20 0.d=20 0. blocked area for different beta angle Relative force 0.15 Fxr Test 0. The model uses engineering design parameters such as αd and β.05 0. 0. Jet Propulsion Laboratory Faculty of Mechanical Engineering University of Belgrade.6% Az=20%.Stefanović.0% Model 0.1986.02 0.28 0.10 Mathematical model and test comparison 0.20 Model Az=5%.12 REFERENCES 0. One of these tools made of high cutting steel. Accuracy and completeness technical standards ISO are very important part quality of manufacturing. Article describes process how to define T-vc dependence for cutting tools made of high speed steel. Email: jan. Research Engineer. T‐vc dependence. Current valid relation extensively through the 1940s in that it can withstand of T‐vc dependence is described by Taylor formed basics higher temperatures without losing its hardness.9] Ceramic cutting tools have been in use for approximately Standard ISO 3685 describes more methods for solution of 90 years.Contents lists available at www. Dependences that are experiment. T‐vc dependence was designed property allows HSS to cut faster than high carbon steel. ISBN 978‐80‐553‐1216‐3 NOMENCLATURE ap f vc T VB is based primarily on favorable material properties. It is The standard ISO 3685 describes for all cutting materials superior to the older high carbon steel tools used common T‐vc dependence. ceramics possess high melting points. Slovakia. is used in standard ISO 3685. As a class of materials. University of Kosice . according to Taylor in logarithmic scale.sk PhD Manufacturing Engineering. Some of these materials are high speed steel. [6] feature of the sintered carbide is the potential to vary its composition so that the resulting physical and chemical THE WAYS OF RESULTS EVALUATION ACCORDING properties ensure maximum resistance to wear. Verification of standards is very difficult process. [2. [12] Interest in ceramics as a high speed cutting tool material INTRODUCTION 64 . and oxidation. [3.orlovsky@tuke. Faculty of Manufacturing Technologies . [10] Knowledge defined by Taylor choice of cutting tools. Ceramics are also chemically inert against most work metals. Standard is valid only for conditions. as new cutting tools were developed.icmem.sk 2 ARTICLE INFO: Category : Technical Note Received: 2 November 2012 / Revised: 14November 2012 / Accepted: 5 November 2012 Keywords:(in causal order) Abstract: Durability Cutting speed Standard ISO F. Standard ISO 3685 obtains cutting parameters and theirs application. [1. machining.7] – Cutting depth – Feed – Cutting speed – Durability – Criterion of depreciation GRAPHICS DEPENDENCE VB=f(s) Graphics dependence VB=f(s) for different cutting speeds was described with Frederick Winslow Taylor in 1906. fracture. 2ndInternational Conference Manufacturing Engineering & Management 2012. [5. TO STANDARD ISO 3685 deformation.6] A key materials are same. realization of process or adequate for Taylor experiments. hardness and toughness results. p. machining.13] for obtaining of tested dependences. There is a presumption that descriptions in standards ISO are not correct and these standards have to be examined and verified.W. because it forms 30% from all technologies of when the criterion of durability is defined as tool wear. cutting ceramic and sintered carbide. Characteristics and dependences for all cutting satisfies the most demanding applications. Citation: Duplak J. Orlovský I.Taylor Turning The main part of Standard ISO 3685 is T-vc dependence for various cutting materials. cutting ceramic and sintered carbide. (2012). For each method that is described new materials that demanded even more rigorous in standard there should be exactly identified procedure machining requirements were also developed. because that this fact have to be confirmed or disproved. he comprehensive comparison of the selected cutting materials with standard ISO 3685 in machining process of steel C60. corrosion.duplak@tuke. usually used in tool bits and cutting tools. This of standard ISO 3685. Faculty of Manufacturing Technologies. some types by means of catalogues from the manufacturer. However. [4. Slovakia. STANDARD ISO 3685 ANALYSIS sintered carbide. University of Kosice. [15] In the turning there are many types of [14] cutting tools used made of different materials. cutting ceramic. because were found deficiencies in valid standard ISO 3685.tk Manufacturing Engineering & Management The Proceedings The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60 Jan Duplak1‐ Imrich Orlovsky2 1 PhD Student of Manufacturing Engineering. Some types of cutting materials are defined by means of descriptions in standards ISO. can be described. The Standard ISO 3685 contains main properties and characteristics for three most important cutting materials those are used in engineering practice. materials. 64‐67. These cutting materials are used for cutting tools made of high speed steel. This standard includes only cutting different technological operations. [12] Very hence the name high speed steel.8] Sintered carbide is significant problem in standard ISO 3685 is evaluation of unique combination of strength. In technical sciences are descriptions for because in that time high speed steel was only available each experiment. High speed steel (HSS) is a subset of tool steels. [16] tests of durability of cutting tools for workpieces made of In engineering can be used for experiments a lot of steel and cast iron. There are a lot of types of cutting materials they have not been defined theirs properties exactly yet and theirs properties have to be defined on experiments.11. technological conditions. sintered carbide and operations is turning. Email: imrich. excellent hardness and good wear resistance. After analyzing of outputs final dependencies described by Taylor are relevant only for high speed steel. Primary Taylor defined that the criterion of blunting was factor of each new discovery or piece of knowledge is the same for all curves VBk. Turning is the most basic process in cutting ceramic. 2 Mechanical properties of C60 Rm [MPa] 900 13 255 Rp0. Tool durability was proven with kinetic machining long‐term test method.57‐ 0. 0.60‐ 0. for few value of cutting speeds at constant cutting parameters and construction curve of blunting.3 T‐vc dependence in logarithmic scale [12] and graduated cutting speeds to the optimal tip blunting. Fig. [10] MACHINING LONG‐TERM TEST METHOD Essentially there is only one machining long‐term test method.020 Tab. 0. [12] ‐ Method of least squares ‐ Interpolation of dependence into unmeasured field of cutting speeds ‐ Guess evaluation THE DURABILITY ON THE BASED OF TV‐C DEPENDENCE ACCORDING TO STANDARD ISO Taylor defined T‐vc dependence according to experiments made with high speed steel. before the actual experiments is consumption. type of cutting tool with defined geometry Fig.1 Curve of blunting for variable cutting speeds [12] Fig. This test is considered as basic and this test set measuring objectivity of machinability for others tests. Tab. Disadvantage EXPERIMENTS WITH CUTTING TOOLS of this test is consumption of workpieces and time First very important step. I. 0. For each cutting speed the Fig. Description of machining long‐term test method: 1) Time measurement process of depreciation on back of tool VBB.19 max.The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60 J.2 Determination of particular durability by the criterion of depreciation [12] 65 Mechanical properties of C60 A5 [%] HB . sintered carbide and cutting ceramic.Duplak.4 Technological system for experiments Workpieces for experiments are made of steel C60. In technological system for these experiments were contained machine ‐ tool ‐ workpiece.40 max. The standard ISO 3685 contains information about T‐vc dependences for high speed steel.65 0. [10 ] specification of technological system.1 Chemical structure of C60 2) Specification criterion of depreciation VBopt and determination tip durability for each cutting speed.40 max.40 max.030 max. Experiment inputs were workpieces with equal diameters. Chemical structure of C60 [%] C Mn Si Cr Ni Cu P S 0. 0. those were used at turning process. 0. Material for workpieces is from specific material list with guaranteed chemical structure and mechanical properties.90 max. These tests according to standard ISO 3685 are valid for all cutting materials.2 [Mpa] 580 These experiments were made under defined technological conditions. Criterion is value of cutting speed and it is done by turning or milling with described constant cutting parameters. Orlovsky Standard ISO 3685 indicates these methods to obtain the 3) Construction Tn=f(vc) dependence in logarithmic scale results: and determination index of machinability for selected ‐ To toggle the line through measured points durability under comparison cutting speed tested material (approximation) and etalon material. 0. 3 mm.8mm. Executed experiments showed. ´r=15 . ap = 0.2 mm. that between the standard ISO 3685 and experiment results are expressive differences. ´r=10° . This standard defines all process how to create and to define cutting tools durability by means of T‐vc dependence according to Taylor. min 5 250 93 230 8 210 105 215 10 125 112 204 13 86 125 148 25 70 137 64 39 118 205 42 46 130 250 23 65 180 310 15 72 205 350 13 Fig. f = 0.5 97 41 3. r=80°.3 2.3 440 6. r=80.5 18 188 14 Every one process in engineering industry is defined by 22 16.4 Results of T‐vc dependence for Al2O3 vc. min 2 55 139 25. m.3 mm.5 8 35 147 25 Fig.7 T‐vc dependence for P20+TiN in logarithmic scale 12 22 153 21 16 19 158 20.8 1.3 88 52 11 33 58 13 22 87 22 21 100 28 14 T. ´r=10° .3 mm .6 T‐vc dependence for Al2O3 in logarithmic scale TECHNOLOGICAL CONDITIONS USED FOR SINTERED CARBIDE (P20+TIN) vc = 5 – 350 m. r= 0. VB = 0. min vc. Tab. Precision and completeness of 55 27.min‐1.3 Results of T‐vc dependence for HSS vc. TECHNOLOGICAL CONDITIONS USED FOR HIGH SPEED STEEL vc = 2 ‐ 100 m.3 mm . Tab.3 mm.min‐1 T.min‐1 T.5mm.9 cutting parameters etc.3 mm.2 standard ISO represents primary factor in technical 85 28.Duplak.min‐1 T. I. ap = 0. m.min‐1 2 105 35 2. o = ‐6 Tab.5 Results of T‐vc dependence for P20+TiN vc. settings. f = 0. m.5 defined in standards these standards described 49 26.3 sciences. r=75. min vc. VB = 0.2 Fig. ap = 0.min‐1.J.5 T‐vc dependence for HSS in logarithmic scale TECHNOLOGICAL CONDITIONS USED FOR CUTTING CERAMIC (AL2O3) vc = 2 ‐ 550 m. dependencies. Defects and imprecision described in standard 100 29.min‐1 T. The following figure (8) shows differences 66 . r= 0. r= 0.8mm. Experiment was finished once wear criterion was reached.min‐1. m. The durability issue of cutting tools is defined in standard ISO 3685.min‐1 T. f = 0. Procedures for technical sciences are 35 15 235 9.8 prevent false information. Experiments are necessary to 130 27 530 5. min vc. m. diverse 51 27 268 8. Orlovsky The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60 diameter should have the same value.5 380 7. m. because examined material has different consistency in different depth.7 CONCLUSIONS 17. VB = 0.5 1.2 mm.8 225 10 some standard ISO.5 510 6 ISO need to be fixed.5 mm.5 253 9 technological conditions. min 8 6 3. This paper was oriented on 136 26 550 5 durability selected ceramic cutting plates in machining process of steel C60. pp.Isakov.”. 383‐400 p.Duplak.5. vol 50.Kohser. no. pp.“Production technology of spindle part “. 10‐14.“ Theory and practise of splinter machining. 152–168. ‐ ISBN 9788055302430 [11] M.” EDIS ŽU Žilina.. s. ‐ Prešov FVT TU. N. “Chip Formation Analysis During Hard Turning.Hloch. because only valid information and correct dependencies may be included in technical standards. 2011. ‐ ISBN 978‐80‐553‐0740‐4 [8] J.316. J. [1] A. In: International Journal of Surface Science and Engineering.Paško. and H.al. Experiment was executed for selected types of cutting plates and for all three types are in graph visible differences. Switzerland. p.al.”Degarmo's Materials & Processes In Manufacturing. Black. 2007. ISBN 978 – 0 – 8311‐ 3314‐6 [5] E. ‐ ISSN 1022‐6680 Fig. ‐ Košice: TU. In: Manufacturing Engineering.Hatala. pp. 2006. ISBN 978‐ 80‐8070‐711‐8 [13] P. P. Janak.et." Intelligently programming of holes machining".” Prediction of distribution relationship of titanium surface topography created by abrasive waterjet.2007. 2/3 (2011). In: Manufacturing Technologies . 1995. p.R.9 Examples of used cutting plates 67 J. No. pp. 6.” The impact of cutting fluids on machining”.Maščenik. ISSN 1748‐572X (online). In: ICPM 2009. 337 – 345..et. ISBN 978‐0‐470‐05512‐0 [7] J. et. ISBN 978‐80‐553‐0152‐5 [10] M.al.” Prentice‐Hall of India Private Limited.” CRCPress. 2009.398. ISBN 978‐81‐203‐1958‐5 [4] E. 138‐139 [9] K.Neslušan. Orlovsky . 4 (2010).Valíček. ISSN 1336‐5967 [12] M.K. ISSN 1748‐5711(print). Vol.Zajac. 19‐22. 5. R.l.. NY 10018.“ Applications of computers in manufacturing engineering“.et. Cuma.” Machining Technology‐ Machine Tools and Operations.Neslušan. B.” Cutting facilities of new type of came cutting material”. 989 Avenue of the Americas New York.The Comprehensive Comparison of the Selected Cutting Materials with Standard ISO 3685 in Machining Process of Steel C60 REFERENCES between standard ISO 3685 and selected ceramic plates. 43‐46.353. No.“ Experimental methods in splinter machining. 2011 P. Following figure shows differences between T‐vc dependence from standard ISO 3685 and T‐vc dependencies from experiments results.” Wiley India Private Limited.” Accompanying phenomena in the cutting zone machinability during turning of stainless steels. J. In: Advanced Materials Research. Vol.1032. p. 1994.Gašpar.” Industrial Press. 2009 p. T.2009. ISBN 978‐0‐8155‐1355‐0 [6] J. et. 2009 p..A. ISSN 0562 – 1887 [15] S. 2008.” Ceramic Cutting Tools. s.Mittal. pp.. Vol. Proceedings of the conference PPTO. 2012. M.” William Andrew Publishing/Noyes. M. Novak‐Marcincin. INDERSCENCE Publisher. Fig. ISBN 978‐1‐4200‐4339‐6 [2] A. ‐ ISSN 1749‐785X [16] Š. Italy. Nagendra. 63‐65.343.” 2011. pp. 9. AEI ´2011: international conference on applied electrical engineering and informatics 2011 : September 3‐10.Panda.Y. 2009.Vasilko. J.Inc.al. Košice.Barišič.Whitney.” The effect of degassing pressure casting molds on the quality of pressure casting”.” Elements of Manufacturing Proces.496.D.Zajac.” Cutting Data for turning of steel. [3] B.Čep. 2009. 2008. 546. El‐Hofy. pp. 428 (2012).” Engineering. Vol.8 Standard ISO 3685 T‐vc dependence and T‐vc dependencies from experiments comparison Deeper exploration of durability cutting materials defined in standard ISO 3685 is very important. J. ‐ ISSN 1335‐7972 [14] R.Michalik. I. International Journal Machining and Machinability of Materials. 25‐30. pp.S.4.” Prešov FVT.Helmi.all. 68 . PhD. Ing. Peter. our knowledge. You are greatly missed for your enormous intellect. that we may know an outstanding scholar.2012 on the age of 51 years. teacher... dear Authors. This page is dedicated to memory of prof. You gave us a lot. our imagination. and kindness… 69 . thank You.03. and great friend with big hearth who really loved this world with smile on your face. Peter Fečko. your endless generosity. who left us forever on 10. our attitudes determine our being.but sometimes we don´t understand. gentleness. member of ICMEM Scientific Committee (VŠB‐TU Ostrava). Dear Delegates... our work.. Faculty of Manufacturing Technologies of Technical University in Košice with a seat in Prešov 5 PhD student. liquid.icmem.Faculty of Manufacturing Technologies of Technical University in Košice with a seat in Prešov 6 PhD student. electrode. In fact. we'll cut through the mystery surrounding the plasma cutter and see how one of the most fascinating tools has shaped the world around us. North University of Baia Mare. So how do people precisely cut and manipulate the metals needed to build some‐thing as large and as strong as an airplane wing? In most cases. It may sound like something out of a sci‐fi novel..Contents lists available at www. gas and then plasma.: Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone. a plasma cutter is extremely simple. and suspension bridges out of precisely formed metal components. Plasma is the fourth and most highly energized state of matter: solid. et al. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Modern industry depends on the manipulation of heavy metal and alloys. distance between nozzle mouth and material have been observed.1 The general principle of plasma cutting Conceptually. we build cranes. plasma gas pressure. The reason is simple. Metals are extremely strong and durable. 70‐73. or both. Romania PhD Mechanical Engineering. (2012). especially sturdy. torch relatively wide thickness extent of cut materials Disadvantages: noise level raises with raising of current cannot create neither little rounds of cut edge nor strait groove serious cut width different cut quality /bad side gets to waste) harmful steams ensuing (exhausting needed) 70 . Citation: Hatala M. The article presents the design and evaluation of plasma arc cutting technological process. but with an important difference ‐ it conducts electricity. The plasma arc results from electrically heating a gas (typically air) to a high temperature. Full Professor. but the plasma cutter is actually a common tool that has been around since World War II. the answer is the plasma cutter. In this article. Faculty of engineering. The funny thing is that metal's strength is also a weakness. The gas is heated in the chamber between the electrode and torch tip. Influence of technological factors on roughness parameters Ra of the steel surface EN ISO S355 have been evaluated using planned experiments. the significance of the four process factors: plasma burner feed speed. p.hatala@tuke. The heat from plasma arc is affected the microstructure of the material too. Because metal is so good at resisting damage.email: michal. ionizing the gas and creating plasma. nozzle diameter. 2ndInternational Conference Manufacturing Engineering & Management 2012. it's very difficult to manipulate and form into specialized pieces. Lecturer. plasma looks and behaves like a high‐ temperature gas. For example. Using factor experiment 24. A fluorescent light is an example of plasma in action. so they're the logical choice for most things that need to be especially big. robots. cars. Fig. This ionizes gas atoms and enables them to conduct electricity. skyscrapers. ADVANTAGES AND DISADVANTAGES OF PLASMA CUTTING Advantages: better cut quality when cutting thick materials (compare to flame cutting) cheaper than laser for cutting of thin sheets low impact of working environment suitable for thicker sheets with medium demand on cut edge quality and correctness high cutting speed (depends on material thickness) possibility of reaching good surface roughness for steels and anticorrosion steels simple replacement of throat.Faculty of Manufacturing Technologies of Technical University in Košice with a seat in Prešov 2 3 ARTICLE INFO: Category : Preliminary communication Received: 2 November 2012 / Revised: 14 November 2012 / Accepted: 15 November 2012 Keywords:(in causal order) Abstract: Plasma arc Factor analysis Quality Almost every technological process can we currently predict somewhat.tk Manufacturing Engineering & Management The Proceedings Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone Michal Hatala1‐Nicolae Ungureanu2 ‐Peter Michalik3‐Ján Duplák4‐Ľubomír Olexa5‐ Miroslav Kormoš6 1 Faculty of Manufacturing Technologies of Technical University in Košice with a seat in Prešov . We need metals to build the tools and transportation necessary for day‐to‐day business. A plasma arc torch spins a gas around an electrode. It gets the job done by harnessing one of the most prevalent states of matter in the visible universe.sk PhD Mechanical Engineering. Faculty of Manufacturing Technologies of Technical University in Košice with a seat in Prešov 4 PhD student. Regression models obtained by multiple linear regression indicates the quality level as observed factors function. The heat used for cutting of material affects its microstructure changes. 6 7. plasma burner feed speed. it is thus tetradimensional model.8 mouth and material (z) In this example we have four factors. et al.2a The process parameters and factor analysis Fig. for example in border of primary length. 3. For the analyzing of this model is used factors experiment. which are including anomalies from the different technology of manufacturing or another effects. Than for four factors particular attempts will be realized in 24 = 16 different relations. (Tab.2 diameter (d) plasma 2 х2 burner feed m/min‐1 0. 1). Factors: nozzle diameter. This experiment evaluates combinations of all planning factors. plasma gas pressure.4 Graph of marginal effects 71 . Measurement in first line Signification of bearing for monitored factors to parameter of roughness Ra in distance one millimeter from upper edge is shoved in Paret´s graph (Fig. Roughness of surface is create by anomalies of surface with small separation. Fig. By the exact test that besides main factors includes also interactions off all combinations of factors and levels. CONDITIONS OF EXPERIMENT PLANNING The process parameters are caused in common interactivity in praxis with plasma cutting.2b The process parameters and factor analysis The roughness was measured in two lines. yRz. As experimental material was constructional steel ISO Fe510 with 6 mm thick‐ness and the plasma gas was air. distance between nozzle mouth and material. Hatala.9 speed (v) plasma gas MPa 0. We made for the experiment 16 pieces of samples. To the coded values of –1 and +1 levels.55 0. 1 х1 Fig.). Such two‐leveled factor experiment will be used for simple specification of factors.1 Table of real level values of factors of experiment Factors N Marking Interval of factors ‐1 +1 Description value nozzle mm 1 1. We suppose that these anomalies are within defined borders. yδ. there have been assigned real level values of these factors.3 Paret´s graph for distance one millimeter from upper edge Fig.68 3 х3 pressure (p) distance between nozzle mm 4 х4 6. there can be investigated the impact of all potentially possible combinations of factors and after elimination of statistically not‐signified factors it can be moved to more detailed and accurate experimental schemes. By two levels of different factors. Tab. where particular levels are coded as –1 and +1 it presents full factor of 2k type. Measurement was realized by apparatus Mitutoyo .6 0. that presents the level of observed area of particular factors. one and five millimeters from upper edge. that statistically significantly im‐ pact the variability of values of variables yRa.Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone M. about 240 HV1 in the deposit across a distance of 0.e.4 mm (thickness 10 mm). Fig.M. a new lattice type is found. From Paret’s graph it is obvious. Damaged created by a plasma torch cut – microstructure was originally a banded pearlite and ferite. The austenite is quenched. thickness 10 mm HEAT AFFECTED ZONE AFTER CUTTING Fig. HAZ goes through the narrow zone of normalization with fine – grained structure and considerably wider zone of partial pre – crystallization. Lowest impact is presented by distance of nozzle mouth from material. rapidly cooled. i. the maximum value immediately at the cut sur‐face increases appreciably about 255 HV1 in the deposit across a distance of 0. et al. 72 . 3% picral etch. Practically all the homogeneously dissolved carbon now has to go to the in homogeneously distributed cementite ‐ by diffusion. Minimal impact level is presented by nozzle diameter and distance between nozzle mouth and material. The result of this show continued growth of austenite. After realization of hypothesis about importance of particular equations coefficients and elimination of not‐signified factors out of linear regression. Passing the eutectoid temperature during cooling requires a radical change. It can be seen little difference in microhardness that results in narrow HAZ. Lower impact to the quality presents the nozzle diameter. that highest impact to the middle arithmetical deviation of surface roughness has feed factor of plasma torch. that highest impact to middle arithmetical deviation of surface roughness has the feed factor of plasma torch. Investigations of microhardness showed that. 6 Graph of marginal effects From Parent’s graph it is obvious.7 mm (thickness 20 mm).5 mm (thickness 15 mm) and about 110 HV1 in the deposit across a distance of 0. Instead. Significant impact to the quality of machined surface has also the pressure of plasma gas. It´s volume is getting down to the core of base material. Austenite formation is found to be complex while heated to a temperature 741 ºC (in between Ac1 and Ac3 temperatures). The heat affected zone from a plasma cut is narrower and peak harnesses are higher than that produced for example by flame cutting. Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone The result from Paret´s graph is the most influence for the roughness Ra factor of the plasma burner feed speed.7 deep. final equation was acquired. Measurement in second line Signification of bearing for monitored factors to parameter of roughness Ra in distance five millimeters from upper edge is shoved in Paret´s graph (Fig. called "martensite". 4.). 7 Relief surfaces after cutting of plasma arc. The carbon stays in place ‐ more or less‐ and this necessarily prevents pearlite and ferrite formation.5 Paret´s graph for distance five millimeter from upper edge Fig. Significant impact has also the pressure of plasma gas. The microhardness is connected basically to the local changes in mechanical properties of the material. that express the middle arithmetical deviation of Ra profile in relevant measured depth h = 1 mm. Original magnification 63x a 600x. The microstructural damage zone (heat – affected zone) is approximately 0. Hatala. Encyklopedia of physical science and technology. 2001. Vol. P. ‐ Tarasovičová. – Monka. A. that impact of process parameters during the material cutting was different in particular depths. s. . Factor Analysis of Plasma Arc Cutting Technological. Bucharest: University Politehnica. Hatala. Ro .7 mm. The extent of the HAZ in low steel is related to process variables. – Ramtech: (2002). Elsevier. 443 446. Methods of planned experiments are used for these evaluations. volume 12. In: Tehni ki vjesnik. Fig.2 (2012). In: Technical Gazette. Among other factors that are less important belongs diameter of nozzle and distance between nozzle mouth and material. importance of four factors was observed (feed rate of plasma torch. Diploma Thesis. J. 18. From the experimental results it can be said.: (2009). ISSN 1338 2365. Faculty of Manufacturing Technologies. HAZ varies with speed and power. R. 1 (2010). J. M. – Čep.: (2001). Monková.4 – 0. 275 278. Academic Press.9 The resulting cracks in steel S355J0 after plasma cutting ‐ 500 x HAZ Findings All of this HAZ measurements were between 0. nozzle diameter and distance between nozzle mouth and material). California. ISSN 1330 3651. :Mathematical model of the spray dry.: Factor analysis of the abrasive waterjet factors affecting the surface rough‐ness of titanium . 1 (2011).: The impact analysis of cutting fluids aerosols on working envi‐ronment and contamination of reservoirs. J. no.Vol. 4. It was found out. I. London.8 Heat affected zone – zoom 63x a 600x [2] CONCLUSIONS Paper deals with definition and evaluation of process factors and parameters of cut surface while cutting the material EN S355J0. A. 1. as well as material thickness. ‐ Duspara. In: ICMaS: proceedings of the International Conference of Manufacturing Systems: 5 ‐ 6 November. that for achieving higher quality of cut surface it is recommended to use higher pressures of plasma gas and appropriate feed rate of plasma torch. Mayers. no. ISBN 1842 3183. Z. ISBN 0‐08‐043152‐6 Kubica. USA. P – Vegnerová. et al. – Bražina.Influence of Factors of Plasma Cutting on Surface Roughness and Heat Affected Zone M. Prešov. . 19. Šomšáková. 1 6. Encyklopedia of materials: Science and technology. In: Internet Journal of Engineering and Technology for Young Scientists. ‐ Kasina. that most significant impact to the machined surface roughness has factors of feed rate of plasma torch and plasma gas pressure. REFERENCES [1] Fig. – Zajac. Čuma. P. On the base of results that were analytically processed by factor analysis it can be said. 2009 P. J. ISSN 1330 3651. M. – Zajac. 2009.: Study of materials with natural rein‐forcement and thermo plastic matrix (Wood Plastic Composite). – Müllerová. Technical University of Košice with a seat in Prešov. that influence the parameter of roughness profile Ra and Rz. 73 77. M.. plasma gas pressure. D. ISBN 0‐12‐227422‐9. p. p. such as cut speed and power. M. Orlovský. Romania: Vol. Using factor experiment. volume 7. Bu‐charest. [3] [4] [5] [6] [7] 73 Buschow. 3]. S. Email: yasharejavadi@yahoo. It has been shown that the residual stresses through the thickness of stainless steel plates can be inspected by LCR waves. 2nd International Conference Manufacturing Engineering & Management 2012. cost. incremental hole drilling. 16]. some of the authors.. meanwhile V12 and V13 represents the velocity in a perpendicular plane (shear waves).sergej@gmail. and structure [ 10. Semnan. and accuracy of the measurement.).icmem.1 LCR probe for PMMA (Plexiglas) wedge on steel Ultrasonic stress measurement techniques are based on the relationship of wave speed in different directions with stress. must be taken into account in choosing an adequate technique. Ultrasonic stress measurement is based on acoustoelasticity. 2Mhz. texture [ 6. as shown in Fig. i. 74‐79. Email: hloch. 8. it is very important to determine the residual stress levels with a non‐destructive method. To achieve a proper design of structure and control their mechanical strength in service. and the ultrasonic waves methods.Contents lists available at www. the ultrasonic stress evaluating technique relies on a linear relationship between the stress and the travel time change. 2c the waves propagating in the other directions and the velocities are shown. The LCR waves are also called surface skimming longitudinal waves (SSLW) by 74 . i. Welding is an assembly process often used in different industries. 2b and Fig. Citation: Javadi. it is slightly sensitive to the microstructure effects (grains size [ 1. i. The LCR technique uses a special longitudinal bulk wave mode. 7. The first index in the velocities represents the propagation direction for the ultrasonic wave and the second represents the direction of the movement of the particles. The V22 velocity is for longitudinal waves propagating perpendicular to the stress direction. 4Mhz and 5Mhz transducers. In Fig. 2. The longitudinal critically refracted (LCR) wave is a bulk longitudinal mode that travels within an effective depth underneath the surface. dangerous thermo‐ mechanical stresses may appear in the welded joint. 9]. Brekhovskii [ 19]. Langenberg et al. Iran. Fig. which travels parallel to the surface.1 . etc. 2a the wave propagates parallel to the load and V11 represents the velocity of the particles in the same direction (longitudinal wave). Basatskaya and Ermolov [ 20]. e. particularly propagating beneath the surface at a certain depth.e. According to the process and temperatures reached during this operation. 14]. Slovak Republic. Islamic Azad University‐Semnan Branch. After the accurate measurement of depth. 12]) and to the operating conditions (temperature [ 13. 2 shows elements of a bar under tension where the ultrasonic wave propagates in three perpendicular directions. 5]. Many studies showed that there is no universal or absolute method that gives complete satisfaction in the non‐destructive stress monitoring of the mechanical components. the accurate depth underneath the surface in LCR waves is measured for 1Mhz. Junghans and Bray [ 21]. Y. However. coupling [ 15. The high industry request for the stress measurement techniques encouraged development of several methods like X‐ray diffraction. In Fig. etc. 18]. carbon rate [ 4. [ 22] had some detailed discussions on the characteristics of the LCR. surface quality. The sensitivity of these waves to the strain has been established by Egle and Bray [ 17] in tensile THEORETICAL BACKGROUND Within the elastic limit. The ultrasonic estimation of the residual stresses requires separation between the microstructure and the acoustoelastic effects. Many parameters such as material. (2012). Hloch. especially in the pressure vessel industry. and normally result from deformation heterogeneities appearing in the material.. They have very important role in the strength and service life of structures. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Residual stresses are present in materials without any external pressure. the relationship of stress and wave velocity in engineering materials. Fig. LCR waves. This paper evaluates welding residual stresses in plate-plate joint of AISI stainless steel 304L. and relatively inexpensive.com Faculty of Manufacturing Technologies TUKE with a seat in Prešov. Because of the residual stress changing through the thickness. residual stresses through the thickness of plates are evaluated by four different series of transducers. the acoustoelastic effect [ 17. This technique uses critically refracted longitudinal waves that travel parallel to the surface. geometry. 11. The ultrasonic technique was selected for stress measurement because it is non‐destructive. easy to use.com 2 ARTICLE INFO: Category : Original Research Paper Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 5 November 2012 Keywords: (in causal order) Abstract: Ultrasonic Stress Measurement Acoustoelastic Effect Welding Residual Stress LCR Dissimilar Welded Joint.tk Manufacturing Engineering & Management The Proceedings Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes Yashar Javadi1 1 Department of Mechanical Engineering.: Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes. e. p. α 2= α 3=‐υ×ε. V11 is the velocity of waves in the direction 1 with particle displacement in the direction 1.3 Measurement devices 75 . The ultrasonic box is a 100Mhz ultrasonic testing device which has a synchronization between the pulser signal and the internal clock. Fig. with one sender and two receivers in order to eliminate environment temperature effect to the travel time. For a fixed probe distance. m. (3) can be rearranged to give the stress variation in Fig. (1) becomes: 0V112 2 [4( 2 ) 2( 2m) (1 2 )]. (2) The relative sensitivity is the variation of the velocity with the strain and can be calculated by Eq. λ. followed by the shear waves when the particles vibrate in the direction of the load. 4Mhz and 5Mhz. The acoustoelastic constant (L) functionally links the stress and the velocity or travel time change. Using these values. and compressive load tests for a bar of rail steel. 2Mhz. The most considerable variation in travel time with the strain was found for longitudinal waves.Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes Y. α 1=ε. is much greater than the other ones. Eq. The measurement device. Javadi terms time‐of‐flight (dt/to). where to is the time for the wave to go through a stress free path in the material being investigated. EXPERIMENTAL PROCEDURES The materials tested (stainless steel 304 and carbon steel A106‐B) are commonly used for pressure vessel applications. 1 2 3 which α1. Two rectangular tension test specimens were extracted from two different stainless steel and carbon steel plates with the same chemical composition and thickness of two pipes to determine acoustoelastic constant. that controls the A/D converter. Using different frequencies helps to evaluate residual stresses through the thickness of the pipes. The same equation can be used for the other directions of the waves. and those with particle motions perpendicular to the stress field showed the least. (4). Stress can be calculated by the one‐dimensional application of the stress–strain relations in elastic solids. where ε is the strain in the direction 1 and υ is the Poisson’s ratio. For a state of uniaxial stress. μ the second order elastic constants (Lame’s constants). Eq. Two 8inch pipes with thickness of 8mm were welded in V‐groove (60° included angle) and three passes butt‐weld joint. Transducers was assembled on a united PMMA wedge. provided the value of the acoustoelastic coefficient L is changed. controlled by the coefficient L11. This allows very precise measurements of the time of flight – better than 1ns. The diameter of all the piezoelectric elements were 6 mm. dV11 / V11 ( 2m) v (1 2l / ) 2 L11 (3) d 2 The values of acoustoelastic constants for the other directions can be obtained in the same way. The waves with particle motion in the direction of the stress fields showed the greatest sensitivity to stress. The other waves do not show significant sensitivity to the strain. The variation in the v11 velocity. n are the third order elastic constants. Twelve transducers in four different frequencies were used which their nominal frequencies were 1Mhz. d E ( dV 11 / V11 ) E dt L11 L11 t 0 (4) where dσ is the stress variation (MPa) and E is the elasticity modulus (MPa). In this equation. the travel time of the longitudinal wave decreases in a compressive stress field and increases in a tensile field. L11 is the dimensionless acoustoelastic constant for LCR waves. shown in Figure 3. includes an Ultrasonic box with integrated pulser and receiver. indicating that these waves are the best candidates to be used in the stress evaluation. l. A three‐probe arrangement was used. computer and three normal transducers assembled on a united wedge. (3). as shown in the Eq. α2 and α3 are components of the homogeneous triaxial principal strains.2 Velocity of plane wave and stress field in orthogonal directions [ 23] The velocities of the longitudinal plane waves traveling parallel to load can be related to the strain (α) by the following expressions: 0V112 2 (2l ) (4m 4 10)1 (1) where ρo is the initial density. 2mm. 1. The second one was extracted from a carbon steel A106‐B plate with the same thickness and chemical composition of carbon steel side of the pipes. Therefore depth of any frequencies can be exactly measured. From this table it can be concluded that depths of LCR wave are 5mm. Acoustoelastic constant represents the slope of the relative variation curve of the time‐of‐flight and the applied stress. The results of these measurements are shown in Table 1.(4). with the low frequencies penetrating deeper than the high frequencies.4 is used here to measure the depth of the LCR wave. The first sample was taken from a stainless steel 304 plate with exactly the same thickness and chemical composition of stainless steel side of the pipes. The hoop residual stresses distribution which is shown in 76 .5 Tensile test to evaluate acoustoelastic constant L11 Fig. Since. To evaluate the residual stress from Eq. Fig. there is not a reliable equation for the relation of LCR depth and frequency and it should be measured experimentally. free stress time‐of‐flight). the ultrasonic measurement concerns the residual stresses through the thickness of dissimilar welded pipes. milling process is stopped and the depth of slot represents depth of the LCR waves for the tested frequency. Javadi Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes DETERMINATION OF LCR DEPTH When the LCR technique is applied to an application with limited wall thickness. 4Mhz and 5Mhz respectively.7 Results of tensile test to evaluate on stainless steel sample RESULTS AND DISCUSSION In this study. 2Mhz. as shown in Figure 6 and Figure 7. The characteristics of welding residual stress distribution in the pipe are very complex especially for hoop stresses. the value t0 is measured directly from the stress‐free samples and the acoustoelastic constant is deduced experimentally from a uniaxial tensile test associated with an ultrasonic measurement (Figure 5). The setup which is shown in Fig. When the amplitude of the LCR wave is equal to the noise. The depth of the slot is increased step by step and the amplitude of the LCR wave is measured in each step.6 Results of tensile test to evaluate on carbon steel sample EVALUATION OF THE CALIBRATION CONSTANTS To evaluate the calibration constants (acoustoelastic constant. A slot is performed between the transducers by milling tool to cut the LCR wave.5mm and 1mm for transducer with nominal frequencies of 1Mhz. Fig.4 Experimental setup to measure depth of Lcr wave Two transducers as sender and receiver with the same frequency are used to produce the LCR wave. Four different frequencies have been used in this work to evaluate the residual stress through the thickness of the plates. The material used here is the same as the welded plates.Y. The measurements were parallel to the weld axis therefore the hoop residual stress of pipes is evaluated. The values of the residual stresses relating to each weld zone were calculated from the equations (1‐4) and the results are shown in Figure 8‐Figure 11. two different calibration samples were prepared. Fig. the depth of the LCR wave penetration is expected to be a function of frequency. 5 0.2 13. A: Amplitude.06 2.28 10.02 2 0.6 ‐ 13.34 11.10 Ultrasonic stress measurement results by 4MHz LCR wave Fig.5 noise ‐ *D: Depth of Machining (mm).33 4 0.6 13.5 noise ‐ 3 0.66 13.5 10. Because.4 11.5 0. Also.29 3.1 0. shows reasonable agreement.47 13. It can be noticed that the results of 1Mhz Tab. T:Time of Flight (µs) Fig.37 4.91 1 0. it is obvious from Figure 9.09 0 0.98 2 noise ‐ 1. But Figure 13 shows the distribution of the hoop stress on the outside surface is very complex. Also it can be concluded from Figure 8‐Figure 11 that peak of the residual stress in stainless steel side is higher than carbon steel side because of higher yields stress in stainless steel. tensile hoop stresses are generated at the weld zone and its vicinity.49 13.14 1 0.54 13.9 Ultrasonic stress measurement results by 2MHz LCR wave 77 . and compressive stresses are produced away from the weld centerline [24].26 2.8 Ultrasonic stress measurement results by 1MHz LCR wave Fig.11 Ultrasonic stress measurement results by 5 MHz LCR wave Fig.33 13.5 0. the thickness of the pipes is 8mm and 1Mhz LCR wave travels more near to the inside surface.18 1.[24] From the simulation and experiment results of D.37 5 0.42 10.6 1.93 1. Figure 12 shows that. Figure 12‐Figure 13 and has been extracted from D.21 2 0. on the inside surface.42 13.3 10.5 0.[24] Comparing Figure 12 and Figure 13 with residual stress results of this paper.5 0. it can be found that the shape is “like a wave and very sensitive to the distance from the weld centerline”.5 0.55 T D 4Mhz A T D 5Mhz A T 10. Figure 10 and Figure 11 that with increasing the frequency (so decreasing the distance from the surface) residual stress distribution is became more similar to the hoop stress distribution on the outside surface of the pipes.Deng [ 24] is more popular in the references.35 10.43 13.37 5.Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes Y.58 1 0.1 The results of Lcr depth measurement 1Mhz 2Mhz D A T D A 0 0. Javadi measurement (which is done in 5mm from the surface) is similar to the average of the inside and outside surfaces of the pipes especially more close to the inside surface distribution.4 13.5 1 0.Deng [24].5 noise 0.5 0.75 0. is capable of inspecting the welding residual stresses through the thickness of the stainless steel pipes. Herzer. 5. all of the frequencies are shown in Figure 14. Grayli.13 Hoop stress distribution on the outside surface of pipes (extracted from [24]) The other difference between residual stresses of two dissimilar pipes is in residual stress distribution in the points far away from weld centerline. it is obvious from this figure that residual stress near the outer surface (higher frequencies) is more sensitive to the distance from the weld centerline. Residual stress exactly on the weld centerline is shown in Figure 15. 3. With increasing the frequency (so decreasing the distance from the surface) residual stress distribution is became more similar to the hoop stress distribution on the outside surface of the pipes. Instrument for the automated ultrasonic time‐of‐flight measurement a 78 . This manner can be observed in Figure 8 but. about the other frequencies there is compressive stress in the carbon steel side too. Effect of microstructure and prior austenite grain size on acoustic velocity and attenuation in steel.15 Residual stress on the weld centreline CONCLUSIONS This paper confirms the potential of the ultrasonic residual stress measurement in the inspecting the welding residual stresses through the thickness of the dissimilar steel pipes. Schneider. The tensile stress of weld centerline decrease with increasing the frequency. REFERENCES [1] N. The peak of residual stress in stainless steel side is higher than carbon steel side because of higher yields stress in stainless steel. pp. Javadi Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes Fig. Residual stress near the outer surface (higher frequencies) is more sensitive to the distance from the weld centerline. To better compare of this difference. 4. Shyne. Rev Prog NDE. The results of this paper show that: 1. 4(B)(1985). Of course this difference considerably increases by higher frequencies of transducers. higher thermal conductivity of carbon steel causes to tensile stress in this zone and compressive stress for the stainless steel side. E. It can be noticed that tensile stress of weld centerline decrease with increasing the frequency. 927‐936.Y.14 Ultrasonic stress measurement results Fig. Ultrasonic is capable of measuring the difference between residual stresses of two dissimilar pipes in the points far away from weld centerline. 6. Generally.12 Hoop stress distribution on the inside surface of pipes (extracted from [24]) Fig. [2] R. which is probably because of complex distribution of outside hoop stresses. JC. The hoop residual stress of the pipes is very complex and very sensitive to the distance from the weld centerline on the outside surface of the pipes. Therefore the ultrasonic residual stress measurement used in this paper. Of course this difference considerably increases by higher frequencies of transducers. 2. Fig. That is because of difference in the thermal conductivity constant between stainless steel and carbon steel. Also. Ultrasonics. J Appl Mech. and Codes and Standards. 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Theoretical study of ultrasonic longitudinal subsurface waves in solid media. June 23‐27. G. 207(2001). 9. Stanley. CM. Nuclear Engineering and Design. [23] D.N. pp. J. pp. 673‐680. pp. Joseph. Goebbels. C.E. Advanced Methods. pp. 36(1991). Javadi . D. J Sound Vib.M. Int J Microstruct Mater Prop. [20] L. 1189‐1197. Numerical simulation of temperature field and residual stress in multi‐pass welds in stainlesssteel pipe and comparisonwith experimental measurements. E. CRC Press. Moysan. Salama. Nondestructive investigation of the effect of quenching and tempering on medium‐carbon low alloy steels. Acoustoelastic response of a polycrystalline aggregate with orthotropic texture. K. Çam.V. Kim. Relationship between temperature dependence of ultrasonic velocity and stress. 58(2007).D. Quantitative non‐destructive evaluation. Calmon. Nondestructive Evaluation.) NDE: Applications. 28(1995). Tang. Bray. Evaluation of Stress Gradients in Steel Plates and Bars with the LCR Ultrasonic Wave.F. Corneloup. pp. 15(1982). 173‐192. Orkun Tuncer. 659‐663. Egle. 52(1985). Acoust. EP. B. Brekhovskii. 29(1984). pp. Materials Charact.E. Schlader (Eds. Acoustical characterization of austenitic stainless‐steel welds for experimental and modeling. GC. Temperature dependence of third‐order elastic constants. Comparison of magnetic Barkhausen noise and ultrasonic velocity measurements for microstructure evaluation of SAE 1040 and SAE 4140 steels.E.2005 tool for materials characterization. Langenberg. NDT. Academic Press. E. 1989. 231‐ 240. D. D. pp. San Diego. In: R. R. Crecraft. YH. Non‐destructive analysis of texture in rolled sheets by ultrasonic techniques. Springer. pp. JH. pp.K. 40(2002). Physical acoustics and microstructure of iron alloys. 76‐81.Using LCR Ultrasonic Method To Measure Residual Stresses Through Thickness of Dissimilar Welded Pipes [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] H. J. and accuracy of the measurement. meanwhile V12 and V13 represents the velocity in a perpendicular plane (shear waves). e. dangerous thermo‐ mechanical stresses may appear in and around the welded joint. Brekhovskii [Error! Reference source not found. After the accurate measurement of depth. 80‐84. Y. must be taken into account in choosing an adequate technique.. 2 shows elements of a bar under tension where the ultrasonic wave propagates in three perpendicular directions.). and structure [ 10. Semnan. A. 3]. carbon rate [ 4. 8.1 . etc. They have very important role in the strength and service life of structures. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Residual stresses are present in materials without any external pressure. Email: bahman_alireza@yahoo. 5]. However. 4Mhz and 5Mhz transducers.].22] had some detailed discussions on the characteristics of the LCR.19]. it is very important to determine the residual stress levels with a non‐destructive method. It has been shown that the residual stresses through the thickness of stainless steel plates can be inspected by LCR waves. residual stresses through the thickness of plates are evaluated by four different series of transducers. 9]. which travels parallel to the surface. Iran. 12]) and to the operating conditions (temperature [ 13. easy to use. 7. 18]. 2a the wave propagates parallel to the load and V11 represents the velocity of the particles in the same direction (longitudinal wave). 2nd International Conference Manufacturing Engineering & Management 2012. LCR waves. the relationship of stress and wave velocity in engineering materials. as shown in Fig. surface quality. also called surface skimming longitudinal waves (SSLW) by some of the authors. and normally result from deformation heterogeneities appearing in the material. Email: yasharejavadi@yahoo. In Fig. This technique uses critically refracted longitudinal waves that travel parallel to the surface. Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves. incremental hole drilling. Iran. Rising demand of industry for the stress measurement techniques encouraged development of several methods like X‐ray diffraction. In Fig. The LCR technique uses a special longitudinal bulk wave mode. According to the process and temperatures reached during this operation. Islamic Azad University‐Semnan Branch. and the ultrasonic waves methods. The V22 velocity is THEORETICAL BACKGROUND Within the elastic limit. 11. geometry. To achieve a proper design of structure and control their mechanical strength in service. 16]. the accurate depth underneath the surface in LCR waves is measured for 1Mhz. Many studies showed that there is no universal or absolute method that gives complete satisfaction in the non‐destructive stress monitoring of the mechanical components. cost. The LCR waves are 80 . particularly propagating beneath the surface at a certain depth. 2b and Fig. Welding is an assembly process often used in different industries. coupling [ 15. and relatively inexpensive.1 LCR probe for PMMA (Plexiglas) wedge on steel Ultrasonic stress measurement techniques are based on the relationship of wave speed in different directions with stress. 2. Because of the residual stress changing through the thickness. Junghans and Bray [21]. Basatskaya and Ermolov [20Error! Reference source not found. the acoustoelastic effect [17. Fig. Fig. 2c the waves propagating in the other directions and the velocities are shown. e. etc.icmem.tk Manufacturing Engineering & Management The Proceedings Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves Yashar Javadi ‐ Alireza Bahman 1 Department of Mechanical Engineering. The longitudinal critically refracted (LCR) wave is a bulk longitudinal mode that travels within an effective depth underneath the surface. i.. [Error! Reference source not found. Semnan. (2012). Bahman. The ultrasonic estimation of the residual stresses requires separation between the microstructure and the acoustoelastic effects. i. Langenberg et al. texture [ 6. This paper evaluates welding residual stresses in plate-plate joint of AISI stainless steel 304L. i.com Department of Mechanical Engineering. the ultrasonic stress evaluating technique relies on a linear relationship between the stress and the travel time change. 14]. The first index in the velocities represents the propagation direction for the ultrasonic wave and the second represents the direction of the movement of the particles. p. Many parameters such as material. The ultrasonic technique was selected for stress measurement because it is non‐destructive. it is slightly sensitive to the microstructure effects (grains size [ 1. 2Mhz. especially in the pressure vessel industry.com 2 ARTICLE INFO: Category : Original Research Paper Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 5 November 2012 Keywords: (in causal order) Abstract: Ultrasonic Stress Measurement Acoustoelastic Effect Welding Residual Stress LCR Ultrasonic stress measurement is based on acoustoelasticity. Citation: Javadi.Contents lists available at www.e. Islamic Azad University‐Semnan Branch. The variation in the v11 velocity. where to is the time for the wave to go through a stress free path in the material being investigated. V11 is the velocity of waves in the direction 1 with particle displacement in the direction 1. followed by the shear waves when the particles vibrate in the direction of the load. EXPERIMENTAL PROCEDURES The materials tested (A240‐TP304L) are commonly used for pressure vessel applications. A three‐probe arrangement was used. For a state of uniaxial stress. (4). The other waves do not show significant sensitivity to the strain. Fig. In this equation. The measurement device. Single pass butt‐weld joint geometry with a back‐weld pass and without root gap was used. where ε is the strain in the direction 1 and υ is the Poisson’s ratio. The sensitivity of these waves to the strain has been established by Egle and Bray [ 17] in tensile and compressive load tests for a bar of rail steel. α 2= α 3=‐υ×ε. 1 2 3 which α1. The waves with particle motion in the direction of the stress fields showed the greatest sensitivity to stress. Two 600*250*10 mm normalized A240‐ TP304L rolled plates were welded in V‐groove (90° included angle). provided the value of the acoustoelastic coefficient L is changed. The ultrasonic box is a 100Mhz ultrasonic testing device which has a synchronization between the pulser signal and the internal clock. Eq. The diameter of all the piezoelectric elements was 6 mm. as shown in the Eq. d E ( dV11 / V11 ) E dt L11 L11 t 0 (4) where dσ is the stress variation (MPa) and E is the elasticity modulus (MPa). shown in Fig. L11 is the dimensionless acoustoelastic constant for LCR waves. controlled by the coefficient L11. includes an ultrasonic box with integrated pulser and receiver. The acoustoelastic constant (L) functionally links the stress and the velocity or travel time change. (3). Two rectangular tension test specimens were extracted from PM (Parent Material) to determine acoustoelastic constant. is much greater than the other ones. Bahman The values of acoustoelastic constants for the other directions can be obtained in the same way. Twelve transducers in four different frequencies were used where their nominal frequencies were 1Mhz. the travel time of the longitudinal wave decreases in a compressive stress field and increases in a tensile field. computer and three normal transducers assembled on an integrated wedge.Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves Y. Transducers were assembled on an integrated PMMA wedge. (1) becomes: 0V112 2 [4( 2 ) 2( 2m) (1 2 )]. Stress can be calculated by the one‐dimensional application of the stress–strain relations in elastic solids. for longitudinal waves propagating perpendicular to the stress direction. Javadi. m. α 1=ε. 2Mhz. Back‐weld and the main weld‐pass were performed by submerged arc welding (SAW) process. The same equation can be used for the other directions of the waves. λ. and those with particle motions perpendicular to the stress field showed the least. n are the third order elastic constants. dV11 / V11 ( 2m) v (1 2l / ) 2 L11 (3) d 2 81 . (2) The relative sensitivity is the variation of the velocity with the strain and can be calculated by Eq. that controls the A/D converter. Using these values. The most considerable variation in travel time with the strain was found for longitudinal waves. 4Mhz and 5Mhz. A. Using different frequencies helps to evaluate residual stresses through the thickness of the plates. α2 and α3 are components of the homogeneous triaxial principal strains. This allows very precise measurements of the time of flight – better than 1ns.3. (3) can be rearranged to give the stress variation in terms time‐of‐flight (dt/to). μ the second order elastic constants (Lame’s constants). l. with one sender and two receivers in order to eliminate environment temperature effect to the travel time. indicating that these waves are the best candidates to be used in the stress evaluation. Eq. For a fixed probe distance.2 Velocity of plane wave and stress field in orthogonal directions [ 23] The velocities of the longitudinal plane waves traveling parallel to load can be related to the strain (α) by the following expressions: 0V112 2 (2l ) (4m 4 10)1 (1) where ρo is the initial density. A. The measurements were parallel to the weld axis.4 Experimental setup to measure depth of Lcr wave Two transducers as sender and receiver with the same frequency are used to produce the LCR wave. Fig. The depth of the slot is increased step by step and the amplitude of the LCR wave is measured in each step.5 and Fig. The setup which is shown in Fig. 2mm. The acoustoelastic constant (L11) is equal to (‐K×E). Fig. 1. Therefore depth of any frequencies can be exactly measured.6 Results of tensile test to evaluate acoustoelastic constant RESULTS AND DISCUSSION EVALUATION OF THE CALIBRATION CONSTANTS In this study.7‐10 show that tensile residual stresses are generated at the weld zone To evaluate the calibration constants (acoustoelastic constant. The values of the residual stresses relating to each weld zone were calculated from the equations (1‐4) and the results are shown in Fig. t and t0 are the time‐of‐ flight measured between the two receivers for stressed and unstressed samples. Four different frequencies have been used in this work to evaluate the residual stress through the thickness of the plates. Since. The results of these measurements are shown in Table 1. 2Mhz.5 Tensile test to evaluate acoustoelastic constant L11 Fig. To evaluate the residual stress from Eq.6). 4Mhz and 5Mhz respectively. Bahman Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves the value t0 is measured directly from the stress‐free samples and the acoustoelastic constant is deduced experimentally from a uniaxial tensile test associated with an ultrasonic measurement (Fig. 82 t0 In Eq. DETERMINATION OF LCR DEPTH (t t0 ) . the ultrasonic measurements were used to determine the residual stresses through the thickness of welded plates. free stress time‐of‐flight). there is not a reliable equation for the relation of LCR depth and frequency and it should be measured experimentally.4 is used here to measure the depth of the LCR wave. A slot is performed between the transducers by milling tool to cut the LCR wave. (5).Y. Javadi.3 Measurement devices K When the LCR technique is applied to an application with limited wall thickness. Two rectangular tension test specimens were extracted to determine acoustoelastic constant (L11) with average of the results. where K is calculated from Eq. the calibration samples were taken from both sides of the plates. (4). The material used here is the same as the welded plates. the depth of the LCR wave penetration is expected to be a function of frequency. When the amplitude of the LCR wave is equal to the noise. respectively. (5) σ is the applied stress.5mm and 1mm for transducer with nominal frequencies of 1Mhz. (5) Fig. milling process is stopped and the depth of slot represents depth of the LCR waves for the tested frequency. Fig. with the low frequencies penetrating deeper than the high frequencies. (5) and E is the elasticity modulus. From this table it can be concluded that depths of LCR wave are 5mm.7‐10. K represents the slope of the relative variation curve of the time‐of‐ flight as described by Eq. 43 13.37 5.1 The results of Lcr depth measurement 1Mhz 2Mhz D A T D A 0 0. Javadi.02 2 0.5 0. and its vicinity. 1Mhz LCR wave (Fig.37 4.66 13.37 5 0.18 1. Of course.14 1 0. It has been shown that the residual stress considerably decrease with increasing the depth of measurement where the lower frequency waves can penetrate.42 10.5 noise ‐ *D: Depth of Machining (mm).5 noise 0. Bahman main weld‐pass.5 0. A: Amplitude.7 Ultrasonic stress measurement results by 1MHz LCR wave Fig. Therefore the ultrasonic residual stress measurement used in this paper.6 1.35 10.06 2. the residual stress on the surface is the highest which is well shown in the Fig.93 1.5 0.33 13.6 13.55 T D 4Mhz A T D 5Mhz A T 10.29 3.26 2. For example.42 13.4 11.5 noise ‐ 3 0.2 13. It can be justified that low frequency waves travel deeper than the high frequencies therefore inspect bulk residual stresses. it can be concluded the residual stresses have been decreased with increasing of the measurement frequencies.98 2 noise ‐ 1.5 0.1 0.Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves Y.54 13. Also.4 13. Since the ultrasonic 83 . 10.91 1 0.8 Ultrasonic stress measurement results by 2MHz LCR wave Fig.28 10.10 Ultrasonic stress measurement results by 5 MHz LCR wave CONCLUSIONS This paper confirms the potential of the ultrasonic method in measurement of the welding residual stresses through the thickness of the stainless steel plate.5 0.5 10.7) travels in 5mm from the surface which is approximately through the root of the Tab.3 10.9 Ultrasonic stress measurement results by 4MHz LCR wave Fig.5 0. This result is in a good agreement with the welding theory. and compressive stresses are produced away from the weld centerline.5 1 0.33 4 0.47 13.34 11.09 0 0.6 ‐ 13. T:Time of Flight (µs) Fig.58 1 0.5 0. is capable of inspecting the welding residual stresses through the thickness of the stainless steel plates.21 2 0. It can be noticed that this frequency shows the minimum level of residual stresses probably because of minimum width of melted zone in this location.49 13. A.75 0. [21] Junghans. pp. Int Mater Rev. 125‐145. pp. Goebbels. 76‐81. Measurement of acoustoelastic and third order elastic constants for rail steel. pp.D. Bahman Measurement of Through Thickness Residual Stresses in Stainless Steel Welded Plate Using Ultrasonic Longitudinal Waves [12] JH. Schlader (Eds. Int J Microstruct Mater Prop. 4(B)(1985). S. [22] K. Cook. [2] R. Herzer. 51‐60. El Guerjouma. Orkun Tuncer. 39‐44. Proc 9th international conference on experimental mechanics. [15] DI. REFERENCES [1] N. 58(2007). JC. Nam. Temperature dependence of third‐order elastic constants.25 V steel using ultrasonic characteristics. there is no damage on the stainless steel plate after stress measuring process. pp. Gengembre. 12(1990).J. Nondestructive Evaluation. [23] D. Pangbom. Çam. Acoustical characterization of austenitic stainless‐steel welds for experimental and modeling. Salama. [11] YH. Eval. [10] C. pp. 179‐185. 28(1995). NDT E Int. Evaluation of Stress Gradients in Steel Plates and Bars with the LCR Ultrasonic Wave.. 1109‐1119 [14] H. 3577‐3581. Boca Raton. [6] MA. 1997. 219‐213. Spies. T. Res. pp.) NDE: Applications.E. D. Bray.K. Springer. 3(1990). Basatskaya. Crecraft. Calmon. R. Fellenger. Modeling of ultrasonic fields radiated by contact transducer in a component of irregular surface. June 23‐27. Ermolov. Soc. 2157‐2167.E. [9] CM. The measurement of applied and residual stresses in metals using ultrasonic waves. Johnson. Langenberg. SH. [16] A.N. Quantitative non‐destructive evaluation. 17(2005). Physical acoustics and microstructure of iron alloys. 59‐81. 673‐680. Schneider. Ploix. 173‐192. In: R. Ultrasonic velocity measurements for estimation of grain size in austenitic stainless steel. [3] P.F. Kim. R. pp. Palanchamy. Brekhovskii. 52(1985). Mohbacher. Cantrell. pp. Marklein. A. 231‐ 240. 2(1990). Effect of microstructure and prior austenite grain size on acoustic velocity and attenuation in steel. B. 1991. 1989. Theoretical study of ultrasonic longitudinal subsurface waves in solid media. E. pp. pp. FL revised edition. 741‐744. 60(1976).M. pp.Y. Sayers.. Schneider. [17] D. Colwfer. pp. 60(2006)..‐216. D. K. Moysan. N. 659‐663. J. Papadakis. [7] M. Proceedings 1991 ASME Pressure Vessels and Piping Conference. and Codes and Standards. On the nature of the so‐called subsurface longitudinal wave and/or the surface longitudinal 'creeping' wave. Nahm. Advanced Methods. San Diego. P. Non‐destructive analysis of texture in rolled sheets by ultrasonic techniques. Chatillon. Bray. Hakan Gür. Tang. Grayli. P. E. Rev Prog NDE. Nuclear Engineering and Design. Chassignole.N. E. Nondest.E. pp. pp.E. Bray. pp. Mater Lett. 5(1967). Stanley. W. 231‐236. K. 40(2002). J Appl Mech. 15(1982). Egle. 27(1980). I.V. Acoustoelastic characterization of materials. J. Salama. 1‐24. Joseph. Lhémery. pp. YI. Evaluation of fracture appearance transition temperature to forged 3Cr‐ 1Mo‐0. J Sound Vib. 927‐936.E. NDT. Am. Jayakumar. J. Acoustoelastic response of a polycrystalline aggregate with orthotropic texture. Javadi. inspection is performed nondestructively. [20] L. Ultrasonics. Bray. 1189‐1197. Ultrasonic velocities in anisotropic polycrystalline aggregates. D. R. P. Hakan Gür. [13] K. CRC Press. pp. Shyne. J. J Phys D Appl Phys. J Soc Adv Sci. ?. 1985.M.. Materials Charact. A. Ultrasonics. Beam characteristics of high angle longitudinal wave probes. Instrument for the automated ultrasonic time‐of‐flight measurement a tool for materials characterization. 207(2001). Bray. pp. G. CA. pp. Relationship between temperature dependence of ultrasonic velocity and stress. [4] EP. 447‐454C. 226‐233. Acoust. 1(2005). Int Mater Rev. [19] L. Comparison of magnetic Barkhausen noise and ultrasonic velocity measurements for microstructure evaluation of SAE 1040 and SAE 4140 steels. D. PVP‐Vol. Nondestructive investigation of the effect of quenching and tempering on medium‐carbon low alloy steels. Text Microstruct . Schneider. NDE Vol. pp. B. Corneloup. [18] D. [5] C. 36(1991). 1(1960).M. [8] GC. pp. C. 29(1984). Academic Press. 84 . Waves in Layered Media.. 9. The structure of the materials is illustrated in Table 1. [8].3 ‐ Milena Kušnerová2. The data reached from the experiments have important influence for interpreting results where friction and wear are measured.. Producers as well as subsuppliers need to find possible savings. there is a friction between shaft and bearing. Alexander Dubček University of Trenčín. the radius (diameter) of a testing shaft – rH. the minimum possibility of changing the parameters during the experiment may be seen as their disadvantage. the experimental determining of tribological features is realised via devices with different configurations. [5]. N. Fig. the normal force – FN. Each experiment is influenced by several factors. VŠB–Technical University of Ostrava. represented by friction force FT effecting rotation movement of the shaft. 85‐ 88. The transmitted torsion moment is defined by friction force FT’ = FT and radius (diameter) of the shaft rH. There is a trend of using devices with low surface speed and loading on few Newtons. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Nowadays. Slovakia Faculty of Mining and Geology. [11]. the given experiment conditions result from the chosen application. Thus. (2012). Bimetallic bearings are made by curling bimetallic strips with different sliding materials. The friction also causes the transmission of torsion moment to the head of testing machine (Fig. the length of testing head’s arm – a. mm. Slovak University of Agriculture in Nitra. The development of microtribology and nanotribology influences the parameters of experimental testing devices. Czech Republic 4 Faculty of Special Techniques. The experiments were realised on Tribotestor M’06 testing machine. Citation: Kadnár M. mm. According to the simple design of existing devices. whereas the weight of factors is different and each of them is determined to solve a partial tribological task [9]. When a journal node is loaded by normal force FN. the experiments with different kinds of journal bearings were elaborated for the purpose of replacing a rolling bearing by a journal bearing. etc. [6].rH . 85 FN .tk Manufacturing Engineering & Management The Proceedings Tribological Features of Journal Bearings Made of Bimetallic Alloy Milan Kadnár1 ‐ Juraj Rusnák1 ‐ Jan Valíček2. i. to influence the range of running parameters.Contents lists available at www. steering servo unit. to provide modification easily. et al. VŠB–Technical University of Ostrava. In most situations. [7]. MATERIAL AND METHODS Test Rig In experiments with reals journal bearings the Tribotestor M’06 testing machine allows: to use the most modern measuring technology. Tribological Features of Journal Bearings made of Bimetallic Alloy. The important correlation between results of laboratory experiments with a model of tribological system and the real journal node may by achieved by maximum approach of simulation features by real running conditions. The active layer is represented by a sliding material which is coated on a steel base in the form of powder and is compressed by rolling. 1). p.1 The diagram of Tribotestor M’06 testing machine The friction coefficient is determined by the formula: Ft . the friction coefficient depends on: the force on the end of testing head’s arm – Ft. The paper presents results of laboratory experiments with real journal bearings made of bimetallic alloy realised to find out possible replacement of a rolling bearing by a journal bearing. 2nd International Conference Manufacturing Engineering & Management 2012. The smooth structure is considered to be the main advantage because the bearings of these materials are usable also within the critical friction. The reason of the purpose was an expected saving. Slovakia 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 14 September 2012 / Revised: 20 September 2012 / Accepted: 30 October 2012 Keywords: (in causal order) Abstract: Bimetallic alloy Journal bearings tribological experiment Tribotestor M’06 The competitive environment forces producers in automotive industry to decrease the costs.icmem. Czech Republic Faculty of Metallurgy and Materials Engineering. There also exist minimum experimental devices which are able to realise an experiment with real journal node during real running conditions as they are usually used to provide durability tests [1]. [10]. however the reached friction coefficient cannot be compared with values of real journal nodes [3].3 ‐ Pavol Tököly4 1 Faculty of Engineering. MATERIAL For the producer of a steering servo unit.a (1) Thus. the real friction node is replaced by a line contact or a spot contact.e. N. [1]. to provide several lubrication modes. It is very common that the experiment parameters are always chosen based on the needs and demands. 4 μm. the complex mode of the experiment for friction measurement was determined. the rotational frequency Load/N 300 200 100 0 Revolutions/rpm 0 200 400 600 800 1000 Time/s 4000 3000 2000 1000 0 0 200 400 600 800 1000 Time/s Fig. The measurement with constant load was undertaken with load of 150 N and revolution of 4000 min‐1 or 500 min‐1. 200 N and 250 N. [4]. we have decided for a compromise. The idea is supported by the fact that the total friction coefficient is not a measured value but a calculated one. The basic features of B10 and B30 materials are illustrated in Table 2.1 ≤0. six tested samples of each materials.3 Phases of the experiment for friction measurement Phase Sliding node stabilisation B10 material is a metal‐polymer composite material with excellent friction features also without lubrication. 2.3 B10 material – friction coefficient depending on load 86 0 Measurement with constant speed Time/s Duration/s Load/N Revolutions/rpm .7 ≤0. Tab.M. [12]. i. the measurement with revolutions of 2000 min‐1 was realised with load of 100 N. the measured data reflects the reality in a tribological node. cemented.5 CuPb10Sn10 11 B30 26‐ rest ≤0. Generally. Before the experiment each sliding node was exposed by test run of 600 s with revolutions of 2000 min‐1 and load of 150 N. Tribological Features of Journal Bearings made of Bimetallic Alloy was used rather than surface speed concerning the features of steering servo unit. The diagram of load and rotational frequency depending on time is illustrated in Fig. The diagram of friction coefficient within constant rotational frequency. Fig. The phase was considered to be a preparatory phase and the reached results are not taken into consideration further. B30 is a bimetallic material with bronze alloy. i. hardened and edged – material ČSN 14 220 (each shaft used only for one measurement). Before measurement with constant load each node undertook another stabilisation which lasted 20 s loaded by 20 N with revolutions of 4000 min‐1. There are many statistical interpretations of friction measurement. The required shaft roughness cannot exceed 0.2 ≤ 0. Consequently. depending on variable load is illustrated in Fig. Kadnár et al. For an application in tribology.5 ≤0.e. Further processed information in a table or a figure is only its interpretation. The both measurements lasted 120 s.e.5 ≤0. At the same time. Each measurement lasted 120 s. The mode included several partial phases which are illustrated in Table 3. KADNÁR (2009) illustrates the selection of experiment parameters.5 ≤0. 150 N.7 ≤0.1 ≤0.2 ≤ 0. the shaft hardness must be over 200 HB. No important vibrations were recorded during test run and experiments themselves. 3. loaded by 20 N with revolutions of 2000 min‐1. Thus.2 Load and rotational frequency depending on time RESULTS AND DISCUSSION Within a sliding node B10 material had stable features in connection with the variable load or variable rotational frequency.02 mm. The most important information is that in the unfiltered record during friction force measurement. The required shaft features are the same as for B10 material.1 Chemical structure of materials (weight percentage) Material Cu Pb Sn Zn P Fe Ni Sb Others B10 9‐ rest 9‐11 ≤0.5 ≤0.e. Based on the parameters. i. bearing clearance of 0. After the test run each node was stabilised.2 Basic features of B10 and B30 materials Materia l B10 B30 Chemical structure CuPb10Sn1 0 CuPb30 Tensile strengt h /MPa Maximum load in static stress/MP a Maximum load in dynamic stress/MP a Maximum operation temperatur e / C 230‐280 200 120 250 90‐107 120 40 160 20 20 2000 20 120 100 2000 140 120 150 2000 260 120 200 2000 380 120 250 2000 500 20 20 4000 Measurement with constant speed 520 120 150 4000 640 120 150 500 Supporting measurement for checking of measuring device 760 30 100 0 790 30 150 0 820 30 200 0 850 30 250 0 Sliding node stabilisation EXPERIMENTS The following conditions were followed during the experiments for friction measurement: shaft of Ф 10. Tab.5 ≤0. for a figure interpretation with illustrating average value of measurement and statistical interval of 95 %.5 CuPb30 33 Tab. no lubrication. the table data is used rather as additional information [1]. [2]. 7 illustrates the diagram of friction coefficient depending on variable load.e. The diagram of friction coefficient with constant load and variable rotational frequency is illustrated in Fig. At the load from 100 to 200 N the friction coefficient was 0. Based on the results the wear resistance of B10 material towards the chosen application is not sufficient. the friction coefficient did not exceed the limit of 0. The diagram of friction coefficient with constant load and variable frequency is illustrated in Fig. It resulted from conditions in sliding node which corresponds to the area of mixed friction. Fig.e. During the experiment the friction coefficient ranged from 0.05. At the load of 250 N. At the load of 150 N there was only a little decrease of friction coefficient.4 B10 material – friction coefficient depending on rotational frequency ‐1 At the frequency of 4000 min the friction coefficient decreased to 0. At the load of 100 N. i. The temperature was practically the same. 4.Tribological Features of Journal Bearings made of Bimetallic Alloy M. the sliding node of B10 material can be evaluated to be favourable. Fig. local wear of thin film. Despite the conclusion. 42 °C.1. 8.7 B30 material – friction coefficient depending on load The test run or experiments themselves when using B30 material recorded more important vibrations. In some parts there was a visible subsurface layer of sintered bronze.Kadnár. it is possible to conclude that the sliding node of B10 material is considered to have stable features. et al. 5). At the load of 250 N the friction coefficient decreased to 0. the separation of surface was recorded.07.05.08. At the rotational frequency of 500 min‐1 the lubrication mode can be considered to be mixed. Thus.6 B10 material – surface before (a) and after (b) the measurement According to the high value of friction coefficient the B30 material is considered to be less favourable.07. Regarding the surface of journal bearing of B10 material. i. The weight loss of B10 material ranged from 9 to 14 mg (Fig. However.05. Fig. sliding layer on a surface of the material (Fig. the friction coefficient was 0. When decreasing the load. Thus. there were only little differences of friction coefficient.9 B30 material – surface before (a) and after (b) the measurement Fig. At the load of 150 N and lower frequencies the friction coefficient decreased to 0. 6).5 B10 material – surface before (a) and after (b) the measurement Fig.10. the friction coefficient was 0.8 B30 material – friction coefficient depending on load Fig. At the frequency of 4000 min‐1 the friction coefficient decreased to 0.08. The temperature was not more than 43 °C.06 to 0. The surface of 87 . Fig. the bearing surface had little wear. . As the literature confirms. PRŠAN J. 10). 2004.. 2001. New York: John Wiley & Sons: 752. 30: 1381‐1385.00/03. Fig.05/2. 2011. 9). Slovak University of Agriculture: 94‐101.. Mechanical Wear Fundamentals and Testing. [10] ŽIAČIK A. et al. [4] KADNÁR M.10 B30 material – weight loss The weight loss within B30 material ranged from 11 to 16 mg (Fig. Technički vjestnik. In: Faculty of Mechanical Engineering.. [12] ÜNLÜ S. 11 228‐241. 2008. Acta Technologica Agriculturae.. 2007. 2nd Scientific Conference. New York: Marcel Dekkerm: 399. The Sliding Properties of the Bearings with Polymer Lining.1. For the chosen application the tested bearings are considered not to be suitable. 88 . April 1‐2. Materials & Design. 18: 95‐98... Lubricants and Lubrication.. Based on the experiment results the wear resistance of B30 material is evaluated to be not sufficient. et al.0040 and ICT No. Žilina: University of Žilina: 40‐44.. 2008.. The tested bearings were stable depending on load as well as frequency. The sliding node had only average features regarding friction and wear and therefore the bearings after the test can be considered to be damaged. Nitra. 11: 43‐49. Materials & Design. The pressure states in hydraulic of tractor ZTS in set agricultural implements. 2002.. ACKNOWLEDGEMENTS The work has been supported by projects VEGA 1/1064/11. Introduction to Tribology. [9] MANG T. Wiley: 790.. R.. 2003. within dry friction the high values of friction coefficient were recorded.. RMTVC No. Analysis of Friction Marks and Wear Products. DRESEL W. The higher rate of noise and vibrations were also recorded. CZ. ATIK E. [6] KUČERA M. whereas the structure of testing head allows the circulation of lubricant and additional influence of sliding node temperature what helps to simulate real conditions better. Tribologic properties of Selected Materials. [8] KUČERA M. 2003. The Design and Verification of Experimental Machine for Real Journal Bearing Testing.. In: International Student's Scientifics Conference. 2008. EDIS. [2] BHUSHAN B.. et al. 28: 973‐977. Selection of Sliding Node for Steering Servo Unit. 2009. Prediction of Characteristics for Pairs of Materials in Condition of Limit Friction. New York.0082.1. 11: 11‐15.. Žilina. In the future it is possible to verify tribological features of tested bearings also within hydrodynamic friction. BRONČEK J. [5] KADNÁR M.. Tribological Properties of Journal Bearings Manufactured from Particle Reinforced Al Composites.1.. 2009.00/01. Acta Technologica Agriculturae. Kadnár et al.M.05/2. B. In: 50th International Scientific Conference of Departments of Machine Design. Tribological Features of Journal Bearings made of Bimetallic Alloy sliding material had local wear (Fig. 1995. Determination of Friction Coefficient in Journal Bearings.1. [3] JOBBÁGY J. Technical Sciences. ŠIŠKA V. [7] KUČERA M. ATIK E. [11] ÜNLÜ S. REFERENCES [1] BAYER G. B. PRŠAN J. CZ. projector and computer. students can not be fully introduced with a number of material tests that can be perform at Department of Materials and Manufacturing Technology. We can expect that correctly video footage helps to students find connection between discussed problems in those subjects.icmem. Czech University of Life Sciences. : Multimedia Support in Subject Material Science. Information and Control Technology in Agro‐food Complex (code 4101R022). This project has support and corresponds with strategic objectives in field of education (not learning) university. Trade and Business Dealing with Machinery (code 6208R065).cz 4 Department of Material Science and Manufacturing Technology.cz) where it can be replay anytime. Bachelor study programs are specialized education leading to qualification with expertise and technical skills. Agriculture (code 4101R012) or Engineering maintenance (code 4101R003) on Technical Faculty at CULS Prague. Students are not clearly introduced with details of material tests. Video tutorials familiarized students with tests of plastics and metal materials and also with their heat treatment. Prague.cz 2 3 ARTICLE INFO: Category : Technical Note Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 5 November 2012 Keywords: (in causal order) Abstract: Education Innovation Teaching Learning Multimedia Article deals about innovation in subject Material Science. Education is unlike learning associated with narrowly defined skills. Currently. target group is about 600 students in regular and combined forms of study. Czech Republic. All videos are described in great detail to perform various tests including detailed view on control of testing machines. Czech Republic. Multimedia data for students are also available via e‐ learning platform Moodle (http://moodle. Strategic objectives in the field of teaching must aim to strengthen education in CULS Prague. deepen practical student knowledge and create multimedia support for subject Material Science. RESULTS AND DISCUSSION Specific outcome of the project is creation multimedia support for subject Material Science.czu. Solution is using multimedia support to familiarize students with practical 89 . This multimedia system enables to the students learn all tests that are in subject Material Science discussed theoretically or teaching in larger groups. Czech Republic. at the seminar students are introduced with issue only theoretically. Students who are using multimedia support and teaching aids in lab reports according to subject schedule are mainly students of bachelor study programs such as courses Waste disposal technology and techniques (code 3904R027). Authors [1]. Innovation consists of creation multimedia teaching materials and facility to improve theoretical and practical part of seminars.tk Manufacturing Engineering & Management The Proceedings Multimedia Support in Subject Material Science Jiří Kejval ‐ Petr Henc2 ‐ Miroslav Müller3 ‐ Petr Chocholouš4 1 Department of Material Science and Manufacturing Technology.czu. Larger teaching groups during seminars do not METHODS Aim of the project is to innovate and improve teaching. muller@tf. et al. 1). Support is based on subject curriculum and its subsequent implementation into teaching. The course is teaching in summer semester in classical form in range of 2 hours lecture and 2 hours seminar per week. Citation: Kejval J. Road transportation and city traffic (code 3708R020). Prague. Due to requirements of current labor market it is necessary not only theoretical teaching students but also quality practical training during seminars.. During testing structure of materials is used multimedia electronic system connected to the microscope eyepiece. 89‐90. Czech Republic. Support is based on curriculum of subject and its subsequent implementation into teaching. Prague. Czech University of Life Sciences. This system allows to all students get to know in detail structure of materials and to teachers help explain the problem (Fig. Therefore. laptop and projector. The course is intended for most students from Technical faculty at CULS Prague in regular and combined form of study. Similar beneficial issue is application virtual reality technology not only in teaching but also in practice training [3]. In field of education strengths are associated with the quality and relevance of education and flexibly adaptation and diversification range of study. chocholousp@tf. p. Application of multimedia facility increase practical teaching of students and simultaneously raise standards of teaching in this field. Created multimedia facility for subject Material Science enrich contemporary concept of teaching and progressive solution is in line with current trends in modern teaching tools and aids. 2nd International Conference Manufacturing Engineering & Management 2012. Technological equipment of constructions (code 3647R021). Czech University of Life Sciences. henc@tf. From above fact it can be concluded that better and improved teaching during semester will have a positive impact on success of students during exams.czu. as stated [1].cz Department of Material Science and Manufacturing Technology. Due to small capacity of the laboratory. Videos are also focused on very detailed view of test specimen. where authors provide a direct link between success of students in the exam and their active participation in the lectures and seminars.czu. Created multimedia facility consisting of multimedia system and projection equipment will help students thoroughly acquainted with these material tests. [2].Contents lists available at www. Czech University of Life Sciences. Using multimedia system (video camera.cz Department of Material Science and Manufacturing Technology. The survey shows that students do not clearly understand link between subjects Material Science and Manufacturing Technology. kejval@tf. camera for microscope. Prague. electronic eyepiece microscope connected to computer) were filmed teaching videos selected material tests which were subsequently implemented in teaching materials. ISBN 978‐80‐ 553‐1216‐3 INTRODUCTION examples of material tests.czu. (2012). Subject Material Science is teaching by Department of Material Science and Manufacturing Technology. Outcome of the project was to purchase system that enables interactive production which is composed of video camera. [2] made analysis. Important innovation is interactive projection of tested material structures using projector. Students are using standards for processing seminar reports such as ČSN EN 10 002. A. Acknowledgement This paper has been done when solving grant of title „Multimedia support in subject Material Science“ Nr.: Augmented Virtual Reality Applications in Manufacturing Practice. Multimedia Support in Subject Material Science allow to all students familiarize practically with the problem. 2419/2012 in area G1 ‐ creative work of students on technical fields and is mainly dedicated to innovation of subject Material Science. 2012. Students at the seminar will learn a number of practical tests which are based on technical standards. J. 2010. increase competitiveness of students in labor market. Faculty of Engineering. 2011. 90 . In. vol.: Study of students’ presence in lectures influence on their examination results. As benefit of project can be considered: improvement of teaching in subject Material Science. In recent years similar multimedia support has not been implemented in the subject Material Science. ČSN EN ISO 6508.. This multimedia system also allows record images to create learning materials. Brázda. 2. increase of students safety. 650 – 654. Brožek. Youth and Sports (University Development Fund) No.. These standards are purchased through online license. ISSN 1691‐3043.: 10th International Scientific Conference „Engineering for Rural Development“. M. Combination of camera. [3] Novák‐Marcinčin. Fig. p. p. laptop and electron eyepiece. [2] Nováková. Fig. ISSN 1211‐4162.. ISSN 1691‐5976. ČSN EN ISO 6506. 2419/2012. 542 – 547. Jelgava.J. Latvia University of Agriculture. The innovation is in making education videos with selected materials tests. For processing seminar reports students will use current standards available in printed form at the seminar. In..: 11th International Scientific Conference „Engineering for Rural Development“. REFERENCES [1] Nováková.: Evaluation of teaching the subject „Basic Engineering Technologies“. Brožek. 2 Using multimedia system during teaching CONCLUSIONS Project "Multimedia support in subject Material Science" was supported by grant from Ministry of Education. 203 – 206. Jelgava. M. This teaching system was implemented at the end of summer semester and students this system evaluated very positively. p. 1 Using multimedia system during teaching Quality digital camera enables observe all tests in detail and students are not at risk of injury. In tensile tests of plastics materials there is a risk of breaking of the specimen and possible injury. as shown in Fig. P. Kuzmiaková. A. Tutorials allow observing during test in high quality. Kejval et al. microscope and projector will allow familiarized students with tests requiring magnification such as microstructure of material and also graphical description of magnified image. 14. Faculty of Engineering. ČSN EN ISO 6507 etc. Latvia University of Agriculture. Purchasing this license was chosen primarily for financial reason which is very effective because buy of one standard is approximately 600 CZK. M. Strojírenská technologie. no: special. significant benefit is the ability to repeat the issue in a later time. 5
[email protected]] Although fiber and matrix can be fully characterized. coefficient of friction at the interface.0 1. i. [2.cm ] Fiberglass 50 1. and the normal pressure (this arises from the shrinkage of the polymer) if the matrix is stressed while the fibre is pulled out. (2012).8.Strength Fiber in Polyvinyl Butyral Matrix Lucia Knapčíková1 ‐ Jozef Husár1 ‐ Peter Oravec1 1 Faculty of Manufacturing Technologies with a seat in Prešov. with heating shorter and thicker.45 Cordenka 833 20 13. a negative coefficient of thermal expansion in the longitudinal direction. interfacial energy. p. the single fibre pull‐out test provides one of the most direct methods of measuring interface parameters. This pull‐out test can be used to provide data on adhesion. a closed treatment of effects. and thus the properties of the fiber changed. [4. Stiff ("high modulus HM"). [6. [5] However. Fibreglass is a ceramic material with a special feature ‐ below a transformation region is the toughness as high (supercooled liquid). like carbon fibers.sk ARTICLE INFO: Category : Short communication Received : 21 September 2012 / Revised: 24 October 2012 / Accepted: 30 October 2012 Keywords: (in causal order) Abstract: Fiber Matrix Polyvinyl butyral Pull‐out Test Thermoplast High strength fibers used in the manufacture of composite materials with thermoplastic matrix. Tab.8 Aramid fiber 100 2.9. [11] On the market there are several types of carbon fibers such as high‐strength ("high tenacity HAS").5 1. Bayerova 1.6] In subsequent papers we´ll describe experiments using these conditions.icmem. the structure of the network. consisting of polyvinyl butyral.5 Carbon fiber 150 2.8] A great deal of effort has gone into ensuring that adhesion is good [3. which have a very high elongation at break (about 2%). but also serve as a reinforcing material in tubes and other industrial applications. Especially the very good volume stability makes Cordenka very popular for use in car industry. The strength parameters of composite materials are determined in a complex way by the micromechanics at the fiber‐matrix interface. at a modulus of elasticity higher than HT fibers There are also ultra‐high‐ stiffness fibers (ultra high modulus UHM). and good resistance to water. visco‐elastic deformation of the matrix and the fiber‐ matrix friction delaminated areas to the total material is largely unclear. Slovakia.8] this is done by the application of special (often organo‐ silane based) coupling agents. A range of adhesion tests has been devised [2] ranging from contact angle measurements to compression of specially shaped blocks of polymer containing single fibres. [6] With the samples prepared to fiber pull‐out tests are performed. With fiber pull‐out tests fibers known to different wettability and thermoplastics widely differing elasticity can be obtained experimentally accessible sizes for qualitative and (semi‐) quantitative understanding. 2nd International Conference Manufacturing Engineering & Management 2012. e‐mail: lucia. or under conditions which prevented the measurement of many of the important interface parameters. In the first of this series of papers we shall re‐examine the dynamics of the pull‐out process. that the body is first converted into another plastic.: High‐ Strength Fiber in Polyvinyl butyral Matrix . and called intermediate modulus (IM). then subjected to a pull‐out test.[1. most of this work has been carried out either on model systems. Department of Manufacturing Management. which is a material with excellent properties. Presov.13] Mainly serves as a glass former SiO2 silica. high‐strain fibers (HS).0 1. If higher requirements are placed on the mechanical properties is the use of carbon fibers is advantageous. et al. ISBN 978‐ 80‐553‐1216‐3 INTRODUCTION The interface between fibres and matrix in a glass fibre reinforced material plays a major role in determining the mechanical properties of the composite. Their specific strength and its modulus of elasticity is significantly lower than that of carbon WORK MOTIVATION AND PAPER GOAL It should be inserted into different fiber different thermoplastic matrix materials. Aramid fibers have. Based on the measurement results statements about the strength of the bond between fiber and matrix must be taken. Individual fibers were embedded 3 and 5 mm in the middle of the matrix. 91 E-modul [GPa] .1 Fiber mechanical properties [13] Fiber Tensile Strength[GPa] Elongation [%] Density -3 [g.5 2.Contents lists available at www. Thermoplastic materials promise inter alia based on the currently developed effective processing technologies and high‐gain with long fibers and the achievement of a broad mass suitability industrial application potential. Citation: Knapčíková L. Technical University of Košice.e. [2. The good mechanical properties of the glass fibers is based on the strong covalent bonds between silicon and oxygen.13] With Cordenka reinforced composites have a very good balance between stiffness and toughness. carbon. By the addition of various metal oxides. Cordenka is processed also to fabrics which are used in the automotive industry as a fabric reinforcement for tires.5 1.5 MATERIAL AND METHODS By the measurement will be used next fiber.0 2. in order to determine the optimum conditions needed to obtain reliable values of as many parameters as possible in the pull‐out process. namely Cordenka . and glass fibers in a thermoplastic matrix.tk Manufacturing Engineering & Management The Proceedings High. such as (thermally induced) biases. and finally into a solid brittle state. [5. However.8] Good adhesion is essential to ensure good off‐axis properties. 91‐93. currently represent high boom of development. The paper is focused on the characteristics of the use of aramid. Homogenization of mixtures was conducted [3] at 150 °C.22 134. but the lenght is 5mm in the middle of matrix. End of the sample are glued with epoxy resin on carton.Strength Fiber in Polyvinyl Butyral Matrix fibers.35 63 On the next figures we´ll see the sample afer pull‐test. at 125 ° C.0 2117 εmax σmax [ %] [MPa] E‐modul [MPa ] Aramid Fibre 1. Was measured at a test speed of 5 mm/min. 3 mm Carton Fig.7 4907 3. torsion moment is 18 1/min. we achieved the desired mix needed to create a composite. MEASUREMENTS AND RESULTS The pull‐out tests [6] are carried out using a Zwick Z020 „Univesalprüfmaschine“[12]. place specimen with fiber so that the fibers lie in the grooves of the die Sample press for 2 min For fixing and as clamping aid for the tensile test.25 393. The Figure 3 show the fibreglass in the thermoplastic polyvinyl butyral. The speed for the modulus of elasticity is at least 1 mm/s in the range of 0. the machine temperature is 200 °C.8 4430 Cordenka 1.1 Scheme of sample preparation Measurement conditions PVB sheet pressing.6 15026 95.9 2936 6. Polyvinyl butyrale arising from the recycling of car glas. we used the material in granular form.2 Sample preparation for tensile test 92 .L. J. Matrix Epoxy Resin Fibre Fig. which was granted by SCHIRMBECK (Germany). Lenght of fibre is 3mm in the middle of matrix. so that the fiber is not damaged by the jaw (see Figure 2).13].2 Results of Fiber in PVB Matrix Fibre 100 mm Matrix Fibre 3 mm in PVB 5 mm in PVB εmax σmax [ %] [MPa ] E‐ Modul [MPa ] 7457 2. 2 min Sample cut on the size 2x4 cm Sample pieces cut on the narrow side Size 3 or 5 mm from the edge of the sample check Insert the fiber ‐bundle to the mark. These experiments yielded the following results. [3] Tab. The matrix of the sample is clamped accordingly so that the zone in which the fiber is buried is exposed (see Figure 2). The gauge length was 100 mm. Since this in the case of individual fiber bundles by simple measurement is not possible. Husár. The homogenization was with kneading equipment (BRABENDER. [3] Therefore it is necessary to specify a width and thickness of the sample. 90 mm Fig. Knapčíková. Germany).42 166. to be repeated.05% and 0.45 128. In conjunction with the positive coefficient of expansion of the matrix resin can be manufactured highly dimensionally stable components. Therefore it was decided to experiment with samples in which the fibers were inserted just 3 mm deep into the matrix. Oravec Hight. are weighed fiber bundles defined length and from the mass and density of the material is calculated a hypothetical width or density.30 124.4 5437 1.25% strain.7 Carbon Fibre 1. Important material is polyvinyl butyrale (PVB) [9].The measurement is performed in accordance with DIN ISO 527‐1. Figure 1 presented the scheme of sample preparation for press. the compressive strength of aramid fiber composites is significantly lower[10. the fiber The samples are clamped such that the protective carton with the edge of the lower jaw closes. 100 mm Fig.39 228. duration 30 min.3 Fibreglass in PVB The Figure 4 presented the carbon fibre in the thermoplatic polyvinyl butyral also.3 8752 Fibreglass 2. P.4 Carbon Fibre in PVB These experiments showed that the path for the fiber out of the matrix is relatively wide. Compared to carbon composites. Useful data on carbon fibres should be obtainable with about the same values for free length and embedded length. carried out under carefully controlled conditions.Available:http://www. Oravec REFERENCES [1] Jurić. Oravec.: Manufacturing Engineering Vol. [Online].M.zwick.R. Kunststoffe‐ Mechanische und thermische Eingeschaften. new production technologies and new product categories combined to make polymer production economical. Landel F.mtu. V. V.Hight – Strength Fiber in Polyvinyl Butyral Matrix L.. [13] 50 years of reinforced plastic boats. [7] M. Fig.. [8] Piggott H. Nr. A. (2010). global polymer production on the scale present today began in the mid 20th century. et al.E. Elsevier (2001). Verbunden. VŠCHT.: The Puck Theory of Failure in Fiber Polymer Laminates. 93 . Vasiliev.Available:http:// www. 4 (2010).edu [Accessed: 19‐September‐ 2012]. glass. Springer Verlag Berlin (2007).me. Praha. (2006). Knapčíková. fiber tension and the surrounding fibrous matrix volume should be investigated. [12] ZWICK‐Z020. p. Verification and Applications. [5] Knapčíková..: Konstruktieren mit Faser‐ Kunststoff.Polymer Composites (1982).reinforcedplasti cs. Elsevier (2001). George Marsh. aramid and Cordenka. In this paper was presented three important categories of fibre used in fabric reinforced plastic. loading direction. P. Fundamentals. The comparison of the fiber used by polyvinyl butyral matrix show that with a aramid fiber with 5 mm in the midlle of matrix has a higher voltages as with carbon fiber. In: Technical Gazette.[online].5 Comparison of fiber in the PVB matrix As expected. and useful data can be obtained on at least three interface properties. loading rate. CONCLUSION With aramid fibers are recorded in matrix material the highest stresses to failure.: Mechanics and analysis of composite materials. at least in the case of glass. It is particularly important to keep the fibre embedded length small (< 3 mm. Available: http://www. Fibre reinforced plastics have been a significant aspect of this industry from the beginning. [6] Knops.: Experimental analysis of the strength of a polymer produced from recycled material. The fibre pull‐out process is governed by at least five factors.P.4 (2011).[online].L. E. An essential parameter which single fiber was varied. which is lower than with a larger contact. Vable.com/.mewa‐ recycling. 627‐631 [2] Nielsen. Morozov: Mechanics and analysis of composite materials. Husár. Can be say. [10] V. J. Springer Berlin (2001). when low material and productions costs.(1998). M. [11] V. Švorčík : Structure and properties of polymers. and its truth. Herzog.de. [4] Schuermann.Available: http://www. Vol.L.H. [3] DIN Taschenbuch 18.18. carbon. in our case) and the free length (the length neither in the grips nor in the polymer) less than 3 mm.com/view/1461/50‐years‐of‐reinforced‐plastic‐ boats‐/. the extract voltage for the samples in which the fibers have a lower contact with the matrix.: Mechanics of materials.. by single fibre pull‐out experiments. 193 [9] „Reifen‐Recycling‐Anlagen“ [online].R. This work aims to evaluate how manufacturing enterprises in Croatia implement a new technology that creates efficiencies. Their risks are typically minimal. and is usually divided on manufacturing technologies and service technologies. If a computer is directly attached and dedicated to the machine tool. but may also offer the chance to achieve competitive advantage through superior manufacturing. multitask production equipment. In text below are shown main characteristics of Croatian industry and institutions for development of technological network. 35000 Slavonski Brod. The new manufacturing technologies allow a drastic shortening of this life cycle in both the design and the production stages. New manufacturing technologies can create life-threatening decisions for industry competitors. 35000 Slavonski Brod. For an implementation to succeed users must learn and develop competence in using the technology. New technologies revolutionize way how products are manufactured. and shipbuilding.Mažuranić 2a. it is called computer numerical control (CNC). manufacture of petroleum products. on a capacity basis. Mile Budaka 1. At first controlled by punched tape. reprogrammable. neglecting the vital issue of how permanently implement new technology. and be satisfied enough with the technology to continue using it willingly. Croatia has not sufficiently developed system for monitoring and encouraging new technologies. A significant proportion of the total revenue realized by the production of food and beverages. their use permits the firm to produce a variety of outputs efficiently in very small batches. not all of which are computerized.B. The advantages of such equipment are: the consistent quality of their product. First. Trg I.J.Strossmayer University of Osijek . There are a large variety of new manufacturing Development of new manufacturing technologies in Croatia Technological modernization of enterprises in Croatia and introduction of advanced technologies or new production initiate economic development. chemicals and chemical products. precision. etc. The mass production model is being replaced by a vision of flexible multiproduct firm that emphasize quality and speedily response to market conditions while utilizing technologically advanced equipment. Robots are now an integral part of manufacturing industry. safety in hazardous situations and flexibility. Industrial products represent 94 . Over the last 200 years. The new manufacturing technologies offer much the same benefits to all enterprises. Industry generates about 20% of Croatian GDP and employs around 277 000 employees. technologies. In the past production has centered on processes. 94‐96. Sigurnjak L. New manufacturing technologies New technologies are considered to be the key factors in the economic and social development at the beginning of the 3rd millennium. especially in comparison to the usual image of mass production. machining flexibility and the reduction in skilled labor required. These technologies can represent a huge cost for adopting firms. The impact of technology on organization is widely used in the production. are not necessarily more expensive than standard equipment. Numerically controlled machine tools (NC) have been around for decades. use those competencies in the manufacturing process.tk Manufacturing Engineering & Management The Proceedings New Manufacturing Technologies in Republic of Croatia Sanja Knežević1 ‐ Lena Sigurnjak1 ‐ Miroslav Duspara2 1 University of Applied Sciences of Slavonski Brod. New machines can be quickly and cheaply switched from one task to another. and employees. though problems may arise for those enterprises still unfamiliar with the technology. p. Modern enterprises must adopt and assimilate new technologies to build and sustain competitive advantage. (2012). materials and costing. Dr. the specialized.icmem. Croatia ARTICLE INFO: Category : Short communication Received : 15 September 2012 / Revised: 15 October 2012 / Accepted: 29 October 2012 Keywords: (in causal order) Croatia Enterprises Industry Manufacturing Technologies Abstract: Croatian industry is entering a crucial period of its profiling and survival in global market. competitors. single purpose equipment for mass production which had characterized factories is being replaced by flexible machine tools and programmable. Technology is term that includes machines and work ‐ production processes. the manufacturing industry has gained significant importance in society by introducing products which dramatically changed the world. Croatia 2 J.: New Manufacturing Technologies in Republic of Croatia.Contents lists available at www. High technology automation is an expensive business that only the giants in industrial economy can afford to chance. 2nd International Conference Manufacturing Engineering & Management 2012. Robots can offer significant advantages in: quality. Citation: Knežević S. which is in all industrialized countries. They are sophisticated. they replace such tools and thus. many of these machines are now controlled directly by a computer. CNC machines are more expensive than regular machine tools. metals and building materials. Mechanical Engineering Faculty. In the late twentieth century the face of manufacturing is changing. electrical and optical equipment. printing. or 25% of total employment in Croatia. manufacture of paper. Croatian industry Croatian industry is intensely changed‐ over the last ten years has mostly been characterized by radical manufacturing and productivity growth.implications of applying new technology to traditional manufacturing processes. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Ever since the industrial revolution the manufacturing industry has played an important role in improving the quality of human life and made possible the mass production of goods. although it causes changes in the overall organizational structure of enterprises. image in the eyes of its customers. potentials and opportunities for manufacturing technology development in Croatia. In the last 15-20 years is not significant invested in new technology and new product development. Duspara M. whether large or small. the basis of market competitiveness. The main point is to present current state. According to Table 2. In preparation of the industrial policy of the Republic of Croatia in the preparation for EU membership.1 EU 27 9.7 Source: made by authors using www. Successful companies are those with a stronger orientation of technological innovation.hr Institutions for development of technological network with reference to investments in Republic of Croatia. for European Union and Republic of Croatia Industrial production and technology (%) 1. concrete benefits from the collaboration. M. formal compulsion and own development.2 Croatia 1. Investments in the last few years in Croatia are increasingly perceived as a kind of magic wand that would be inefficient to restructure Croatian economy should one go and immediately create new value.7 percent of GDP. Ireland 20. Tab. technology Source: made by authors using www.. innovation. but no general business climate in the country. in 2010 amounted to only 1. new market opportunities and competitive advantages must continually be searched to create or sustain market leadership. Tab. reaching 16. Finland 23. Investments in manufacturing technologies In a hyper‐competitive environment. Centre for Karst. This leads to decreasing profitability of any market segment and the fall of weak players. 95 Country . Despite this fact.6 7. for example.2 Share of government budget appropriations or outlays for research and development. The main activities of the Directorate for Informatics and Technologies are focused on the implementation of the two basic programs for technological development: the establishment of the national network of institutions focused on the development. it may have disadvantages that hurt business and reduce profitability. market opportunities quickly disappeared and competitive advantages are quickly replicated. located at the bottom of the European scale. and the existence of sufficient funds for investment in research and development. customer innovation. including the existence of long‐term vision of development. Centre for Innovative Technology Rijeka Ltd. application and financing of new technologies. introduce quality standards. where the problem is not just taxes. Croatian industry in not developed enough. stimulating business demand for research and developments. The Croatian industry as a whole has to be restructured towards “new industries” based on competitiveness achieved through knowledge. A small investment in innovation in the longer time will determine our future as a result will be lower rates of economic growth. implement new technologies. Technology Centre Split. Slovakia and Bulgaria while the allocation of. L. creating a technology infrastructure that will support small and SMEs based on knowledge and newly Technology‐based companies. Duspara almost 97% of Croatian exports.1 Government budget appropriations or outlays for research and development Business Total Year sector Industrial production and 39 929 16 295 2010. Characteristics of new technologies: Some new technological investments are not cheap and force your business to take on debt. importance of innovation and new technologies. diversity of funding research and development.. fiscal. attracting private sector investment and the creation of venture capital. the ability of scientists. but also law enforcement. Government has identified six major goals of promoting business innovation and Technology development: Promote creation and growth of knowledge‐based enterprises. the development of the system of the national measures supporting technological development and innovation such as various financial. So. transfer. promoting public confidence in science and awareness of the importance innovation.7 5. such as enabling an increase in mass production of manufactured products in factories. Latvia 12. The need for access to technology and the market is the largest in small firms. Croatia is by investing in industrial production and technology. Czech Republic 13.2 4.7 6. Hungary 16. It’s important to strength exports. creativity. Technology and Innovation Centre Osijek Ltd. Behind us are Poland.dzs. sustainable development and advanced technology in all areas of operation. Table 2. 7 percent of gross domestic product (GDP). development and innovation for the manufacturing industry. and lowest in large. Croatia lags pretty average for the European Union.hr.6 9. management of intellectual property. Slovenia 16. Austria 14.. However. develop manufacturing processes. The main factors that motivate Croatian companies to develop and progress can be: innovation and business.9 3. shows investments in production and technology in top 10 countries in European Union Advantages/disadvantages of investing in new technology New technology may have a lot of advantages. is shown investments in industrial production and technology in Republic of Croatia in 2009 and 2010.. Research and Development Centre for Mariculture. Germany 12. technology Industrial production and 17799 537 2009. In Table 1. this starts from the Croatian strategic commitment to its development based on the knowledge economy and the directives of the European Union and therefore provides a significant increase in aid earmarked for programs of research.3 8. Sigurnjak. As reasons for small business and government investment in innovation experts usually emphasize the low awareness of the society.New manufacturing technologies in Republic of Croatia S. Knežević. Centre for Technology Transfer. follow ecology requirements and achieve cost efficiency. administrative and similar benefits and incentive programs.5 2. Romania 14. technology and market access. Croatian Institute of Technology – HIT Ltd. Within the national technological network the following institutions have been established so far: Business Innovation Centre of Croatia ‐ BICRO Ltd. Belgium 31. neighboring Slovenia. Innovation is not going to hand or poor educational structure.dzs. the availability of new technology.6 10. pp.. Croatian industry development guidelines (Online) [Accessed: 28‐May‐2012]. R.: Handbook of Industrial engineering. [7] [8] CONCLUSION Entry into the European Union for Croatian manufacturing enterprises will mean the opportunity and the challenge. Vol. 1999. Vol 45.S. Vol 30.K. New technology streamlines the business process. 3rd edition. no. Old technology responses to new technology threats: demand heterogeneity and technology retreats. M. Volume 19.25. Chrakavarty.943‐ 962 Naik. Vol. Vol..H. new technologies and innovations.. It will need to invest in innovation and technology because that’s the way that can increase productivity.: Comparative advantage of educated workers in implementing new technology. International journal of production.: Strategic responses to new technologies and their impact on firm performance..R. L. LXIX. M. Journal of information system.G. Green. Journal of Marketing. pp. Technology and operation management. 22. Business may become susceptible to sabotage through hacking of confidential information. H.. D.P. G.. Zagreb Salvendy. number 5. 2011.o. No. Strategic acquisition of new manufacturing technology: a review and research framework. No. Academy of management journal. F.: Learning new technologies: the effect of ease of learning.o.. [13] [14] 96 Ministry of science education and sports of the Republic of Croatia: http://public. 2002. [9] [10] [11] [12] REFERENCES [1] [2] [3] [4] [5] Roger G.hr/hrvatska/gospodarstvo/industrija [Accessed: 8‐May‐2012] Drvenkar. R. et al. Frajman‐Jakšić. Mate d. 2001.2. but it also may result in downsizing and outsourcing. pp. 68 (October 2004). 2008.. If you want to succeed in the global market and be competitive to apply new technologies and new technological production processes. The effect of new technology adoption on employee skill in the prosthetics profession.C. Vol. making some jobs redundant.. S. Snow. John Willey and sons. R. Knežević. 2002. implementing new manufacturing technology: the related effects of technology characteristics and user learning activities. R. pp. Noble C.K. Number 1 Ander. T. New York http://www. International journal of production research. pp. 2008. pp171‐.P.M. Enterprises in Croatia wishing to compete must adapt productivity and must have a high technological level. will be exposed to greater competition and therefore need to turn to investment in knowledge..mzos. 6461‐6478 Smith. Grewal.29.. A.1655‐1675 Loraas. Industrial and corporate change.157‐171 Bartel A.aspx?sec=3201 [Accessed: 27‐August ‐2012] Lee. The adoption of radical manufacturing technologies and firm survival. Lichtenberg. Croatia is currently at a low level of investment and the introduction of new technologies into production.. A. pp. Diaz..A. Strategic management journal. Sigurnjak.194 Wagner. No. 1575‐1601 . Vol. N.hr/Default. 421‐430 Sinha. Duspara New manufacturing technologies in Republic of Croatia [6] It may be difficult to integrate the new technology into workforce and may have to spend extra finances to ensure it is viable. 46. which may come into the possession of competitors. The review of economics and statistics. Schroeder: Upravljanje proizvodnjom. L..7.. B.2.. As the currents induced in the material are strongest near the coil. Eskisehir Osmangazi University. Turkey. In the method eddy currents are produced in the product by bringing it close to an alternating current carrying coil. Measurements of non‐conductive coating thickness and conductivity can be done. (2012). p. Therefore.edu. B. 2 illustrates a type of coil which can be inserted into a tube to inspect discontinuities on the inner circumference of the tube. The first prototype wireless eddy current (EC) probe for on‐wing inspection was demonstrated in a F100 PW‐220 engine without external cabling at the Air National Guard overhaul facility in Des Moines Iowa. Fig. the eddy current method can also be used to distinguish between pure materials and alloy compositions and to determine the hardness of test pieces after heat treatments. 1st Airforce Command. Eskisehir.tr Aircraft Maintenance. 97‐99. Internal probes Internal probes consist of circular coils used to test the interior of tubes or circular holes. Eskisehir. of Mechanical Engineering. Turkey. Fig. the internal coil is more sensitive to defects lying on or near the inner surface of the tube. contact mail : tolga. which depends on the condition of the part near to the coil. Basic Principles of Non‐Destructive Testing (NDT) Non‐destructive testing is the use of physical methods which will test materials. et al. to sort materials. aircraft maintenance field has so many applicable areas for this method. Eskisehir. Turkey. 2nd International Conference Manufacturing Engineering & Management 2012. components and assemblies for flaws in their structure without damaging their future usefulness. effective and flexible operation conditions can be reached.: A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts . [1] By designing Wireless Eddy Current Probe for all aircraft maintenance inspections. to measure thin walls from one surface only. In addition. Turkey.icmem. Citation: Kushan MC. Fig.tk Manufacturing Engineering & Management The Proceedings A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts Melih Cemal Kushan1 ‐ Tolga Unalır2 ‐ Engin Gode3 ‐ Hakan Ekinci4 1 Dept. b) Encircling probe.unalir@eczacibasi. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Eddy Current Testing method has a wide usage in the field of Industry. This method is applicable to electrically conductive materials only. The choice of the type depends upon the test situation. contact mail : engingode81@yahoo. the internal coil induces currents that encircle the entire circumference of the tube so that the entire section surrounding the coil is inspected. 1st Airforce Command. Especially. contact mail : hakanhanekinci@gmail. The alternating magnetic field of the coil is modified by the magnetic fields of the eddy currents.com. 97 .Contents lists available at www.com 2 3 ARTICLE INFO: Category : Short communication Received : 14 September 2012 / Revised: 2 November 2012 / Accepted: 13 November 2012 Keywords: (in causal order) Abstract: Aircraft maintenance Current test probe Wireless eddy The Use of Eddy Current testing method is very common in aircraft maintenance field. Following are the three major types of probe mainly used in eddy current testing: a) Internal (bobbin type) probe. to measure thin coatings and in some applications to measure casedepth. Conductivity is related to the composition and heat treatment of the test material. New probe design and its applications were studied in this paper.1 Basic Eddy Current Testing Method 1) Types of Probe: The eddy current probes can have a variety of forms. contact mail : mkushan@ogu. This modification. As with the encircling coil. The aim of this study is to design wireless Eddy Current test probe in aircraft maintenance applications. [2] A. Eskisehir Osmangazi University. a wide variety of inspections and measurements may be performed with the eddy current methods that are beyond the scope of other techniques.tr Graduate School of Engineering. NDT is concerned with revealing flaws in the structure of a product. c) Surface probe. 1 shows basic ET system. Eddy Current Testing (ET) This method is widely used to detect surface flaws.com 4 Aircraft Maintenance. is then shown as a meter reading or cathode ray tube presentation. Eskisehir. Other variations of surface probe designs are pancake probe. flat or contoured for defects or material properties. The width of the coil is a function of the application. The study showed that wired eddy current probes could be converted to wireless probes [2]. conductivity.4 Surface Probe 98 . Fig. horse shoe or gap probe. spring loaded probe spinning probe and pencil probe [3]. Cemal Kushan et al. we intend to measure defect sizes as absolute values rather than interval values as in conventional Eddy Current inspection. 1.2 Internal Probe Encircling probes Encircling probes are similar in structure to internal probes except for the fact that the test material is passed inside the coils. Fig.5 Block Diagram of The Prototype Wireless EC Probe System Results were comparable to wired and state‐of‐the‐art EC technology used to inspect engines. The surface probe may be hand held or mounted in automated scanning equipment. The coil mounted in the end of the probe is provided with a protective coating of epoxy to serve as a wear surface. flat probe. These are also called probe coils. Flexibility in maintenance working areas is considerable when encountered small and complex control areas.2 Applications of Wireless Eddy Current Probe It is thought that Eddy Current Testing Device will work more efficiently and functionally with wireless probe in aircraft maintenance activities. Cable systems have so many difficulties for inspection in that it limits the control area due to its equipments. unfixed on‐ground operations. 7 and fig. e.g. 4 shows a typical surface probe. 5 shows a block diagram of the prototype wireless probe system. 6 shows this kind of a place [4]. By using more visual LCD monitors we will be able to transmit a data to another monitor and reach various inspection data regarding preceding inspections. Wide coils cover large areas. Defects can either be surface or subsurface. 8 show some examples of such difficult operations. Fig. By means of this apparatus complex surfaces will be able to reached easily. Fig. They are primarily used to inspect the outside surface of round materials such as tubes and rods. The results were compared to a wired EC tester. Our aim is to design a new wireless Eddy Current probe instead of wired systems.1 Designing of Wireless Eddy Current Probe The first prototype wireless eddy current (EC) probe for on‐wing inspection was demonstrated in a F100 PW‐220 engine without external cabling at the Air National Guard overhaul facility in Des Moines Iowa.M. Generally. The cable makes difficult working conditions and leads to signal deterioration. so they respond mostly to bulk effects. The magnetic field induces eddy currents in the bar that encircle the entire circumference of the tube or rod so that the entire section under the coil is inspected at any one instance. The magnetic field of the coil extends slightly beyond the ends of the coil. Flexible probe holder is other part of the our design. In difficult workspaces in different applications such as on‐ aircraft body operations. Fig. Fig. The operator will reach complex and narrow workplaces swimmingly. narrow areas. A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts 1 WIRELESS EDDY CURRENT PROBE 1. the cable arise as a hindering occasion. Fig. whereas narrow coils sense small areas and so are more responsive to small changes such as those produced by discontinuities.6 A girift Aircraft İnspection Area. 3 shows an encircling coil. Furthermore. Fig. Fig.3 Encircling Probe Surface probes Surface probes are one of the most widely used eddy current probes for inspecting surfaces. in maintenance applications wireless systems are required to control surfaces easily. The magnetic field produced by a coil is approximately of the size of the coil. Fig. [4] M.A New Design For Wireless Eddy Current Testing Probe & Its Applications For Aircrafts M. REFERENCES [1] J.Gode.” Eddy Current Testing at Level 2: Manual for the Syllabi Contained in IAEATECDOC‐ 628/Rev.Ekinci.G. Baaklini. Singapore. R.” Vieanna 2011. Electrical and Computer Engineering Conference. pp. Cemal Kushan et al. 22‐24. ‘Training Guidelines for Non‐Destructive Testing Techniques. Graubard.C. doi:10. 2011. 2012. 414‐420. Kushan. pp.1711652 [3] Internaitonal Atomic Energy Agency. D. Dickerson. 2525‐25‐65. L.8 Eddy Current Inspection of an Aircraft Part Wireless probe system will eliminate all these destructive effects.Brasche. pp.” Wireless Eddy Current Probe Design and Applications In Aircraft Maintenance” Mechanical.3390/s110302525 [2] M.” Non‐Destructive Techniques Based On Eddy Current Testing” Sensors 2011. Reid. Martin. 1‐121. G. J. pp.V. Fig.1063/1. J. AIP Conference Proceedings. Y. 11.Smith. Raulerson. Feb. Feb. H. ACKNOWLEDGMENT The authors wish to acknowledge 1st Main Jet Base NDT aircraft maintenance staffs for their supports. 2. Sanchez. Gil. Volume 700. Aug. 99 . Training Course Series 48. E. K. A. J. doi:10. T.Unalır. E. Weber. B.7 Eddy Current Inspection of an Aircraft Part Fig.” Wireless Eddy Current Probe for Engine Health Monıtoring” Quantitative Nondestructive Evaluation.G. ISBN: 978‐93‐82208‐05‐1. 2004. If it A1. we're doing very well.. where n jobs have to be processed on m machines in the same order. where all the events Ai have the same probability 1 / n ‐ in this case is H (P) = ‐log2 (1 / n).Contents lists available at www.. According to previous findings the order of parts on the entering the system affects to some extent a complexity of the system. A1 ∩ A2 = ∅. we get the information I (A1) =‐log2 (0.9. Complexity is based on: Fig. Two classes of complexity have been identified: structural and operational [4]. flow‐time [1]. By borrowing the notion of entropy from information theory. Reisman et al. In a statistical review of flow‐shop scheduling research. Hence a schedule is uniquely represented by a permutation of jobs. Technical University of Košice. ∑ ∑ (1) ∑ log .. where the order in which each machine processes the jobs is identical for all machines.sk ARTICLE INFO: Category : Original Scientific Paper Received : 12 November 2012 / Revised: 15 November 2012 / Accepted: 17 November 2012 Keywords: (in causal order) Abstract: Network complexity Shannon entropy Scheduling Simulation model Throughput of production system One of the biggest problems in production system is comprehensive system to verify condition of all equipment.g. get the 100 Where H is the entropy of a system S consisting of N different states. This system includes: scheduling part. In this paper are joined three different issues to one verification system.1.lazar@tuke.. (2012).e. Suppose now that the experiment was carried out a large number of times ‐ e. we can directly apply it to manufacturing systems. N. p.15 bits. Bayerova 1.. (2) where: pij: Probability of resource i being in scheduled state j S: Number of scheduled states M: Number of stations DEFINITION OF ENTROPY We therefore define uncertainty ‐ entropy H (P) = {P experiment A1.32 bits. Flow‐shop scheduling problems present an important class of sequencing problems in the field of production planning. The structural complexity of a multi‐station system can be defined as [5]: Complexity: The complexity is one of the features that characterize systems. 100 times. The entropy of a system can be written as: With the advent of just‐in‐time manufacturing philosophy which maintains a limited in‐process inventory.The permutation flow‐ shop scheduling problem (PFSP) is often designed by the symbols n|m|P|Cmax. 1 Dependence of system complexity log .9) = 0. it happens only one tenth of the cases..1) = 3. The common objective is to find a schedule that minimizes the makespan Cmax. the time at which the last job is completed on the last machine.icmem. ISBN 978‐80‐553‐1216‐3 INTRODUCTION This complexity or network complexity of production system can be closer specified using Shannon entropy. In this paper. P (A2) = 0. But what if events do not have the same probability experiment? Suppose that Ω = A1 ∪ A2. however. This theory is well known as information theory and provides a measure of the amount of information associated with the occurrence of given states. simulation part and part of that is taken from information theory and is called Shannon entropy. In 90% of cases. but where it becomes A2. The entropic measurement was first derived by Shannon in 1948 [3]. The processing of each job on each machine is an operation which requires the exclusive use of the machine for an uninterrupted duration called the processing time. we get only information I (A2) =‐log2 (0. If the result of the experiment A1. Citation: Lazár I. 100‐106. We use entropy as defined by Shannon to measure variety and uncertainty within manufacturing systems [3]. Slovakia. Solving this problem means finding a permutation of jobs to be processed sequentially on a number of machines under the restriction that the processing of each job has to be with respect to the objective of minimizing the total processing time i. ivan. from i=1. P (A1) = 0.tk Manufacturing Engineering & Management The Proceedings Verification of Sequential Patterns in Production Using Information Entropy Ivan Lazár1 1 Faculty of Manufacturing Technologies. This entropy is used in information science to determine complexity of information and to finding it´s benefit. we will focus on structural complexity. A2.. comes A2 and the majority of cases we're doing wrong to get information [6]. concluded that there is lack of relevance to practice for the overall majority of research in this field [2]. . 2nd International Conference Manufacturing Engineering & Management 2012. In about ten cases. “P” indicates that only permutation schedules are considered. 080 01 Prešov. the flow‐ shop scheduling problem with minimum make‐span and optimization approaches to minimize manufacturing cost started to be intensively studied). Verification of Sequential Patterns in Production Using Information Entropy. but. An}. The resulting information thus depends on the outcome of the experiment. Pi is the probability of the system being at state i. 7/100 = 0. The second step is sorting out the earliest due date among the jobs. In the case of automated production for such cases is not ready. This means that if there is any condition (expected and unexpected) on one channel will not affect the operation of other stations. the set Ai occurs with zero probability. the expression ‐P (ai). 1997. print shop and manufacturing job shops. The average information per experiment is 46.. (5) However. job processing times and due dates are important pieces of information. and the uncertainty will be the same as in experiment P[7 ].7 bits. MRP processing. such entry obscures some form of non‐zero summands formula.is natural to supplement function η (x) as follows η x log 0 0 . get the information bits 0. Entropy H (P) of experiment P is mean a discrete random variable X which takes on a subset Ai value I (Ai) t. and the 0. a measurable decomposition of the set Ω) we add the empty set (i.. For example. information bits 3. 0 (4) Then by Shannon's formula for entropy should be in the form ∑ . Priority Rules try to minimize completion time. can be used in structural complexity theory. while maximizing facility utilization. affect the availability and recovery stations / machines. 2 Example line material flow system If station A failure occurs. Tab. . It is a quantitative measure that captures the impact of network forms. Then. Shannon's definition of entropy. A B C The delays is calculated from the flow time and due date. the overall information obtained can be quantified as 10 × 3. . On reducing the complexity should be the priority objectives of the reorganized system and reducing costs.log2 (0) is defined.15. the above assumption of "independence" can be difficult to achieve because the size or storage tank is still limited.. j. The flow time is the accumulations of processing time each job by each job. consider a system consisting of three stations that are connected in series. Calinescu. Let P = {A1. A2. Because lim → log . 2000) is the main objective to evaluate the impact of changes in the complexity of the product. In such cases. calculate the flow time of each job by using the processing time. One option. However. and then continues to station B in the second stage etc. integration and product range [4. 4 “The shortest job are handled first and completed. An} is experiment.15 = 33.5 = 46.32 +90 × 0. we get a new trial P '. Network complexity is defined as the structural complexity of the production network (system). A. This means that the station B and C will stop if the buffer is emptied. Influence of different networks and linkages is analyzed and it is not very difficult to determine the effective distribution and to make changes to improve overall performance.32.” Longest Processing Time (LPT) shown on Fig. 8]. log .” The steps are using this rule are: Firstly. approximately 90 cases. and job lateness. as in the general case is an attempt to introduce entropy to define it as the mean information [6]. Job times usually include setup and processing times. we can say that the stations are independent of each other and we can use the fourth equation In practice. Due dates may be the result of delivery times promised to customers. The product enters the first Phase A station. this equation can only work provided that the conditions of one station are not dependent on changes in conditions at the second station. and so we do agree as follows: Shortest Processing Time (SPT) shown on Fig. In this case. the job names. no temporary storage on the production line. Thirdly.” Earliest Due Date (EDD) shown on Fig. 1993. An}. number of stations. 5 “The longest job are handled first and completed. A2.e. Lazár part of it..e. ∑ ∑ . 3 “The job with the earliest due date is selected first by using EDD.. P) is a probability space on which information is given by I (A) =‐log 2 P (A). Agreement : From now we will assume that the term 0. the due date of each job or use the data values given at the starting point.Verification of Sequential Patterns in Production Using Information Entropy I. the station B and C must unceasingly continue to operate if they have an unlimited supply of input lines or tank. impossible outcome). or managerial decisions. (3) PRIORITY RULES Priority rules provide guidelines for the sequence in which jobs should be worked. Let (Ω. the processing time. 1 Processing times J1‐J4 on all machines Machine/Job M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 Fig. log2 P (Ai) is not defined. The rules are especially applicable for processs‐focussed facilities such as clinics. This paper seeks to address these problems. A consistent reader should now be able to ask what happens when in experiment P = {A1. The second case is that it stops the whole system breaks down when a 101 J1 J2 J3 J4 5 3 4 6 3 4 5 4 3 2 4 4 7 6 7 8 6 5 6 5 8 9 7 8 12 10 15 11 11 13 13 11 10 10 11 10 2 2 2 2 . and this is the first problem [5]. the user will input: the number of jobs.2 +13.log2 (0) =0. Less processes. number of jobs in the system.. From equation (2) can be seen that the reduction of complexity can be achieved by simplification. The rules generally involve the assumption that job setup cost and time is independent of processing times. This well reflects the fact that if some experiment P (i. From the literature (Deshmukh. fewer states and fewer variations in conditions that may take to reduce complexity. In using this rules.467 bits. The second problem is the lack of process analysis network. • fi cost function fi. The main input data are mainly: • mi number of machines. because the interference must be applied in the simulation. It is essential that it is necessary to machine the parts completely change sort or just modify a dimension possibly tool. • Tij total processing time of the j‐th operation. 7. 4 SPT schedule with sequence 2‐1‐4‐3 Fig. 6 shows the process of simulation model with all the interference determined by the manufacturing system to operate. but it is not on real time. To create a simulation model. If we want to create the most exact model we need to plan the deployment of machines in the simulation model. • Ci completion time j‐th operation • Li machine downtime Another part of this diagram is information about the deployment machine. 6 Scheme of formation of simulation model When creating a simulation model is required to realize that the simulation respectively simulation model is an accurate model of reality. Fig. Simulation can be carried out during several periods. First we must identify all input data. 5 LPT schedule with sequence 3‐4‐1‐2 Processing time of all jobs is: SPT rule ‐ 104 min LPT rule ‐ 117 min EDD rule – 105 min Processing time in this case does not include transportation time. At the outset of developing the model we had to specify the number of simulation values. simulation during selected hours. Fig. This chart graphically expresses the main aspects on which we consider in the simulation. etc. • nj number of operations. • di desired time for the job Ji. • ai = di ‐ ri maximum permitted length of stay job Ji in the system. Lazár Verification of Sequential Patterns in Production Using Information Entropy Fig. The input data are key information affecting the model and simulation programs are usually awarded even before simulating. we need to identify all aspects that affect the real system. The third part of the diagram is prioritizing access to production parts. Given our program in this area provides many options.I. simulation for one day. As can be seen in Fig. First we must define the time (length) of simulation. Prioritizing access to system components is very important because it is essential to identify what component parameters for each follow. simulation during one shift. because any difference in distance between model and real production system can brings erroneous information to other calculations distances and transport times. • ri earliest possible start processing job Ji. which presents a simulation model created using Witness from the Lanner Group. such as: unlimited length of simulation. 3 EDD schedule with sequence 1‐2‐3‐4 Fig. repair time and failures. • pij processing time. 102 . • gij lead time. Machines can be deployed freely in the simulation field or in the layout that you downloaded from a predetermined menu or from a file *. machines: M1‐ M10. This graphical representation is called “mathematical model of the real production system. mathematical modeling can at relatively low cost test several variations of their properties and to detect possible defects. These external and internal functions of machines are generally described in Fig. 8 Description of the separate elements of the mathematical model. mathematical modeling is the opposite of physical modeling. Conveyors: Conveyor1‐Conveyor8. In such cases it is not necessary to insert so‐called “layout” to the model. The simulation model can express mathematically even prior simulate. ADEQUACY OF THE MATHEMATICAL MODEL OF A REAL OBJECT ‐ INDICATORS model has sufficient accuracy to describe both quantitative and qualitative properties of the object. It is possible to achieve arbitrary precision values. Each machine has its internal interactions and conditions that we describe in any simulations. Buffers: SCH1‐ SCH6. dwg which is create in AutoCAD.Verification of Sequential Patterns in Production Using Information Entropy I. Simulation also allows us to monitor the capacity of warehouses. Fig. which increases approximately with the square of the length of the simulation. The deployment of machines should respond to the real state of the company. where for each machine can occur at the same time only one of these conditions: 103 . The values of probabilities of states on different machines. 7 Simulation layout with description The simulation includes: Parts: Part1‐Part4. mathematical description of the measure is comparing by the measured values and values that has a mathematical model under the same conditions. simulation is an approximate method. Employees: Operator1‐ Operator8. The results of simulations are probabilistic and can be used to estimate statistical parameters of search. Lazár graphic characters and absolutely meets if the parameters are the same distances and times. it is immaterial whether the model corresponds to reality in Fig. but rather it complements the methods of mathematical analysis. Outlet stores: OS1‐OS4. Fig. buffers and current status of parts on machines. which acts on its surroundings and environment acts on it. Another important information and choice is layout of machines. Thus. but often are similar only in numerical terms. 8. The outputs of these simulations are of great benefit. On the machines can came about seven states.” In thus mathematical models we are considering each machine as a separate element. Cost simulations are rising approximately linearly with the length of the simulation [9]. In some cases. 9 Mathematical model (schema) of real production system. 2088 0 ‐0.001 0 0 M7 0.0099 0 0 . which occurred on the specified machines. It is likely that at a particular time the machine is in the state. Then Working rate (Wi) M6 machine reaches Wi = 1 Working rate of other machinery is then: . Status inequality occurs when the number of input components is equal to the number of components at the output.61 0.4421 ‐0.4588 0 ‐0.3206 0 ‐0.007 0 0.044 0.006 0 0.4008 0 ‐0.5062 0 0 M9 ‐0.2710 ‐0. Dark box marked states. 5.0489 M5 ‐0.4059 ‐0.4572 ‐0. 10 Basic states of machine in Witness simulation tool (6) where x=6 in our case.14 0. 3 Calculation of complexity S1 S2 S3 S4 S5 S6 S7 M1 ‐0.85 0.142 0 0.0506 M3 ‐0.261 0 0 M9 0.632 0.225 0.04 0 0.610 0.20 0.2620 ‐0.3394 0 0 M10 ‐0. These states of machines can be called natural or basic.0501 0 ‐0.5055 ‐0. 3. This means that each machine may be in the only one of the above conditions simultaneously.007 M3 0.4328 ‐0.146 0. This may be the case if the machine that created malformation (scrapped part) or other unexpected failure occurs.4669 ‐0.2013 ‐0.094 0 0.88 1 0. Lazár 1. that crossed over i th machine.272 0. 4.0643 M4 ‐0.44 0. and NpSi is a number of components.001 0 0.55 0.0099 ‐0. 2.4691 ‐0.34 0.4178 ‐0.067 0.71 0.0099 0 0 M7 ‐0.4743 ‐0. These conditions are appropriate in this case ten machines. The second reason is that at least one of these conditions occurs during the simulation for each machine.004 0 0 M6 0.0442 0 ‐0.011 0 0.006 0 0.4867 0 ‐0.3310 ‐0.2043 ‐0. Greatest number of components in this case passed through the machine M6.0376 0 0 CALCULATION OF TH ( ∗ ) 104 M6 ‐0.4867 0 ‐0. Fig. Fig.6 0.85 0.099 0.0725 0 ‐0.2004 ‐0." Optional states are programmed to Tab.103 0 0 M10 0. Verification of Sequential Patterns in Production Using Information Entropy Idle Busy Blocked Cycle wait labor Setup Setup wait labor Broken down simulation tool give us their automatically extract to the simulation field.4348 ‐0.29 CALCULATION OF CPL ( ∗ ) Tab.2620 ‐0.54 0.787 0.0099 0 ‐0.5109 ‐0.015 M2 0.4371 ‐0.4842 ‐0.058 0.228 0 0.228 0 0. One reason is that most of them are pre‐ programmed into the simulation tool. 7.93 0.91 0.0448 0 ‐0.006 M5 0. All the probabilities of a machine together give a value ≅1. These types of states may be described as "optional states. Another types of states we manually programmed into the simulation model.192 0.009 M4 0. 2 States of machines in case of sequence 1‐2‐3‐4 Name Idle Busy Blocked Cycle Wait Labor Setup Setup Wait Labor Broken Down State S1 S2 S3 S4 S5 S6 S7 M1 0.046 0.0937 ‐0.193 0 0.3871 0 0 M8 ‐0.045 0. 11 Optional states of machine in Witness simulation tool The above‐mentioned simulation model contains 10 machines.172 0. On some machines there was a state of inequality. Each of these machines has undergone a number of components.8 0.I. 6.4765 ‐0.0908 M2 ‐0.4586 ‐0. Each of these states pertains to a certain amount of probability.067 0.001 0. Fig.001 0 0 Working rate Wi 0. 10 is described as a state machine and marked with specific colors.2382 ‐0.487 0.67 0 0 M8 0.19 0.203 0.4092 ‐0. 071 0 0.1876 0.403 ‐0.2511 0 0 0 0 M7 0.00392 0.6624 0 0 M8 M9 0.053 0.055 0.207 0 0.649 0.090 ‐0.Verification of Sequential Patterns in Production Using Information Entropy I.0056 0.00896 0.001 0.7 Th = 8.095 0.001 0 0.566 0.522 0.007 105 M5 0.13784 0.195 0.134 0.01 M4 0.306 0 ‐0.492 ‐0.0318 0.543 0 0 M8 0.012 0 0.413 ‐0.430 0.017 0 0.002 ‐0.325 ‐0.7923 0.007 M3 0.1449 0.48 0.20952 0.218 0 ‐0.05384 S3 0.0008 S6 0 0 0.012 0.078 0.079 0.5164 0.1328 0 0.001 0.0048 0.589 0.005 0 0.0008 S4 0 0 0.477 ‐0.1644 0.259 0 0 0 0 0 M4 0.2325 0.091 0 ‐0.451 ‐0.589 0.1141 0.001 0 0 .323 ‐0.012 0 0.0153 0. 7 Calculation of throughput in case 2 S1 S2 S3 S4 S5 S6 S7 M1 0.0357 0.488 ‐0.0752 0.003 0 0 M6 0.18296 0.536 0.4881 0.078 0.1548 0.048 0 ‐0.393 0 0 M8 ‐0.0368 0. 5 States of machines in case of sequence 2‐1‐4‐3 Name Idle Busy Blocked Cycle Wait Labor Setup Setup Wait Labor Broken Down State M1 M2 S1 0.0152 0 0 0.0048 0.445 ‐0.0157 0 0.012 0 0.924 0.168 0.138 0 0.2176 0.075 0.07952 0.452 ‐0.108 0 0.001 0 0.0916 0 0 0 0 M10 0.765 0.026 0.562 0.266 ‐0.190 0.15 0.485 0 0 M9 ‐0.152 0.1829 0.466 0 ‐0.075 0 0 M10 0.1536 0.011 M2 0.446 0.241 0 0.0008 0.153 0.0966 0.0054 0 0 0 0 0 0 The resulting complexity and throughput values for the selected system components and the order of 1‐2‐3‐4: CPL = 13.041 0.065 0.229 0.50616 0.041 0 0.034 0 0 M6 ‐0.51 0.469 ‐0.482 0.1192 0.198 0.015 0.3896 0.094 0 ‐0. 6 Calculation of complexity in case 2 S1 S2 S3 S4 S5 S6 S7 M1 ‐0.44 0.542 0.0076 0.63024 0.6617 0.0002 0.1423 0.263 0 0 M9 0. 4 Calculation of throughput M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 S1 0.9336 0.05384 0.051 M3 ‐0.005 M3 0.147 0.256 ‐0.489 ‐0.0044 0 0 M6 0.054 0 0 0 0 0 Tab.192 0 0.092 ‐0.104 0 0 M10 0.1803 0.687 0 0 M8 0.0068 S4 0 0 S5 0.5246 0.219 0.001 0.0008 0 0 0 0 0 0 S5 0.423 ‐0.489 0.11 0.162 0 0.0956 0.386 0 ‐0.205 0 0 0 0 M7 0.19 0.74616 S2 0.012 0.053 0 0.201 0.036 0.2274 0.2026 0.1551 0.222 0.315 0 0 M10 ‐0.0073 M3 0.0464 0 0 0 0 0 0 0 S7 0.007 The resulting complexity and throughput values for the selected system components and the order of 2‐1‐4‐3: CPL = 12.0066 M5 0.158 ‐0.2343 S6 0 0 S7 0.05 0.051 0.0869 0 0.038 0.394 ‐0.187 0.016 M2 0.4 ‐0.092 0 ‐0.1624 0.509 ‐0.07 Tab.1723 0.1172 0.2682 0.08312 0.005 M5 0.449 ‐0.43704 0.186 0 0 M9 0.063 M4 ‐0. 8 States of machines in case of sequence 3‐4‐1‐2 Name State Idle S1 Busy S2 Blocked S3 Cycle Wait Labor S4 Setup S5 Setup Wait Labor S6 Broken Down S7 M1 0.0095 M4 0.089 M2 ‐0.49032 0.116 0.6376 0.216 ‐0.882 Tab.5 0 0 0 0 M7 ‐0.001 0 0 M7 0.611 0.18 0.0146 0.118 0.423 0.776 0.0664 0 0 0 0 0 Tab.038 0. Lazár Tab.437 ‐0.001 0 0.245 0 0.005 0 0.2058 S3 0.490 0 ‐0.613 0.49 Th = 7.545 S2 0.625 0.141 0.512 0.156 0.0056 0.047 M5 ‐0.005 0 0 M6 0.099 0 0. 001 0 0.459 ‐0. A. I.. where we watched the status changes of individual machines. EFSTATHIOU.‐5.230 ‐0.577 0 0 M8 0. 517 – 519 [2] Reisman.452 ‐0. Jr.. or repair. Kybernetika a manažment..063 0.D.11. Bell Syst.001 0 0 Tab. 1952‐1994. (1995).322 ‐0. When was the selected order 2‐1‐4‐3 we get the complexity of the value 12. (2000). IEEE Transactions on Engineering Management. On the other hand we have this change came the sequence of inputs to reduce system throughput by 0..299.07 and in the third case 3‐4‐1‐2 we get the complexity of the value of 13. SCHIRN. 106 ..280 ‐0..287 ‐0.131 0. Complexity and chaos in manufacturing systems.095 M2 ‐0.3..49.410 ‐0. (1982). (2011).D. HARRIS.126 0. which produced 1.009 0 ‐0.. There are significant changes in values. This article proposes one way how can be given the complexity monitored and positively influenced.166 0.004 0 0 M6 0. Quart. DUPLAK. (1997)..220 0 0 M9 0.046 0. [8] CALINESCU.449 ‐0.394 0 ‐0. 1 elektronický optický disk (CD‐ROM). In our case. P.009 0 0 M4 0. [5] HANKERSON..179 ‐0.. A. AND HUATUCO.009 ‐0. 2011 P.031 0.464 ‐0. ‐ Ostrava : VŠB‐TU.A. S.330 0 ‐0.. ORLOVSKY. and then the probability that a given machine studied phenomenon occurs. processing and Removal Times Separated. Sequencing n Jobs on Two Machines with set up.206 0 0.0798 0. not to mention the production process. A Mathematical Theory of Communication“. [9] HATALA.I. D.46.092 0. (2002). WOODCOCK E. Vol 15. (1993). Int’l Journal of Operations & Production Management. 316‐329.006 M3 0.001 0 0. [3] SHANNON.043 0 ‐0.434 ‐0.202 0 0.. Vol. 10 Calculation of throughput in case 3 S1 S2 S3 S4 S5 S6 S7 M1 0.29. G. Ph.494 0 ‐0.16 0.472 0. J. Tech.: Introduction to Information Theory nad Data Compression.504 ‐0. No. BENKO. [7] DESHMUKH. This means that only with the four components achieve reducing the complexity of 1.112 0. Košice : Elfa.115 0 0.41 0. LIGUŠ.009 0 0 M7 ‐0.192 0.105 ‐0. Log.181 CONCLUSION System complexity is in today's technologically advanced and modern times often discussing topic.11.2011.001 0.497 0 ‐0. Measuring complexity as an aid to developing operational strategy. D.46 Th = 8. J. A. V.283 ‐0.470 0 ‐0.475 0.083 0 0.009 0 ‐0.372 0 0 M8 ‐0.004 0 0.. C. J. 44. (1998).157 0. Complexity in Manufacturing: An information theoretic approach.224 0 ‐0. we chose a 1‐2‐3‐4 sequence using information theory we get the complexity of the value 13.651 0.013 M2 0.087 0 0 M10 0. 3. SIVADASAN.009 0 ‐0. Even a small change of complexity. H. JOHNSON.001 0.506 0 0 M9 ‐0.000 0 0 M7 0.099 0 ‐0.462 ‐0.066 M4 ‐0.05 M5 ‐0. . A.052 M3 ‐0. No.776 0.009 ‐0.467 ‐0.495 ‐0. Flowshop scheduling/sequencing research: A statistical review of the literature. 9 Calculation of complexity in case 3 S1 S2 S3 S4 S5 S6 S7 M1 ‐0. Lazár Verification of Sequential Patterns in Production Using Information Entropy Tab. 623‐ 659 [4] FRIZELLE.5. Each production system or a non‐manufacturing system can be characterized by the concrete value of complexity..168 0.. CRC Press LLC.350 ‐0. ‐ ISBN 978‐80‐248‐2502‐1 CPL = 13. In the first case.014 0 0.428 0. can bring about great changes in practice and in some cases save a lot of money to invest.001 0 0..000 representatives component base. L.. J.494 0. J. J.. Purde University. 27. Motwani.In: Progresivní metody ve výrobních technologiích : sborník anotací příspěvků sympozia : mezinárodní vědecké sympozium : Perná.432 ‐0.388 ‐0.065 0. (1948).. but in practice can bring huge savings. 379‐423. 1‐5.486 ‐0. Kumar.. Naval Res.005 M5 0. M.418 ‐0.186 0.173 0 0. ISBN 0‐8493‐ 3985‐ 5 [6] SARNOVSKÝ. Comprehensive identification of cutting ceramic durability in machining process of C60.008 REFERENCES The resulting complexity and throughput values for the selected system components and the order of 3‐4‐1‐2: [1] Sule.037 0 0 M6 ‐0.514 0. Thesis. O.E. G.339 0 0 M10 ‐0.42.R. Proceedings of International Conference on Complexity and Complex Systems in Industry. we simulated the production process only 4 components.465 ‐0.51 0. J.044 0 0.482 ‐0. as the weakest points. ending well above local yield stress levels. According to other specifications.rs Innovation Center of the Faculty of Mechanical Engineering. processing definicies may become apparent only after the product is in use. In addition. 2nd International Conference Manufacturing Engineering & Management 2012. with ultimate tensile strength above 800 MPa. Tatić2 ‐ Simon A.e. Serbia.ac. In this way overall behaviour of the large welded penstock has been verified. University of Belgrade. The necessity to perform testing of full scale model was recognized also in the case of penstock of reversible hydro‐electrical power plant „Bajina Bašta“.tk Manufacturing Engineering & Management The Proceedings Quality Assurance of a Large Welded Penstock Manufacturing by Means of Full-scale Model Testing Algoul M. Djurdjevic2 1 Faculty of Mechanical Engineering. e. welding is to be treated as a “special process” since welds cannot be fully verified by subsequent inspection and testing of the product to ensure that the required quality standards have been met. Sedmak2 ‐ Andrijana A. Sedmak1 ‐ Blagoj Petrovski2 ‐ Uros S. allowing an evaluation of crack significance and "fitness‐for‐purpose" assessment. welding procedure specification and its qualification were strictly required. 11000 Belgrade. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Within the ISO 9000 series of standards for quality systems. low alloy high strength steel (HSLA). 11000 Belgrade.07. This requirement can be satisfied by HT80. weldable. modeled as prototype of the penstock most stressed part (Fig. FULL‐SCALE MODEL TESTING Two full‐scale pressure vessels. and thus. The selected manufacturers were for the first time in situation to weld a penstock of a quenched and tempered HSLA steel of 700 MPa yield strength and 47 mm thick. Citation: Mahdi A. All weded joints were undermatched. Having also in mind the inevitable presence of residual stresses and strains. certification of welders. Kraljice Marije 16. : Quality Assurance of a Large Welded Penstock Manufacturing by Means of Full‐scale Model Testing .g. depending on the requirements level. mail:asedmak@mas. crack propagation and arrest. tunnel conditions and strict requirements could be satisfied only with educated. determined according to the responsibility of welded joints and the overall risk level. This has been done in accordance with ISO 9000 series. Japan. 107‐108. Due to limited experience in welding of steel of this strength class. were produced of SUMITEN 80P (SM 80P) HSLA steel. Mahdi1 ‐ Aleksandar S. and this was regarded as the upper limit in plate fabrication for this steel class. More or less extensive destructive and non‐destructive testing should be performed. Accordingly. skilled and approved personnel. Penstock welding was to be partly performed in the field. stable crack growth). where welding is defined as a special process since welds cannot be fully verified by subsequent inspection. The burst test was performed on pre‐ cracked model for testing resistance to fast fracture and crack arrest properties. a kind of “fitness for purpose” was required. Anyhow. one can expect significant plasticity in 107 . Serbia 2 ARTICLE INFO: Category : Technical Note Received : 21 October 2012 / Revised: 16 November 2012 / Accepted: 17 November 2012 Keywords: (in causal order) Abstract: Full‐scale testing Pressure vessel Welding Quality assurance The paper deals with the full‐scale model testing as a crucial step in the quality assurance of a large welded penstock manufacturing. similarly to nowadays approach accepted in standards EN287 and EN288. 3. For only one penstock the application of structural steel of yield strength level 700 MPa was inevitable. 2. continuous monitoring and/or compliance with documented procedures is required to ensure that the specified requirements are met. Therefore. a higher safety margin is required.7 regarding steel yield strength according to German specification for the HSLA steel.Contents lists available at www. 4. Japanese experience with this steel grade recommended a minimum safety margin 2. Kraljice Marije 16. The plate thickness in the penstock most stressed part is 47 mm. 47 mm thick plates. The selection of mild structural steel of yield strength 350 MPa for penstock of requested capacity required expensive solution with two penstocks and two tunnels. to crack‐like defects. p. The overall behavior of a welded penstock under load was analyzed based on results of three approaches (crack initiation. Practical training had to be done prior fabrication of penstock. The full scale model has been tested by a sequance of increasing pressure. [1]. "Sumitomo". i.icmem. Following facts additionally contributed to make a decision to produce two full scale prototypes of this penstock in order to gather the data about its integrity: 1.bg. only a full‐scale testing provides complete insight in welded joints and complete construction behaviour. The second problem was adopted low safety margin of only 1. et al. in order to understand better crack significance. meaning that yield strenght was lower than the yield strength of base metal. The maximum thickness in previously constructed penstocks with this steel is only 32 mm. (2012). The hydro‐pressure test on a model with no crack enabled the post‐yield experimental analysis of weldments. Selection of HSLA steel opened two new problems. which was produced of high strength low alloy steel (nominal yield strength 700 MPa) about 40 years ago. in some cases. ISO3834/EN729 series of standards have been prepared to describe welding quality requirements suitable for application by manufacturers using welding as a means of fabrication. which is the topic of this paper.M. presents the crucial step in quality assurance procedure. 1). quenched and tempered. including resistance of weldments. 35 9 9. No 1‐ 2. No 2. but in any case. When the pressure starts to decrease. Such a complex behaviour has been noticed in other experiments.A. This behaviour is almost parallel to the plastic part of the strain.8 9 7. after which the base metal takes all the pressure (having much higher yield strength than the weld [1]) and starts deforming elastically. Once it reaches 12. Mahdi. verifies quality of welded joints and penstock as a large welded construction. p.1 The full‐scale model CONCLUSIONS The full‐scale model testing has been used as a crucial step in the quality assurance of a large welded penstock manufacturing.Sedmak. LS2. The results of the second test for the above mentioned strain gauge are given in Tables 1 and. indicated complex elastic‐plastic behaviour. 13.2 Position of strain gauges along the circumference of the model REFERENCES [1] S. as described in [2]. Below the pressure of 10. for loading and unloading. 2013 Tab. More specifically.35 2.8 MPa. and only elastic deformation was present.95 7. respectively. monitored by the SG 34. and this time plastic strain also occurred at the welded section at strain gauge 34.5 12. Adžiev. The stress increases until approximately 9. 1. additional strain gauge was added at the place with highest stress concentration (strain gauge 34. Djurdjevic. A. the most stressed region of full‐scale model.05 MPa.3 Pressure‐strain diagram DISCUSSION The diagram in Fig.5 0 Strain in axial 6529 5105 4583 4125 2899 2261 2172 ‐6 direction (x10 ) 108 . Vol. The second test was performed with pressure that started with 0 and was gradually increased up to 12. M. accepted for Structual Integrity and Life. 2002. Suggested explanation would be that because of significant difference in yield strengths of materials. an experimental model was made from the central section including the 5° angle. No.95 0.05 MPa and is subsequently unloaded an unusual behaviour appears when pressure is reduced from 12. Fig. 5. as the weakest points. A. when yield strength of weld seam is reached.8 11. Vol.8 MPa.05 to 10. it starts to buckle. LS3). Residual Strength Assessment of Cracked Welded Spherical Storage Tank Structual Integrity and Life. From the purpose of testing.1 Results for Strain Gauge 34 – loading Pressure (MPa) 0 0.5 2. to crack‐ like defects. et al. the base metal and the welded seam started behaving as expected. except for LM1 and CM which were done manually. At one point plastic strain becomes too large and the base metal also starts to deform noticeably. Sedmak. and was closed at the top and bottom in order to apply test pressure. 3 shows elastic behaviour up to the value of approximately 9 MPa. in accordance with ISO 9000 series. and then decreased back to 0.8 MPa. U. Vol. 3. Adžiev. A. 20‐22 [3] S. Fig. Fig. Integrity of Penstock of Hydroelectric Powerplant Structual Integrity and Life. is given in [3]. Figure 2). Welded seams were made as automatic (marked as LS1. including resistance of weldments.M. Arsić. 2005.05 Strain in axial direction 445 534 1154 3026 3884 5355 5740 6131 6576 ‐6 (x10 ) Tab. 59‐70 [2] T. The first test was performed for the pressure of 9 MPa. Sedmak.Sedmak. overall behaviour of the large welded penstock has been verified. which needs further investigation. G. including numerical simulation by using the finite element method. we assume that elastic strain of the base metal (in the area around the welded seam) starts to behave as a spring and starts to compress the weld metal. Tatic. Sedmak.05 10. at which point plasticity in weld metal occurs. Testing was performed using various values of pressure. More detailed analysis. along with the diagram in Fig. 2.2 Results for Strain Gauge 34 – unloading Pressure (MPa) 12. p. where welding is defined as a special process since welds can not be fully verified by subsequent inspection.8 10. A. Quality Assurance of a Large Welded Penstock Manufacturing by Means of Full-scale Model Testing the most stressed welded joints. By using a sequance of increasing pressure. Numerical simulation of weldment behaviour during full‐scale testing of large penstock. Following this test. which was then decreased to 0. equipment and machining regimes are practically applicable for various cavity types and different tests in dental practice. 1. 15 extracted and 15 plastic molars were used.tk Manufacturing Engineering & Management The Proceedings Procedure Development for Standardized Tooth Cavity Preparation for in Vitro Research Purposes Milos Milosevic1‐ Nenad Mitrovic2 ‐ Aleksandar Sedmak2 ‐ Dragica Manojlovic3 ‐ Nikola Momcilovic2 ‐ Vesna Miletic3 1 Innovation Center of Faculty of Mechanical Engineering. where it is important to maintain the same cavity dimensions in multiple teeth. Plastic molars had exact same dimensions considering that they were prefabricated (KaVo Dental GmbH. in vitro. to analyze free polymerization shrinkage and shrinkage between the opposing cavity walls using digital image correlation method. 1).) and a circular slow‐ Fig. However. 109‐112. : Procedure Development for Standartized Tooth Cavity Preparation for in Vitro Research Purposes. when placed in combination with adhesive systems [2. Biberach. resin‐based composites offer excellent aesthetics. 2). even though it is difficult to maintain the same cavity dimensions.. authors reported frequent fractures associated with mechanical cavity preparation. 1 Dimensions of the prepared cavity in a plastic tooth For cavity preparation. 13]. Obtained cavities in this paper will be used. where it is important to maintain the same cavity dimensions in multiple teeth. while extracted molars had similar dimensions. all resin‐based materials exhibit volumetric shrinkage during polymerization as one of the main disadvantages [4‐8]. Kraljice Marije 16. Displayed procedures. For in vitro testing in restorative dentistry. The dimensions of the prepared cavity are shown in Fig. even though it is difficult to maintain the same cavity dimensions. Rankeova 4. radius form end mill. They are used to analyze the influence of cavity preparation design on fracture resistance of posterior Leucite‐ reinforced ceramic restorations [12. 2 Extracted tooth embedded in acrylic 109 . straight shank in accordance with DIN 1835 B. equipment and machining regimes are practically applicable for various cavity types and different tests in dental practice. For in vitro testing in restorative dentistry. manual cavity preparation is mostly applied. 13]. University of Belgrade. Obtained cavities in this paper will be used in vitro to analyze free polymerization shrinkage and shrinkage between the opposing cavity walls using digital image correlation method. 11000 Belgrade. 3]. Digital image correlation method (DIC) is becoming a common method in determining mechanical properties of biomaterials [14‐ 17]. Belgrade. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Current light‐cured.Contents lists available at www. University of Belgrade. p. University of Belgrade. Serbia Faculty of Mechanical Engineering. speed diamond saw. MATERIAL AND METHOD Milling and cutting of both plastic and extracted human molars were performed in this paper in order to obtain modified class II cavities of standardized dimensions. up to the enamel‐ cementum junction (Fig. In these studies. Fig. 2nd International Conference Manufacturing Engineering & Management 2012. For material application and recording procedure.icmem. 17 molars extracted for the orthodontic purposes and 17 plastic molars were chosen. 11000 Belgrade. Displayed procedures. Mechanical cavity preparation may also cause tooth fracture [12. Germany). improved mechanical properties [1] and good bonding to tooth structure. Polymerization shrinkage is associated with polymerization stresses that may cause cusps movement. Preparation and processing of all samples were performed using the same procedure. 11000 Belgrade. which may result in microleakage and postoperative pain [9‐11]. enamel fracture and cracked cusps. Standardized cavities with the same dimensions were prepared in all teeth (Fig. Each tooth was embedded in 30 x 30 mm cold acrylic cubes. manual cavity preparation is mostly applied. Citation: Milosević M. Currently available literature shows that instruments for mechanical cavity preparation are not often used. (2012). Serbia School of Dental Medicine. Serbia 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 20 October 2012 / Revised: 27 October 2012 / Accepted: 2 November 2012 Keywords: (in causal order) Abstract: Dental composites Polymerization shrinkage Preparation Tooth cavity All resin-based dental composites exhibit volumetric shrinkage during polymerization as one of the main disadvantages. Tools used in this procedure are a milling cutter (d1= 2mm. centre cut. finishing teeth. et al. Kraljice Marije 16. Movement and spatial arrangement of monomeric units are responsible for this volumetric change during polymerization. M. Milosevic, et al. Procedure Development for Standardized Tooth Cavity Preparation for in Vitro Research Purposes Considering the different dimensions of human molars, the depth of the cutting of the occlusal and proximal surfaces was directly dependent upon the dimensions, particularly width, of the crown. Occlusal and proximal surfaces were cut on an Isomet 4000 precision diamond saw (Buehler, Lake Bluff, IL, USA; University), whereas the subsequent cavity preparation was performed in a milling machine а LOLA HMC 500 (LOLA Institute, Belgrade). Processing of occlusal and proximal tooth surfaces by cutting Each sample was manually positioned in the Isomet 4000 machine using a mechanical stopper so that the side of the tooth was always parallel to the axis of the saw (Fig. 3). Fig. 3A illustrates cutting of the occlusal one third of the crown and Fig. 3B cutting of the proximal surface to expose flat dentin. Cavity preparation by milling After the occlusal and proximal surface cutting, samples were fixed using a universal mechanical clamp (Fig. 4A) and prepared in HMC 500 machine with the milling cutter (Fig. 4B). Fig. 4 Processing by HMC 500 machine: A. Sample fixation B. Positioning of milling cutter Cutting regimes on the HMC 500 machine: the velocity of the auxiliary motion of the tool for plastic teeth: 60 mm/min the velocity of the auxiliary motion for extracted teeth: 5 mm/min the velocity of the rotation of the mill: 1500 round/min cooling: circulation of cooling liquid. The numerical control is based on automatic controlling of the machine workspace upon a predefined motion pattern. The order of operations and movement of machine parts was controlled by a defined program. However, it was necessary to define a zero point for each extracted tooth due to slight differences in their dimensions (G58). The position of the sample considering the reference point on the HMC 500 machine was defined by the zero point (G58) of the sample or by xn yn zn coordinate (Fig. 5). Fig. 3 Processing a tooth using Isomet 4000 machine. A. Occlusal surface B. Proximal surface The main motion of the saw was the rotational motion of the tool defined by the cutting velocity n [round/min]. The auxiliary motion was defined as the linear motion of the tool per unit of time [mm/min]. The regimes of cutting on the Isomet 4000 machine: the velocity of the auxiliary motion of the tool: 5.3 mm/min the velocity of the rotation of the saw: 1000 round/min cooling: circulation of cooling liquid. Using a precise measuring gauge (precision up to 0.01mm), the saw was positioned to lightly touch the most prominent point of the tooth. That point represented the zero point for determining the depth of the cutting. Gradually increasing the depth is followed by visual control for the reason of obtaining the necessary optimal surface of the measuring sample that is later on controlled with the movable digital gauge. Gradual increase in cutting depth was visually controlled in order to get an optimal flat dentin surface for further cavity preparation. Following cutting, each sample was measured using a digital caliper (precision 0.01 mm). Fig. 5 Defining the zero point G58 (N) using reference axes of the cavity in relation to the proximal (side) and occlusal (top) surface 110 Procedure Development for Standardized Tooth Cavity Preparation for in Vitro Research Purposes The zero coordinate xn defined the position of the longitudinal axis of the cavity yk and presented the centre of the cavity. Coordinate yn defined the position of the surface of the tooth parallel to the axis of the tool and axis yk. Coordinate zn defined the top of the sample (Fig. 5). The sensitivity of the tool and fore of the spindle was 0.001 mm. Coordinate xn was defined by fine positioning of the tool until the crossing of the cavity axis (yk) with xk axis, coordinate yn until the first contact with the occlusal surface of the tooth, and coordinate zn until the first contact with the proximal surface of the tooth. After the zero point of the sample had been defined, the sample was processed in two passings of the milling cutter in order to obtain the desired shape of the cavity. The trajectory of the milling cutter is shown on Fig. 6. M. Milosevic, et al. during high velocities of the tool motion (15mm/min) occurred due to irregular geometry and smooth enamel surface. This resulted in curved and irregular tooth surfaces. Irregular surfaces caused deviations up to 1mm (50%) compared to the desired dimensions of the depth of the cavity. If the tool were in contact with the sample that had irregular surface, further processing would open the pulp chamber. Those teeth would be rejected and not used for analysis. In order to prevent these events, it was necessary to adjust or lower the velocity of the tool motion to 5.3 mm/min, so that the saw could penetrate enamel and dentin gradually and provide the desired direction and cutting depth. The perpendicularity of the surfaces was controlled using a comparator with 0.001 mm precision. The mean value of the cutting depth occlusally was 2.6 mm and proximally 1.29 mm. CONCLUSION Based on the analysis presented in this paper, the optimal number of passings and depth of cutting is proposed for the preparation of standardized cavity for in vitro research purposes. The deviations in tooth processing can be accidental but rarely systematic and cannot be predicted. However, with the proper technology and cutting regime, the deviations can be substantially reduced. During the cutting process, the deviations occur perpendicular to the surfaces, while possible deviations during the milling process are associated to the shape, position and dimensions of cavity irregularities. For teeth that exceeded the chosen tolerance limits (5%), the additional process of reducing the minimal thickness of the layer could be performed. Teeth with non‐adjusted geometry can be further processed if the controlled dimensions were over the top limit for outer, and below the lower limit for inner dimensions, so that in further processing the tool would not open the pulp chamber. Obtaining the replicable and predefined cavity shapes for analysis of polymerization contraction and contraction between opposite cavity walls using the digital images correlation method is feasible but requires machine processing of teeth. Fig. 6 The trajectory of the milling cutter in one passing For each sample a different zero point (G58) was defined due to the differences in dimensions between samples. All samples were processed in two passings with the milling cutter, so that the depth of cutting was 1 mm per passing. PROCESSING CONTROL The control was performed in order to ensure if the controlled dimension (value) was below predefined tolerance limits. Processing precision respresented the degree of similarity of shapes and dimensions in Fig. 1. After the cutting process, the comparators were used in order to control the cutting surfaces. Teeth below the tolerance limits (5%) were additionally processed by means of reducing the minimal thickness of the tooth. The final assessment showed that three teeth had exceeded the allowed limit. These teeth were rejected so that additional processing would not damage the pulp chamber. A digital calliper was used to control the depth, width and length of the cavity after milling. The deviation values did not exceed 5% in comparison to the reference dimensions. REFERENCES [1] Vojvodic, D., Kozak, D.; Sertić, J.; Mehulić, K.; Čelebić, A., and Komar, D., Influence of Depth Alignment of E‐ Glass Fiber Reinforcements on Dental Base Polymer Flexural Strength. Materials Testing, 2011. 53(9): p. 528‐535. [2] Arola, D., L.A. Galles, and M.F. Sarubin, A comparison of the mechanical behavior of posterior teeth with amalgam and composite MOD restorations. J Dent, 2001. 29(1): p. 63‐73. [3] Brackett, W.W., D.A. Covey, and H.A. St Germain, Jr., One‐year clinical performance of a self‐etching adhesive in class V resin composites cured by two methods. Oper Dent, 2002. 27(3): p. 218‐22. [4] Chiang, Y.‐C., Polymerization Shrinkage with Light‐ Initiated Dental Composites. Dissertation, LMU München: Faculty of Medicine, 2009. [5] Weinmann, W., C. Thalacker, and R. Guggenberger, Siloranes in dental composites. Dent Mater, 2005. 21(1): p. 68‐74. [6] Chuang, S.F., C.H. Chang, and T.Y. Chen, Spatially resolved assessments of composite shrinkage in MOD restorations using a digital‐image‐correlation technique. Dent Mater, 2011. 27(2): p. 134‐43. [7] Milosevic, M., et al., Measurement of Local Deformation Fields in Dental Composites Using 3d Optical System. Chemicke Listy, 2011. 105: p. S751‐ S753. DISCUSSION Each teeth was positioned in the middle of the silicone mould and embedded in acrylic so that the crown remained free, which enabled easier manipulation and positioning of the sample while processing the tooth. Acrylic was necessary to mix in exact 1:1 ratio of the liquid and the powder phase. It was noticed that a higher amount of the liquid phase resulted in negative strength and hardness properties of the acrylic which, in turn, led to a weak tooth‐acrylic connection, difficulties to position the sample into the clamp and higher vibrations during processing. An inadequate ratio between the liquid and powder phase prevented full control of the processing. Due to the vibrations of the teeth embedded in acrylic with higher percentage of the liquid phase, the dimensions of the cavity increased by 2% in all three directions (width, depth, length of the cavity). The saw performed main rotational and auxiliary linear motion to ensure complete processing of the teeth. Changes in the saw direction 111 M. Milosevic, et al. Procedure Development for Standardized Tooth Cavity Preparation for in Vitro Research Purposes [8] Miletic, V., et al., Analysis of local shrinkage patterns of self‐adhering and flowable composites using 3D digital image correlation. Quintessence International, 2011. 42(9): p. 797‐804. [9] Ausiello, P., A. Apicella, and C.L. Davidson, Effect of adhesive layer properties on stress distribution in composite restorations‐‐a 3D finite element analysis. Dent Mater, 2002. 18(4): p. 295‐303. [10] Bouschlicher, M.R., M.A. Vargas, and D.B. Boyer, Effect of composite type, light intensity, configuration factor and laser polymerization on polymerization contraction forces. Am J Dent, 1997. 10(2): p. 88‐96. [11] Bowen, R.L., K. Nemoto, and J.E. Rapson, Adhesive bonding of various materials to hard tooth tissues: forces developing in composite materials during hardening. J Am Dent Assoc, 1983. 106(4): p. 475‐7. [12] Soares, C.J., et al., Fracture resistance of teeth restored with indirect‐composite and ceramic inlay systems. Quintessence Int, 2004. 35(4): p. 281‐6. [13] Soares, C.J., et al., Influence of cavity preparation design on fracture resistance of posterior Leucite‐ [14] [15] [16] [17] 112 reinforced ceramic restorations. Journal of Prosthetic Dentistry, 2006. 95(6): p. 421‐429. Sedmak, A., Milosevic, M., Mitrovic, N., Petrovic, A., Maneski, T., Digital image correlation in experimental mechanical analysis. Structural Integrity and Life, 2012. 12(1): p. 39–42. Tanasic, I., et al., Optical Aspect of Deformation Analysis in the Bone‐Denture Complex. Collegium Antropologicum, 2012. 36(1): p. 173‐178. Sojic, L.T., et al., Compressive strains and displacement in a partially dentate lower jaw rehabilitated with two different treatment modalities. Gerodontology, 2012. 29(2): p. e851‐7. Mitrovic N., Milosevic, M., Sedmak A., Petrovic A., Prokic‐Cvetkovic R, Application and Mode of Operation of Non‐Contact Stereometric Measuring System of Biomaterials. FME Transactions, 2011. 39(2): p. 55‐60. Contents lists available at www.icmem.tk Manufacturing Engineering & Management The Proceedings 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design Predrag Miloš1‐ Nikola Davidović2 ‐Branislav Jojić3‐Đorđe Blagojević4‐ Marko Miloš5 1 PhD Mechanical Engineering, Research Engineer, EDePro, Belgrade, Serbia,email:
[email protected] PhD Mechanical Engineering, Research Engineer, EDePro, Belgrade, Serbia, emai:
[email protected] PhD Mechanical Engineering, Professor, Faculty for Mechanical Enginering University of Belgrade, Serbia 4 PhD Mechanical Engineering, Professor, Faculty for Mechanical Enginering University of Belgrade, Serbia 5 PhD Mechanical Engineering, Associate Professor, University of Belgrade, Faculty of Mechanical Engineering, Serbia 2 3 ARTICLE INFO: Category : Technical Note Received: 2 November 2012 / Revised: 14November 2012 / Accepted: 5November 2012 Keywords: (in causal order) Abstract: Thrust vector control Rocket motor testing Jet tab Stewart platform The objective of this study was to show that is possible to use innovative type of test stand (based on Stewart platform design) of relatively simple construction to measure rocket motor thrust in space during his work with high quality. Basic test stand design principles, procedures for test stand calibration, mathematical model for test results calculation as well as test results for jet tab TVC system are presented. Citation: Predrag M., et al.: DOF Thrust Vector Control Test Stand Based on Stewart Platform Design, 2ndInternational Conference Manufacturing Engineering & Management 2012, (2012), p. 113‐121, ISBN 978‐80‐553‐1216‐3 NOMENCLATURE Aeb F m Fz rel. Fy rel. 4. Separate thrust‐producing devices that are not part of the main flow through the nozzle; Mechanical systems are based on different mechanical obstacles, which are used to modified flow around obstacle and/or in the nozzle and thus pressure distribution. Both aerodynamic and mechanical techniques have been use to redirect the motor thrust and provide steering forces. Aerodynamic techniques have demonstrated very rapid response rates, but also suffer motor thrust losses at large TVC vector angles. The higher losses with the aerodynamic jet tab, jet vanes and bleed control concepts are a result of the physical creation of side force by creating a shock pattern in the exit cone thrust i.e. the higher the TVC angle required, the larger the percentage of thrust involved. Jet tabs or vanes have been used for rapid thrust vector control steering, especially early in flight when missile speeds are too low to achieve effective control with external aerodynamic fins. These systems usually require tungsten or refractory metal components to minimize the erosion from the solid particles in the hot exhaust gas. The jet tab TVC system has low torque, and is simple for missiles with low‐are‐ ratio nozzles. Its thrust loss is high when tabs are rotated at full angle into the jet, but is zero when the tabs are in their neutral position outside of the jet. On most flights the time‐averaged position of the tab is a very small angle and the average thrust loss is small. Jet tabs can form a very compact mechanism and have been used successfully on tactical missiles. Four tabs, independently actuated, rotated in and out of the motor’s exhaust jet during rocket motor operation provide control a vehicle’s pitch, yaw and roll motions. Side forces and roll torques are usually relatively small compared to the main thrust and the pitch or yaw torques. Their accurate static test measurement can be difficult, particularly at low vector angles. Multi‐ component test stands employing multiple load cells and isolation flextures are needed to assure valid measurements. In this paper is presented novel design of 6 degree of freedom thrust vector control test stand. His verification is performed on measuring thrust vector angle deflection and thrust losses of jet tab TVC configuration in – Relative nozzle exit area blockage – Total impulse of force in Z direction (thrust) – Total impulse of force in Y direction (side force) – Consumed mass – Relative loss of thrust – Relative side force – Deflection angle INTRODUCTION In addition to providing a propulsive force to a flying vehicle, a rocket propulsion system can provide moments to rotate the flying vehicle and thus provide control of the vehicle’s attitude and flight path. By controlling the direction of the thrust vectors through the various mechanisms it is possible to control a vehicle’s pitch, yaw and roll motions. Most tactical motors require some steering to meet flight maneuvering requirements. In addition to, or replacing, traditional external aerodynamic control fins, steering control has been demonstrated by deflecting the nozzles hot exhaust gases, or the motor thrust. Effectiveness of the thrust vector control systems is inversely proportional to the dynamic pressure. That means that effectiveness will be increased with decreasing of dynamic pressure. Therefore, effectiveness will be highest when flight velocity is small and/or atmosphere density is low. That is, clearly, dominant over an aerodynamic control.TVC systems are classified primarily by nozzle type, either fixed or movable, and second by the method of providing actual thrust vector control. TVC mechanisms can be classified into four categories: 1. Mechanical deflection of the nozzle or thrust chamber; 2. Insertion of heat‐resistant movable bodies into the exhaust jet (such as jet vane, jetavator, jet tab, axial jet deflector, domed deflector); 3. Injection of fluid into the side of the diverging nozzle section, causing an asymmetrical distortion of the supersonic exhaust flow; 113 P. Miloš, et al. 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design middle of supporting roads, capable to measure loads in both direction (compression and tension) enables the measure test stand response on external loads. static conditions and results as a function of nozzle exit area blockage percentage are presented. TEST STAND DESIGN The test stand design originates from Stewart platform design idea. A Stewart platform is a type of parallel robot that incorporates six prismatic actuators, commonly hydraulic jacks. These actuators are mounted in pairs to the mechanism's base, crossing over to three mounting points on a top plate. Devices placed on the top plate can be moved in the six degrees of freedom in which it is possible for a freely‐suspended body to move. These are the three linear movements x, y, z (lateral, longitudinal and vertical), and the three rotations: pitch, roll and yaw. The term "six‐axis" platform is also used. Fig.3 Rod design In this case external loads will be thrust components of rocket motor which is fastened to the upper plate. System for motor connection with the upper plate also ensures positioning of jet tab always in same position, perpendicular to the Y axis. In order to calculate applied forces and position of act onto test stand, system must be fully calibrated which means calibration upon of forces along X, Y and Z axis as well as upon moment around those axis Mx, My and Mz. On that way is obtained 6x6 calibration matrix (A). Our task now is to solve system of 6 simultaneous linear equation using matrices. A∙F=S (1) Where F is load matrix and S is matrix of test stand response (values from load cells). The solution to the system of equations is given by: F=A^(‐1)∙S (2) Where A‐1 is inverse matrix of matrix A. Fig.1 Example of Stewart platform design Unlike the original design upper platform is not movable, because instead of six actuators are mounted six rigid rods. Different loads acting on the top plate will produce different reactions in roads according to the vector of their actions. ⋮ ⋮ ⋯ ⋱ ⋯ ⋯ ⋱ ⋯ ⋮ ⋮ ; ; ; (3) A preliminary analysis of the system was performed by usage of software package NASTRAN. Fig.2 Test stand design Lower plate of test stand is connected to the basement by the rigid connections‐bolts. The upper plate is connected to the lower plate by six rods attached to the both plates by the spherical plain bearings. On that way they can only transfer loads along their axis. Placement of load cells, in Fig.4 Model of test stand loaded by Fx 114 while a problem with a high condition number is said to be ill‐ conditioned. et al. or 2.177363362 0.1003752 0. 4 and 6.8089484 ∙ With condition number 16. Load cell position 2 ‐0. first calibration matrices have to be calculated for all three cases.8089484 Load cell position 3 0.20075016 ‐1.17736336 0.8E‐06 0.177363362 0.8791101 Load cell position 5 0. Tab.92 Fig.177363362 0.8791101 Load cell position 5 0.173856 0.8089484 Load cell position 6 0. Because of that special attention was paid to the introduction of the dead‐weight loads on the test stand. The following rule of thumb is a useful way to express the above estimate. Here. cond A norm A ∙ norm A (4) Condition number measures the sensitivity of a linear system solution to errors in input vector.8 Test stand calibration X axis .5 Reactions in rods upon applied load By applying different loads we can obtain reactions on those loads and thus build our calibration matrix A. in solving the equation Ax=b. along Z axis. Miloš. It states that if m=log10(cond(A)) then m is the number of digits accuracy lost in solving the system of equations Ax=b. This analysis will helps to make a choice of the best possible location for load cells.100375 ‐0.1 Calibration matrix Ap2 with load cell placed on position 2 ‐Mx My Fz Fy Load cell position 1 ‐0.8089484 Load cell position 4 0. As mentioned earlier for measuring jet tab TVC system we will use 4 load cells. divided by the relative error in the right‐hand‐side vector is given by the condition number of A.1738526 0.1738562 0. Obviously. Loads in X and Y direction were applied on the test stand over special pulleys system (see figure 6) on two different elevation.1003751 0.1003751 0.07016276 Fig.1738562 0. when solving a system of linear equations Ax=b. the first combination will be used.20075016 ‐1.1003752 ‐0.1738526 0. 3 and 5.879110 With condition number 6.2007502 2E‐06 0.1003752 ‐0.20075016 ‐1.17736336 0.1738526 0.87911 ∙ With condition number 16.8E‐06 0.177363362 ‐0. 4 and 6).177363362 0. There is typically additional error due to the many calculations needed in solving the equations.6 Test stand assembled in laboratory TEST STAND CALIBRATION In order to accurate calculate forces and moments it is necessary to perform precise calibration of the test stand.1003751 0.7 Test stand calibration Z axis ∙ 115 Load cell position 1 ‐0.17736336 0.8E‐06 0. From above results it is obvious that placement of loads cell on position 2 will lead to inaccurate calculation and placement of load cell on positions 4 or 6 will lead to results of same accuracy.1003752 ‐0. So. A problem with a low condition number is said to be well‐conditioned.1773634 ‐0.1773634 ‐0.1738526 0.2 Calibration matrix Ap4 with load cell placed on position 4 ‐Mx My Fz Fy Load cell position 1 ‐0.177363362 0. This number clarifies how accurate is expected the vector x to be.07016276 Load cell position 3 0. so the last fourth load cell could be placed in positions 2. In order to determinate which position is the best. the relative error in the solution.14 ∙ 10 Load cell position 5 0.471 Tab. Condition number of some matrix A is the product of two matrix norms.07016276 Load cell position 3 0. three load cells have to be placed symmetrically around the Z axis (rods 1.0701628 Fig.1773634 ‐0. Load in Z direction was applied on the test stand over real nozzle mounted on the test stand in the same way as it was during firing test. Tab. after which their condition numbers will be calculated.1738562 0.6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design P.3 Calibration matrix Ap6 with load cell placed on position 6 ‐Mx My Fz Fy Fig. The estimate for additional losses is given by log10(n) if the matrix A is n x n. 21182E‐06 ‐1.6158 Channel 6 1160.36543 Channel 1 ‐1747.000346069 0. stainless steel universal load cells.11 Load cell calibration upon Fx Fig.7634 33282.11116 ‐1093.6 Calibration matrix (in this calculation positive sign is for compression) Fz ‐0.25577932 437828. 116 .14351E‐06 Channel 2 ‐2994.48407E‐07 ‐3. et al.000139995 ‐9.000255414 Fx (z=104.000140783 ‐0. it is necessary to perform total of five calibrations. an inverse matrix of matrix A e. Miloš.232781 ‐23075.6077 Tab.9 Test stand calibration Y axis Fig.00104816 ‐5.77692 3915.11189 10238.000179637 0.0528 ‐18997.15314 4963.000140783 ‐0.2638E‐05 0.24708 ‐121.59442 1399. Now is possible to create matrix A for calculation of applied forces.23798 ‐883.5 Calibration matrix (in this calculation positive sign is for compression) Channel 0 Channel 1 Channel 2 Channel 6 Fz ‐0.77388 Fy (z=105.27911 Fy (z=0) 0.000135575 Reaction in rods (load cells) for applied unity forces (reciprocal values of slopes).7 Inverse matrix of calibration matrix for calculation Fz Fy ‐Mx My Channel 0 ‐2430. and two moments Mx and My.3814 Channel 0 Channel 1 Channel 2 Channel 6 Fx (z=0) 947. repeatability combined.11324 ‐5566.76717E‐05 Fx (z=0) 0.000951222 Tab.53552E‐06 ‐1. matrix A‐1 must be found.4213669 ‐277855.95712 7143.001052508 ‐0.80964 ‐1051.22485 ‐954.P.000508067 0. hysteresis.905159 ‐650.51265 7375. Tab.25% FSO linearity.56635E‐07 ‐1.00105516 ‐0.08584E‐06 ‐7.24394 1666.00071471 ‐0.000201452 ‐0. were built in test stand rods.76717E‐05 Channel 0 Channel 1 Channel 2 Channel 6 Fy 0.4 Load cell shopes (in this calculation positive sign is for compression) Fz 7103.000914266 Fy (z=105. Maximum capacity is 5000N and accuracy is 0.000346069 0.i.9609 359749.50298E‐07 My ‐9. Fig. one for Fz and two for each moment (calibration of Fy is already in Mx) on different elevations from the nozzle (first calibration on the nozzle exit level and second calibration is elevated by the approximately 105mm).597754 364.8) 0.000600154 ‐0. (5) (6) To calculate loads according to the applied forces.50551E‐06 1.000139995 ‐9.000890382 ‐0.001131465 ‐0.997 Fy (z=0) 2889.000914266 ‐Mx 1.4864 ‐56978. ‐M M . For that.000201452 ‐0.5) 0.72346 ‐1123. Miniature.00071471 ‐0.2083 Fx (z=104.16883 ‐950.4628 ‐446089. 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design As mentioned earlier in measuring jet tab TVC system 4 load cells were used and for that reason calibration was performed for two forces Fz and Fy.5) 1968. with capability to measure in both tension/compression directions.3075106 ‐24915. .29029 .8) 1047.347703 50.001052508 ‐0.10 Load cell calibration upon Fz Tab. .000954905 ‐0. Tabs are made from molybdenum to withstand thermal loads. This test will be used as a benchmark.5% of aluminum powder.P. thus consumed propellant mass should have some influence on results and has to be incorporated in calculation. Fig. time Fig. Fig.17 Pressure vs. Length of slots was tailored to provide neutral burning (pressure and thrust versus time are almost without changes . et al.14 RM before firing 117 . 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design ROCKET MOTOR Rocket motor (RM) used for testing.16 Nozzle after test Aeb=20% TEST RESULTS First test was without any tab. Results are presented in following figures 17 and 18. time Test stand is of vertical type. was of a slotted propellant grain configuration. Exit diameter of nozzle is 47mm.18 Thrust and side force vs.neutral). time can help in that.12 Rocket motor nozzle cross section Fig. To the exit nozzle surface is possible to attach different obstacles (tabs) in order to block desired percentage of exit area. Propellant used in test is thermo-plastics composite propellant with 1.13 Nozzle exit surface and used tabs geometry Fig.15 RM during firing Fig. Thus if some other result was to be obtained that would be a signal that. Total pressure in nozzle was also measured during motor burning time. Graphite nozzle throat was used in order to eliminate throat erosion. something went wrong for sure. the expansion ratio is 5 and half divergent angle is 20 degrees. to compare these results with other tests’ results in which variant percentage of the nozzle exit area were blocked. needs to be calculated by using formula: Fig. in this first test. Miloš. It is also known that. First the characteristic velocity. Measuring of pressure vs. side force must be zero. et al. time Fig. 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design ∗ ∆ Total impulse of side force is negligible so it can be claimed that the observed system works correctly in this case. so called Fztotal.22 Deflection angle vs. Fig.24 Y position of result trust vs. time Exit nozzle area blockage of 5% Fig. Applying moment equations is obtained: x=‐M_y/F_z (9) y=(M_x+z∙F_y)/F_z (10) (7) after that it is possible to calculate how much propellant mass is consumed over any time interval by using formula: ∆ . rightly assuming that side force in X axis direction is zero.P.23 X position of result trust vs. time Fig.20 Y position of result trust vs.19 X position of result trust vs. time Exit nozzle area blockage of 10% 118 .21 Thrust and side force vs. Miloš. time Fig. From measured Mx and My moments it is possible to calculate position of thrust vector in XY plane. time Fig. ∗ (8) Consumed mass from time zero up to current time in calculation should be added to the value of Z force in that moment to get a real force in Z direction. time P. time Exit nozzle area blockage of 20% Fig.26 Deflection angle vs. Fig. time Fig. time Fig.32 Y position of result trust vs.30 Deflection angle vs. time 119 . time Fig. time Fig. time Fig. et al.25 Thrust and side force vs.29 Thrust and side force vs.6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design Fig. Miloš.28 Y position of result trust vs.31 X position of result trust vs.27 X position of result trust vs. P.6 6.0 rel.0 13. time Fig.37 Test results as a function of relative nozzle exit area blockage Tab. as well as by performing analysis of results can be concluded that it is possible to use this type of the test stand for accurate measuring of the rocket motor thrust in space with all 6 degree of freedom.9 Ns ‐ 225.34 Deflection angle vs.3 1. α % 1 arctg % ∆ ∗∆ % % ∆ ∗∆ % (11) (12) (13) % CONCLUSION Regardless of the fact that for measurement of presented single and not movable jet tab TVC system it is not necessary to have test stand with more than 2 DOF (because position in space of jet tab is known and remain invariable) up to 4 load cells were used.9 17. this test stand can be used for testing other TVC’s systems in both: static and dynamic conditions.6 3988. Design and manufacturing of presented test stand is very simple and doesn’t require special precision. time Fig. Fig.6 Kg 2.7 3907. % 0 5 10 20 30 Ns 3999.36 Y position of result trust vs.35 X position of result trust vs.5 % ‐ 3. Excellent results of testing domed deflector TVC system in dynamic conditions were obtained. Although this study only outlines the results of tests with jet tab.9 26.6 3459. because by calibration the exact test stand response can be obtained.7 11.045 2. The reason for that is to validate results and to prove the concept. time ∆ . time Fig. Miloš.070 % ‐ 0. Even an inaccurate symmetry of the test stand (all rods are not at the same angle to the bottom or/and upper plate) does not present a problem. et al.055 2. ∆F .070 2.3 1059.5 784. and that is the most important. 6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design Exit nozzle area blockage of 30% Fig.4 3715. % ‐ 5.8 Summary results Aeb m Fz Fy rel.33 Thrust and side force vs.6 9.9 19.2 5. By comparing the obtained results to the other published results and some theoretical models.070 2.5 120 .2 392. M. [2] George P. May 1975‐June 1977. Final report AFRPL TR‐77‐ 49.2000 [3] B. Đ. Jet Propulsion Laboratory Faculty of Mechanical Engineering University of Belgrade. 1996. Volume 170 Progres in Astronautics and Aeronautics.V. 121 . 1984‐1986. Editor in Chief: Tactical Missile Propulsion.Jojić.Fotev.G.Eatough: Improved jet tab thrust vector control for the BGM‐34C booster.Marko and others: Rocket propulsion research‐thrust vector control. A Wiley‐Intersience Publication.6 DOF Thrust Vector Control Test Stand Based on Stewart Platform Design P. Acknowledgement REFERENCES Research of this paper is result of the national project financed by Serbian Ministry of Education and Science (TR 35044). Oscar Bilbarz: Rocket Propulsion Elements 7th edition. Miloš. [4] R. Inc. et al.Blagojević. Sutton. American Intitute of Aeronautics and Astronautics. [1] Paul Zarchan. Taking in mind the need for process structure simplification. None of these studies solved the problem adequately [4]. it is useful and important to manage process structures and to measure their complexity. [11]). . management and production structures increase the requirements concerning the characteristics of the process structures. Spearman rank order correlation To gain some insight into the relation between the properties of the individual parameters under the given conditions. [8]. it is required that the random variables are normally distributed. for example. Case studies have mostly been based on frameworks.modrak@tuke. (1) (2) 3 . The primary research methodology has been based on the application of general axioms of graph theory for selected problem area. METHODOLOGY Graph Theory One of the useful methods for evaluation of structural properties of manufacturing processes is a graph theory. Comparison of Complexity Indicators for Assessing General Process Structures . [10]. 2nd International Conference Manufacturing Engineering & Management 2012. The fundamental concept of a graph theory is the graph G=(V.Contents lists available at www. In this research all initial parameters of the examined process graphs (see fig. a set of complexity indicators is tested. vladimir. (2012). Corrected Spearman correlation coefficient is formalized: LITERATURE REVIEW Current research on process structures` complexity is characterized by different ways of complexity exploration. In the proposed approach the structural properties of manufacturing process will be examined in terms to which the primary elements of the process structure: vertices (or nodes denotes by N) and edges (of links denotes by L) are subjected. p.sk ARTICLE INFO: Category : Original Scientific Paper Received : 13 November 2012 / Revised: 14 November 2012 / Accepted: 17 November 2012 Keywords: (in causal order) Abstract: Complexity Structure Graph theory Vertex degree This paper focuses on the comparison of different complexity indicators for complexity assessment of selected general process structures. the tendencies and relations in the development of organizational. It is clear that the complexity is an important factor determining the production system`s quality and therefore process complexity is connected with its performance. Under the assumption of Gaussian violation (as in our case). nonparametric Spearman's rank order correlation (corrected) is calculated. Bednár S. They are primarily based on the systems theory or mathematical modeling of a structure. ISBN 978‐80‐553‐1216‐3 INTRODUCTION comparison with other known approaches. The obtained results of this theoretical study show that all proposed indicators can be effectively used for analyzing structural complexity of general process structures.icmem. Different aspects of business performance measurements and control were discussed. such as the use of a single correlation coefficient rc between two random variables. (iii) Relation between process structure complexity measurement and process performance measurement. Technical University of Kosice.E) that conceptually consists of a set of vertices V(G) and edges E(G). Faculty of Manufacturing Technologies with seat in Presov. In classical statistical tests. The main objective in this study is to test their ability to uncover assumed differences in structural complexity among observed general process structures. 122‐125. We will use the indicator in this study in n rC i 1 C x . Slovakia. in [5] or [6]. On the other hand a unified procedure for complexity assessment of process structures is still missing.tk Manufacturing Engineering & Management The Proceedings Comparison of Complexity Indicators for Assessing General Process Structures Vladimir Modrák1 ‐ David Marton1 ‐ Slavomír Bednár1 1 Department of Manufacturing Management. (ii) Measurements of system complexity and lowering the complexity of a system. Marton D. The two points connected by a line are said to be adjacent. Citation: Modrák V. Nowadays. statistical analysis was performed.C y 122 C x C y d i2 CX n n Tx 12 . Bayerova 1. Moreover.1) are know with certainty. In order to obtain the relationship. Obviously there are other literature sources discussing the issue of process complexity from different angles of view (see for example [9]. Simulation and non‐linear dynamics is are used to gain data for the structure`s analysis [1]. Mostly used key words in context of measuring methods are: number of elements of the structure. Another relevant approach to the complexity measurement is based on graph theory (see for example [2]). It is possible to identify the following research areas: (i) Theoretical discussions of production systems complexity. manageability. The obtained values of the correlation coefficients are summarized in Table 2. It is necessary to decrease the complexities of production structures especially for planning and work distribution problem in the high variety systems. Two lines that share an endpoint of the graph are incident. so that the problem is deterministic. This is one of the reasons of an increasing number of research works on complexity of manufacturing process structures. There is a link between the complexity and the performance of the same system [3]. an Average Shortest Path (ASP) and a Modified Flow Complexity (MFC) have been extended and presented [7]. (20) COMPARISON OF COMPLEXITY INDICATORS Representing of manufacturing process structures In order to assess the relevance of the compared complexity indicators for the selected complexities of manufacturing process structures they have been assessed for a set of graphs. It can be expressed by (13) and it counts all Tiers (including Tier 0). Presence of repetition is included in Links count. Dij is the shortest path between i and j. (6) t t chosen. (18) Since the maximum entropy is when all wi =1. Aggregate complexity indicator AC In order to measure structural complexity of supply chains it seems to be useful to apply AC indicator constructed by Modrak [13]. such that rij=1 if there is a path from the vertex vi to vj. weighted with determined. the MFC indicator can be expressed as follows: DESCRIPTION OF COMPARED CMPLEXITY INDICATORS FOR MANUFACTURING SYSTEMS RT n FC Ti N s LKij . Modrak. Bednar 3 Restrictiveness estimator RT RT is practically the same measure as Order Strength defined by Mastor [13]. TN ‐ Number of Nodes per i‐ th Tier Level. Nodes are counted only once. For this purpose we selected 10 models that are shown in Fig. (5) Ty t t 12 . even if they are repeated in Tiers. In MFC indicator. Nodes and Links are counted only once.( N 1) Where: dij – is the shortest path in the network for all nodes from i till j. and coefficients. d ij . LK ‐ Number of Links per i‐th Tier Level. and coefficients. (9) 1 n1 SD N1 N 2 i1 m (13) Where: Ti ‐ i‐th Tier. and Multi‐Link ratio (MLR). Flow complexity FC The FC is proposed by Crippa [14]. where the zero is for parallel directed graphs and 1 for series directed graphs. TX t3 t 12 . MFC basically counts all Tiers (including Tier 0). 123 i 1 j 1 V s 1 k . (8) Where: L B 1 N 1 . (11) in which: N1. L ‐ Number of Links. LK ‐ i‐th and j‐th Link.Comparison of Complexity Indicators for Assessing General Process Structures Cy d R( xi ) R( yi ) n n3 n Ty 12 . (14) TN N MTI T 1 N . otherwise rij = 0. 1. i 1 (3) (4) i1 . 2 n 2 i V. (17) Where: N ‐ Number of Nodes. A concept of this indicator is based on the aggregation of three sub‐indicators: Binding of structure (B). (19) By substituting W=∑deg(v)i and wi = deg(v)i. S. D. MTR and MLR we can determine. even if they are repeated in graph. Structure diversity (SD) a Diameter of network (D). In mathematically term. Alex and Efstathiou [7] used it for interpretation of robustness complex networks as fragmentation of network. and coefficients. and N is a number of nodes in a graph. Nodes and Links and adds all these counts. cij represents number of heterogeneous paths the i‐th input node to the j‐th output node of the graph (without any possibility to pass twice through the same node within one route). N2 are numbers of initial and final nodes. N . Average shortest length ASP The ASP is a network indicator which is applicable for determination distance of network between every pairs of nodes. (15) MTR TN N . Presence of Nodes and Links repetition is included in coefficients. Modified flow complexity MFC Modified flow complexity indicator [8] combines FC together with Multi‐Tier ratio (MTR) and index (MTI). i 1 n LK MLR L AC log(( B SD D / 3 )) . (16) H W W log 2 W wi log 2 wi i 1 . the information content of the vertex degree distribution of a network called as Vertex degree index (Ivd) is derived by Bonchev and Buck [15] that is expressed as follows: V I vd degv i log 2 degv i i 1 . T ‐ Number of Tiers. then D max ij ( Dij ) . The following expression for an Aggregate complexity indicator is formulated: n2 j 1 (10) MFC T N L . Nodes and Links and adds all these counts. RT ranges from 0 to 1. Formally can be described as follows: 1 (12) ASP . Marton. Formally RT is expressed by the formula: 2 rij 6 ( N 1) ( N 2) ( N 3) (7) Where rij is an element of the reachability matrix. Using MTI. weighted with arbitrary H max W log 2 W . Vertex degree index Ivd The information entropy of a graph with a total weight W and vertex weights wi can be expressed in the form of the equation: cij 1 . Ns – s‐th Node. 59 1. Bednar Comparison of Complexity Indicators for Assessing General Process Structures Fig.61 1.88 2.5 3 2.88 1.21 65.3 Comparison of Ivd.05 158.99 0.05 84.05 71.1 Results of compared indicators NO.2 Comparison of AC.05 318.00 70.7 1 FC MFC Ivd 200 150 100 50 0 1 Fig.5 0 Tab. 3 show that in spite of different concept of the paired indices.1 61.00 51.00 52. Modrak.00 86.82 3.05 89. 4 offers scatter plots and rc‐squared values.51 300 Graph 1 0.79 1.00 57.4 62. namely AC and MFC are comparable measures with the existing indicators and are usable to measure structural complexity of manufacturing processes.7 54.6 53.1 Representation of Kaimann´s process structures (adopted from [9]) 4 RT AC ASP 3.48 0.52 0.83 1.9 60.5 Results of computational experiments Table 1 shows the results of the implementation of compared complexity indicators that were described above. sometimes the correlation coefficient may not necessarily express the true causal relationship between two variables. However. All selected models of manufacturing processes which is presented in Table 1 are listed in ascending order based on the indicator Ivd.51 250 Graph 2 0. MFC and FC The obtained values of correlation coefficients are summarized in Table 2.13 1. RT.1 Graph 6 0.00 63.00 53.88 1.05 45.99 2.00 45.30 0.2 71.4 Graph 8 0. Fig. a significant positive correlation was found between variables Ivd and MFC.05 90.26 1.5 1 0. The graphs in Fig. 2 1. S. D.00 54.05 49.99 1.05 113.91 Graph 7 0.63 0.78 1.73 59. Marton.V.2 78.8 Graph 4 0. and ASP MFC Ivd 350 Graph 10 0. 124 . 2 and Fig.00 46. they generate comparable results. Based on these results we can state that both novel indicators.4 Graph 3 0. RT AC ASP FC Fig.3 94. To identify mutual correlation among respective values of testing indicators.05 201.7 Graph 5 0.28 Graph 9 0. Statistically. pp. Efstathiou. Bogerd. Manufacturing systems configuration Complexity.. 2. R. R. CIRP Annals Manufacturing Technology. pp.. D.” (no. 728‐ 746. 1974. Comparison of process structure complexity in manufacturing before and after redesign. This paper also supports the need for parallel use of alternative indicators to be used as a basis for a development of objective evaluation of process structural properties. 145‐171. Klundert. in press. 1970. Assessing the structural complexity of manufacturing systems configurations. Representing and measuring flow complexity in the extended enterprise: the D4G approach. D. Fig. D. H. ElMaraghy. Management Science. It is well known that the Graph theory is useful for modeling and analyzing a variety of empirical systems including general process structures. [12] Mastor. pp. N. M. R. B. 357‐ 360. 2006 vol. It is because the nodes and links consist of different entities that interact in a network. Everett. K. 2005.988 1 REFERENCES [1] Wiendhal. no. 2012.. 2001. [11] Kuzgunkaya. 054TUKE‐4/2012) 125 . D. Y. ASP AC. Crama. Chramcov.. 231‐ 242. 19.. V. Quantitative measures of network complexity. Kuzgunkaya. H. 2007 vol. Grigoriev.. Control th of the serial production systems. Eds. Marton. pp.P. RIRL 6th International Congress of Research and Logistics. ACKNOWLEDGMENT This paper has been supported by KEGA project “The Development of a Web Learning System to Support an External Form of Education in Study Program Manufacturing Management. Springer. A graph‐theoretic perspective on centrality. Physics Procedia.. 2066. [10] Kaimann. Finding a complexity measure for business process models.. vol. L. V. D.3 Mutual comparisons of used indicators RESULTS This study showed that developed indices are usable for assessing the given attribute in case we want to compare a static complexity of different process structures. 172‐177. pp. vol. ASP Ivd. pp. [15] Bonchev. [9] Latva‐Koivisto. Structural Robustness of Complex Networks. H. S.646 0.48. vol. [2] Borgatti. Bednar granted by the Ministry of Education of the Slovak Republic. 2. vol. An experimental investigation and comparative evaluation of production line balancing techniques.A. Marton. [5] Bucki. 28.872 0.S. CIRP Annals Manufacturing Technology. A. FC MFC. [4] Brauner. vol.. [8] Modrak..A. FC Corrected Spearman coefficient 0. Multiplicity and complexity issues in contemporary production scheduling. [7] Alex. 467‐472 [14] Crippa. S. pp. 1 2 3 4 5 6 Correlation Between RT. H. pp. 1999. International Journal of Flexible Manufacturing Systems. 565‐581. vol. Society Networks.. Complexity Metrics for Assembly Supply Chains: A Comparative Study..H. Bonchev. O.. A. P. Modelling and Simulation. 2011. Statistica Neerlandica.3. vol. pp. International Journal of Operations and Production Management.. vol. [3] ElMaraghy. 1999.Ng. 2006.. Vos. 466‐484. pp. [6] Akkermans. Biology and Ecology. pp. Management Science.A. A. 16. Larghi. van de J. Buck. 445‐450. Bertacci. O. Tab. Physical Review..A. but it is necessary to say that the Graph theory does not have an answer for all the questions we have towards the overall process structural complexity. H. Scheffczyk. vol. G.988 0.. WSEAS 13 International Conference on Automatic Control.18.A. Simulation based analysis of complex production systems with methods of nonlinear dynamics. Modrak.. N. Research Report. Rouvray.P. 2006. Coefficient of network complexity: Erratum. Urbanic.Comparison of Complexity Indicators for Assessing General Process Structures V. Virtuous and vicious cycles on the road towards international supply chain management.2 The results of Spearman correlation coefficients No. Complexity in Chemistry. INCOM 2006 12th Symposium Information Control Problems in Manufacturing.406 0. J. [13] Modrak. 75‐91.G. 2006. 2005. MFC Ivd.J. pp. 1‐25. 61. pp. 21. pp. 1. 175‐188. A. WSEAS Press. 54. AC RT. 191‐235. R. Preprints. 352‐356. This fact leads to the necessity to take into regard also the soil chemistry when solving the wear resistance. The alternative to this solution is introducing the ceramic materials which have proved their positive wear resistance. Email: muller@tf. He states the laboratory test results of various ceramic materials [6]. The research aim of various working groups can be defined as following: finding suitable materials and methods for the production of optimum tools whose mechanical properties would extend the tools lifetime and they would decrease the energetic consumption of the soil processing owing to the lower resistance. 2nd International Conference Manufacturing Engineering & Management 2012. Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools. Currently many experts deal with the problems of increasing the lifetime of segments processing the soil [1. vanadium and tungsten. The high wear resistance is explained with very uniform microstructure with the small volume of glassy phase. Suchánek et al. 126‐131.czu. significant tool wear occurs which is connected with the wastage of this tool. Regarding the wear conditions and the process intensity are an integral part of a lifetime and reliability not only of tools. An adhesive bonding is the general bonding technology which enables to bond heterogeneous materials in effective way. p. A similar problematic tendency can be observed at hard overlays containing the chromium.g. equipments and their partial segments working under conditions of the agriculture are exposed to an intensive abrasive wear. However. namely in a sphere of the soil processing. Prague. Machines. Important producers of exchangeable parts of the soil processing machines increase the wear resistance of their tools owing 126 . namely in an integration with keeping an ability to secure aliment and connected food stuff production. Chotěborský et al. 10]. the better is its wear resistance under conditions of the abrasive wear [12]. Suchánek states the fundamental knowledge in his book that the higher toughness and higher hardness the ceramic material is. The paper presents the results of the research focused on using the adhesive bonding technology as the possible A complexity and a sustainability of systems in the agriculture are key factors. ISBN 978‐80‐553‐1216‐3 INTRODUCTION to the e. g. This paper deals with the application possibility of the ceramic materials and adhesives in the sphere of the tools processing the soil. namely the tungsten carbide in the soil processing tools. Czech University of Life Sciences. (2012). this method is expensive and it cannot be applied in all cases. This statement is not valid for metals at which the increased wear resistance and hardness are often reached of detriment to lower fracture toughness.Contents lists available at www. Citation: Müller M. When processing the soil it is necessary to take into regard also the impact dynamic point of view that means the material toughness which affect the integrity of not only the surface layers in the negative way. The wear resistance increasing of the soil processing tools leads to the increase of the tool lifetime and to the decrease of the energetic consumption demands. The tool wear can be decreased by used high wear resistance material. when the soil processing. This technology is not innovated in the field of bonding tools for the moment. The ceramics Al2O3 was tested. Currently are used the brazing and soldering. Carried out experiments with the dry rubber wheel test ASTM G65 proved that tested oxide ceramics is of the same wear resistance as WC – NiCr and Cr3C2.icmem. states that Al2O3 and ZrO2 are suitable as the ceramic materials exposed to the conditions of the intensive abrasion [12]. Microscopic particles get unbarred into the soil and the tungsten carbide can contaminate the soil when it is applied. Email: choteborsky@tf. namely in the sphere of the soil processing.czu.tk Manufacturing Engineering & Management The Proceedings Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools Miroslav Müller1 ‐ Rostislav Chotěborský2 1 Faculty of Engineering. Among unusual ways of increasing the wear resistance ranks the application of the technical ceramics and so creation of new functional surfaces. Bonding methods are the defined problem of various materials. The problematic aspect is not the sufficient wear resistance of the tool. but its fragility. Laboratory tests showed that a suitable choice of an adhesive increased the system rigidity that means it is increased the energy absorption during the impact on the ceramic surface. The aim of research is the evaluation of shear impact strength of adhesive bonds and the possibilities of using the ceramic materials as the wear resistance materials in the sphere of the soil processing. Sintered carbides are the most widespread cutting material these days. Czech University of Life Sciences. Both producers of machines for the soil processing and also many research institutes all over the world deal with the intensive research. One of means reaching the sustainability in the sphere of the food production can be a conventional soil processing. Also Medvedovski found out similar conclusions.cz 2 ARTICLE INFO: Category : Original Scientific Paper Received : 30 October 2012 / Revised: 13 November 2012 / Accepted: 15 November 2012 Keywords: (in causal order) Abstract: Adhesive bond Ceramics Shear impact strength Wear resistance Machine. but also the whole systems. Prague. equipments and their partial segments working under conditions of the agriculture are exposed to an intensive abrasive wear. Czech Republic. 9. Above mentioned presumption defines explicitly the priority of research of the wear resistance increase possibilities. e. The possible solution is a creation of bimetallic tools on one hand and various additional materials on the other hand. However. Important producers of the agricultural machine use sintered carbides. 8. 4.cz Faculty of Engineering. Applying this solution demands coping with the adhesive bonding technology of firm and strength bonds that means the interaction ceramics/steel. When soil processing the essential point of view is namely the dynamic behaviour of the whole system in contact with the soil. The effectivity of high chrome overlays is investigated by many authors. Czech Republic. Chotěborský R. Stated values of the wear are tested in accordance with ASTM B611 and ASTM G65. the tungsten carbide. [5]. Ceramic plates based on Al2O3 (92 and 96 %) of sizes 25 x 25 x 6 mm were tested. Fig. However. The laboratory test course is described in the standard CSN EN ISO 965 which states mainly the shape and sizes of the tested samples [3]. The testing process carried out at the temperatures 22 ± 2 °C and 100 ± 2 °C. The reason is the friction during the soil processing which increases the temperature of the tool. upper size 25 x 25 x 10 mm) was tested which simulates in effective way the conditions of presumed loading in practical application that means in the soil processing. This fact is essential in the application in the sphere of exchangeable wear parts processing the soil. METHODOLOGY An untraditional material applied on the soil processing tools is the technical ceramics distinguished for high wear resistance. The constructional design of the impact hammer enables the testing variability owing to the exchangeable crashing plate provided that the conditions about the minimum width against the impact area of the tested sample given in the standard are fulfilled. The tool wear can be decreased not only by the material distinguished for increased wear resistance but also by the accessory equipment which solves given problem in the effective way. Two‐component epoxy adhesive Lepox 1200 (L1200). For setting shear impact strength it is suitable to use the impact hammer. The suggestion and design of the equipment for the evaluation of the shear impact strength of adhesive bonds were the subject of the utility pattern no. filler – rubber). Two‐component epoxy adhesive UHU Plus endfest epoxy 300 (UHU300). Testing was carried out on developed equipment at temperatures 20 °C. R. The experimental research helps to find limits and possibilities of the adhesive bonding technology and to confirm or refute presumed hypotheses necessary before application in series. Following adhesives were tested: Adhesives based on two‐component epoxy adhesives. The tests were carried out in 20 cycles that means in repeated impact of the impact hammer working part until the first discontinuities in surface layers occurred (speed 14 km per hour). Then the shear impact strength of adhesive bonds (steel/steel. Metyl‐methacrylat Novatit (N‐MET). Then it is possible to speak about the constructional solution which requires to find suitable bonding technology. cyanoacrylates and the polymeric particle composite system (matrix – epoxy adhesive. but also the temperature affecting the adhesive. One group of samples was not adhesive bonded to the basic material but it was fixed by means of locks. the impact hammer and the equipment part for fixing the tested sample. the suitable constructional setting of the tested equipment is not defined. Metyl‐methacrylat UHU plus multifest (UHUM). The integral part of the research work is the evaluation of not only the own impact strength.65 ± 0. Cyanoacrylate adhesive Novax (N‐K). 60 °C and 100 °C (temperatures 60 °C and 100 °C were reached in the laboratory chamber). However. The modification consisted in the fact that there was not kerf on the impact area of the ceramic plate. It is essential to observe the temperature influence during the laboratory tests focused on the soil processing. The following list presents the identification of tested adhesives and their identification which is used in text for better clear arrangement: Two‐component epoxy adhesive Loctite Nordbak 7256 (LN7256).1 Apparatus for testing shear impact strength of adhesive bonds fixed in Charpy hammer. The adhesive bonded steel surface was eroded by Al2O3 of the fraction size F80 and consequently chemically cleaned. The application of this solution requires knowing the adhesive bonding technology in the sphere of firm and sufficiently toughness bond that means the interaction ceramics/steel. Ceramic plates were adhesive bonded with the epoxy adhesive to the basic material – steel (S235J0). Chotěborský . Adhesive bonds were left in the laboratory conditions (temperature 22 ± 2 °C) for hardening for 48 hours. 1 and fig. based on aminoetylaminopropyltrimetoxysilan. Many adhesives resist very little against the dynamic loading. The subject of the utility pattern is the tester for the evaluation of the shear impact strength of adhesive bonds. Adhesive based on aminoetylaminopropyltrimetoxysilan Novatmel (N‐ tmel). The disadvantage of the adhesive bonding technology is namely low impact strength. The technical solution is visible in fig. The equipment is composed of two parts. Two‐component epoxy adhesive 3‐TON Epoxy adhesive 30 min (3TON). polyester. Polyester MTB (MTB). metyl‐methacrylates. The research aim is to evaluate the possibility of ceramic materials application as the potential wear resistant material in the sphere of the soil processing. Fig. Müller.2 Impact hammer for testing shear impact strength of adhesive bonds fixed in Charpy hammer. CZ 23585 U1 [7]. this tester is not the in supply of the tested equipment and it has to be designed. 127 M. Tests were carried out according to modified Charpy test valid for metal materials with 25 J impact hammer [2].05 mm was the same for all tests. namely impacts loading. but it is necessary to use different tester. 2.Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools way for bonding or securing various accessory materials distinguished for increased wear resistance. In the technical practice the impact strength is set by the Charpy method on the impact hammer [3]. The impact hammer fell on the level area of the ceramic plate which was adhesive bonded to the steel basic material. bottom sizes of the sample 45 x 25 x 20 mm. filler in form of rubber (KLP). The adhesive layer thickness 0. Polymeric particle composite system – matrix: two‐ component epoxy adhesive Lepox 1200. The adhesive bonded surface of the ceramic plate was not mechanically nor chemically treated. 9 was of the cohesive type. 4.m‐2. 8. 3). Müller. however the statistical indicators are not arguable. acrylate. 60 and 100 °C. Adhesives LN7256.m‐2. When evaluating the tested set of various adhesives it was evaluated great difference in reached values which were in interval from 3440 to 18360 J. It was occurred only minor failure visible in fig. Chotěborský Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools From the experiment results it was able to claim that the ceramics is suitable wear resistant material. impact energy 25 J. Fig. When testing boundary ceramics/steel the mean value was at the adhesive N‐MET and at the laboratory temperature 6360 ± 578 J. TEST RESULTS Testing of ceramic plates based on Al2O3 (92 % and 96 %) of thickness 6 mm.6 Shear impact strength of adhesive bonds. place of crashed is marked). The failure area of above mentioned adhesives visible in fig. Fig. When testing the composite system based on the two‐ component epoxy adhesive and the matted rubber it is essential to reach the highest possible rubber representation. It was tested a few types and sorts of adhesives (epoxy adhesive. Against standard offered adhesive the composite system showed the increase of the shear impact strength up to 80 %.4 Crashing area of ceramic plate after impact 25 J of Charpy hammer (adhesive bonded. Ceramic plates based on Al2O3 showed the ability to resist against this dynamic loading 25 J at the impact speed 14 km per hour but only in case of using the adhesive bonding technology. Fig. After reaching 20 cycles of the Charpy hammer impact it came to the delamination in the adhesive layer and consequently to gradual destruction of the ceramic plate (fig. The number of repeating cycles was 20. 5). Tested ceramic plates were fixed by means of locks to the steel basic material. Adhesives behaved differently during testing For application at the soil processing namely the group of adhesives distinguished for increasing or constant shear impact strength of adhesive bonds with increasing temperature is important. L1200 and KLP showed increasing trend with the temperature of the application.5 Ceramic plate failure and its delamination in adhesive layer. Fig. cyanoacrylates). temperatures 22 ± 2 °C and 100 ± 2 °C.3 Crashing area of ceramic plate after impact 25 J of Charpy hammer (was not adhesive bonded). 128 .M. Fig. Fig. When comparing the same adhesive in the boundary steel/steel the value was at the laboratory temperature 6960 ± 1267 J. 7. Results of the measurements showed the trend in the decrease of the shear impact strength when changing the adherends.7 Failure area of cohesive type – adhesive LN7256 The research showed potential significant application of the rubber filler in the two‐component epoxy adhesive.m‐2. 6 shows the results of shear impact strength at the temperatures 22. R. It was defined a problem in the boundary line of the adhesive layer which has to be solved. methyl‐methacrylate. Tested ceramic plates without the layer of the adhesive were completely broken during the first impact (fig. N‐tmel. 10 – 13). Müller. UHU300 and UHUM showing the increase of the impact strength of adhesive bonds owing to the temperature until the temperature 60°C. Fig.12 Failure area of cohesive type – adhesive UHU300 Fig.Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools Fig. Secondary benefit for practical application is up to 20% savings of the adhesive consumption. The failure areas of these adhesives were also of cohesive type (fig. 14 – 16).11 Failure area of cohesive type – adhesive N‐tmel Fig.9 Failure area of cohesive type – adhesive KLP Fig. R.8 Failure area of cohesive type – adhesive L1200 Fig.10 Failure area of cohesive type – adhesive N‐MET Fig. Chotěborský . The results of composite systems based on the polymeric particle composite on basis of grinding the retreaded tyres show wide spectrum of solutions. MTB and N‐K which showed the decrease of the impact strength of adhesive bonds owing to increasing temperature.14 Failure area of cohesive type – adhesive 3TON 129 M. The third group are adhesives 3TON. These adhesives were also cohesive failure (fig. The second group are adhesives N‐MET.13 Failure area of cohesive type – adhesive UHUM The results showed that the final impact strength can decrease about 30% against saturated solution of prepared composite mixture. 2001. V and W coming from the hard overlays or cemented carbides. Prague. REFERENCES CONCLUSION [1] BAYHAN. ‐2 One dimensional tests of significance. At the temperature 100°C.633369E+08 2 1. Adhesives ‐ Test method for shear impact strength of adhesive bonds.368363E+10 7422. KLP (p=0. elastic and temperature resistant bond. laying on and stability in the bond during the hardening process would be significantly improved. Plastics ‐ Determination of Charpy impact properties ‐ Part 1: Non‐instrumented impact test. 39 (6): 570‐574. [2] ČSN EN ISO 179‐1.15 Failure area of cohesive type – adhesive MTB Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools Fig.2).12)..001 <0. the adhesive MTB has the same impact strength with the adhesive L1200 (p=0. ACKNOWLEDGEMENT This paper has been done when solving TAČR TA01010192 (2011‐2014.002 <0.507088E+09 8 3. non‐iron and non‐metal materials distinguished for high wear resistance which do not contaminate the soil during the wear process coming into being during the soil processing. the adhesive N‐MET with the adhesive UHUM (p=0. the impact strength increases till given temperature at some adhesives and consequently the impact strength decreases with higher temperature. It can be the topic of next testing.6) and UHUM Tab. effects of force and impact strength of adhesive joints J. The effective solution applied in the agriculture are the iron.004 . FILIPOVI D. the laboratory experiments proved the ability of the adhesive layer to be a damping member in the system metal/ceramics. the adhesive UHU300 with the adhesives N‐tmel (p=0.368363E+10 1 2.019 Error 8. The same is valid for the adhesive L1200 (p=0.19).69).5 Euro (at the adhesive layer thickness 0. In the paper there are stated results of the research focused on untraditional possibilities of increasing the wear resistance of the soil processing tools by means of the application of ceramic plates on exposed place of the tool. Müller. Chotěborský Fig.190628E+06 sufficiently firm. The adhesive bonding technology solves the problem with creation 130 p <0.938 Adhesive*temperature 8.16 Failure area of cohesive type – adhesive N‐K T ‐ test results of dependence show that the impact strength of the adhesive LN7256 (p=0. The disadvantage of these materials is low ability to resist against the impact of various firm particles contained in the soil. the adhesive KLP has same strength with the adhesive LN7256 (p=0. 2008. The experiments showed that the elasticity of constructional adhesives could be increased by adding the filler in the form of the rubber.874 adhesive 2. EMERT R.816684E+08 56.221 Temperature 3. (in Czech) [4] HORVAT Z.430287E+07 17.21) is the same with the adhesive 3TON at the laboratory temperature.3 – 0. From the practical application point of view it is possible to recommend developed adhesive on the basis of the polymeric particle composite with the rubber admixture.. Costs per one bond of sizes 50 x 15 mm are in the interval 0. However.24). Owing to its viscous nature the handling. Czech Standard Institution. N‐tmel (p=0. the impact strength of adhesives 3TON and MTB (p=1) are the same. Reduction of wear via hardfacing of chisel ploughshare. On the contrary.06 mm).. UHUM (p=0. The combination of the influences of the temperature and type of adhesive show that it does not exist a general trend only about the influence of the temperature and the properties at various temperatures depend on the type of adhesive.73) and N‐tmel (p=0. The laboratory experiments confirmed that the ceramic material based on Al2O3 is fragile.M.12) and L1200 (p=0. temperature and resulted shear impact strength (Tab. Reduction of mouldboard plough share wear by a combination technique of hardfacing.003 <0. Costs for creating bond are lower against brazing.688459E+08 16 5. 2006. Prague.1 ANOVA test (p=0. At the temperature 60°C.m SS (the sum of squared deviations) degrees of freedom MS (mean square) F Intercept 2. 1). Increasing of its impact strength can be presupposed when applying the filler in the form of the rubber. 2010. Reaching the marginal state of the adhesive layer delamination the ceramic plate was broken consequently. The analysis shows the significant dependence among the adhesive type.4). (in Czech) [3] ČSN EN ISO 965. R.94). TAO/TA). Tribology International. So it is not possible to prove the decrease of the impact strength value with increasing temperature or contrary. 41 (8): 778‐782. The second disadvantage is the necessity to create firm bond and reliable bond. The advantage of this solution is the ecological aspect in minimizing the soil contamination by the elements Cr.710415E+08 273 3.133860E+08 98. KOSTIC S.46) and N‐MET. Y. Tribology International. Czech Standard Institution. . PANDAZARAS. Tribology International. 249: 821‐828. 54(4): 192‐198 [6] MEDVEDOVSKI. 42 (2): 171‐176. [10] OWSIAK. The influence of soil type. [9] NATSIS. JIRKA M. Development of methodologies for evaluation of wear‐resistant materials for mineral industry. 131 M. 2012 [8] NATSIS. Influence of local soil conditions on mouldboard ploughshare abrasive wear. [11] SARE I. Abrasive wear of high chromium Fe‐Cr‐C hardfacing alloys. Wear‐resistant engineering ceramics. 1997. CONSTANTINE A. G. ZDRAVECKÁ E.. A. 203‐204: 671‐678. E. 41(3): 151‐157. MÜLLER M. 1999. rate of work and tillage quality. R. R. CZ 23582 U1. Wear of symmetrical wedge‐shaped tillage tools.. soil water and share sharpness of a mouldboard plough on energy consumption. 1997. Wear. KUKLÍK V. Chotěborský . Research of Agriculture Engineering. 2007. Müller. 2008. Journal of Agricultural Engineering Research. G PAPADAKIS a J PITSILIS. Wear. 43(3‐4): 295‐308. M. [12] SUCHÁNEK J. Prague. Z. HRABĚ P. 2001. Soil and Tillage Research.. Abrazivní opotřebení materiálu (Abrasive wear of materials). [7] MÜLLER. PETROPOULOS a C.. 2008... R. A.. G. CTU. CHOTĚBORSKÝ. Apparatus for evaluation of shear impact strength of adhesive bonds.Unusual Possibility Research of Wear Resistance Increase in Sphere of Soil Processing Tools [5] CHOTĚBORSKÝ R. SAVKOVÁ J.. (HILS‐ Hardware in Loop Simulation) Before the identification of dynamic parameters. where it is reduced to minimum by using new 132 . Serbia. remains. Serbia 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 2 November 2012 / Revised: 14 November 2012 / Accepted: 16 November 2012 Keywords: (in causal order) Abstract: Electro‐hydraulic actuator Flexible nozzle Load simulator Servo‐distributor This paper presents the reasoning behind experimental simulation of dynamic behaviour of rocket engine flexible nozzle. Using a simulator does not require construction of nozzle within a rocket engine chamber. Usually. Project Engineer. ISBN 978‐80‐553‐1216‐3 INTRODUCTION constructions and sealing systems. actuator’s own frequency is important initial input in the control system synthesis process. development of linear or non-linear mathematical model based on the real. Faculty of Mechanical Engineering. These forces primarily influence own frequency of closed electro‐hydraulic actuator system. in this paper. complete nozzle construction and rocket engine chamber.e. suggestion is to design a load simulator that can realistically simulate intensity of actuator’s load. Still. which changes in time. prior to the identification of electro-hydraulic actuator system. stricter than in reality. University of Kragujevac. Positively. so simulation techniques become increasingly important. Electro‐hydraulic system for the simulation of dynamic behaviour of rocket engine flexible nozzle thrust vector control. Serbia PhD Mechanical Engineering. Sometimes. Standard solution in design practice is identification of dynamic behaviour.tk Manufacturing Engineering & Management The Proceedings Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control Dragan B. PPT‐Engineering. much unfavourable character of change in load. Since. This means that load intensity can be realistically simulated. This imposes a question of determining. Flexible nozzle is an extremely complex load to be mathematically modelled. is the identification. Besides. Assistant Professor. as an inter‐phase in electro‐hydraulic actuator systems design. Electro‐hydraulic actuator systems are characterized by severe non‐linear nature. its load. Based on this information. can be defined. Pršić DH. external friction for almost all loads is significantly bigger from the friction in hydraulic cylinder. In flexible nozzle. Citation: Nauparac DB. 2nd International Conference Manufacturing Engineering & Management 2012. In practice.e. that can be verified on the example of flexible nozzle. Miloš M. solely based on concentrated mass. Identification is performed on already built model of completely realistic load. mathematical model is essential in the design of electro-hydraulic actuator system. thus compensating for the lack of real flying conditions for testing. Pršić2 ‐ Marko Miloš3 1 MSc Mechanical Engineering. different type of analysis should be applied. work of actuator system with no saturation on control and no saturation on hydraulic cylinder stroke and selection of cylinder with two‐sided piston rod. as an inter-phase in the design of electro-hydraulic actuator system. P regulator should achieve satisfactory results (sinusoid change of actuator’s target position value). as well as the applicability of simple P regulator. it increases the level of actuator system’s damp. dominant is viscous friction that can significantly change over the time. mass is almost never loosely tied to the piston rod. so called. e‐mail: dnauparac@beotel. A general rule is that for the half of a bandwidth. a significant part of electro‐hydraulic actuator system’s non‐linear nature can be compensated by making a good choice of components of electro‐ hydraulic system. for the synthesis and analysis of its control algorithm. actuator system bandwidth can be immediately evaluated.net PhD Mechanical Engineering. frequency that is usually calculated. by generating adequate force in time. flexible nozzle is characterized by severe non-linear nature that cannot be precisely modelled. This is adequate criterion for testing an actuator system with a load simulator. measured responses of an actuator system. and load simulation can be performed with certain reserve on character of change in load. External friction’s nature is also non‐ linear. [1] It is more difficult to solve a problem of non‐linear nature of real actuator system’s load. Non‐linearity can originate from the very configuration of an electro‐hydraulic system and load. Electro-hydraulic actuator system sets in motion and controls flexible nozzle. in this problem. Among these components. Generating greater load intensity than expected in reality can compensate for not knowing the character of change in load.Contents lists available at www.icmem. In practice. This paper elaborates on justification for using adequate load simulator for testing electro-hydraulic actuator system. This means that the dominant friction is external and as a load. Previously stated confirms that when a direct mathematical modelling cannot result in a precise model. identification is relatively complex. loosely tied to an end of a piston rod. because it depends on real elastic forces and friction forces that change with a temperature. as a function of real drop in pressure in actuator. (2012). Associate Professor. as well as taking into count elastic forces between concentrated masses. come: servo‐distributor with zero lap. Belgrade. which gives an actuator system a non‐stationary character. Faculty of Mechanical Engineering Kraljevo. As a load to electro-hydraulic actuator. it has both positive and negative role. p. One of the technologies for obtaining missing information on actuator system. However. In reality. 132‐136. Nauparac1 ‐ Dragan H. advantage over real load (real flexible nozzle) is created. such as: load mass is perceived to be concentrated. Crucial is that simulation conditions. there is at least one other link to the environment. reduced or equivalent mass. while character of change in intensity cannot be precisely determined. on the example of the design of electro‐hydraulic actuator for rocket engine flexible nozzle’s thrust vector control. significant simplifications are used. actuator’s load cannot be a subject of un-modelled dynamics and unknown parameters. Previously described testing technology for actuator system is presented. By doing so. University of Belgrade. primarily due to its non‐linear nature. a load is presented with a several concentrated masses with appropriate elastic joints between them [6]. In the case of flexible nozzle. in the first place. while negatively. By doing so. i. only non‐ linearity of flow characteristic. since conditions identical to those during the flight cannot be obtained on the ground. i. from the envisioned. can be generated. it can be a cause of instability. First. and are being transferred from the chamber to flexible joint and nozzle. this paper separately EM Fig. is not possible to provide both a wide range of options for change in load intensity and adequate simulation of elastic forces. but the change in force is being observed when the piston rod speed changes in load cylinder. load is simulated via cylinder that is connected to actuator cylinder. there is a possibility to load an actuator cylinder with adequate forces (variable load) at given speed of actuator system. O63/36x200 O50/28x200 Fig. this type of a load can be defined as a non‐ideal spring. A Fig. because it requires a running rocket engine. L ac Fm DB Nauparac. defined through following equations. Separate pumps are used to power servo‐ distributor. meaning also a cheap. On electro‐hydraulic actuator. covered entire scope of assumed changes in load and broadening the scope in order to provide with guarantee for actuator robustness and control algorithm. 1. in paper [2]. If a non‐ linear identification is applied. construction. flexible nozzle’s dynamic behaviour. it is performed based on one input signal. joint stiffness and influence of real inertial load (reduced mass) are being verified on the very model. when expecting significant change in some of the load parameters. and inserted in the functions from Fig. suggested the initial modelling of flexible nozzle’s dynamic behaviour by using certain functions in MatLab together with experimental data from stress‐deformation diagram. 13. which is a big limitation.3 Functional scheme of electro‐hydraulic simulator 133 . In one load simulation configuration. Alternative to this concept would be a load simulator with pendulum. Second. 3 shows functional scheme of electro‐hydraulic simulator of flexible nozzle’s dynamic behaviour. 2 shows flexible joint characteristic character force‐angle after modelling. It is said average since nature of the object is such that a significant repetitiveness cannot be achieved. i. several different transfer functions will be obtained for different amplitudes of input signal. discusses hydraulic force simulator and force simulator with pendulum for flexible nozzle’s electro‐hydraulic actuator. the very identification process has couple of shortcomings. in much wider scope then it realistically happens on average. Third. Since maximal forces can be determined from experimental data for flexible joint. et al. it is irrational to conduct large number of real experiments with flexible nozzle. In mechanical sense.Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control FLEXIBLE NOZZLE ACTUATOR’S LOAD Flexible nozzle construction is shown in Fig. spectrum of forces can be created to load electro‐hydraulic actuator. relatively easy. control the cylinder that simulates load. i. Hence. this is relatively simple. but simulation of load force change in character. on flexible nozzle. [7] Having this setup.2 Static load characteristic after modeling. In this case. as well.e. but at the same time. In general.e. i. nominal values of variables around which the linearization was performed. When control synthesis results are confirmed in such situations. force simulator enables having. In the functional scheme it can be observed that the basic idea was to have servo‐distributor and actuator distributor.1 Schematic view of flexible nozzle construction. When that is the case. using data from [2]. 6. Its advantage is that certain elastic joints can be defined in structure. It should be pointed out that hydraulic simulator enables loading actuator with force oscillations that originate from pulsing operations of rocket engine. was proposed and block diagram in Simulink presented in Fig. Fig. Fig.e. a very complex one for mathematical modelling as a hydraulic cylinder load. MATHEMATICAL MODEL OF AN ACTUATOR AND SYSTEM FOR SIMULATION OF HYDRAULIC CYLINDER LOAD For the simulation validation of force simulator construction. if a linear identification is applied. THE IMPORTANCE CONSTRUCTION ax B h OF FORCE SIMULATOR Construction of a force simulator is very important when actuator load is flexible nozzle type. 5 shows position of force transducer that enables measuring real losses. a hydraulic simulator enables force simulation up to the sought intensity. a mathematical model. Flexible joint is characterized by high hysteresis that changes in time depending on temperature. primarily due to the friction in cylinders when simulating a force. Basic actuator system is being observed as positional. Mathematical description of this spring is not simple. such as real build‐in. certain influences of load structure. Group of authors. Fig. Nozzle is represented by a pendulum supported by elastic support structure – a flexible joint between nozzle and rocket engine chamber.. then change in speed and position. Nauparac et al. so that for mathematical simulation following equations are obtained in the form of: p1 p2 (Q1 AT x ) VTc10 VTc 02 (5) (AT x Q2 ) Equations (5) are implemented in block diagram for simulation in Fig. ( mTc mLc ) x p1 AT p L AL FFT FFL FFT FFL p1 AT p L AL ( mTc m Lc ) x (1) FL p L A FFL FFL FL p L AL Based on (1) and (2) equation for force is obtained: (2) FFT ( FL p L AL ) p1 AT p L AL ( mTc m Lc ) (3) Fig. in order to enable generation of forces that correspond to the real load. Simulink model x AT AL p L2 p1 pL1 LOAD CELL p2 m TC m LC Fig. knowing that when an actuator system acts on the load.5 Build‐in force transducer Mathematical model of a load simulator for an actuator is based on classical linear description [5].V V AT x dt Tc1 Tc10 dt dV V dp Q2 Ql 2 Tc 2 Tc 2 2 . under the assumption that internal leaks in cylinder (Ql1 i Ql2) do not exist. but pendulum and Q1 Ql1 (4) 134 .x. Fig. 6 is developed is: (7) m eq x p1 AT p L 2 AL 2 p 2 AT p L1 AL1 FF sign ( x ) In global approach. In that case load cylinder is expected to have a greater bandwidth for the force than the actuator cylinder. equation for flow: MATHEMATICAL MODEL OF AN ACTUATOR AND SYSTEM FOR SIMULATION OF MECHANICAL PENDULUM LOAD dVTc1 VTc1 dp1 . following equation in final form is obtained (6): p L1 p L 2 VLc10 VLc 02 (QL1 AL1 x ) (6) ( AL 2 x Q L 2 ) Actuator cylinder (test cylinder) and load cylinder motion equation. inertial load component can be easily changed. 6. [6] so the following is obtained: .B.D. since those are the most important factors for provision of the greatest possible bandwidth for force.4 Load simulator with pendulum. By modelling load cylinder the same way as the actuator cylinder was modelled. 4 shows the constructing idea of force simulator with pendulum. Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control Previous equations (1) – (4) can be simplified. In this model.6 Block diagram of simulator’s mathematical model with load defined via cylinder FFT p1 AT ( mTc m Lc ) FL Actuator.VTc 2 VTc 20 AT x dt dt Fig. There are not many concentrated masses. based on which a complete block diagram in Fig. as well as that the constant volume inside a cylinder is significantly bigger than variable VTc1(2)0>>AT. the fastest is the change in forces. This fact needs to be taken into consideration when choosing the load cylinder dimensions and servo‐distributors. M. Change in pressure in a load cylinder can be given in many forms. But together with pendulum type load simulator. D. 11 and 12 show the simulation results of controlled actuator when a flexible nozzle as a load was modelled by equivalent pendulum and when a character of spring load changes as an ideal spring (Fig. 8). Mechanical part of a load on actuator is modelled. through adequate argumentation and results from mathematical simulations. 9). but only a change in intensity of force (Fig. Design Criterion to select adequate control algorithm for electro‐ hydraulic actuator applied to rocket engine flexible nozzle thrust vector control under specific load.Nauparac.Pršić. REFERENCES [1] [2] Fig. FME . 14 th ITI.10 Response in the case of the insensitivity zone existence [3] 135 D. Fig. 9. (All is open loop control for different desired angle of nozzle.Miloš.N. could not simulate the entire load dynamics.12 Change in response when viscous damp in spring is reduced Provide with constant common speed of piston rods. Fig. Design Selection of Adequate Control Algorithm for Electro‐hydraulic Actuator Applied on Rocket Engine Flexible Nozzle Thrust Vector Control. D. Popov.7 Test cylinder’s speed change for oscillating change in pressure Fig. The model of hydraulic simulator has very high nonlinear nature and fine adjusting is necessary.Miloš. 10. of +/‐ 20% of predetermined speed.) Fig. (closed loop control) of load cylinder and actuator.9 Change in referent angle (Fir) and angle (Fi) when an ideal spring is observed Acknowledgement Research of this paper is result of the national project financed by Serbian Ministry of Education and Science (TR 35044). October 2011. can be completely modelled with all elements of non‐ideal spring type load (Fig.Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control DB Nauparac. Masinostorenie. when there is a saturation in static characteristic (Fig. which is one of the basic requirements in load simulation by intensity. 6 and Fig 7). see Annex and then the model in introduced in Simulink model. 11) and with the change in viscous friction component (Fig.11 Response in the case of saturation of spring static characteristic Fig. Dresden. when there is an insensitivity zone (Fig. dynamic behaviour of an actuator with a flexible nozzle load type. Moskva. D. 12). 9‐12) Fig.Nauparac. It is clear that only one type of load simulator – a hydraulic cylinder. M. movable actuator mass (piston and piston rod) are modelled as a single mass. D. Dinamika i regulirovanie gidro‐ pnevmosistem.Pršić. et al. 10). 1976. first through bond graph (Fig.8 Bond graph of pendulum as mechanical simulator of load CONCLUSION This paper presents the justification of steps in experimental load simulation for an actuator system. Symposium. 2009 . "Bond Graph Modeling In Simscape". Hydraulic Servo‐systems. Identification and Control.Scott. March 2013. The MathWorks. A. page 31‐37. September 2009. Nedić N. Dubonjić Lj. H..E.A. 2012. Accepted for printing. D. International Journal of Mathematics and Computers in Simulation. T. Alborg University. 239‐247 Simscape 3.Henriksen.D. Pršić D. Djordjević V. Hydraulic control systems. Wiley.. M. 41. Vol.A.Jelali.Kroll. No 1.. Merrit. pp. Design and Construction of a Facility for Testing Friction in Hydraulic Cylinders (student report).B.E.Schinstock. Language Guide. [4] [5] [6] Electro-Hydraulic System for the Simulation of Dynamic Behaviour of Rocket Engine Flexible Nozzle Thrust Vector Control Transaction. Volume 6. Nauparac et al. Modeling and Estimation of Electromechanical Thrust Vector Control of Rocket Engine [7] [8] [9] 136 D. Issue 2. Modeling.Haskew. New York 1967. Springer D. Aalborg. Belgrade.. tomasz. Laser interferometry systems could offer superior accuracy and very high dynamic range in displacement measurements. The maximal velocity of tracked translation is up to 7m/s. nowadays they are becoming an attractive alternative for linear scales in many industrial applications. 137‐140. Analogue sine and cosine or digital quadrature signals are generated by the feedback system. electronics error and nonlinearities are the largest contributors to the instrumental error group. (2012). There are discussed errors caused by frequency stability of laser source. Error [μm ] A helium‐neon laser tube with digitally controlled stabilization loop and ferroelectric crystal was used for the 137 2 Geometry . et al. Due to lowered prices.podzorny@pwr. but it is hard to implement those techniques in the industry. In this work there is presented an approach to use innovative error compensation techniques combined with high performance digital processing devices to provide accurate feedback signal for positioning applications. Instrument 0 4 6 8 Environment 10 12 14 Fig.wroc. Displacement measurements are performed by high linearity laser interferometer with resolution of 100pm..1 Relation between the main error groups for 10m displacement. like Lasertex or Renishaw. The Abbe error was calculated with 10 μrad and 0. Abbe error minimization due to direct measurement of an object and high dynamic range are the main advantages of laser interferometery devices. The cosine error was estimated using an assumption that measurement beam changes position according to the reference beam by 5mm on the whole measured distance. by the quality of optical path alignment and by environment conditions. They can be grouped into: environmental errors. Error cancelation and linearization techniques allow to obtain decent accuracy for various applications. According to this analysis software and hardware methods to minimize error sources are proposed. It is also possible to provide decent positioning parameters for nanotechnology applications that need the resolution and accuracy in the range of few nanometers. geometry errors and instrumental errors. Achieved accuracy for stage positioning is below 1μm per 10m for non-vacuum applications. ERROR BUDGET IN LASER INTERFEROMETRY SYSTEM The relation between uncompensated errors caused by environment. In general the environmental error group is the main contributor to the overall error. Fast signal processors and efficient algorithms enable accurate measurements in a typical industry environment. Despite the fact that the instrumental errors group is the lowest contributor to the overall error. This is mainly caused by fast development of machine and nanotechnology industries. 2nd International Conference Manufacturing Engineering & Management 2012.5 ppm at long distances.1mm of Abbe angle and offset respectively between a target and a retroreflector.tk Manufacturing Engineering & Management The Proceedings Laser Feedback System for Accurate Sub-Micrometer Positioning Tomasz Podżorny ‐ Grzegorz Budzyń1 ‐ Janusz Rzepka1 1 Institute of Telecommunication and Acoustics.pl ARTICLE INFO: Category : Technical Note Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 5 November 2012 Keywords: (in causal order) Abstract: Metrolgy Interferometry Micrometry range measurements Nanometry range measurements Positioning This paper presents an approach to a laser interferometry based feedback systems for accurate sub-micrometer range positioning. Achieving the accuracy in this range is a very demanding task. Applications requiring fast and accurate positioning in a sub‐micrometer range are becoming more and more popular. The uniformity of the target retroreflector error was calculated for optics with quality of λ/10. Wroclaw University of Technology. Abbe [3] and uniformity errors of retroreflector or mirror. Error compensation is a very important task in the industry applications where it is impossible to maintain stable conditions during measurements. The geometry errors have similar properties but they are lower than environmental errors. According to leading manufacturers of such devices. It was presented by Joo et al [1] that there is a possibility to reduce error even to the value of few picometers. For geometrical error there were taken into account cosine.5 ppm to 1. There is presented error budget for a heterodyne setup of the laser interferometer and accuracy is estimated. it is possible to measure displacements with accuracy in the range from 0.Contents lists available at www. though. Laser Feedback System for Accurate Sub‐Micrometer Positioning. especially in a long distance and long term measurements. Errors were calculated for 10m displacement and deadpath set to zero. Janiszewskiego 7/9. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Introduced methods allow to obtain accuracy in the range of few micrometers at long distances for machine industry where high dynamic range is expected. pressure and humidity change respectively by 1 °C. Presented work introduces three main groups of error sources which are significant contributors to overall accuracy of the system. in the region of few nanometeres is has to be taken into account. p. 1 hPa and 10%. 50‐370 Wroclaw. Every group is analyzed and most significant errors are indicated.icmem. There are many error sources affecting the accuracy in the displacement measurement. Laser stability. It is even possible to measure displacements with a resolution of few picometers using interferometry devices. Those signals are automatically compensated by digital signal processing. Citation: Podżorny T. geometry and instrument is presented in the figure 1. In the nanometry range nonlinearities are subject of interest of many research groups. The environmental error was calculated according to Edlén’s equation [2] with an assumption that temperature. According to the findings included there.02 0. The electronics error in the overall instrumental error is in the range of 0. The parasite beams results from frequency mixing and their value is determined using circle fitting algorithm. They were estimated to be in the range of 15nm. heterodyne and homodyne setups [6.001 ppm [4]. because the laser beam is reflected almost in the same point of the optical component. The noise level was in the range of 0. half and quarter wave plates and the laser source. The controller unit is built using FPGA logic to provide fast and accurate 138 .02mm on the whole measured distance. frequency and polarization mixing errors. Motion controller unit is updated with compensated measurement data at 100kHz rate. 7.025 0.T. The instrumental error is a concern especially in dynamic measurements. The presented heterodyne laser interferometer based feedback system provides compensated analogue sine and cosine or digital quadrature signals with configurable resolution. Amplitudes of parasite orthogonally and parallel polarized beams are indicated respectively by α and β.2 Relation between the main error groups for 0. Instrument 0 0. Error [μm ] Fig. Error caused by nonlinearities has cyclic characteristic.005 0. Error sources caused by the environment and geometry can be also neglected in the short term and short distance measurements. This unit is presented in the figure 4 and is multiplied for ISA and ISB signal paths. The cosine error was calculated using an assumption that measurement beam changes position according to the reference beam by 0. The modified setup is very difficult to use in industry conditions. errors caused by electronic circuits and algorithms.01m. It is possible to compensate of cyclic error in a real time without modification of the optical setup.3 Block diagram of the presented feedback system. Podżorny et al. because it compensation has to be performed internally in the measurement device. In the figure 3 there is shown the block schematic of presented technique. 8].2nm. The frequency stability for short and medium averaging times was in the range of 0. According to the presented results instrumental error is not applicable for long range measurements. The electronics error value was estimated to 0.01 Geometry 0. In the figure 2 there is presented relation between error groups for 0. Presented work introduces methods that help to eliminate those errors as low as it is possible in present measurement conditions. Introduced method is based on the digital signal processing. However. There are introduced techniques for minimization of all the above mentioned error sources for non‐vacuum applications. The environmental and geometrical errors start to dominate over the instrumental error in the overall accuracy budget in displacements exceeding 0. All the assumptions made for figure 1 are valid except cosine and target uniformity errors. More feasible approach is based on digital signal processing and it is used for both. Presented method is very effective but it requires a more complicated optical setup.015 analogue and digital signal generation. Errors are automatically compensated in the real time using software and hardware blocks. Experimental results presented by Joo et al [1] revealed that cyclic error was compensated to the level of 20pm. First technique is based on an optical setup which directly compensates parasite effects due to modification of the classic heterodyne configuration. quadrature measurement signal can be expressed by two equations: C C I SA AB cos2f D t A B (1) 2 2 C C I SB AB sin 2f D t A B (2) 2 2 where A and B are amplitudes of orthogonally and parallel polarized beams respectively. Approach presented in this paper is based on circle fitting technique introduced in the previous work [6]. 1/f noise and sensitivity to laser power variation.001ppm and can be neglected for displacements up to 10m. It can be expected that error resulting from nonlinearities achieve a value up to 20nm [6]. Obtained values are used to drive cyclic error compensation unit implemented in the hardware. such as polarizing beam splitters. the instrumental error is the most important. It is related to the quality and alignment of polarizing optical components. Those techniques implement circle or ellipse fitting algorithms. The most significant factors that increases the instrumental error in the heterodyne configuration are frequency and polarization mixing effects. The laser frequency stability error is in the range of 0.01m displacement. The Environment 0. The heterodyne configuration exhibits larger nonlinearity effects that a homodyne configuration [5] and they are the largest contributor to the error in the instrumental error group.2nm and its value is independent on the displacement value.2 nm. Electronics errors are mainly caused by noises and nonlinearities from electronics circuits and algorithms.035 Fig. It is the lowest contributor to the overall error but other error sources can be eliminated by proper alignment of the measurement path and maintaining stable environmental conditions. The target uniformity error was also reduced.01m displacement. Main contributors to that error are nonlinearities and noise level of analogue and digital algorithms blocks. Signal processing algorithms were simulated and it revealed that the nonlinearities were in the range of 0. Offsets are corrected using offset amplifier (OFF) through digital to analog converter (DAC) and amplitudes by variable gain amplifier (VGA). Heterodyne configuration of the laser interferometer eliminates effects like offsets and their drift.03 0.1nm for the presented equipment. Minimization of those errors in general relies in a responsibility of the user of the laser interferometry measurement system. ERRORS COMPENSATION TECHNIQUES The instrumental error group consists of laser frequency stability error. Laser Feedback System for Accurate Sub-Micrometer Positioning experiments. There are two main approaches to eliminate cyclic error in the heterodyne configuration. 2 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 -0. It is not possible to notice small misalignment on a short axis. Wavelength of the laser source was compensated using the Edlén’s equation and data from temperature.6 Laser interferometer nonlinearities measured without signal correction.1hPa accuracy pressure measurement was obtained using integrated silicon pressure sensor with temperature compensation. 139 10 .08ppm. Expected 0.6 -0.01m measurement length results in 3μm error. but it is feasible to use additional sensors to measure temperature of the components in the measurement path and compensate their length change in a present temperature. In the figure 6 there is presented error with nonlinearities compensated by introduced technique. Fig.1nm resolution. The interpolation results in 0. It generates various standards of signal for positioning applications. In the figure 5 there is presented error caused by nonlinearities of laser interferometer with nonlinearity correction block deactivated. The Abbe error is related to the alignment and it is constant over the entire measurement length.5 Laser interferometer nonlinearities measured without signal correction. The sampling rate of the system is 100kHz and it is able to track the displacement up to 7m/s translation velocity. Alignment with such accuracy resulted in reduction of the cosine error below 1nm for short displacements. 4 Block diagram of the hardware circuit for cyclic error compensation. air pressure. circuit and 12‐bit analog to digital converter. Achieved accuracy was in the range of 0.Laser Feedback System for Accurate Sub-Micrometer Positioning T. The alignment can be monitored in the real time over USB interface. In this work only air refraction index changes are taken into account.5mm over 0. Also the target uniformity error appears in the same condition. Temperature measurement were performed using 18‐bit analog to digital converter.8 0. MEASUREMENT AND SIMULATION RESULTS Presented techniques were adopted to the heterodyne configuration of a laser interferometer system. In presented work there was used position sensitive device (PSD) and conditioning electrical circuit for orthogonally polarized reference and measurement beams. pressure and humidity sensors.4 -0. Direct measurement of the object in the interferometry measurements and proper alignment of the retetroreflector to the measured axis allow its minimization. Interpolated data is corrected using environmental data and feed to the motion controller unit. It was possible to detect position change with accuracy better than 5μm. It is caused by laser’s wavelength dependence on the air refraction coefficient that is related to environmental conditions (temperature. Temperature measurements were performed by microcontroller using multiple point calibration table and averaging. The measurement system uses 12‐bit phase interpolation algorithm implemented in the digital processing unit. Humidity measurement was based on digital integrated sensor with applied external averaging. CO2 content) and temperature expandability of components in measurement path. precise low drift current source for producing a reference voltage over precise low ppm resistor and voltage across PT1000 sensor. The velocity limit and the resolution are correlated. In the figures 5 and 6 there are presented accuracy improvement by nonlinearity correction in instrumental error group. but to decrease error bellow 1nm. The orthogonal position change of the target by 0. It is also possible to reduce the cosine error by using second approach. The only problem with reducing those two errors is related to the accuracy of the alignment. It is possible to increase the velocity limit with decrease of the resolution and vice versa. Reduced environmental error caused by the air refraction index change was in the range of 0.6 Error [1 nm] 0. Podżorny et al. it has to be measured with 1% accuracy. Data from external environmental sensors is collected during the measurement and the result is compensated in a real time. According to the presented static measurements compensated nonlinearity error is lower than 1nm. Humidity according to Edlén’s equation has the lowest impact on the wavelength change. because of target mirror flatness uniformity and reflection point change.8 Distance [10 nm] Fig. humidity. precise signal conditioning 16 14 Error [1 nm] 12 8 6 4 2 0 -2 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Distance [10 nm] Fig. 0. Measurements were also obtained using microcontroller with stored multipoint calibration table and averaging.05°C. The cosine error appears when measurement beam changes its position according to the reference beam orthogonally to the measurement axis.2 0 -0. Measurement results were collected over USB link on the personal computer and also the configuration was performed in this way. It is possible to minimize that error using mirror’s surface mapping or reducing orthogonal movements of the stage to the measurement axis by proper alignment of the optical path.4 0. Data from analog to digital converter is also feed to the linearization algorithms and calculated results are used to improve signal quality. The main contributors to the geometrical error in the interferometry measurements are the cosine error and the target uniformity error. geometrical error consists of the Abbe. cosine and target uniformity errors. In that case also target uniformity error was significantly reduced. Non‐vacuum applications require also environmental error reduction. . According to the presented findings errors caused by environment and geometry were the biggest contributors to the overall error. [7] Eom T. Rzepka J. 2005. Issue 17. Choi H. Buice E.. geometrical and instrumental error sources. [6] Budzyń G. Vol. . Su C. Environment REFERENCES 0 0. “Nonlinearity in measurements of length by optical interferometry”. Kurosawa T.0025 Error [μm ] Fig..2 0. B. Gonda S. S. 13.3 Geometry 0. Sci.T.1 0. [3] Abbe E.7 Relation between the main error groups for 10m displacement. “A Universal Laser Interferometer For High Linearity Measurements”. Optics Express.5 displacements up to 10m in a non‐vacuum applications.. PhD Thesis. “Optokomutacyjna stabilizacja lasera dwumodowego”.1μm.01m displacement. Lee K. M. “The Refractive Index of Air”. 2(2):71‐80. H. Wrocław University of Technology. There could be noticed significantly reduction of instrumental error impact on overall accuracy. Huang Q.001 0. S. Meas. K..8 0. N.. In this case RSS error value was reduced below 2nm.1966. “Messapparate fur physiker”. Presented research revealed that it is possible to reduce the overall error below 0... 44.. Instrument Geometry Acknowledgement This work was co‐financed by European Union within European Social Fund. 2006 [5] Wu C. H. 10:446‐448. Choi T. Zeitschrift fur instrumentenkunde. 1890. 1995.002 0. Laser Feedback System for Accurate Sub-Micrometer Positioning Instrument 0 0. W.1μm for 140 [1] Joo K. Effective and real time error reduction in the laser interferometry systems is required for fast and accurate feedback applications. “A simple method for the compensation of the nonlinearity in the heterodyne interferometer”. Applied Optics..4 0.7 0. Lee S. [8] Keem T. Technol. Further error minimization is still possible by using better environmental sensors and more accurate beam position detection unit. Technol.9 Error [μm ] Fig.. Podżorny et al.6 0. In the figure 7 there is presented relation between error groups for 10m displacement. Vol. Issue 2. [2] Edlén B. Y. 10th International Conference on Vibration Measurements by Laser and Non Contact Techniques. Root square sum (RSS) of those errors sources yielded overall error below 0. “High resolution heterodyne interferometer without detectable periodic nonlinearity”. Ellis J. [4] Budzyn G. Podżorny T. 2010. D.0005 0. The environmental error was reduced using introduced environmental block with external sensors. Their minimization is a very important and difficult task for demanding positioning and measurement applications. CONCLUSIONS Accuracy is significantly affected by environmental. 18.. The relation between error groups for 0. 2002. Sci.. Wrocław. Misumi I. Metrologia.. real‐time method for removing the cyclic error of a homodyne interferometer with a quadrature detector system”.8 Relation between the main error groups for 0.. “Simple.01m displacement is presented in the figure 8. Munning Schmidt R. Environment 0. 7.0015 0. Spronck J. Meas. S. The geometrical error was reduced by proper alignment of the optical path with measurement and reference beams monitor.. AIVELA 2012. which was reported to be independent on the pulse duration. The most commonly used dielectric fluid is kerosene. which being a hard material poses difficulty in machining through conventional methods. G. it is found out that the developed hybrid machining process results in increase in MRR and reduction in TWR. The pulse can be defined in terms of the gap voltage (Vg). This work aims at developing a hybrid process using both liquid and gas as dielectrics to check the feasibility of the process and to study the effect on tool wear rate and material removal rate. Having known that conventionally the use of kerosene as a dielectric in EDM process has never been questioned and that EDM can be achieved in gas. Soni et al (1994) have observed an interesting phenomenon related to providing rotary motion to the tool electrode. pulse‐on time (Ton) and pulse‐ off time (Toff).. In this work. EDM in gas is a new machining method which was proposed by Kunieda and Yoshida (1997). Hauzkhas. Indian Institute of Technology Delhi. and consequently improves MRR. Empirical models for MRR and TWR have been developed for the hybrid machining process. discharge current (I). Work piece is characterized by energy‐dispersive X‐ray spectroscopy (EDX) (Fig 1). i. The gap distance cannot be independently controlled on this machine. Electrical discharge machining (EDM) is generally carried out in a dielectric liquid. The experiments are conducted following Taguchi design of experiments. Their work showed that high velocity gas flow through tool electrode reduces debris reattachment after a spark. discharge current (DC). the use of a tubular electrode with very thin wall (< 0. EXPERIMENTAL SETUP All the experiments have been conducted on a Z numerically controlled (NC) oil die‐sinking EDM Machine.e. The liquid dielectric has decisive role in the performance of the process as it serves as the cooling medium in the discharge gap and flushes machining debris out of the working gap.: Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric . 2nd International Conference Manufacturing Engineering & Management 2012.5 cm) of high speed steel (HSS). Further. duty factor (d) can be represented in terms of the pulse on and off times as: (1) d Work piece is taken as square block (size‐1. rotation/planetary motion of the electrode and high‐speed gas flow. pulse-on time (Ton) and gap voltage (V). The electrode which may be considered as a cutting tool is generally made of a conducting material such as brass or copper. Singh. In this machine.3mm). EDM in gas is a new machining method which has a great advantage of very low level of electrode wear which is reported to be independent of the pulse duration. Citation: Prakash. They have shown that MRR increases with speed because of centrifugal force which helps to flush out debris. The debris reattachment is much lower for a thin walled tube and this increases the MRR. the Z axis is servo controlled and can be programmed to follow an NC code which is fed through the control panel. (2012).tk Manufacturing Engineering & Management The Proceedings Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric Animesh Prakash ‐ Gorvendra Singh 1 Mechanical Engineering Department. The greatest advantage of EDM in gas is the very low level of electrode wear (almost zero).07 – 300 kHz. Tool electrode is made up of a 141 . Kunieda and Yoshida (1997) also observed that rotary and planetary motion given to tool electrode also serves the purpose of dealing with the problem of short circuiting that might occur in EDM with gas. This study takes into account the influence of three design factors. 141‐148. India ARTICLE INFO: Category : Original Research Paper Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 5 November 2012 Keywords: (in causal order) Abstract: EDM Material removal rate Tool wear rate Taguchi DOE EDM has been conventionally carried out in a liquid dielectric. They observed that the performance of EDM using gas (air and oxygen) can be better than that with a liquid dielectric under some especial situations. A. The servo control feedback is based on the gap voltage between the tool and the work piece electrodes. Signal/Ratio analysis and Analysis of variance calculations have been done to obtain the optimal value of design parameters. p. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Electrical discharge machining (EDM) is a non‐ conventional process of machining of electrically conductive materials by using precisely controlled sparks that occur between an electrode and a work piece in the presence of a dielectric fluid.. All three axes have an accuracy of 5μm. The same was verified by Mohan et al (2002) in their experiments. we are intrigued to develop a hybrid process of EDM employing both liquid (kerosene) and as (compressed air) as dielectrics with the objective to study the effect of various machining parameters on MRR and TWR. An additional parameter. The power supply system produces a DC pulsed power in the frequency range of 0. New Delhi‐110016. thus considered to be effective in flushing. The X and Y axes are manually controlled. Material removal rate achieved with oxygen was higher than that achieved with air (55%) and EDM oil (21%) and it is suggested that the heat generated by oxidation is responsible for the increased MRR. EDM has great advantage in machining a work piece with a special shape or in machining hard material. the efficiency and the accuracy of performance have been found to improve when a forced circulation of dielectric fluid is provided. The pulse has been idealized by considering the pulse delay time as negligibly small.icmem. negative polarity of the electrode.Contents lists available at www. to obtain optimal tool wear rate (TWR) and material removal rate(MRR) and to evaluate the effect of introduction of air on surface integrity. Apart from these Teflon pulleys.1 shows that that use of air as dielectric results in increase in MRR. The power rating of the motor is 0. (c))). (b). (c)) and TWR (Fig. To incorporate the rotation of tool. 4. decrease in TWR and also reduction in percentage electrode wear.5 mm) which has been made hollow to allow the passage of compressed air. the design factors and response variables used in the experimentation will be described. The pressure range of the pressure regulator is 10 bar. The compressed air is delivered to the unit by a compressor fitted in the laboratory. In this section. The ratio of the diameter of pulleys is 5:1 so that the rotary motion is amplified by a factor of 5 making the tool to rotate at 300rpm. discharge current (DC). surface studies are done to evaluate the effect of introduction of air on surface integrity.6 MPa. Further set of experiments were carried out keeping one of the parameters among gap voltage. experiments are conducted to study the effect of various machining parameters on MRR and TWR. and discharge current constant at the average level and varying the remaining two parameters to the four levels as selected in design of experiments.A.003 horse power. a comparative study of EDM is done with one case using only kerosene as dielectric and the other case using both kerosene and compressed air as dielectrics. In the experimentation. A comparative observation of MRR and TWR in the Table 4. The trends clearly depict that increase in MRR and reduction in TWR is achieved by employment of air along with kerosene in the EDM process. Further. rotary motion has been provided to the tool electrode. In the fully assembled setup (Fig. Nozzle connection is done on the tool for the supply of compressed air at 0. Rotary motion has been found to improve the material removal rate (MRR).1).1 Design parameters Parameter Discharge Current A Pulse on time (μs) Gap Voltage V DESIGN OF EXPERIMENTS The present work uses Taguchi method for conducting the experiments and the analysis of the results hence obtained.2(a).3(a). Fig. Singh Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric Methodology Based on the above mentioned design factors. material removal rate (MRR). 2]. pulse on time. G. A motor is used for providing the rotary motion to the tool required for experiments involving introduction of air. A flow control valve is used to adjust the rate of gas flow as per the requirement of experiments. 2). 4. copper pipe with thin wall (thickness ‐ 0. and percentage tool wear rate (percentage TWR) which are defined as follows: TWR MRR percentage TWR ∗ (2) (3) Level 2 Level 3 Level 4 3 4 5 6 100 200 300 400 40 50 60 70 Fig. compressed air is kept at a constant pressure of 0. Further. Prahash.2 Experimental set up RESUTLS AND ANALYSIS The MRR. Speed of the motor is 60 rpm with a torque of 3Kgcm. connecting hoses and rubber V belts are used for completing the experimental setup. The air then flows through the flow control valve which sets the flow rate as per the requirements. pulse on time (Ton) and gap voltage (V) are selected as design parameters which are then varied to four levels (Table 1) resulting in a L16 orthogonal array of experiments. A pulley is press fit onto the tool electrode which is rotated with the help of a belt connecting to the pulley on a motor shaft. (4) 142 Level 1 . it is held in a bearing which itself fits inside a tool holder having a step hollow passage of 3. TWR and percentage electrode wear are calculated for both the cases: L 16 set of experiments using kerosene only and using both kerosene and compressed air (Table 4. The hose is then connected to pressure regulator which is used to provide compressor air to the setup at desired pressure. before finally reaching the tool orifice. A wooden stand is used for fixing the motor and the stand is itself fit onto the machine bed. The observations are pictorially displayed for MRR (Fig. This behavior can be explained by the effect of spindle rotation on the discharge phenomenon [1. Signal / Noise (S/N) ratio analysis and Analysis of Variance (ANOVA) tests are then used for optimization of process parameters to obtain optimal TWR and MRR and to identify the significant parameters. the compressed air coming through the nozzle and the kerosene simultaneously are used as dielectrics in the machining process.2 cm diameter step. (b).1 EDX of HSS Tab. Response variables selected The response variables selected for this work are tool wear rate (TWR). respectively. Design factors selected In this work. Finally.6 MPa and the rotational speed of tool at 300 rpm. Empirical models for MRR and TWR will be developed by performing a design experiment based on the central composite design of experiments. A pressure regulator with range of 10 bar is used for sending compressed gas to the tool electrode in a controlled manner. 364207 10 0.022600 1.000333 0.600000 0.408451 39.000200 0.000267 0.032520 78.000467 0.008333 5.000267 0.018200 1.060606 57.264317 64.697987 0.020467 2.370072 8 0.000333 0.004933 9.021200 2.590674 0.435897 66.956521 58.018400 1.808989 4 0.471760 11 0.577400 13 0.684210 51.000333 0.011867 2.439024 Using kerosene and air TWR MRR Percentage (g/min) (g/min) TWR 0.027933 1.515723 0.000133 0.015133 0. Singh Tab.000467 0. Fig.018067 1.000200 0.010400 2.015333 3 0.000267 0.020067 1.931596 0.020733 1.247191 60.074866 0.000400 0.021800 1.294498 56.090909 0.000267 0.000133 0.000467 0.107011 52.111111 68.474926 48. Discharge Current (Ton = 250μs) 143 .670644 0.000200 0. Discharge Current (Vg=55V) Fig.177777 7 0.000333 0.281553 0.022467 1.000333 0.000600 0.534759 2 0.223242 45. Prahash.008867 5 Increase in MRR (%) Reduction in percentage TWR (%) 52.030533 1.000000 63.000067 0.276643 16 0.564103 0.400000 58.000333 0.098901 20. Analysis Using Signal/Noise (S/N) Ratio parameters and effects of various factors on the two Analysis using S/N ratio is done to obtain the optimal response variables MRR and TWR. No.000267 0.328904 20.171309 14 0.959544 9 0.020600 1.286174 41.869565 47.000200 0.000467 0.000533 0.888889 25.333333 60.316602 0.017267 2.590405 4.000333 0.768115 12 0.026600 2.2 Design parameters Experiment 1 Using kerosene only TWR MRR Percentage (g/min) (g/min) TWR 0.009933 4.698324 68.008200 2.459459 0.012867 2.215686 55.Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric A.48368 53.528384 0.000467 0. G.021000 1.440922 23.281938 6 0.023667 1.015000 0.086956 0.086957 38.363636 59.012467 0.681520 S.000533 0.4 MRR vs.000400 0.3 MRR vs.500000 0.269841 36.005013 0.181818 53.928571 55.000267 0.023133 1.005133 9.105633 15 0.511278 0.013333 2.000467 0.881057 26.000133 0. 5 MRR vs.6 TWR vs.5A) 144 . Discharge Current (Vg=55V) Fig. Gap Voltage (DC =4.1 10 log10 1 N ∑ 1 y2i (5) Fig.5A) Analysis for MRR Since material removal rate is desired to be maximum.8 TWR vs.A. Gap Voltage (DC=4. Discharge current (Ton=250μs) Fig. G. Singh Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric Fig.7 TWR vs. Prahash. equation corresponding to larger is better condition is chosen and S/N ratio for MRR is calculated using equation 4. voltage gap while effect of pulse on time is insignificant. G. While using kerosene only as dielectric.4) for kerosene only and. The values of square sums obtained from ANOVA calculations are used to plot pie chart (Fig 4. It implies that using level 4 of current gives maximum MRR for both the cases. 6 A.e.2. analysis of variance (ANOVA) is done to determine the parameter which is most affecting the result of experiments i. From the average S/N ratio for each parameter at every level.10 Percentage contribution of design parameters to MRR and TWR 145 With With With With kerosene kerosene kerosene kerosene and air both only and air both only 6A 6A 3A 3A Pulse on Time 400μs 400μs 100μs 100μs Voltage 70V 70V 40V 40V . then comes Current Fig. Tab. contribution of discharge current lowers while voltage gap and pulse on time gain significance. from Table 4. discharge current is the most important parameter.2) as the level for which S/N ratio is maximum.9 S/N Ratio and Means plot for MRR Main effects plot for S/N ratio and Means are drawn for MRR (Fig.Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric A. optimal value of parameter is identified (Table 4. Prahash. that current becomes less significant and pulse on time and voltage becomes important. the optimal value of current in case of MRR for both with and without air cases is level 4 i.4.5) which gives the percentage contribution of each parameter on the response variable MRR. On employing air as well in the experimental design.e. the parameter which significantly affects the material removal rate. Singh Fig.3 Optimal value of parameters for MRR and TWR Parameter Optimal Value for MRR Optimal Value for TWR Further. For example. It is probably due to cooling and the flushing as well as oxidizing effect provided by air. kerosene and air both experiments. 5: most significant parameter for TWR. The final Since tool wear rate is desired to be minimum. ΔY=fα/2.000005 Regression analysis Vg (8) On analysis of the experimental data obtained from the Figure 15. Singh Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric there are less than 0.2) at the level for which S/N ratio is to have some errors.38 which imply that the model is significant. Prahash. Further. From the average S/N ratio for each The model developed for MRR of hybrid process is bound parameter at every level.3: S/N ratio for TWR is calculated using equation 4. based on a two‐factor interaction model. the error present in the model cases is level 1 i.6) for kerosene only and. According to analysis. G.000287 +0. gap voltage and pulse on time gain significance upon use of air. 16 and 17 show the response surface diagrams Taguchi design of experiments. the the percentage contribution of each parameter on the obtained model F‐value of 44 implies that the model is response variable Similar to the case of MRR.00137 + 0. TWR (Fig. from Table 4. the compressed air as dielectric error calculated for the model of TWR using equation 4. significant.DF√Ve (9) Regression analysis for MRR A two‐factor interaction model was found to be the most suitable model based on the ANOVA sequential sum of squares test. the optimal value of parameter is identified (Table 4.4: Using F table for calculating the f – values of current in case of TWR for both with and without air required in the expression. 3 A. current gives less TWR for both the cases. This error is calculated by using the maximum.4.2 the optimal value equation 4. The final regression equation for TWR in terms Moreover.11 S/N Ratio and Means plot for TWR 146 . It implies that using level 1 of is found to be 0.5) which gives Similarly. Fig.00179 DC + 0.4 Analysis for TWR comes out to be 0.00191. kerosene and air both Error in the model developed for MRR experiments.000000 Ton +0. TWR = ‐0. For example. the values of square sums obtained from ANOVA Regression analysis for TWR calculations are used to plot pie chart (Fig 4.e. factor effects were obtained for MRR and TWR for the Error in the model developed for TWR developed hybrid process of EDM using both liquid and In a similar fashion to error for the model of MRR.A.2 MRR = ‐ 0.000014 Ton + 0.0005 chances that such a large ‘Model F‐Value’ could occur due to noise. 13 and 14 show the response surface diagrams Main effects plot for S/N ratio and Means are drawn for of MRR as a function of the design factors.000329.000165 ∑ 10 log (6) Vg (7) Figure 12. equation regression equation for MRR in terms of the actual corresponding to smaller is better condition is chosen and parameter values is shown in equation 4.000040 DC +0. The obtained model F‐value is 54. models with significant of TWR as a function of the design factors. . usage of air results in voltage gap becoming the of the actual parameter values is shown in equation 4. 025 0.6 REFERENCES 1.015 Pulse On Time(microsec) Fig. a hybrid model of EDM using both liquid and gas dielectric has been successfully developed.019 0. Using S/N ratio analysis.015 0. pulse on time and gap voltage have been obtained.024 -4 x 10 0.5 2 2 1 70 0.5 4 40 4 40 Gap Voltage(Volts) Material Removal Rate (g/min) 2. G.02 0.023 Gap Voltage(Volts) 3 Fig.017 6 300 3 3 2.5 0.02 0. Ton and DC Fig. The successful accomplishment of this work opens new avenues of further investigation on the affect of use of liquid‐cum‐gaseous dielectrics in electrical discharge machining.016 300 50 200 40 100 0. K. A.022 Electrode Wear Rate (g/min) Material Removal Rate (g/min) 0. V and Ton -4 x 10 3.022 0. Rajadurai. ANOVA tests lead to the conclusion that gap voltage becomes the most significant parameter when both kerosene and air are used as dielectric as compared to discharge current being the most significant when only kerosene is used.5 2 60 6 5 Electrode Wear Rate (g/min) 3 3 0.6 2.023 4 0.021 0.2 2 1 400 1.4 2 2. Journal of Materials Processing Technology 124 (3) (2002) 297– 304. Prahash.02 0.019 0.02 0. Experimentation using Taguchi design of experiments has led to the findings that use of compressed air leads to increase in material removal rate and reduction in tool wear rate.17 Response surface of TWR vs. experiments can be conducted by warming the kerosene to just below its flashing temperature.02 0.Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric A.15 Response surface of TWR vs. discharge current.024 1. [2] J.016 3 Discharge Current(Ampere) 1.017 0. V and DC 0. Singh -4 x 10 3.021 0.016 0. Further.5 4 0. Satyanarayana.019 0.016 50 3 0.022 0.5 300 0.4 4 100 3 In this work. Soni.023 Electrode Wear Rate (g/min) Material Removal Rate (g/min) 0. V and DC -4 x 10 0.015 0. V and Ton Fig.2 4 3 2. Empirical relations for MRR and TWR have been developed for the hybrid process with a confidence level of more than 95%. G.8 3 2.024 -4 x 10 0.4 -4 x 10 3. Chakravarti.022 Pulse On Time(microsec) Discharge Current(Ampere) CONCLUSIONS 0.018 0. Mohan.01 70 60 Discharge Current(Ampere) [1] B.01 400 0. Also improvement can be done in the field of tool geometry and equipment.015 4 100 Pulse On Time(microsec) 400 60 5 200 50 40 Gap Voltage(Volts) 200 100 Pulse On Time(microsec) Fig. Wear 171 (1–2) (1994) 51–58.16 Response surface of TWR vs. Fig.12 Response surface of MRR vs.14 Response surface of MRR vs.8 6 300 5 200 1.018 0. S.02 0.021 0.13 Response surface of MRR vs.025 . 0. G. Machining characteristics of titanium alloy with rotary electro‐discharge machining.015 Gap Voltage(Volts) Discharge Current(Ampere) 0. optimal values of design parameters viz. Ton and DC 147 3.018 0. Moreover.018 50 2 1 70 6 5 0. The concept can be applied to know the response of different work and tool material to the hybrid process. Effect of SiC and rotation of tool electrode on electric discharge machining of Al–SiC composite.014 70 0.017 400 60 0. Other design parameters like the rotational speed of tool and gas pressure can be varied to study the effects on response variables. International Journal of Electrical Machining 10 (2005) 15–20. Nakajima. Sano. Karato. Bo. Singh Electrical Discharge Machining of High Speed Steel Using Both Liquid and Gas Dielectric CIRP Annals—Manufacturing Technology 53(1) (2004)183–186. [4] M. T. N. [5] M. Takahashi. Taniguchi. M. Kunieda. S. N.A. Y. [3] M. Nakano. S. Yoshida. T. Kunieda. M. N. M. Electrical discharge machining in gas. Furuoya. Zhanbo. Kunieda. Takaya. Prahash. Improvement of dry EDM characteristics using piezoelectric actuator. Kunieda. Y. Ramani. Inert‐Gas Electrical Discharge Machining. G. [7] V. 1985. Yoshida. M. Cassidenti. 148 . CIRP Annals—Manufacturing Technology 52(2003) 147–150. K. Miyoshi. S. Z. J. Takaya. CIRP Annals— Manufacturing Technology 46(1997) 143–146. L. Taniguchi. Kunieda. CIRP Annals—Manufacturing Technology 40(1991)215–218. Nakajima. High speed 3D milling by dry EDM. [8] Y. [6] M. Feasibility of 3‐D surface machining by dry EDM. Improvement of EDM efficiency by supplying oxygen gas into gap. N. NASA Technical Brief Number NPO 15660. and a second layer of rubber. using various techniques including adhesive bonding. Rubber-based material and steel have good properties and are able to be recovered. Tab. nylon.2 Textile fibers obtained from tire shreds POSSIBILITIES FOR REUSE OF THE TEXTILE FIBERS The textile components of scrap tires can be sold to the flocking industry. [5] Chemical analysis has been carried out by atomic absorption spectrometry and energy dispersive X‐ray fluorescent spectrometry (EDXRF).kg‐1] Zn 22514 Cu 623 Mn 158 Co 63 Pb 35 Cr 18 As 6 Cd 1 Tl 0. geotextiles or insulation pads. a layer of closely‐ spaced steel cords. and a second layer of rubber). questions regarding environmental suitability still persist. Textile Recovery from Srap Rubber Tires. (2012). Nonwoven fabrics are normally made from continuous filaments or from fiber webs or batts strengthened by bonding. [5] The typical chemical composition of textile obtained from scrap tires is listed in Table 1.tk Manufacturing Engineering & Management The Proceedings Textile Recovery from Srap Rubber Tires Agáta Radvanská Technical University of Kosice. [8]. The main problem is to find the area of textile recovery obtained from scrap tires.1 The construction of a tire [6] The body ply consists of rubber layer.Contents lists available at www. Citation: Radvanska A. roofing felts. particularly the potential impact on ground and surface waters and aquatic life due to
[email protected] ARTICLE INFO: Category : Short Communication Received : 31 October 2012 / Revised: 5 November 2012 / Accepted: 17 November 2012 Keywords: (in causal order) Abstract: Tire‐derived textile Scrap tires Fibers Non‐woven textile Geotextile Shredded scrap tires alone or mixed with other materials can create the possibilities for their use in civil and environmental engineering applications. belt package (calendered sheets consisting of a layer of rubber. [8]. later materials include rayon. Although the reuse of scrap tires and materials obtained from their manufacturing have become more common. cushion gum and other components (Figure 1).g. Tire‐ derived textile is characterized by high zinc content originating from zinc oxide added as activator in the process of vulcanization. Email: agata. p. and have associated health risks. body ply (fabric and rubber). Slovak Republic. [3] Fig. Truck tires. The earliest textile used was cotton. mechanical interlocking by needling or fluid jet entanglement. The fabric cords are highly flexible but relatively inelastic. The paper provides a review of possibilities for tire-derived textile recovery and properties of the obtained material. and stitch bonding. 149 . needlefelting. Faculty of Manufacturing Technologies with the seat in Presov. polyester. Fig. beads (bands of high tensile‐strength steel wire coated with special alloys of bronze or brass). tread (thick extruded profile that surrounds the tire carcass). but being petrochemical‐based products. Body plies give the tire structure strength. 2nd International Conference Manufacturing Engineering & Management 2012.icmem. 149‐150. still containing 10 to 15% of rubber material and small portion of steel thus the characteristics are different from the synthetic textile material (Figure 2). ISBN 978‐80‐553‐ 1216‐3 INTRODUCTION The main components used in tire assembly are inner liner (halobutyl rubber). reinforcing fabric. trunk liners or insulation. Passenger tires typically have one or two body plies. off‐road tires. sidewall (non‐reinforced extruded profiles with additives – antioxidants and antiozonants). The possible use of tire‐derived textile is to form nonwoven fabrics. and aircraft tires have progressively more plies. and Kevlar.1 Analysis of tire‐derived textile Chemical analysis of tire‐derived textile [mg. furniture padding etc. loudspeaker cones. Items are shredded for fillers in car insulation. panel linings. it is a mixture of rubber and textile.03 Tire derived textile is not a pure textile material. apex (filler). Nonwovens from recycled fibers can be potentially used as automotive fabrics e. The needlepunching. This CHARACTERISTICS OF TIRE‐DERIVE TEXTILE Man‐made polymers have the advantage of not decaying under biological and chemical processes. or needlebonding method can be used for fabricmaking. thermal bonding. and they also cause environmental pollution in their manufacture and use. they are made from nonrenewable resources.4 Hg 0. K. In: Strojárstvo. Proceedings of the International Workshop IW‐TDGM 2007. BURAK. COSKUNTUNA Esra: Manufacturing Nonwovens Using Recycled Fibers. Alton R. drainage. [3] JAMES. pp. 2009‐02‐ 13] Accessed at WWW <http://en. [2] Needlepunched fabrics are used where it is required to prevent leakage and protect groundwater and soil. or thermoplastic bonding agent in solution. the best method to fabric manufacture seems to be a chemical bonding system in which a chemical is used to reinforce the web. [6] The construction of a tire [cit. No. shoes insulation. silt fences. reinforcements. c2009 [cit. powder. The binder fibers must have a lower melting point than the fibers in the web and will be softened or melted by a hot‐ calendering process. and roofs. [4] Fabrics from recycled fibers used for landscape applications should be strong enough to withstand the most vigorous stresses of application. WILSON. [1] The sound and shock absorbing materials are formed from resin‐bonded webs transformed into flat molded parts with self‐adhesive surfaces or with a heavy coating. FREDRICK. with it. [7] CONCLUSIONS In Slovakia. reinforcement.strojarstvo. mostly because of high zinc content.buffalo.edu/courses/ce435/2001ZG u/Firestone_Tires/FirestoneTiresReport. 1994 Academic Press Inc. Next group consists of hard‐pressed parts used to line doors. Mark. The predominant form of fabric construction are spunbonded and needlepunched nonwoven fabrics. densities. Agáta: Spracovanie odpadových pneumatík. 2006. for example. YASUHARA. The most significant parameters of such fabrics are not only the performance and the durability. [4] LANGLEY. RADVANSKÁ.weedbarrier. Sergej. E. should have an even.. backs of seats. [2] For the tire‐derived textile fibers.org/wiki/Tire_manufacturing> 150 . The tire‐derived textile could be the secondary raw material to product various forms. The felted products that can be manufactured are as follows: car insulations. Radvanská Textile Recovery from Scrap Rubber Tires means to use barb needles to entangle a fiber web or batt by mechanical reorientation of some of these fibers within its structure. Agáta: Struktura. The fabric must be porous enough to allow water and air to pass freely to the soil. noise and vibrations dampening mats. SODOMKA. VALÍČEK.eng. Another consists of molded parts with or without textile lamination and serves both as sound insulators and as self‐supporting stylish components. ISBN 80‐8073‐668‐5. as blankets in drainage systems inside the landfill. 2012‐09‐04] Accessed at WWW <http://www. in the roof section.sk> ISSN 1335‐ 2938. Tire Manufacturing. or fiber forms. Internet: <www. 1. 2009‐03‐05] Accessed at WWW <http://www. in the variable thickness. insulation fitted under the hood. and finishes. Fiber adhesives in the volume of 5 to 40% by weight are mixed in with the base fibers. 2009‐03‐04] Accessed at WWW <http://www. separation. vlastnosti. diagnostika a technologie textilií. causing the bond to form.. Erman. Geotextiles are permeable textile materials used for filtration. Eirich: Science and Technology of Rubber. Prešov.wikipedia. etc. When a fabric does not accept water freely it tends to wash off the fabric taking any mulch covering.pdf> [5] RADVANSKÁ. 12 (2006). 277. and a small enough opening size to keep weedy grasses from coming up through the fabric.htm> [7] Western Landscape and Geotextile Supply. drainage. asphalt overlay. Japan [2] HLOCH. vyd. Kenneth D. Yokosuka. erosion control. typically a rubber‐based. These can be used for soil stabilization or separation. R. The main disadvantage of pour permeability is the problem of runoff. 60‐61. H.com/> [8] Wikipedia. Vydavateľstvo Michala Vaška.. mostly because of lack of knowledge of the material recovery possibilities. or other constructional materials. rock or bark. and in trunk linings. Jan. vol. REFERENCES [1] HAZARIKA. c2009 [cit. thermoreactive. primarily because of cost and performance.org/pdf‐ rpts/AnRp98/f97‐d02. Pp. as a geotextile cushion specifically where there is need for puncture protection on top of the liner.A. rock. and as underneath riprap (gravel‐like material) for erosion control. gaskets and seals. liquid filtration felt circles.: Scrap Tire Derived Geomaterials ‐ Opportunities and Challenges. and consistent distribution of fibers. Lubomír. c2009 [cit. The web is then hot‐calendered to cause the bond to form. environmental protection fabrics. as a tarpaulin on the outside of the landfill.ntcresearch. liners. and stabilization purposes as an integral part of civil engineering structures of earth. energetic use of tire‐derived textile is still preferred. The investigations of the characteristics are required for understanding the basic parameters of recycled fabrics from tire‐derived textile. but also the environmental impact. 10. but are adjusted in order for the price to be expressed in an appropriate manner (in this case EUR2011). price of apparatus at the moment А. as given by the equation: C A / I A CB / I B (1) where CA . The number of passes of fluid at the tube‐ side and at the shell‐side is usually one or two. The most common correlations for estimating prices of shell and tube heat exchangers found in open literature were tested using the market data for a comparison and they have shown significant deviations. 2nd International Conference Manufacturing Engineering & Management 2012. : Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils . Fig. we conducted an analysis the goal of which was to determine to what extent the discrepancies arose when using the existing equations (2 21). the operating pressure. Kraljice Marije 16. ISBN 978‐80‐553‐1216‐3 INTRODUCTION general case include costs of materials for apparatus.Contents lists available at www. CB . Serbia Institutе Goša. energy. Budimir3 1 Project Management College. Fig. p. (2012).icmem. Serbia 2 ARTICLE INFO: Category : Short communication Received : 20 October 2012 / Revised: 30 October 2012 / Accepted: 2 November 2012 Keywords: (in causal order) Abstract: Correlation Costs Heat exchanger Helical tube Manufacturing The paper deals with the manufacturing costs for shell and tube heat exchangers with parallel helical tube coils. Budimir 2 ‐ Marko S. where they are not given in its original form. the material the apparatus is made of.Shts. 151‐154. The simplest method which takes into account the increasing costs due to market trends. 11000 Belgrade. The number of passes of fluid at the tube‐side is provided by means of baffles allocated in the stationary head‐channel. The main types of shell and tube heat exchangers with parallel helical tubes are with fixed tube sheets (Figure 1) and heat exchangers with floating head (Figure 2) [2]. labor. Deviation in prices calculated using the correlation 2 21 and the actual price of apparatuses (data obtained from the manufacturer) is expressed using statistical indicators: correlation ratio (CR) and the root‐mean square deviation (RMSD). price of apparatus at the moment B. IA index of price at the moment А. 11000 Belgrade. Serbia 3 Innovation Center of the Faculty of Mechanical Engineering. CALCULATION PRICE OF HEAT EXCHANGERS We can find several correlations for estimating cost of shell and tube heat exchangers in the open literature. Taking this into consideration. IB index of price at the moment B [3].2 Shell and tube heat exchanger with parallel helical tube coils ‐ floating head type Although the aforementioned heat exchangers have been used in thermal engineering and process industries for almost half a century. Milana Rakića 35. Rakonjac1 ‐ Stevan J. whereas the number of passes of fluid at the shell‐side is provided by longitudinal baffles allocated in the cylindrical shell [1] [2]. Citation: Rakonjac IM.tk Manufacturing Engineering & Management The Proceedings Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils Ivan M. These costs in 151 . etc. Jarić3 ‐ Nikola J. 11000 Belgrade. et al. They are based on knowledge of the design of the apparatus. problems related to their economic costs have not been fully explored. the primary objective of this paper was to determine the manufacturing costs of shell and tube heat exchangers with parallel helical tubes. The most often cited correlations are listed in Table 1. the heat transfer surface.1 Shell and tube heat exchanger with parallel helical tube coils ‐ fixed tube sheet type ANALYSIS OF MANUFACTURING COSTS OF HEAT EXCHANGERS WITH PARALLEL HELICAL TUBE COILS For heat exchangers with parallel helical tubes with a fixed tube sheet we encounter no correlation for the assessment of investment costs in the literature. Prices of apparatus should be translated also from the year in which they were manufactured (Table 2) in the year for which the analysis is done. A new correlation for calculating prices of heat exchangers with helical tubes (when the shell is made of carbon steel and the helical tube of copper) was determined in the following form Cin = 700 + 310. and other costs. Therefore. Shell and tube heat exchangers with parallel helical tube coils (HEHTC) consist of a large number of helical tube coils which are placed within a cylindrical shell in the form of a tube bundle. Krfska 7. which are also shown in Table 3. 69 303.54 S 0.35 S ‐ 0.38 581.92 Cin 11821.98 Shts Cin 7191.94 37.95 22.58 (2) ‐ 0.432 hts 0.22 S [4] 0 413.68 hts 0.20 S Cin 1722.14 S 0.72 590.79 S ‐ 9 90 2007 2007 2009 Carbon steel ‐ Carbon steel 2009 Admiralty 2009 Copper–brass 50 Cin 1422.75 32.85 Cin 7191.8 Cin 5910. m 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2.55 11.35 S hts Cin 8500. CR RMSD Eq.56 15.58 S [4] 0 189.22 Shts [4] (6) Cin 8443.93 hts .20 Manufacturing year Cost of apparatus in manufacturing year Cost of apparatus EUR 2011 2005 2010 2009 2009 2008 2010 2008 2009 2008 2010 2008 2009 2006 2008 2010 2008 1200 1600 3900 3600 3600 4500 5800 6200 6600 5600 9300 7300 11900 9600 11000 11880 1568 1760 4690 4329 3515 4950 5663 7456 6445 6160 9081 8779 14580 9374 12098 11600 Тab.1 Correlations for estimation price of shell and tube heat exchangers by various authors Year Material (Shell‐Tube) Temp.03 18.13 28.551 hts [10] (19) 0. Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils Тab. et al.42 S hts Cin 30800 3748 S 0.68 hts [9] (17) Stainless steel ‐ Stainless steel 300 50 ‐ Cin 9231.68 Cin 3183.68 hts [9] (15) 2007 Carbon steel ‐Monel ‐ Cin 6684.68 hts [9] (18) 0.18 26.24 28.38 581. range ( C ) Pressure range ( bar ) range ( m2 ) ‐ ‐ ‐ ‐ ‐ ‐ Correlation Ref.60 18.92 hts 0.91 hts 0.68 S 0.2 Apparatus Manufacturing year No.91 hts Ref.68 S [9] (16) Carbon steel – Stainless steel 300 300 50 2007 ‐ Cin 5411.679 hts [10] (20) [10] (21) 0.42 S 0.71 (6) 152 0.71 Cin 1278.56 11.93 Cin 14776.17 35.69 303.02 8. Year 1 1990 Material (Shell‐Tube) 4 Carbon steel‐ Carbon steel Carbon steel ‐Stainless 1990 steel Stainless steel ‐ Stainless 1990 steel 1990 Carbon steel ‐Titanium 5 1990 2 3 Titanium ‐ Titanium S hts Temp.27 1998 Carbon steel ‐ Carbon steel ‐ 20 30 10 600 1998 Carbon steel ‐ Brass ‐ 20 30 10 600 1998 Carbon steel ‐ Stainless steel ‐ 20 30 10 600 1998 Stainless steel ‐Stainless steel ‐ 20 30 10 600 2001 Carbon steel ‐ Carbon steel 350 10.11 345.45 Shts [4] (5) 1990 Titanium ‐ Titanium ‐ ‐ ‐ 0.5 9 6500 Cin 906. 72 590. S hts .86 hts 0.679 hts Тab.71 111.84 273.4345 119.18 S hts [9] (14) Carbon steel ‐ Aluminium 300 50 ‐ Cin 4138. range ( C ) Pressure range ( bar ) Shts range 1990 Carbon steel‐ Carbon steel ‐ ‐ ‐ ‐ ‐ Correlation ( m 2 ) 0.11 345.51 4.85 hts 0. ‐ 0. [4] (2) [4] (3) 1990 Carbon steel ‐Stainless steel 1990 Stainless steel ‐ Stainless steel ‐ ‐ ‐ [4] (4) 1990 Carbon steel ‐Titanium ‐ ‐ ‐ 0. Eq.45 S [4] 0 332.66 S [6] (10) [6] (11) [7] (12) Cin 1400.23 S ‐ 9 90 ‐ 9 90 Cin 1957.35 Shts [4] 0 161.57 (4) ‐ ‐ ‐ Cin 11821.84 273.19 (3) ‐ Cin 8443.64 hts [5] (7) [6] (8) 0.58 S 1995 ‐ ‐ ‐ 0.82 Cin 1874.81 hts 2004 Stainless steel ‐ Titanium ‐ ‐ ‐ [8] (13) 2007 Carbon steel ‐ Carbon steel 300 50 ‐ 0.8 Cin 5910.11 24.IM Rakonjac.15 S hts [6] (9) Cin 1302.98 Shts [4] 0.1 (5) ‐ ‐ ‐ Cin 14776.41 S 0.3 Apparatus Manufacturing year No.05 0. EUR [5] 0 49. EUR (3) for range 2. Bulatov. on the basis of the data given in Table 2 (for 2011 year price).64 (17) [9] 0 982. [2] Jaric. 2011. a new correlation was found in the following form (Figure 3): Cin 700 310 Shts .. Cost estimation and energy price forecasts for economic evaluation of retrofit projects. S.4072 ‐ 9 90 Cin 1422. M. m .3 Apparatus Manufacturing year (continue) S No. M. Correlation ‐ ‐ Carbon steel – Stainless 300 steel Stainless steel ‐ Stainless 300 steel Carbon steel ‐ Carbon steel Admiralty Copper–brass hts range 2 (m ) 0. it was concluded that a new correlation needs to be found. where the apparatus shell is made of carbon steel and the heat exchanger’s tubes are made of copper).432 Cin 906.10%.64 Cin 1400. [4] Taal. Тab.20 S 0. Faculty of Mechanical Engineering.54 S hts 0.7 (19) 0 70.66 Shts [6] 0 154.86 Cin 1302.41 S hts Cin 1278. I. p.05 0.18 S RMSD ‐ The analysis proved that these correlations show significant deviations and that they cannot be successfully used to describe the manufacturing costs for the mentioned type of shell and tube heat exchangers (a heat exchanger with parallel helical tubes with a fixed tube sheet.679 hts [10] 0...04 (14) [9] 0 386.68 hts 0..23 S 50 ‐ ‐ 9 90 0.50 S hts 38.679 Cin 1722. J. range (°C) Pressure range (bar) 6 1995 ‐ ‐ ‐ 7 1998 Carbon steel ‐ Carbon steel ‐ 20 30 10 600 ‐ 20 30 10 600 20 30 10 600 20 30 10 600 10. University of Belgrade.71 hts 0.35 S [6] 0 225.57 (11) Cin 8500.31 (9) 0. Industrial & Engineering Chemistry Research. Applied Thermal Engineering 23 (2003) pages:1819–1835 12000 10000 8000 6000 4000 2000 0 2 6 10 14 18 22 26 30 34 38 Heat transfer surface.66 (16) [9] 0 535. Cin 3183. Heat exchanger Selection. 1968. The cost analysis was conducted using the actual price (data obtained from the manufacturer) of apparatus with helical tube coils in the Republic of Serbia..6391 53.79 Shts [10] 0.68 hts 70.. The new correlation for determining the price of shell and tube heat exchangers with parallel helical tube coils (when the shell is made of carbon steel and the tube is made of copper) has the following form (2) p 30 bar Its statistical parameters are CR=0. et al. Stehlik.9068 and RMSD=17. In the above equations (2 21) the value of heat transfer surface (Shts) was expressed taking into account the outside of the tube.15 S 0. and the operating pressure p 30.Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils IM Rakonjac. Cin 700 310 S hts . Therefore.68 Shts [10] 9 90 ‐ 0. bar .81 hts 0. P.50 S hts 38. and RMSD = 17. Research On Thermal Performances And Pressure Drop Of Shell And Tube Heat Exchangers With Helical Tube Coils. 1987.82 hts ‐ Cin 4138.3 Manufacturing costs for apparatus versus to heat transfer surface 153 Eq. Klemes.42 (12) [8] 0 1266.62 (10) Cin 1874.76 (18) 0. Shts.65 (13) [9] 0 275.68 hts 0. m 2 Cost of heat exchangers. 18000 REFERENCES 16000 C in 700 310 S hts 14000 [1] Jensen. CPE‐Heat transfer Survey.24 (20) 0 104. September.47 (7) [6] 0. [3] Weidlicht.27 .5 9 6500 8 1998 9 1998 10 1998 11 2001 12 13 14 15 16 2004 2007 2007 2007 2007 17 2007 18 2009 19 2009 20 2009 Carbon steel ‐ Brass Carbon steel ‐ Stainless ‐ steel Stainless steel ‐Stainless ‐ steel Carbon steel ‐ Carbon 350 steel Stainless steel ‐ Titanium ‐ Carbon steel ‐ Carbon 300 steel Carbon steel ‐ 300 Aluminium Carbon steel ‐Monel 300 2.10%. EUR CR Cin 30800 3748 S 50 Ref.68 hts 0.14 S 50 ‐ Cin 6684.. hE and . U.68 (15) [9] 0 684.551 Cin 1957.68 S 50 ‐ 50 0.1372‐1381. J. PhD Thesis. Modified UNIFAC Model 1.71 111.11 (8) [6] 0 66. Prediction of VLE.. Year Material (Shell‐Tube) Temp. m2 Fig.68 Cin 5411. Gmheling. After examining the correlations currently found in the existing body of literature on investment costs of shell and tube heat exchangers. vol 26.42 Shts Cin 9231.907 .42 Shts [7] 0 171.. Statistical parameters of the equation are 2 20000 CR 0.51 (21) CONCLUSION The paper presents the main types and manufacturing costs for shell and tube heat exchangers with parallel helical tube coils. Shahi.. 2003.. Process Equipment Cost Estimation. P.. Reza. Applied Thermal Engineering 29 (2009). Chemical engineering August (1995) pages: 68‐73 [6] Sinnott.. A potpourri of equipment prices. K. January 2002. Iran Journal of Chemistry 154 . M. P... Gosselin. Lyons. Third Edition.. M. Minimizing shell‐and‐ tube heat exchanger cost with genetic algorithms and considering maintenance. Butterworth‐Heinemann. [7] Loh. Department of Energy. Damangir. International journal of energy research.. J..IM Rakonjac. Cost effective heat exchanger network design with mixed materials of construction. O. White. M. E.. pages: 1026–1031 [5] Vatavuk. Vol 23.. W.. H.R.S. [8] Reza. 2004. (2007). No 2. L.. Chemical Engineering Design.. Vol 6... C. Soleimani I. P. W. pages: 89‐100 [9] Wildi‐Tremblay. U. H. Oxford.. Hassan.. Manufacturing cost of Shell and Tube Heat Exchangers with paralel Helical Tube Coils and Chemical Engineering.. M. Design optimization of shell and tube heat exchangers using global sensitivity analysis and harmony search algorithm. National Energy Technology Laboratory. Volume 31 pages: 867–885 [10] Fesanghary. et al. Contents lists available at www.Mechanical. Folgar Portillz. TamilNadu. India Multitech Dr. but the large scale growth in the marketplace for these materials will require less costly processing methods and the prospect of recycling will have to be solved. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles . the net shape forming of these . the strength at elevated temperatures and the elastic modulus of these should be improved. Vijayakumar3 1 St. Magnesium reinforced with SiC particles were prepared by powder metallurgy technique. ISBN 978‐80‐553‐1216‐3 INTRODUCTION To realize the application of the light Mg‐alloys. nuclear. Avadi. p. particularly for reciprocating components. Mahieux et al. Thermal fatigue behaviour of a 2014/Saffil composite has been investigated. It is found that there is no reaction and grain growth in the specimen prepared. With applying of reinforcement in the form of fibers or particles. the re‐arrangement rate increases with temperature. aerospace. electrical and optical properties can undergo order of magnitudechanges over a 100°C temperature change and moisture diffusion can vary by as much as three orders of magnitude. This composite was produced by infiltration of preforms of Saffil fibers (Al2O3‐SiO2 fibers) with a 2014 aluminium alloy (Al‐4. Their thermal‐expansion coefficients (CTEs) were measured between 25 and 500 °C with a high‐ precision thermal mechanical analyser (TMA). Aluminium‐matrix composites containing thermally oxidized SiC particles of controlled diameter ranging from 3 to 40 μm have been produced successfully by vacuum assisted high‐pressure infiltration. TamilNadu.Rangarajan Dr.icmem. automotive.com Department of Mechanical Engineering Anna University of Technology Tirunelveli. Avadi. resist fatigue loading and are easily maintainable and repairable. At elevated temperature the composites and unreinforced aluminium alloy definitely show cyclic softening. TamilNadu. Manivannan2 ‐ D. As the data on the service life of composite structures is becoming available. electronic and sporting goods industries.7Cu‐1. processes for fabrication of aluminium‐alloy composites containing paniculate non‐metals. It can be done by reinforcing ceramic particles.Peters College of Engineering and Technology. Citation: Shankar R. a weight saving optimization should be taken into consideration that leads to the selection of carbon fibers instead of ceramic fibers. 155‐162. et al. This could be achieved by reinforcing the Mg‐composites with a high strength component. Mehrabian [29] studied Composites of aluminium alloys. Furthermore the micro structural analysis and micro hardness test were carried out to see the behavior of material properties towards heating and cooling. The micro hardness of composite increased by 30 % than that of aluminum composite. it can be safely said that they are durable. composites with fly ash can be used to reduce the cost of the metal matrix for applications in automotive and small engine applications. but due to their high cost. This work aims to experimental evaluation of thermal behavior of Mg‐composites reinforced with SiC in addition with variation of fly ash. Wear rate shows a greater improvement of 10% wear resistance than that of aluminum composite. SiC or C.Sakunthala Engineering College. [5] have studied the effect of temperature on polymer matrix composites. Composite structures have shown universally a savings of at least 20% over metal counterparts and a lower operational and maintenance cost [1]. So.6 Mg). India. 2nd International Conference Manufacturing Engineering & Management 2012. Fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by product during combustion of coal in thermal power plants. R. contact mail: raviannauniv23@gmail. Chennai. After 1000 cycles both the microstructure 155 and the mechanical characteristics of the composite samples were investigated. vijiaji@gmail. and compared with the predictions of various theoretical models. experiments are usually done to reduce the cost of the composites and inexpensive materials are utilized for metal matrix composites.com 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 20 August 2012 / Revised: 12 November 2012 / Accepted: 18 November 2012 Keywords: (in causal order) Abstract: Green sand compaction Fly ash Micro hardness Thermal cycling Optical microscope Metal matrix composites are used mostly in space ships. fabrication and wear behaviour. maintain dimensional integrity. Composites will continue to find new applications. Thermal cycling tests were performed on specimens (either as fabricated or in the T6 temper) in the temperature range between 25 and 220°C. [23] studied the thermal fatigue behaviour of a 2014/Al2O3‐SiO2 (Saffil® fibers) composite processed by squeeze casting.tk Manufacturing Engineering & Management The Proceedings Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles Ravi Shankar1 ‐ A. Han et al. Generally speaking. (2012). Badini et al. Hosking. Céline A. The cyclic stress response characteristics and low‐cycle fatigue endurance of powder‐metallurgy‐processed commercially pure aluminium composites reinforced with SiC particles of different sizes and of the unreinforced matrix were studied under a range of cyclic plastic strains at 441 K. This could be achieved by reinforcing the Mg‐composites with a high strength component. continuous fibers or short fibers from Al2O3.0Si‐0. The literature survey is carried out as a part of the thesis work to have an overview of the production processes. Elomari et al. properties and wear behavior of metal matrix composites. Wunderlin and R. biotechnology. [16] studied the effect of reinforcement size on the elevated‐temperature tensile properties and low‐cycle fatigue behaviour of particulate SiC/Al composites. [9] have studied the Thermal Expansion behaviour of particulate metal‐ matrix composites. India. F. Composites with particulate additions of size larger than 5 m possessed homogeneous structures. Above critical temperature amplitude of about 150 degC an acceleration in creep under the load occurs.% silicon carbide particles (average size 43 μm) were tested for sliding wear at different loads using a pin on disc machine. Huang et al. The particles were then retained in the matrix until interface interaction. the stress change during the thermal expansion coefficient measurements of the composite subjected to TMC was calculated. Y. Ramasesh and M. the dimensional stability is of great concern. exhibit excellent wear resistance whilst those with small to moderate amounts of non‐ metals possess tensile properties comparable to the matrix alloy. The non‐metallic particles were added to a partially‐solid vigorously‐agitated matrix alloy. The present paper investigates the thermal fatigue of the short fiber reinforced KS1275® piston and AE42 alloys. [17] studied the Transverse and Cyclic thermal loading of the fiber reinforced metal‐matrix composite SCS6/Ti‐15‐ 3. The results indicated that TMC could induce the interfacial degradation of the composite. The present work will focus on fabrication and characterization of Al matrix composite reinforced with varying quantities of SiC and Flyash. were faciliated. B. using simplified methods of analysis. Pickard. but it could deplete due to its reaction with the SiO2 in the fiber or in the binder. The magnesium is essential for the formation of strengthening precipitates. Thermal cycling experiments can simulate the service conditions of the materials and give an evaluation how the dimension changes during their service in the changing temperature environments. Surappa[26] presented the theory that Aluminium alloy (A356)‐SiC composites containing 15 and 25 wt. The thermal expansion behaviour of boron fiber‐reinforced aluminium matrix composite subjected to thermal–mechanical cycling (TMC) was studied. the paper investigates the relationship between the observed behaviour and the predictions. [15] have studied the on the behaviour of metal matrix composites subjected to cyclic thermal loading. or boron fibres. microhardness and thermal dilatometry tests. [22] studied the thermal behaviour of short fiber reinforced AlSi12CuMgNi piston alloys. Huang et al. the more serious the interfacial degradation of the composite became. Al2O3.He et al. [10] studied the Effect of thermal–mechanical cycling on thermal expansion behaviour of boron fiber‐ reinforced aluminium matrix composite. at the same time leading to the formation of an iron‐rich layer on the surface. Composites of two wrought (2014 and 2024) and one cast (201) aluminium alloys containing 2 to 30 wt% of Al2O3 and SiC particles in the size range of 1 to 142 m were prepared. The proposed one‐ dimensional analysis model was proved to be a simple and qualitative approach to probing the interfacial degradation . S. SiC. [13] have studied the Thermal Expansion and stress relaxation of metal‐matrix composites. Mykura et al. Through the study of experimental data. et al. Shankar. tended to cluster.M et al. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles composites. The coefficient of thermal expansion (CTE) of a series of Al‐6%Si matrix samples. Commercial purity aluminium reinforced with SiC particles has been used to model the behaviour of metal matix composites (MMCs) during thermal cycling. with reinforcements of carbon. or the higher the applied stress level of TMC. Scanning electron microscopy examination of worn surfaces and sub surfaces show that the presence of dispersed SiC particles help in reducing the propensity of material flow at the surface. when subjected to cyclic thermal loading. It was shown that composites containing large amounts of non‐metals. This is accompanied by a reduction in the creep stress exponent from 15 to 1. significant work has abeen done on production and characterization of MMC’s using different methods. the formation of MgAl2O4 spinel in the case of Al2O3 particles. or ceramic particles was measured in the range 60°–220°C with a dilatometer. a method was investigated of producing components with high weight‐fractions of non‐metals near their surface In past. This work investigated both the aging and thermal cycling behaviours of the short fiber reinforced AlSi12CuMgNi piston alloys using X‐ray diffraction. The coefficient of thermal expansion (CTE) is affected by both the microstructure and internal thermal stresses generated from the both heating and cooling. but the effects of thermal cycling on Aluminium composites using SiC and Fly ash together have not been investigated. The mechanical properties of metal matrix composite materials are strongly affected by thermal cycling. with an emphasis on the changes in the strain and hardness before and after thermal cycling. S. The paper is concerned with the load‐bearing capacity of a body with a regular periodic microstructure with elastic and elastic‐perfectly plastic phases. A number of researchers have done experimental analysis on composites subjected to thermal cycling. their friction and wear behaviours and their mechanical properties are described. Used as engine components. The wear behaviour of the composites was studied using a pin‐on‐disc type machine. The experimental results show that during thermal cycling up to 47 times the stress relaxation proceeds through the plastic deformation and matrix recovery. The reduced stress exponent leads to a superplastic deformation behaviour with extensions in excess of 150 % recorded. Finally.S. and the more the numbers of TMC cycles. Composites exhibited better wear resistance compared with unreinforced alloy up to a pressure of 26 MPa.Transition wear behaviour of SiC‐particulate‐ and SiC‐whisker‐ reinforced 7091 Al metal matrix composites Qin. particles of size 1 m. Ponter et al. Using a simple analysis model of internal stress in the fibers. for an aluminium / alumina continuous fibre composite. such as a metal‐matrix composite. Both the KS1275® piston and AE42 alloys and their composites have realistic and/or potential applications as engine components in the automotive industry. [24] studied the behaviour of metal matrix composites during temperature cycling. Fibers and matrix have a mismatch in the 156 coefficients of thermal expansion that induces thermal stresses in addition to those caused by mechanical loading. The transverse properties of a SiC fiber reinforced Ti alloy matrix composite subjected to transverse mechanical and cyclic thermal loading have been investigated.[14] have studied the bounding properties of metal‐ matrix composites subjected to cyclic thermal loading. and therefore the age hardening could be suppressed. These composites were solidified and subsequently reheated to above their liquidus temperature and formed under high pressure in a closed‐die forging type of apparatus. of classical plasticity models for the matrix material. however. Experimental results showed that TMC affected greatly the thermal expansion behaviour of the composite. Ponter et al.R. [20] investigated on Investigated on thermal fatigue of aluminium‐ and magnesium‐alloy based composites. Pramila Bai. 20 wt%. for example. Jansson et al.K. cloths. their microstructures. Increasing the amount of particulate additions results in reduced ductility. Transmission electron microscopy studies of the deformed microstructures show an essentially constant dislocation structure between as‐received MMCs and those after 90% strain. In this work. Increasing the volume fraction of particles in a composite reduces its wear rate but generally increases the wear rate of the counterface. Elongations obtained via thermal cycling are compared with those from room temperature and isothermal testing. In all cases. The particulate composites exhibited some residual strain when cooled down from the peak temperature to room temperature. the mechanism of wear under these conditions. a study of the behaviour of AA6061 reinforced with alumina particles produced by casting and extrusion.The . it exhibited the lowest wear rate (lower than that of the SiC‐reinforced composite). There has been an increasing interest in composites containing low density and low cost reinforcements. A hybrid A356 Al composite containing 20 vol. alloy reinforcement resulted in a reduction in wear rate and an increase in the load at which the transition from low rate wear to high rate wear occurred. The initial wear rates of the composites depend strongly upon reinforcement orientation. an optimum volume fraction of particles exists at which wear is lowest. parallel) with the exception of wear at 3. the mild to severe wear transition was raised to a range between 310–350 °C.55 N) and sliding speed (0. % SiC and 10 vol. Wang and H. Comparisons are made with unreinforced AA6061 matrix. Material selected for experimental Purposes was Mg/SiC 15p. The sliding wear behaviour of the extruded composites has been studied as a function of load and particle volume fraction and has been compared with a commercially available SiC‐ reinforced composite. The absence of severe wear phenomena in this composite contributes to the inhibition of comminution and fracture by graphite entrained in the surface tribolayer. Likewise. et al. The work also looks at the differences in cycling at different frequencies.e high velocity and short sliding distance. The mechanism of wear under these conditions was surface‐fatigue‐related surface cracking. It is suggested that when both counterface and composite wear are considered. At sliding velocities greater than 1. Hence. an addition of 20 vol. reduced wear rates being observed in the reinforced composites. However. This is attributable to the formation of protective transfer layers of comminuted reinforcing particulates and transferred steel debris from slider counterfaces. Wilson and A. composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications. elevated wear rates during the initial period of sliding. Kennedy and A. PROBLEM FORMULATION In present work. R. Graphite in the hybrid composite introduced greater mild wear losses compared with the other composites due to increased friability and contact surface extrusion effects. Alpas [28] studied the Effect of temperature on the sliding wear performance of Al alloys and Al matrix composites. fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by‐product during combustion of coal in thermal power plants. In addition. [6] studied the thermal expansion of various fiber‐ and particle‐ reinforced metal‐matrix composites has been measured and the experimentally obtained values compared with the predictions of various theoretical models. Rack[27] studied the wear behaviour of unreinforced and reinforced 7091 Al.% SiC particulates (SiCp) or 20 vol. These composites exhibited very small residual strains when cooled down from the peak temperature to room temperature. % graphite remained in a mild wear regime at the highest test temperature of 460 °C. whiskers) and orientation (perpendicular vs. An increase in load generally resulted in an increase in wear rate of both the composite pin and counterface. [19] have studied the Thermal Cycling processes in metal‐matrix composites. In the low rate wear regime. Among various discontinuous reinforcements used. and also with the same composite re‐extruded to obtain finer grain sizes.J.2 m s−1. automotive. Wear of the steel counterface depended on the mechanism of wear of the composite. the highest wear rates being observed the perpendicularly oriented SiCw composite. The effect of ceramic particulate and graphite additions on the high temperature dry sliding wear resistance of two Al alloys was studied. is presented. SiC reinforcement does not affect wear resistance. Conditions were selected such that the materials in contact were kept in an isothermal atmosphere and the generation of frictional heat was minimised by the use of a low load (11. A. was studied as a function of sliding distance and sliding velocity under unlubricated conditions. being controlled by subsurface‐cracking‐assisted adhesive transfer and by abrasion. these elevated wear rates were maintained by the unreinforced alloy.% Al2O3 to 6061 Al.Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles of unidirectional fiber‐reinforced metal matrix composites during TMC. Rajendra U Vaidya et al.6 m s−1 where the parallel‐oriented SiCw composite was superior. the thermal expansion response was not linear over the test temperature range but exhibited regions of distinctly different slopes. J. the wear rates of the reinforced materials were lower than for the unreinforced matrix. range and rate. During steady state sliding. biotechnology. nuclear.% SiC whiskers (SiCw). and the reasons for this are presented. the latter containing either 20 vol.1 m s−1). i. The magnitude of this strain was a function of the peak temperature and number of thermal cycles. With the addition of 20 vol.2 m s−1. Wear debris produced from both the unreinforced and reinforced materials was predominantly metallic and was small in dimension and dark in color. electronic and sporting goods industries and are rapidly becoming candidates as structural materials for high temperature applications. Shankar. and since the TiC‐reinforced A356 alloy was the hardest (due in part to the grain refining action of TiC). the wear coefficients of all the alloys in both the reinforced and unreinforced states were similar. Wilkes[25] has studied that TiC‐reinforced MMCs have been produced in a range of aluminium alloys using a novel casting technique which results in spontaneous incorporation of the particles into the melt and thus strong bonding between the particles and the matrix. the Effects of fly ash on Compacted Mg‐ SiC‐fly ash Composites are investigated. for the AA6061 matrix composites. T. the steady state wear rates of the composites were generally independent of reinforcement geometry (particulate vs. Metal matrix composites (MMCs) are a range of advanced materials that can be used for a wide range of applications within the aerospace. under the action of strain control and thermal cycling conditions. All the reinforced alloys were able to withstand considerable thermal softening effects while remaining in a mild sliding wear regime.% SiC to the A356 Al increased this transition to 440–450 °C. Shipway. For unreinforced 6061 Al and A356 Al alloys a transition from mild to severe wear occurred in the ranges 175–190 °C and 225–230 °C respectively. Both the unreinforced alloy and the SiC‐reinforced composites exhibited 157 R. The experiments were performed using a ring‐on‐flat sliding contact against hardened SAE 52100 bearing steel counterfaces on an apparatus built for testing at controlled temperatures. Tan et al. At sliding velocities below 1. R. Shankar, et al. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles help of 100,220, 500, 800, 1000 & 1500 µm grit size emery paper. Load used on micro hardness machine used was .1 N. Sliding wear behavior Abrasive wear has been defined as the displacement of material caused by hard particles or hard protuberances where these hard particles are forced against and moving along a solid surface. Two body sliding wear tests were carried out by using a Pin on disc wear testing machine shown in fig (1) and parameters like normal load, sliding velocity, percentage SiC were varied. A cylindrical pin of size 10mm diameter prepared from composite casting was loaded through a vertical specimen holder against horizontal rotating disc. Before testing, the flat surface of the specimens was abraded by using 2000 µm grit paper. The rotating disc was made of steel of diameter 50mm and hardness of 64 HRC. The principal objective of investigation was to study the effect of variation of normal load, sliding velocity and percentage SiC on wear rate. addition of Fly Ash is done to it in 5 %, 10 % and 15 %, 20% by weight keeping the SiC proportion constant. The specimens produced are tested and then subjected to varying temperatures (1000C to 450 0C). Once again different tests are performed on specimens after thermal cycling to find change in properties of material. OBJECTIVE OF WORK To see effect of fly ash particles on specimens, which are prepared by varying the fly ash content in original material. In initial stage the specimen are produced using powder compaction technique. Different tests are performed on these test samples. The specimens are then subjected to varying temperature 100 °C to 450°C and changes in the properties of the specimens are observed. The tests performed on the samples are as below: 1. Micro Hardness Test. 2. The Microstructure. 3. Wear Test. 4. Differential Scanning Calorimeter (DSC). EXPERIMENTAL PROCEDURE Materials In this study, elemental magnesium turnings of 99.5% purity (supplied by MERCK, Noida, INDIA) were used as the base material and silicon carbide particulates (MICRO FINE CHEMICALS CHENNAI) with an average size of 0.6 lm, were used as ceramic reinforcement. Fly ash from India Cements, Sankar Nagar is collected for experimental purpose. Sample Preparation The sample is prepared by filling the Magnesium in the Die considering the total volume accommodated to be 100 % volume by Magnesium. The samples are prepared then by mixing the proper proportion of Magnesium, Silicon Carbide and Fly ash. The mixed component is filled in the Die with which the die is made with three segmented parts. The Top component of the die is made of stainless steel. The bottom two components are made of carbide on the inner part of the component which is highly polished. The polished area is coated with Graphite or Zinc striate for the easy removal of the material from the die. After filling the material in the die the top punch covers the material for high pressure compaction of the material. The low density material is used so there could be no need for heavy load for compacting the material. Isothermal Heat treatment Isothermal heat treatments were carried out on selected extruded rods. Heat treatment was carried out at 1500C (the re crystallization temperature of Mg [1, 8] for 5 h using a resistance heating furnace. Prior to heat treatment, the rods were coated with colloidal graphite and wrapped in aluminum foil to minimize reaction of the Mg/SiC composite with oxygen present in the furnace atmosphere. Micro Structural Characterization The extruded rods, both heat treated and un‐heat treated were sectioned, metalographically polished and examined. The micro structural characterization was carried out to investigate the reinforcement size and distribution, grain size and the presence of porosity. The etched specimens were used to measure the grain size using the Scion Imaging software. Micro hardness The term micro hardness test usually refers to static indentations made with loads not exceeding 100 N. The testing is done on a microscopic scale with higher precision instruments. The surface being tested generally requires a metallographic finish and it was done with the Fig.1 Wear test (Pin and Disc Arrangement) RESULTS AND DISCUSSION Optical Microscopy Examination Micro structure was visualized with the help of an optical microscope. For the sample preparation first all the samples were cut down into small cuboids shapes then the sample were grinded on different grades of grit size paper sequentially by 180, 220, 320, 400, 600, 1000, 1500 and 2000 µm. After grinding, the samples were polished using chemical etchant. 80ml of distilled water and 20ml of sulphuric acid as an etchant for Magnesium composites and its alloys for polishing. Microscopical examination of the extruded (in longitudinal direction) and heat treated samples revealed the existence of a recrystallized matrix exhibiting equiaxed grains. The results indicate no change in grain morphology as a result of heat treatment. Fig. 2 shows an optical micrograph of the as‐prepared Mg/SiC/Fly ash composite. The SiC particles are not uniformly distributed in the matrix; they form in many cases small clusters. The mean SiC particle size was found to be about 9 µm. As it is visible from Fig. 2, the heat treated specimen appears mainly constituted of very small equiaxed grains (generally ∼3µm) after accurate optical microscopy observations. No grain growth has been observed during the deformation tests at elevated temperatures. 158 Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles R. Shankar, et al. composites and unreinforced specimens under dry sliding condition are presented. Fig.4 Wear of reinforced composite at applied load of 29.4 N The wear rate of test specimens in mm3/min obtained from the height loss of the specimens during sliding is plotted against sliding distance in figure 4 and 5 for two different applied loads: 29.43N (3kgf), 39.24N (4kgf). From figure 4 the average wear rate between each composite with respect to its sliding distance is about .021 mm3/min. As observed from wear tests, addition of fly ash to specimen in higher percentage decreases their wear resistance. But when the specimens were tested for after termal cycling the resistance to wear of specimen number 1 and 5 decreased whereas of specimen number 2 and 3 increased by small amounts. Threfore ,there is need to carry out more number of experiments to generalize the effect of thermal cycling on wear resistance. In each figure, wear rates of unreinforced alloy and five different composite specimens with varying volume percentage of particle reinforcement (0 to 20%) are shown. From the Figure 4 the wear rate increase gradually due to the fewer load applied in the specimen. Fig.2 Optical micrograph of the heat treated Mg/SiC/Fly ash10p composite. Fig 3 shows an optical examination of the prepared Mg/SiC/Fly ash20p composite with large particle sizes of fly ash with small color change which is also dissolved in the SiC matrix. The optical microscopy examination were carried out at 400X Magnification and due to elevated temperature the fly ash particulate were trapped in the SiC particulate and thus not having any reaction. Fig.3 Optical micrograph of the heat treated Mg/SiC/Fly ash10p composite. There was also no evidence of surface oxidation of heat treated rods, indicating that the graphite coating and aluminum wrapping were effective in shielding the rods from oxidation. Wear Test Characteristics The sliding experiments were conducted in air at room temperature in a pin‐on‐disc wear testing machine. The pins were loaded against the disk by a dead weight loading system. The pin specimens were flat ended pins of 10mm diameter and 26 mm in length. The disc test piece was 100mm in diameter and 10mm in thickness. The pin slid on the disc at a radius of 50mm.The material of the counter disc was high quality hardened steel with hardness HV256. Before the wear test, each specimen was ground by 1µm alumina powder and the counter disc was ground by 2000 grit paper Wear tests on composite specimens and unreinforced Mg alloy were carried out under dry sliding condition under three different applied loads of 29.43N (3kgf) and 39.24N (4kgf) for a total sliding distance 2400m at a constant sliding speed of 2.09 m/s for all sample. During the tests the relative humidity and temperature of the surrounding atmosphere was about 50% and 25ºC respectively. The test duration was 15minutes at a constant disc speed of 400rpm for all the tests. The wear test results of the Magnesium hybrid Fig.5 Wear of reinforced composite at applied load of 39.24 N The results indicate that the volume content of the particulate reinforcement has a marked effect on the wear rate. The wear rate of the composite specimens decrease with increasing volume percentage of particulate reinforcement. As expected, the wear rate of a composite specimen with a fixed volume percentage of reinforcement increases with sliding distance (fig.5). At constant applied load, the composite specimens exhibit a lower wear rate compared with the unreinforced alloy. The addition of SiC and there will be some of these particles may be formed in cluster at the major end of the pin. Due to the compressive load and increase in sliding distance in the specimen the wear rate gradually decreases which is shown in fig 5. The wear rate with 20 percent of fly ash exhibits a lower wear rate when compared to the other four specimens. The results indicate that the volume content of the particulate reinforcement has a marked effect on the wear rate. The wear rate of the composite specimens decrease with 159 R. Shankar, et al. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles Figure 8 shows typical DSC thermo grams of Mg and its composites, while it show the expanded views of the thermo grams and peaks, with low enthalpies, in the thermo grams. The presence of these peaks in the thermo grams suggests that either different phases formed and dissolved in the samples or stresses relaxed as temperature increased. It can be seen that the peak “a” did not occur in the composites, suggesting that fly ash inhibits the dissolution of β‐phase in Mg. The endothermic reaction labeled “b” can be seen in the MMCs between 90 and 456 o C. This peak is most likely due to an endothermic dissolution reaction in the composites. increasing volume percentage of particulate reinforcement. As expected, the wear rate of a composite specimen with a fixed volume percentage of reinforcement increases with sliding distance (Fig.5). At constant applied load, the composite specimens exhibit a lower wear rate compared with the unreinforced alloy. Micro Hardness test Composite samples show higher hardness than that of their unreinforced counterparts (Chart 1). The composite sample (4) with 15 micro meter size particles shows higher matrix hardness value than that of the composite sample (2) with 150 micro meter size particles. The micro‐ hardness near the particle/matrix interface is higher than that of interior region of the matrix in all the cases. Fig.6 Micro hardness value before and after thermal CyclingWear of reinforced composite at applied load of 39.24 N The interfacial region in sample (2) and sample (3) composites shows considerable decrease in the hardness after treatment. Fig 6 shows the micro hardness of different composition materials and a decrease in hardness of each specimen was found after thermal cycling. Addition of Fly ash particles up to 20 % resulted in an increase in micro hardness of specimens. Differential Scanning Calorimetry Figure 7 shows typical DSC thermo grams obtained for high‐purity Magnesium and SiC in the temperature range 16 to 500 o C. The expanded views of the different sections o of the thermo grams are shown. The data below 16 C and o above 500 C were not presented because of thermal lag in the DSC equipment during measurements. As can be seen from Figure 7, the peak of the exothermic reaction labeled a occurred at about 89.4 o C in Mg/SiC composite. The presence of β‐phase was also reported in sample 1. On the basics of these two literature results, it can be concluded that peak “a” is due to the dissolution of β‐ phase and high purity of Mg in the composite. This peak is due to melting of the alloy as it occurred within the same temperature range as those of high purity magnesium. 0 Fig.9 DSC thermo gram of Mg/SiC between 96 to 410 C Fig.10 Temperature change with respect to time Figure 10 shows the DSC thermo grams of Mg and the composites co‐plotted with that of fly ash for samples heated from 100 to 500 o C. As can be seen, fly ash showed Fig.7 DSC thermo gram of Mg/SiC 160 Fig.8 DSC thermo gram of Mg/SiC between 96 to 410 0 C Figure 9 shows the DSC thermo grams of Mg and the composites when cooled from 500 to 100 o C. The expanded views of different sections are shown. It can be seen from that some of the phase changes that occurred during heating did not reoccur during cooling. This can be discerned from the absence of reactions such as “a” in Figure 7 and 8. Also, it can be seen that the samples solidified between 200 and 476 o C during cooling. These crystallization temperatures are less than the dissolution temperatures obtained during heating. Effect of Fly Ash Particles on the Mechanical Properties and Microstructure on Compacted Magnesium Reinforced With SiC Particles no detectable reaction peak in the temperature range studied. Therefore, it can then be concluded that it is due to the dissolution of the phase that formed between fly ash and Mg during fabrication. Fig.11 DSC thermo gram of Mg/SiC between 16 to 475 0 C Figure 11 shows the thermo grams of Mg and the composites co‐plotted with that of Mg‐SiC‐fly ash mixture. It can be seen that the peaks obtained between 100 and o 500 C for Mg and the composites matches those in the mixture. The endothermic reaction takes place between 200 and 400 o C in the mixture could be attributed to the melting magnesium and SiC as they have very close melting temperatures 7. This peak does not match with peak “b” in the composites. Hence, it eliminates phase transformation in the Mg‐SiC‐fly ash mixture sample as its possible cause. R. Shankar, et al. that the endothermic peaks observed in the samples at about 376.14o C were due to a reversible dissolution reaction in the MMCs. CONCLUSION From the experiments carried the following conclusions have been derived: 1. The specimen with 20 % fly ash Content were found to be more stable under compressive loading and higher temperature as compared to Mg/SiC ,Mg/SiC/fly ash 5p, Mg/SiC/fly ash 10 p and Mg/SiC/fly ash 15p specimen tested. 2. The Optical images revealed that both SiC and fly Ash particles are well distributed in Magnesium Matrix. 3. With the addition of fly ash with higher percentage the rate of heat transfer from specimens decreases as revealed by temperature time plot for heating and cooling. 4. Increase in area fraction of reinforcement in matrix result in improved hardness values. 5. A decrease in hardness of each specimen was found after thermal cycling. Addition of fly ash particles up to 10 % resulted in an increase in micro hardness of specimens. 6. With the addition of fly ash to Mg‐SiC the wear resistance of the composite decreased which is due to the clusters of SiC particles in the specimen. The specimen with highest percentage of fly ash worn out more rapidly as compared to the other specimens during wear test. 7. During the DSC test the endothermic reaction occurs with a maximum peak and area of heat transfer of 376.24oC and 150 J/g respectively which shows the heat is absorbed by the fly ash particles. ACKNOWLEDGEMENT The authors are grateful to Dr.K.V.Rama of IIT Madras for supporting this research collaboration between five participating organizations. Our thanks are also extended to Prof. D.Vijayakumar for his useful suggestions and the academic and technical staff at Veltech Multitech Dr.Rangarajan and Dr.Sakunthala Engineering College. Author Extend his Sincere Thanks to Dr A.Manivannan of Anna University of Technology Tirunelveli for bringing out valuable informations and Dr K.Purushothaman of St.Peters College of Engineering and Technology Chennai. Fig.12 DSC thermo gram of Mg/SiC/fly ash 20p between 10 0 to 490 C Figure 12 shows the thermo grams of Mg and the composites co‐plotted with that of Mg‐SiC‐fly ash mixture o on heating from 16 to 500 C and showing the exploded views of various sections. As can be seen, the thermo gram of the mixture shows that an exothermic phase change occurred at 400 o C, which is about 15 o C more than the melting temperature of the Magnesium MMC reinforced with weight of 20 % fly ash. This peak is most likely due to melting of either aluminum or magnesium in the mixture and the differences observed between the peak positions of the mixture and Mg could be attributed to the presence of other alloying elements in Mg. Another prominent endothermic reaction peak can be seen in the mixture at 376o C. This slight difference in the peak positions could be attributed to the presence of other elements in the alloy which are in the mixture.The peak labeled c in the mixture is due to solidification of Magnesium. The peak labeled b' at about 376.14 o C in the mixture shows that the reaction that occurred during heating (see Figure 12) reversed during cooling. It can be seen that the positions of the endothermic peaks in Mg‐ SiC‐fly ash mixture occurred at about the same temperature as those of the test materials. This confirms REFERENCES [1] Mechanics of Composite Materials, Autar K.Kaw, CRC Press,Boca Raton,New York [2] Basics of Metal Matrix Composites, Karl Ulrich Kainer [3] Sudip Kumar,J.Ananada Theerthan, Production and Characterization of Aluminum Fly‐ash composite using stir casting method, National Institute of Engineering and Technology,Rourkela 2008 [4] N. L. Han, Z. G. Wang, W. L. Wang, G. D. Zhang, C. X. 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Mehrabian Composites of aluminium alloys: fabrication and wear behaviour Springer Netherlands 1982 Some papers consider an interval called “due window” rather than due date. B. also the manufacturer is not allowed to hold them for more than the given post‐ production shelf life. a job is expected to be completed exactly at its due date. respectively. with the sequencing and scheduling of different jobs on a single machine. All the jobs must be processed before the given deadlines. Additionally. However. In Section 4 the cyclic version of the problem is discussed. Iran. p. It is also verified that the cyclic version comprises some independent noncyclic problems. the results verify that cyclic schedules increase flexibility and the manufacturer’s ability to satisfy customer’s orders. The single machine scheduling problem deals. Tehran. In this problem 3 and 2. [4]. 4. is also considered as a dummy deadline in the noncyclic problem.ir Grupo de Sistemas de Optimización Aplicada.2. The rest of the paper is organized as follows. Early or late production imposes earliness or tardiness costs. for the companies that produce dairy products or the ones that have long term contracts with retailers. [5] and [6] are instances of recent studies on this area. Huo et al. ̅ 4 and ̅ 6. we focus on the scheduling of perishable items that should be processed before the given deadlines. the scheduling window is the only feasible scheduling interval and jobs are not allowed to be completed outside of this window. storage in the production site for longer than shelf life is not permitted. Early jobs can be held in the production site with a holding cost . Spain. Section 5 is to illustrate the numerical experiment and the last section concludes the paper and suggests topics for future research.upv. “Assignable due window” is another extension in the classic form in which the early and late due dates are treated as decision variables.Contents lists available at www. ISBN 978‐80‐553‐1216‐3 INTRODUCTION are to investigate both the noncyclic and the cyclic versions of the problem. Perishable Product Scheduling on Single Machine with Deadlines . Citation: Shirvani N. (2010) have investigated a factory that manufactures perishable goods while considering a time window for a safe completion time of products [9]. Camino de Vera s/n. shadrokh@sharif. but job cannot be stored for more than units of time. Acc. Universitat Politècnica de València. Cheng and Gupta (1989) [1] and Baker and Scudder (1990) [2] provide a review on scheduling problems involving due dates and earliness/tardiness. Since the finished products are highly perishable. Jobs must be produced during an allowed time window which is at most of shelf life length and ends at the deadline. Also in some instances. Tehran. shirvani@mehr. 46022 Valencia. Iran. Numerical experiments reveal the efficiency of the proposed solutions for solving the tested instances. We refer readers to [7] and [8] as examples of this subject. 2nd International Conference Manufacturing Engineering & Management 2012. in its simplest form. Edifico 8G. In Section 2 we describe the problem and the notation.edu 2 ARTICLE INFO: Category : Original Scientific Paper Received : 31 October 2012 / Revised: 19 November 2012 / Accepted: 23 November 2012 Keywords: (in causal order) Abstract: Single machine scheduling Perishable products Deadlines Release dates Scheduling time windows This paper studies a realistic single machine scheduling problem in presence of highly perishable products that need to be delivered on time to customers. (1986) carried out the first due window study [3]. we consider a short time scheduling period and plan the jobs in a limited time horizon.tk Manufacturing Engineering & Management The Proceedings Perishable Product Scheduling on Single Machine with Deadlines Nargess Shirvani1 ‐ Rubén Ruiz2 ‐ and Shahram Shadrokh3 1 Industrial Engineering Department. Shadrokh S. show the distinctive deadlines. In our study. This problem is a typical scheduling subject in fresh food and dairy industries. Furthermore. Each job ∈ needs a given processing time and has a fixed deadline ̅ . Deadline of jobs are grouped into distinct sets where and . Ciudad Politécnica de la Innovación. rruiz@eio. … . In the first type. Two different versions of the problem have been considered. 2. (2012).icmem. 163 . Sharif University of Technology. beside the deadlines. the jobs are subject to an ) which is known earliest possible start time ( ̅ as release date of the job in the literature. the production orders come up iteratively through the cycles. 0 ∈ ∶ 1. coordinators of different stages may be faced by such a problem. In the other every job is limited from ̅ words. Extended forms of the problem have been widely investigated by researchers. of different jobs in a time horizon of length . Sharif University of Technology. cyclic schedules dramatically decrease the total cost. Section 3 is dedicated to the development of an algorithm for the problem with limited time horizon.es 3 Industrial Engineering Department. As an example suppose an instance problem ̅ ̅ with 5 jobs such that ̅ 2. In the classic form of the problem. a single machine is considered to process a set ∶ 1. while the interaction between adjacent cycles is taken into account. A revised WSPT rule is proposed and the noncyclic problem is solved by a two-phase algorithm. Hence the feasible region for the completion of to ̅ . Instituto Tecnológico de Informática. Here we NOTATION AND PROBLEM DESCRIPTION In the current research. … . The jobs should be scheduled in such a way that minimizes the total holding cost while adhering to the release dates and deadlines constraints.sharif. This problem has been thoroughly studied in the scheduling literature with the consideration of countless additional constraints. This research studies a realistic version of the problem where finished products are subject to deadlines and are produced and delivered based on customers’ orders. Ruiz R. In the current research. Anger et al. 163‐166. 6 are considered as distinct deadlines. There is an abundance of published researches considering single machine scheduling subject to due dates or deadline constrains and earliness/tardiness penalties. These manufacturers are usually interested in designing a routine production plan for consecutive cycles. The final products are highly perishable and storing them in the production site incurs in a holding cost. when production is performed between independent parties in a chain. All the combinations of those jobs can be considered as the available backward groups. So the possibilities of postponing in sequence should be checked. We first discuss on these cases by considering the solution generated by the algorithm and checking the following criteria: There is a deadline . The above mentioned criteria means that the job should start later in comparison to job due to the WSPT rule. the algorithm starts from the point in order to schedule all the available jobs on the machine without any idle time. processing of the remaining available jobs before is impossible and as a result the problem is infeasible. the cyclic version of the problem is also considered in the current research. our intention is to schedule all the available jobs as late as possible. an empty candidate list forces the next available job to be scheduled later. Updating of the candidate list and the selected job continues until all the available jobs are scheduled. The set of jobs ∈ ∶ . The internal loop of the algorithm is iterated at most for times. Since the algorithm is always adhering to the WSPT rule unless the release date and deadline constraints force it to change the job sequence. 164 . Then is considered as the decision time for scheduling. then decreases are completely scheduled before by 1. However. PHASE 1: INITIAL SOLUTION Corresponding to each deadline . In order to minimize the holding cost. So in this case there is no feasible solution for the problem. adopts the well known WSPT rule and revises it for scheduling a single machine in presence of release dates and deadline constraints. ̅ which includes the jobs that can be moved backward in the sequence . Once the availability list is an empty set. The whole procedure is iterated until no deadline satisfies the criteria. 0 reveals that processing all jobs in the available time horizon is impossible and extra time is needed. the decision time is increased to the completion time of the scheduled job ( ). that For the previous adjacent job of in sequence . This improvement is investigated by a simple local search which is now detailed. Algorithm 1 starts from the last deadline and generates an availability list of the jobs. The removed jobs are added to availability list in addition to the jobs with ̅ . a sequence of the jobs. Otherwise. including all the unscheduled jobs where ̅ . and the forward jobs are sched‐uled regarding the WSPT rule as late as possible. is used to demonstrate the output of the algorithm. which has the lowest priority for scheduling close to the deadline. PHASE 2: IMPROVED SOLUTION Algorithm 1 generates a solution for the problem by determining the start time ( ) of every job ∈ . Because of this idle time. A two‐phase algorithm has been designed and it is described in the following. Once the backward and the forward groups are selected. At each decision time if the candidate list is empty while some available jobs have not been scheduled yet. 1 0 and pj Di 1 Di 1 0 0 ∈ ∶ Once all the are calculated. The original sequence is replaced by the new sequence . R Ruiz. so the time complexity of the algorithm can be considered as cubic time . is selected. all the members of backward group are removed from the schedule. ∈ and a job ∈ such and and. ̅ is also generated. we can continue by using Algorithm 1 to generate an initial solution for the problem. The candidate jobs are then sorted in increasing order of and the job with minimum ratio . In case for a deadline . This algorithm. At each time a candidate list of the available jobs is updated by considering release date limitations. the scheduling of the jobs related to the previous deadline is started by removing the jobs which . Sh Shadrokh Perishable Product Scheduling on Single Machine with Deadlines Regarding these real cases. Then all the jobs which are completely scheduled before are removed from the schedule and Algorithm 1 is then applied to reschedule all the unscheduled jobs. After setting the start time of the job to . the problem is infeasible. in increasing order of the start times. Then.N Shirvani. Then. the output is expected to be a relatively good one. and consequently results in an idle time. The reason can be explained as follows. we first determine a set ∈ ∶ . is calculated by a recursive formula as below: where max 0. We define as the minimum period of time before that should be dedicated to process the jobs related to the next deadlines. hence for each deadline ( ). the whole procedure is iterated to schedule all the remained jobs. NONCYCLIC SCHEDULES In this section we consider a short scheduling period where the manufacturer should schedule jobs between dummy deadline and the last deadline . However. there are still some cases that reveal the potential for improvement of the solution. if provides a solution with better holding cost. before the deadline. ∈ the criteria are valid. including the jobs that can be moved forward in the sequence and in the same manner all the combinations of these jobs are considered as the possible forward groups. called job . 16 1.20 0. . As the first step. all samples have feasible solutions.00 0. corresponding to the idle time started from there is no job such that and . In other words.1 and 0.94 is the best solution for the example problem. 8 and 9.Perishable Product Scheduling on Single Machine with Deadlines N Shirvani. In order to minimize the total holding cost. Job 4 that is related to 4 is the only job that crosses a deadline ( 2). the values of and must be calculated base on Eq. In each group there are some instances which are infeasible. 3 15 5 m 15 20 30 15 20 30 15 20 30 15 20 30 CPU time (ms) 0. in optimum solutions jobs are scheduled as late as possible before their deadlines and idle times therefore must be inserted just after a deadline such as . the best solution is the alternative solution that provides the minimum holding cost. For each combination of the parameters we generate 5 samples such that all instances are feasible at least for the cyclic version. Based on Property 1. there is at least one deadline such that by considering a results in ̅ . 3 7 5 CYCLIC SCHEDULES We now consider the same problem in the case that the manufacturer establishes a long term relationship with the customers and needs to design a routine plan for production cycles.36 0.84 0. Based on the assumptions. 23 have no feasible solutions in the noncyclic schedule. So in each solution the machine should be idle for a while.73 0. can be applied for solving them. Instead of designing a dedicated solution for this problem we show that the cyclic version can be converted to some independent noncyclic problems and the algorithm. 8. With deadline 7 are schedule between 2 4 1. The Gantt chart of the initial solution is illustrated in Figure 1. we can use Algorithm 1. T Fig. 15 and the total number of job is supposed to be 15.30 0.98 8. depicted in previous section. in the optimum solution there is a deadline such that the jobs that started before the deadline have no interaction with the next deadlines of the cycle. ∀ ∈ . All instances are successfully solved.1 Job specification of the example problem. We consider the planing horizon length to be 7. to generate values.91 0. Tab.15 1.74 3. After updating the problem parameters to obtain a cycle started from zero. respectively. 9 . reveal that adopting cyclic schedule might increase the manufacturer’s ability to satisfy the customer’s orders. j 0 1 2 3 4 5 6 7 8 9 p h d 0. every deadline .09 0 Tab.09 ‐0.16 ‐1. and the shelf lives are generated from uniform distributions 0. the whole procedure presented in Section 3 is applied to find a candidate solution. The deadlines are randomly determined in the time horizon and the jobs are assigned to these deadlines randomly.3 % of instances 165 n .35 Feasiblity 40% 60% 80% 40% 80% 40% 80% 40% 80% 80% 60% 60% Next.76 6. in comparison to the previous experiment.2 Calculation of in the example problem.41 COMPUTATIONAL RESULTS In the current section. therefore job 7 goes after job 8 in the solution. AN ILLUSTRATIVE EXAMPLE The algorithm is applied to solve an example problem with 10 and 7.05 0. unless there is no job ∈ such that and ̅ .10 0. Checking the criteria reveals that the second criterion is not valid for the job and therefore no improvement is possible.33 2.16 ‐1. Based on the WSPT rule sequence of these three jobs should be 7.15 6.27 2 1 4 1 4 3 3 2 3 2 2 2 2 4 4 4 4 7 7 7 j 2 3 2 1 3 2 2 1 2 2 h /p 2. cycle ends to the .30 7. we computationally evaluate the performance of the algorithm presented for the cyclic version with the same instances. Sh Shadrokh Property 1 In the optimum solution of the cyclic problem.25 0. the machine cannot be idle at time . Tab.3 Computational results of noncyclic problems. Job specifications are presented in Table 1. 20 and 30.3 0.72 0. Proof 1 An obvious condition for feasibility of the problem is that summation of all process times should not exceed the cycle length.15 0. numerical experiments are conducted for 60 random instances.39 6. Here. Table 3 illustrates average CPU time and the percentage of feasible instances.38 4.91 *Total Required Process Time for ∈ ∶ ̅ 0 ‐0. All instances are successfully solved and as it was expected. but since the shelf life of job 7 is 1.09 and 7. the job is not allowed to be prepared before time 6. 0 1 2 3 0 2 4 7 ∗ 0 1. In this case it is possible to break the cycle from this point and treat it as a limited time horizon problem.21 0. R Ruiz. Among the 60 instances. Property 1 is directly derived from this assumption. The processing times.7 2.20 0. Finally.43 0.65 0.05 0. we suppose that in the feasible solution . 2. Also two level 1/2 and 2/3 of horizon length are considered as number of deadlines . First we test the instances by considering noncyclic schedules.1 The Gantt chart of the initial solution for the example problem. Table 2 shows these 0.20 0. These results. As it is shown all the jobs are scheduled between dummy deadline 0 and the last deadline 7.14 0. The presented solution with the total holding cost 14.09 5.65 0. ∈ is independently selected as a break point. So to solve the cyclic problem. Since an initial solution. 1 and Eq. The jobs 7.05 0. 38. It is supposed that the manufacturer and the customers are working based on a long term contract that obliges them to satisfy fixed repeated orders during the cycles. 166 . European Journal of Operational Research. [7] G. Ottoni. that means 20 percents of instances are improved and average of improvement among these instances is 6.Y. Scheduling identical jobs and due‐window on uniform machines. Electronic Notes in Theoretical Computer Science. [5] J. Huo. Integrated production and delivery scheduling with disjoint windows.00% 20 0. REFERENCES [1] T. These results showed that cyclic scheduling increases the flexibility and the manufacturer ability to satisfy the customer’s orders and reduced holding cost. In addition as an extension we can consider distribution planning beside production scheduling to coordinate a two stage supply chain of perishable products.S.Y. In the current experiments. 2012.00% 20 0.L. [4] G. Discrete Applied Mathematics. 38 (2):156–166. 1989.E. 135(1):222–230. Mor and G. and A. 2010. and X.50 100% 1 25% 2. Wan and B. The finished products have been considered to be highly perishable and the manufacturer was not allowed to store them for more than the given shelf lives.90% [2] K. Lee. The overall problem was to schedule all the jobs on a single machine such that the orders delivered to the customers on deadlines at the minimum possible holding cost.D. 136(3):512–527. Single machine scheduling with tight windows. Scudder.00% 15 0. [9] Y. Sarig.N Shirvani.10 100% 1 33% 50.55 100% 1 33% 1. R. R Ruiz.35 100% 0 0% 0.50 100% 1 33% 1. 158(8):921– 931. Wang.P. 2002. Tabu search for single machine scheduling with distinct due windows and weighted earliness/tardiness penalties.10% 30 0. Martin‐Vega. Gupta.50% 30 1. 281: 5–19. Leung. 2002.90% 15 0. Chen and C. 2010.55 100% 2 67% 3.C. It has been also verified that the cyclic version consists of some independent noncyclic problems and we can use the same algorithm for solving them. among instances which are feasible in both cases there are samples in which the cyclic schedule decreases the holding cost up to 50%. Operations Research.65 100% 0 0% 0. Oliveira Paiva. Furthermore. Computational results revealed efficiency of the proposed algorithms for solving the instances. CONCLUSIONS AND FUTURE RESEARCH In this paper we studied a single machine problem in two cases of noncyclic and cyclic forms. Department of Industrial and Systems Engineering. Developing the problem by adding setup time and setup cost.C. Cheng and M. Sh Shadrokh Perishable Product Scheduling on Single Machine with Deadlines are infeasible in the noncyclic version.95 100% 1 50% 22.65 100% 1 25% 2. European Journal of Operational Research. 15 0. The noncyclic problems were then solved by a two‐phase algorithm that takes advantage of a good initial solution to find a near optimum solution in efficient way.4 Computational results of the cyclic problems. % Ave. C. [3] F. Parallel machine scheduling with a common due window. Scheduling a maintenance activity and due‐window assignment based on common flow allowance. 1986. European Journal of Operational Research.7%. T n 3 7 5 7 15 10 Improvement over noncyclic m CPU time (ms) Feasible Instance No.A.20 100% 2 50% 5. Survey of scheduling research involving due date determination decisions. Baker and G.10% 30 0. 38(1):22–36. Anger. [6] Z. University of Florida. European Journal of Operational Research. Yen.00% 30 1.60 100% 0 0% 0. the solution of 12 instances improve in cyclic version. International Journal of Pro‐ duction Economics. 2011.C Arroyo.90 100% 2 50% 20.10% 20 1.C. and L. 1990. Multi‐ objective variable neighborhood search algorithms for a single machine scheduling problem with distinct due windows. A revised WSPT rule was designed for a single machine scheduling problem with release dates and deadlines.Y. Sequencing with earliness and tardiness penal‐ties: a review. Research Report 86‐16.50% 20 0. 201(3):712–719.00% 15 0.D. Lee. Tab.R.E.T. 142(2):271–281. [8] B. Mosheiov and A. Table 4 details these results. J. and replacing deadlines by due dates or due windows can be considered in future research. Mosheiov. metals. drive shafts.1 Birch plywood strips glued to fir by epoxy adhesive. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Material systems are composed of a mixture or combination of two or more constituents that differ in form or material composition and are essentially insoluble in each other. figures 1‐2. Second. brakes. Polyurethane glue SIKAFLEX 221st was used as adhesive. The solution was the use of composite beams wood of poor quality. ease of manufacturing. shaped by cold rolling. and clutch plates. by rigidly joining the two parts together. Birch plywood Epoxy Fig. It is a single component material which hardens in contact with moisture from the air.. adequate capacity and a low degree of complexity of production. Composites consisting of resin matrices reinforced with discontinuous glass fibers and continuous glass‐fiber mats are widely used in truck and automobile components bearing light loads. [3‐5]. Geometrical and technological characteristics of composite beams: 167 Sikaflex 221 . purchasing materials and preparation time. pistons for diesel engines. or inorganic. [1‐2]. First. the upper temperature limit of the composite. the ability of the matrix to support the fibers or particles and to transfer load to the reinforcement is equally important. composites can be constructed of any combination of two or more materials metallic. There are two main benefits of composite action in structural members. boxed fir beam.Contents lists available at www. for example. the resulting system is stronger than the sum of its parts. thus creating significant advantages over laminated wood beams. in accordance with the basic idea of the beams supporting the development of low cost. Materials used in the preparation of composite beams and their characteristics are very important. the length and arrangement of rings and the presence of nodes. The most important characteristic in this case is the rigidity of the applied material and its elastic modulus. In principle. Two sets were done with three identical pieces of different composite beams: a) Carbon steel strips reinforced. Citation:Smiljanic P. and polymers. composite action can better utilize the properties of each constituent material. glasses. wheels. Composites consisting of resin matrices reinforced with discontinuous glass fibers and continuous glass‐fiber mats are widely used in truck and automobile components bearing light loads. assembly and reducing weight. While composite strength is primarily a function of the reinforcement. (2012). organic. A number of matrix materials are available. SIKAFLEX 221. University of Belgrade Innovation Center of Faculty of Mechanical Engineering Belgrade 2 3 ARTICLE INFO: Category : Short communication Received: 15 September 2012 / Revised: 24 October 2012 / Accepted: 24 October 2012 Keywords: (in causal order) Abstract: Adhesive Composite beams Composite materials Bonded joints Stress‐ strain A structural member composed of two or more dissimilar materials joined together to act as a unit. This material has enabled the development of load bearing components with structural fasteners.2 Fir and carbon steel strips bonded by elastic polyurethane glue. To create a beam. et al. both in price and in ease of manufacturing. the matrix frequently dictates service conditions. was not taken care of in the process of choosing the right wood for the experiment. 167‐169. Advanced composites possess enhanced stiffness and lower density compared to fiberglass and conventional monolithic materials. Fir wood beams were cut to size.: Experimental and Numerical Stress‐strain Analysis of Composite Beams .tk Manufacturing Engineering & Management The Proceedings Experimental and Numerical Stress-strain Analysis of Composite Beams Petar Smiljanic1‐Aleksandar Sedmak2‐Dzindo Emina2‐ Emil Veg3 1 Company ‘Problem’ Belgrade Faculty of Mechanical Engineering. ceramics. St35. including carbon. p. Also. and fir wood category III. Testing of adhesives is done 48 hours after EXPRERIMENTAL RESULTS The experimental part includes the following: composite wooden beams reinforced with steel bands. Fir Carbon steel Fig. but the constituent forms are more restricted. such as interior and exterior panels. The cutting mode.icmem. rotors. 2ndInternational Conference Manufacturing Engineering & Management 2012. leaf springs. the following materials were used: Low carbon steel in the form of strips and sheets (cut into strips). b) Carbon steel strips reinforced fir solid beam. 1 Applied forces and measured flexions Beam box Beam box Beam box Force (N) Flexion (mm) 33.00 7. Results are given in Tab.39e+10 N/m^2 Constant Poisson's ratio‐xy 0.9431 mm.4 Free‐Body Forces Selection Units Sum X Sum Y Sum Z Resultant set Entire N 8.105957 4905.626 mm) Node: 266 449.6e+7 N/m^2 Constant Fig. Experimental and Numerical Stress-strain Analysis of Composite Beams bonding.592 mm.63e+7 N/m^2 Constant Yield strength 7.5e+6 Mass density 1200 Tensile strength 1e+6 Compressive strength 1e+6 Yield strength 1e+6 Analysis of stress and strain at the highest load.10 1. 449. (MPa) 110. Smiljanic.14 284.3 F=284N.‐ 0.04 2700.2059e+8 Linear Elastic Isotropic Max von Mises Stress Units Value Type N/m^2 Constant NA Constant N/m^2 Constant kg/m^3 Constant N/m^2 Constant N/m^2 Constant Sum Y Sum Z Resultant 0 0 1e‐033 Location Max (‐19.6e+007 Compressive strength 4. 449. Selection Units Sum X set Entire N‐m 0 Body Name Type Min VON: 0.5 Free‐Body Moments Tab.9717 mm.7 mm. Von‐Misses Stresses ‐ detailed view.86 mm) (‐19. 0 mm) Node: 6291 Location (‐0.206856 4905.48 Shear modulus 1. Polyurethane glue SIKAFLEX 221 and Plain carbon steel properties are given in Tab. Von‐Misses Stresses Material name: Birch plzwood (3‐layer) Material Model Type: Linear Elastic Orthotropic Default Failure Criterion: Max von Mises Stress Property Name Value Units Value Type Elastic modulus 1. 3.9717 mm.69 mm.7e+6 N/m^2 Constant Compressive strength‐y 5.430787 (4.9431 mm.3 Study results Selection Units Sum X Sum Y Sum Z Resultant set Entire Body N ‐0. 47.9983e+8 Yield strength 2.02279e+8 N/m^2 Constant Compressive strength‐x 6. 2. (MPa) ‐47.003275 Stress2 Mises (MPa) Stress Node: 6810 SIKAFLEX 221 Polyurethane Linear Elastic Isotropic Max von Mises Stress Units Value Type N/m^2 Constant NA Constant N/m^2 Constant kg/m^3 Constant N/m^2 Constant N/m^2 Constant N/m^2 Constant Material name: Plain Carbon Steel Material Model Type: Default Failure Criterion: Property Name Value Elastic modulus 2.1e+11 Poisson's ratio 0.26 mm.2 Material properties Material name: Description: Material Model Type: Default Failure Criterion: Property Name Value Elastic modulus 3e+6 Poisson's ratio 0.9e+010 Mass density 390 Tensile strength 7. et al. Tab. 168 .9e+10 Mass density 7800 Tensile strength 3.0019229 0.9e+007 Yield strength 4. Element: ‐59.00206181 Body 005 NUMERICAL ANALYSIS Numerical analysis was performed by the finite element method. The applied forces and Flexion were recorded.6 mm) (16. 15.28 Shear modulus 7. Result Tab.69 mm.4459 mm.000738807 0.9 mm) (‐22.77008e‐ 0.3e+010 Poisson's ratio 0.3 mm mm.13 Fracture caused by the force on the beam.9 mm) Material name: Fir Material Model Type: Default Failure Criterion: Property Name Value Elastic modulus 1.1398 mm. Testing was performed by simple three point bending.31 ‐52.42 NA Constant Shear modulus 7.27 mm. 376.697 NA Constant Poisson's ratio‐xz 0.4 F=284N.0e+7 N/m^2 Constant Tensile strength‐y 1. 1 Tab.P.0e+007 Linear Elastic Isotropic Max von Mises Stress Units Value Type N/m^2 Constant NA Constant N/m^2 Constant kg/m^3 Constant N/m^2 Constant N/m^2 Constant N/m^2 Constant Fig.92548 ESTRN: e‐006 Strain1 Equivalen Element: t Strain 646 VON: von 0. ‐25.626 mm) Node: 266 18.31 (‐0. 110.0032756 Stress1 von Mises (MPa) Stress Node: 6810 URES: Displa Resultant 0 mm cement1 Displace Node: 6299 ment 6.6643 (‐20 mm.592 mm.35 Tab.22413 mm) 2131 669. ‐52.0e+8 N/m^2 Constant Mass density 620 kg/m^3 Constant Tensile strength‐x 1.35 ‐0. Results of numerical analysis are presented in Tables 3‐5 and Figures 3‐7. 376. ‐37.929 mm.39 Shear modulus 7.35 0. That was also the position of the applied load. Vol. Equivalent strain. Data were obtained for samples of materials. McDanels “Analysis of stress‐strain. No 6. DISCUSSION The results of numerical calculations of load and deformation of the composite beam were confirmed by testing the beam samples. L. support distance was 900 mm. This allows us beam calculation the to maximize potential of used materials. Journal of Applied Mechanics. fracture. producing simplicity. Fellow. which may not fully correspond to those included in testing. Fig. I: Energy Approach”. Deformation was measured in the middle of the tested beam. The reason is beam buckling under the force. 7 F=284N. In the beam bending test we were able to determine the mechanical properties of used materials. and the geometric characteristics of the beam were exactly the same as in the numerical model. Beam deformation. In the box‐beam bending. Journal Of Engineering Mechanics November 1999 [2] Chi Kin Iu “Inelastic finite element analysis composite beams on the basis of the plastic hinge approach”. and the assumption that the numerical model of birch plywood is anisotropic.5 F=284N. In examining the box‐beam there was a fracture at the buckling force of 2700 N and deflection of 7. 169 . Engineering Structures (2008) Volume: 30 [3] Bob Matthews “Applied Stress Analysis” Section XI Composite Materials [4] Hastin. 16. with the same support span of 900 mm. Value of the force at which the fracture zone was created has caused greater deformation than the calculated one. Force values are higher because of greater rigidity of the beam materials. We can notice that the distributions of stresses due to the different elasticity modulus are not equal. Examination of the solid wooden beam was done in the same way. 50/481. REFERENCES [1] Zdenek P.Smiljanic. Using low quality wood material as bearer filling. Examination of the solid beam was done in the same way. Analysis of Composite Materials”. September 1983 [5] David L. For the force range from 1962 N to 4905 N and the deflection of 5mm‐13. This is a basic idea for usage of composite beams. “Compound Size Effect In Composite Beams With Softening Connectors. The force values. The study confirms the characteristics of calculation capacity. Force values are higher because of higher beam material modulus. ASCE.13 mm. CONCLUSIONS Fig. Increase of the beam deflection is proportional to the increase in bending force. (1985). Z.2mm there was no beam fracture. for corresponding deflection. material acquisition and production time. Bažant. The values for the corresponding deflection of force are different from the numerically obtained due to higher stiffness of the used wooden beams.Experimental and Numerical Stress-strain Analysis of Composite Beams P. 1105‐1115. Total Strain Energy. and ductuly behavior of aluminium matrix composites containg discontiunuos silicon carbide reinforce‐ ment”. with the same range. are different from the numerically obtained due to higher stiffness of the wooden beam materials. Metallurgical and Materials Transactions A. Analyses were performed with at the maximum loaded beams. Fig.6 F=284N. Vítek. Vol. et al. gives significant advantage in comparison to laminated wood bearings in terms of price. Advances in industries like nuclear reactors. Institute of Physics. TOPSIS. However. E‐mail: marta. In the second section research methods are introduced briefly. automobiles. complexity of decision making processes changed in the course of time proportional to the improvements in science. production of complex shapes. These methods are powerful tools which are widely used for complex problems featuring high uncertainty. VŠB‐Technical University of Ostrava.edu. environmental impact.temucin@gmail. decision making process wouldn’t be easy as formerly because of the increased number of inputs such as conflicting criterions. proportional to the increase in the strength of work material. fuzzy set theory. Ideal Solution is the choice with best performances in every criterion which is indeed impossible to come true. Czech Republic. Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) is used both in crisp and fuzzy environments.icmem. conflicting objectives. In this case. The remainder of this study is structured as follows. and etc. Thus. it is claimed that the capacity of human is limited in the solution of complex problems. In this section. Such developments in the field of material science points out them as indispensable processes due to some benefits such as economic cutting speed. conclusions and further recommendations are highlighted in the last section. This study provides distinct systematic approaches both in fuzzy and crisp environments to deal with the selection problem of appropriate NTM process and proposes a decision support model helping decision makers to assess potentials of distinct NTM processes. Czech Republic. VŠB‐Technical University of Ostrava. and shortage of the experienced planners [4]. p. TOPSIS The first method used in this study is TOPSIS which is developed by Yoon and Hwang in 1980. evolution of MCDM methods has started. 2nd International Conference Manufacturing Engineering & Management 2012.harnicarova@vsb. Consequently. ISBN 978‐80‐553‐1216‐3 INTRODUCTION methods to be widely used [4‐7]. 170‐175.com. Humans used this vital ability in decision making process which can be defined as the procedure to find the best alternative among a set of feasible ones [1]. MCDM has been one of the fastest growing problem areas during at least the last two decades [3]. nuclear reactors. rational. and turbines require high strength and temperature resistant alloys.valicek@vsb. In this respect. and Fuzzy TOPSIS methods are explained briefly. In this context. and making use of past studies.cz Nanotechnology Centre. time of process. E‐mail: tolga. automobiles. Method’s logic is understandable. However in the course of time traditional machining processes wouldn’t be sufficient to produce complex shapes in the strengthened materials such as titanium and stainless steel.tk Manufacturing Engineering & Management The Proceedings A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection Tolga Temuçin1 ‐ Hakan Tozan1 ‐ Jan Valíček2 ‐ Marta Harničárová3 1 Turkish Naval Academy. This method is employed for [8‐11]: Computation procedure is simple. The method uses the concepts of Positive Ideal Solution and Negative Ideal Solution to determine the best choice. Consequently. and efficient. htozan@dho. therefore I exist” is perhaps the best comment that discloses the importance of thinking in human life. The purpose in this study is to propose a decision support model which is used to select the best non‐traditional machining process option for cutting operations of a specific material. An application of the proposed model is also performed to show the applicability of the model. Department of Industrial Engineering. The well‐known philosophical statement denoted by René Descartes “I think. According to this method the best alternative is the one which is 170 . The required data for decision matrixes is obtained via a questionnaire to specialists as well as deep discussions with experts. and etc. quality of surface finished. deep discussions with experts. the choice nearest to the ideal solution must be preferred. and making use of past studies. and perspectives [2]. the ill‐structured and multi criteria nature of NTM process selection problems involving many uncertainties concluded MCDM Research Methods: TOPSIS and Fuzzy TOPSIS As a decision support tool. Temuçin et al. multi interests.tr Mining and Geological Faculty. The positive ideal solution is one maximizing the benefit criterion and minimizing the cost one while for the negative ideal solution the opposite is true [8]. Tuzla.Contents lists available at www. uncertainties concerning the process capabilities. missiles. Finally. NTM processes are characterized by the presence of a large number of viable alternatives. Istanbul/TURKEY.: A Fuzzy Based Decision Support Model for Non‐traditional Machining Process Selection. (2012). cutting tool materials also required to be harder which caused the evolution of NTM processes. According to the concept of “restricted rationalism”. the selection process for the proper NTM process requires the usage of multi criteria decision making (MCDM) methods due to conflicting criterions such as initial cost of technology. importance weights. E‐mail: jan. In the third section firstly the proposed decision support model is introduced and then a case study is performed. Criterions for the proposed model and weights that represent the rate of importance for those criterions were identified via questionnaires to specialists. and Importance weights are incorporated into the procedure. They help to improve the quality of decisions by making the process more explicit. and etc. Citation: T. This forced scientists in the field of material science to develop higher strength materials.cz 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 21 February 2011 / Revised: 24 October 2011 / Accepted: 24 October 2011 Keywords: (in causal order) Abstract: Multi‐criteria decision making Fuzzy logic TOPSIS Usage of non-traditional machining (NTM) processes has increased recently since demand for materials like high strength and temperature resistant alloys has expanded proportionally to the improvements in technologically advanced industries such as aeronautics. .. cn by alternatives with respect to each criterion defined by a ij i 1. (7). et al. y ij xij * w j j P j P (2) max p . can be calculated with Eqs. w1 . n .J c ij 1 ij 1 ij ij 2 (3) 2 (4) Si n (y j 1 ij S i* and S i (y ij y j ) 2 (5) (6) Determine the highest value of a3 ' s in that column. a3 . Temuçin. 2. “On the contrary to many cases that involves human judgment.…. Error rate defined for decision and weight matrixes helps to obtain a triangular fuzzy number (TFN) for each crisp number. a . a a . crisp sets divide the given universe of discourse into basic two groups. In this step the Step 8: Rank Preference Order: The alternative with the highest C i* is the best choice.…. which certainly are not. It is a precise logic of imprecision and approximate reasoning [13]. the most extreme values The normalized value of a a1 . a triplet positive and negative ideal solutions can be determined with Eqs.m inp . ai . m j 1. am . max p . noisy... Step 7: Calculate Relative Closeness to the Ideal Solution: The relative closeness to the ideal solution.. and the performances of weight matrix. a2 . ambiguous. On the contrary of crisp set theory. Step 2: Convert Criterions to the Same Type: Conversion is done by dividing “1” with the evaluation values in the column of criterion which is desired to be converted..…. (8). having the weights defined by Si Si Si* Step 1: Construct Decision () and Weight (ࢃ) Matrixes Step 4: Construct Weighted Normalized Decision Matrix (ࢅ): The weighted normalized decision matrix can be constructed with Eq. or missing input information [14].…. and the middle one can be computed with Eq. 2. The algorithm of this method is described as follows: Step 1: Construct Decision () and Weight (ࢃ) Matrixes: The decision matrix.. Step 3: Construct Normalized Decision Matrix (ࢄ): The normalized decision matrix can be constructed with Eq. a 2 . * * * For cost criterions: x x x . 2. criterions defined c1 . c j . fuzzy set theory is developed to cope with these kinds of indefiniteness. It provides a simple way to arrive at a definite conclusion based upon vague. Ci* defined by a1 . . Considering a TFN formed by If c1 and c2 are benefit and cost criterions respectively. imprecise. W . Step 2: Convert Criterions to the Same Type Step 5: Determine Positive and Negative Ideal Solutions: ෩ ) and Weight (ࢃ ෪) Step 3: Construct Fuzzy Decision ( Matrixes: Criterions can be grouped as objective and subjective ones [16]. Zadeh in 1965. (2).. which are certainly belonging the set and non‐members. wn for each criterion satisfying w j 1 j 1 a11 a1n A a m1 amn Fuzzy logic (FL) notion was first introduced by L.A.. The basic difference of FL is its capability of data processing using partial set membership functions” [15]. m . Si* 1 error rate a1 = crisp data crisp data * 100 a2 (crisp data) (8) Step 6: Calculate Separation Measures: The positive and negative ideal separation measures. Very often in MCDM problems data is imprecise and fuzzy [3]. 171 3 ෩ ): Step 4: Construct Normalized Fuzzy Decision Matrix (ࢄ Normalized fuzzy decision matrix is constructed as follows: For benefit criterions: n j 1 y *j ) 2 2 error rate a3 crisp data crisp data * 100 respectively.J c .J c m inp . 3. These components are viable alternatives T. (5) and (6). (1) to make the data dimensionless. is also need to be constituted. members. w j . ak ... for each alternative can be calculated with Eq. a .…. Equalize the highest value of a3 ' s in that * column to x .A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection nearest to the positive ideal solution and farthest to the negative ideal solution [12]. (3) and (4). C i* .…. c2 . xij aij Fuzzy TOPSIS (1) m Principal steps of fuzzy TOPSIS method can be described as follows: a 2 kj k 1 (7) where 0 C i* 1 and i 1. A consisting three components has to be determined.J c . This delimitation which arises from their mutually exclusive structure enforces the decision maker to set a clear‐cut boundary between the decision variables and alternatives. Fuzzy sets theory in MCDM n w2 . . safey. AISI 309 is a heat resistant alloy with oxidation resistance to 19000F. 2. Step 6: Determine Fuzzy Positive and Fuzzy Negative Ideal Solution Sets: Fuzzy positive ideal reference point FPIRP. The chemical composition of AISI 309 is given in Table 1 [20]. 1 2 2 2 n1 m1 n2 m2 n3 m3 3 (11) Step 8: Calculate Relative Closeness to the Ideal Solution Step 9: Rank Preference Order Tab. w j 1.m Manganese numbers [17]. Additionally. HH. A are defined with Eqs. m2 .045 ‐ 0.1. TSU. SO. S. If n n1 . PC. and R are cost criterions where lower values are always preferred. R.1 Structure of the machining process selection decision support model Step 7: Calculate Separation Measures: Vertex method can be used to compute the distance between fuzzy m1 . HH. AP. A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection are benefit criterions where higher values are desired. and making use of the past studies [4. IC.. Additionally. water jet and abrasive water jet are the most rapidly improving technological methods of machining materials [19]. DTE. Determine the smallest value of a1 ' s in that column. 2.0. has to be multiplied with fuzzy weight.00 Determination of the weights concerning each criterion..1 Chemical composition of AISI 309 (%) [20] Proposed Decision Support Model and a Case Study for Machining Process Selection Proposed decision support model Oxy‐fuel. N.. error rate (10%). m j 1.3. ease of fabrication. j 1. S. in this study concern is focused on these five machining process alternatives. n2 . Fig. and CS (m/min) are objective criterions that have absolute numerical values. Tab.. while OC.. m3 A case study for machining process selection AISI 309 stainless steel is considered during the evaluation phase of each alternative machining process in terms of criterions.00 ‐ 1. laser.. N. . DTE (mm).6]. aij i 1.6]. 1 illustrates the skeleton of the proposed model including criterions and alternatives. a3 a2 a1 The normalized value of a Step 5: Construct Weighted Normalized Fuzzy Decision ෩ ) Matrix (ࢅ Each fuzzy evaluation value... and UF MIN MAX 22.. vn (9) A v . Determination of the criteria for the proposed decision support model was done via questionnaires filled in by specialists as well as deep discussions with experts studying in Faculty of Manufacturing Technologies of The Technical University of Kosice. W. TSU. x* x* x* .. V. Fig. AP. CS. and plasma machining processes are the most common ones [18]..00 12. The high chromium and relatively low nickel content of it provide good resistance to high temperature sulphur bearing atmosphere.00 ‐ 0..T. (9) and (10). 2. n.3. SO. while OC. W. . toxicity are some criterions that should be used in the comparison of some distinct non‐traditional machining technologies [4. A v1 . n . and UF are subjective criterions which are evaluated on a scale of 1‐10 by specialists and experts of this field. Temuçin. ESCAS. et al. A and fuzzy negative ideal reference point FNIRP.. v . SR. Among these criterions... j to obtain weighted normalized fuzzy decision matrix. The developed decision matrix is illustrated in Table 2. V. (11).20 ‐ 0. IC.00 24. SR (µm). 2. PC.00 15. Therefore.1 and v j 0.0 . and performances of alternatives in terms of each criterion was done via a questionnaire filled in by specialists as well as deep discussions with experts studying in Faculty of Manufacturing Technologies of The Technical University of Kosice.. n . v2 ..... v (10) where v j 1. n3 and m Sulphur Phosphorus n Carbon 2 Nickel 1 Chromium . ESCAS. Surface finish.. Equalize the smallest value of a1 ' s in that * column to x . cost.3. and good weldability. Some features of this stainless steel are moderate strength at high temperature.. are two TFNs then the distance between them is calculated with Eq..030 ‐ 2.2 Decision matrix 172 Silicon d n . 013 0.970 0.250 1 5 0.111 0.158 0.167 O‐FUEL 5 5 1 8 7 7 7 0.041 0.010 0.010 0.375 9 9 9 2 WJM 5 7 1.063 0.876 0.058 0. Equations (5).407 0. et al.008 0.001 0.143 0.024 0.201 0.143 0.688 WJM 0.292 0.6*10 0.467 0.002 0.250 8 0.318 0.474 0.195 0.610 0.500 0. Finally.250 ESCAS PC Tab.030 0. Temuçin.015 0.041 0.065 0.015 0.011 0. Machining Process Selection with TOPSIS: Cost criterions in the decision matrix shown in Table 2 are converted to benefit criterions.052 0.790 0.027 0.3 Reconstructed Decision matrix S HH CS SO ESCAS PC UF LBM 3 4 0.039 0.019 0. negative ideal solution.065 0.011 0.273 0.643 0.012 0.052 0.061 0.250 1 2 0.024 0.045 0.030 0. The fuzzy normalized decision matrix and the fuzzy weighted normalized decision matrix are presented in Table 8 and Table 9.046 0.016 0.013 ‐6 ‐5 10 0. The Machining Process Selection with Fuzzy TOPSIS : decision matrix shown in Table 2 and the weight matrix shown in Table 4 (last row of the table) are fuzzified via Eq.080 0.500 9 9 9 3 OC IC DTE W SR 0.438 0.461 2 WJM 0.111 0.503 0.021 0.046 0.2*10 0.333 0.052 0.098 AWJM 0.707 0.045 0.026 0.111 0.020 0.289 1*10 0.333 0.283 0.030 0.667 0.016 O‐FUEL 0.010 0.242 0.005 0. The required data for the study is obtained via questionnaires given to experts and making use of past studies.014 0.938 0.172 Tab.013 0.011 0. respectively.482 0.4*10 0.333 0.016 0.019 0.482 0. The results reached by TOPSIS and fuzzy TOPSIS methods showed that WJM is found to be the best alternative while AWJM is the second and LBM is the third alternatives in the rank order.125 1. (8).527 0.603 0.065 0.369 0.143 0.077 0.438 0.024 0.009 0.018 0. The fuzzy decision matrix and fuzzy weight matrix are presented in Table 7.039 0.109 0.583 0.052 0.020 0.143 5 0.466 0.482 0.219 0. Further researches can be performed using other fuzzy MCDM methods such as fuzzy ELECTRE.333 10 1 TSU V N AP R 0.167 0.065 0.032 0.018 0.167 0.244 0.188 0.409 0. The weighted normalized decision matrix shown in Table 5 is constructed via Eq.008 0.556 1 PAM 0.688 ‐5 ‐4 PAM 0.120 0.467 0.174 0.398 0.361 1.048 0.027 0.007 0 0.500 0.019 0. On the other hand.200 0.024 0.023 0.500 10 PAM 2 2 5 8 9 7 1 0.474 0. Relative Closeness’s to the Ideal Solution and Preference Orders Positive Ideal Solution Negative Ideal Solution Relative Closeness’s to the Ideal Solution Preference Orders LBM 0. (6) and (7) are used to determine positive ideal solution.068 0.041 6*10 PAM ‐4 10 V 0.250 2 0.043 0. negative ideal solution.395 0.065 0.018 2.019 0.143 0.415 0.052 0.010 ‐5 Tab.500 0. Equations (11) and (7) are used to determine positive ideal solution.4 Normalized Decision matrix S HH CS SO UF OC IC TSU DTE W SR V N AP R ‐5 LBM 0.610 0.033 0.039 0.083 0.016 0.182 0.104 0.250 0. and relative closeness’s to the ideal solution for each alternative shown in Table 6.557 0.167 0.6 Positive and Negative Ideal Solutions.012 0.043 0.125 0.159 0. to the ideal solution for each alternative shown in Table 10.250 0.006 AWJM 0.466 0. Determined weights shown in Table 2 are normalized and presented in Table 4 within the normalized decision matrix which is constructed via Eq.094 0.027 0.058 DTE W SR ‐6 ‐4 0.093 0.276 4*10 0.119 0.024 0.200 0.467 0.200 0.014 1.050 9 9 10 7 0.003 0.500 0.661 0.115 O‐FUEL 0.395 0.026 0.154 0.065 0.006 0.819 0.022 0.040 WJM 0.197 0.032 0.070 0.040 0. PAM and Oxy‐Fuel Machining seem to be on the fourth and sometimes on the fifth rank in the sequence depending on the chosen method for application.364 4 OXY‐FUEL 0.065 0.024 0. a comprehensive decision support model is proposed to assist decision makers in the selection of the right machining process for a specific material.661 0. fuzzy PROMETHEE or the ones which take into consideration the influences between alternatives and criterions such as fuzzy Analytic Network Process (FANP).250 0.6*10 0.5 Weighted Normalized Decision matrix S HH CS SO ESCAS PC UF OC IC TSU ‐6 N AP R LBM 0.722 0. and relative closeness’s CONCLUSION In this study.415 3 AWJM 0.200 0.234 0.047 0. Tab. A case study is also performed.189 0. The reconstructed decision matrix is presented in Table 3.292 0.503 0.031 0.500 WJM 6 8 0.036 0.362 0.500 0.283 5 173 .466 0.031 0.023 0.415 0.030 0. (1).250 0.636 0.250 0.023 0.181 1.065 0.466 0.438 0.369 0.214 2*10 WEIGHTS 0. (2).065 0.A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection T.282 0.302 0.019 0.024 0.707 0. 818.0.0.0.450.2.514 0.0.0.002.0.100) (5.205.150.333.0.1.764 0.12*10‐7) W (0.000.0.0.900) (0.450.0.024.5.0.047) (0.0.018) (0.573.000.0.275) (0.0.0.5.0.1.0.048.225.286) (0.034.0.818.0.045 1 PAM 16.450.0.038.0.0.0.071) (0.035) HH (0.550) (0.0.000.250) (0.0.818.1.0.0.182.061.0.909.200) (1.0.000) (0.0.0.0.700) (0.117.036.0.010.200.071) (0.0.157) (0.0.275) (7.0.1.000) (0.0.2.375.013) (0.182.500) (2*10‐5.030) (0.24*10‐6. A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection Tab.682.0.038.818.000.0.400) (0.400) (16*10‐7.409.0.0. Temuçin.143.500. 15*10‐6.065.052.1.0.800) (0.0.0.800.736.0.0.200.0.167) OXY‐FUEL (0.0.058.250.000) (0.008.0.040.016.0.545.1.7.0.0.409.111.0.1.0.099.0.053.300.900) (6.0.052.800) (8.0.0.0.338.0.909.051) UF (0.000) PAM (0.0.0.016.0.0.0.050.390.9.0.027.614.0.0.059) (0.059.0.0.10.020.667.0.0.9.1.818.0.0009.0.022.0.4.040) (0.059) (0.1.222) (0.071) (0.450.048.8.000) (0.071) (0.273.909.0.071) (0.7.020.062) (0.273.059.034.413) (8.333) (0.8.0.0.0002.0.909.0.7.0.0.0.014) (0.000.0.0.057) AP (0.0.0003) (0.0.0.909.636.009) AWJM WJM (0.7.220) (0.048.636.007.0.409. no.0.0.0.0.032) (0.048.273.0.000.023.0.000.143.909.300) (3.818.010) (0.0.275) (0.0.909.500.018) (0.682.250) (0.0.000) (0.0.1.200) (0.1.000.0.143.0.8.012.0.5.048.364.033) (0.008.900) (8.260.2.303.183) (0.0. LBM S (0.044.333.180.299.000) (0.042.015.000) (0.18*10‐6) (0.000.047.0.000.234.0.020.0.020) IC (0.0.200.043) (0.038.200) (0.0.071) (0.038.030) (2*10‐5.0.0.300) (0.1.3.026 4 Acknowledgements funded by Structural Funds of the European Union and state budget of the Czech Republic and the project RMTVC No.012) DTE (8*10‐6.039.0.6.0.000.0.0.009.035.800.040) (0.0.0.0.0.300.333.052.0.011.013.00) (6.009.000) (0.038.0.041.12*10‐7.021.065.606.043.136.042.200.9.909.500) (4.047.1.550) (0.021) (0.1.019.100.068.059.0.0.400) (0.027.0.117.100) (1.0.0.234.833) (0.650) (8.5.299.000.003.0.18*10‐7.900) (2.0.019) (0.0.0.0.028) (0.064) (0.818.0.0.727.043) (0.020) OC (0.0.0.0.0.0.250.023.071) (0.1.0.0.0.500.0.0.0.1.9.9.0.0.1.808.059.493 0.0.025) (1*10‐5.0.300) (0.113.225.0.052.0.614.0.0.500.716.1.0.157) (0.0.025.0040 This research has been elaborated in the framework of the IT4Innovations Centre of Excellence project.125.0.205.143) AWJM (0. CZ.065.220) (0.200) (0.200) (0.032.818.10 Positive and Negative Ideal Solutions.0.129.227.028) (0.T.0.0.1.0.0.0.046.0.000) (0.200.500.333) (0.065.455.0.000) (0.043.154.0.0.0.0.800) (0.500) (0.0.0.053) SR (0.0.164.225.0.682.11*104) (0.818.367) (0.053.0004.0.0.011) TSU (0.0.700) (6.030.029.1.367) (9*104 .818.667) (0.045.047.625) (0.500.0.900) (0.700) (6.007.058.063) (0.364.044) (0.0070 supported by Operational Programme 'Research and Development for Innovations' 174 .0.0.057) (0.180.0.033.052.019.0.0.682.909.029 3 AWJM 16.143.0.0.0.071) (0.000) (0.0.059.333.0.455.700) (0.000.033.429) (0.053) (0.182.0.0.0.9.234.818.909.0.0. 2*10‐5.818.025.0.164.010) (0.545.0.1.0.300.409.049.303.0.225.050) (0.200) (4.1.138) (0.8.0.0.707.058.047.250) Tab.100.000) (0.900.205.000.012.008.300.909.9.795.038.300.0.0.0.000.0.017.064) Tab.036.0.0.100) (0.011.000) (0.015.021) (0.020.004.818.409.0.052.234.250) (14*10‐6.0.017.455.0.167.0.071) (0.029.778) (0.7.035) CS (0.043.167.250.1.0.0003.027.275) (1.122) (0.900.014) (0.0.2.0.009.245.900.059.059.00071) (0.058.0.038.390.0.600.909.0.0.2*10‐6) (0.200.227.0.057) (0.059.0.0.0.9.113.024) (0.000.636.0.0.409.1.8.500) (0.018) R (0.0.0.3.275) (0.568.909.0.273.058.100) (0.036.0.909.455.000.000) (0.000.010.019.0. /ALT.0.057) N (0.000.0.0.0.833) (0.275) (0.0.038.058.1*10‐6.0. S H CS SO ESCAS PC UF OC IC TSU DTE W SR V N AP R LBM AWJM WJM PAM OXY‐FUEL WEIGHTS (2.0.0.059.818.367) (0.9.0.303.5.1.220) (0.0.3.0.051.0.0.042.057) (0.048.138.100) (7.682.065.0.511.500) (0.037.1.0.028) (0.0.205.371 0.260.012.0.023.065.0.750) (0.0.0004) (0.909.00/01.122) (0.0.14*10‐7) (0.012.0.0.048.1.818.500.818.0.400.614.00048.0.000.0.0.046.808.043) (0.0.014.0002.11*104) (0.286) (0.0.1.758.011) OXY‐FUEL (0.000.00.0.0.000.057) (0.000) (0.0.0.0.0.0.275) (0.0.130.047.0.0.000) (0.246 0.000. S HH CS SO ESCAS PC UF OC IC TSU DTE W SR V N AP R LBM (0.600) (7.1.042.157) (0.286) (0.028) (0.227.2.100.0.003) (0.7 Fuzzy Decision Matrix and Fuzzy Weight Matrix CRI.225.071) (0.057) (0.0.550) (0.122) (0.818.0.7.8 Fuzzy Normalized Decision Matrix CRI.0.1.0.048.020) (1*10‐6.152.11.0.052.0.0.0.0.0.024) (12*10‐6.0.909.024.059.0.071) (0.909. 105 .059.000.063) (0.455.058.436 0. et al.057) (0.250.750) (0.682.0.550) (0.0.900) (8.0014) (0.0.0.424 0.800) (6.129.059.0.0.129.0.202.019) (0.0.0.1.0.064) PAM (0.227.002) (0.143) (0.0.5.059.0.900) (1.0.909.0.614.000.018.042.047.0.012.0.9.1.727.000) (0.015.0.9.014) (0.0.750) (0.0.327.500) (6.0.0.250.0.455.0.300.071) (0.750) (0.0. reg.012.450.0.000) (0.010.286) (0.225.0.013.1.0.0.000.0.0.351.573.167.9.450.0.0.303.900) (9.700.013.0.0.909.0.1.058.7.150.0.167.037 2 WJM 16.0.055) (8.071) (0.758.0.052.9 Fuzzy Weighted Normalized Decision Matrix CRI.0.004.260.0.205.0.012.429) (0.582 0.7.0.041.500) (0.071) (0.169) (0.075) (0.202.700) (0.550) (0.000) (0.0.909.17*10‐6) (0.4.000.909.180.7.0.909.05/1.0.0.029.026.0.0.046.000.889) (0.1.183) (4.0.614.200.044.05/2.260.0.9.002.0.606.0.052.0.8.0.1.0011.000) WJM (0.0.016.0.0.017.818.273.000.129.9.071) (0.900) (8.0.0.100.0.9.818.008.010.1.000.0.0.0.0.0.0.200.0.058.0.048.500) (0.016) (0.100.227.818.129.0.818.818.0.058.000) (0.7.2.0.013.017.700) (0.500.250) (0.0.225.0.250) (0.029.071) (0.900.0.0.0.047.2.0./ALT.0.071) (0.019.682.0.0.157) (0.500.275) (0.048.0.0.057) (0.222) (0.0.006.0.0.099.0.500.500.700) (1.0.000.000) (0.057) (0.065.029.0.2.071) (0.025 5 OXY‐FUEL 16.0.130.875) (0.9.0.0.033.333) (0.045.000.111.030.049.0.0.9.0.7.227.909.040.014.0.0.833) (0.350.5.000.016.100.818.550) (9*104.5.003.0.800.00059.3*10‐5) (0.409.000.046.071) V (0.0.500) (0.909. Relative Closeness’s to the Ideal Solution and Preference Orders Positive Ideal Solution Negative Ideal Solution Relative Closeness’s to the Ideal Solution Preference Orders LBM 16.333) (0.016) Tab.367) (0.021.0.064) (0. 2*10‐5) (0.057) PC (0.900.455.0.638 0.0.0.0.0.0.250.059.009.005) SO (0. 105.818.700.909.0.9.047.182.010.0.1.138) (1.736.0.250.100.500.0.065.0.889) (0.700) (0.014.569 0.00/02.14*10‐7) (0.0.500) (0.018.0.0.225.0.0.000.064) (0.143.667) (0.150.0.100.0.000) (0.057) (0.150.818.0.000.250.0.299.450.205.15*10‐6.0.014) (0.6.016.048.071) (0.0.0.0.750) (0.550) (0. CZ.818.071) (0.1.046.0.000.035.250.1.157) (4.071) ESCAS (0.0.1.800.111.800.0.058.0.0.051) (0.014.000) (0.180.2.023.048.0.0.7.2.818.0.900) (8.050) (0.048.275) (1./ALT.8.053.900) (8.0.125.183) (0.0.220) (0.818.000) (0.909.0.000.057) (0.065.183) (0.500.1.200) (0.044) (0.008.1.099.0.0.225.12*10‐7.1.100.0.0.071) (0.0.0.008.8.500) (7.048.327.035.351.0.299.0.3.0.0. R. J.2 or door No. Turkey [20] Davis J. J. 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Journal of Manufacturing Systems 30:41‐53 [5] Das C. Expert Systems with Applications 36:702‐715 [13] Zadeh L. Computers & Operations Research 27:963‐ 973 175 T. (2011) Selection of non‐ traditional machining processes using analytic network process. door No.. Information Sciences 178:2751‐2779 [14] Kaehler S. Chakraborty S. H... (2011) Non‐traditional machining processes selection using data envelopment analysis (DEA). İstanbul. Kahraman C.A Fuzzy Based Decision Support Model for Non-traditional Machining Process Selection References [1] Cebi S. England [16] Wu M. (2010) Developing a group decision support system based on fuzzy information axiom. 01 October 2009. Y. Expert Systems with Applications 39:2822‐2841 [3] Triantaphyllou E. Fuzzy Sets and Systems 114:1‐9 [18] McQuade. (2012) Organizational strategy development in distribution channel management using fuzzy AHP and hierarchical fuzzy TOPSIS. (2008) A combined TOPSIS‐AHP method based approach for non‐ traditional machining processes selection. (2003) Development of a multi‐attribute selection procedure for non‐ traditional machining processes. A. D. C.1. N.. job losses to the workers and permanent damage to the environment [2]. which are targeted to key point of equipment. 2nd International Conference Manufacturing Engineering & Management 2012. Juga P. 3. Biogas stations have had several accidents in the Czech Republic. Currently 327 biogas stations with installed output in the range from 50 kW (municipality Zavidov. It is internationally accepted method developed by Dow’s Chemical Company for identification of fire and explosion of process units. so three employes were intoxicated by this gas. Department of Agriculture. 2. the residual biogas ignited during adjustment of gas tank on the May in the year 2009. The rest of biogas stations are located above all on farms and in the lesser extent in the industry [3]. Where together 96 biogas stations are located in the waste water treatment plant and 53 is located in the closed landfill of municipal waste. The next aim was to obtain method for relative evaluation of processing units. Index methods belong to generic methods of risk identification. which relate with this. 1.Contents lists available at www. Citation: Trávniček P. which was not devoted big attention to this date. The typical representative of index methods is Dow’s Fire and Explosion Index method [1]. (2012). Email ARTICLE INFO: Category : Professional Paper Received : 15 October 2012 / Revised: 30 October 2012 / Accepted: 15 November 2012 Keywords: (in causal order) Abstract: Biogas storage Fire and Explosion Index Hazards Process safety Biogas stations and their gas storages are potential sources of the fire and explosion risk. Calculation Fire and Explosion Index Value for the Biogas Station. During this time the method was applied in many industries and activities. For example. The quantity of biogas stations grow up in the Czech Republic. Therefore is an important evaluation of the risk for these sources according to the chosen method.icmem. But the high fire and explosion potential have for example equipments for storing or carbon‐hydrogen processing [6]. Vítěz T. The purpose of the F&EI system is [4]. These methods are not equipped to. For this reason the numbers of risks grow up. Dow’s Fire and Explosion Index evaluates only explosive and flammable substances. METHODS The five model examples of biogas stations were assigned for purpose of this paper. This potential can have also biogas stations. The F&EI uses almost 50 year. 176‐177. 2012. Membrane gasholders were 176 . Zemědělská 1. similar to other types of analogous equipments (for example storage tank for methane). These risks were overlooked to date. which were gradually developed for identification on the base of experience. CH4 and CO2. The installed power of all biogas stations is 224. explosion and reactivity incidents in realistic terms. 1 Consequences of the explosion of biogas reactor in the municipality Daugendorf [5] The F&E Index can be one of tools for risk evaluating of biogas station. serious injuries. Non‐traditional application of this method can be for example integration of F&EI to the process design and optimization of chemical devices with respect to safety [7].5 MW of an cogeneration unit get approximately 800 m3 of buffer volume gas tank so maximal volume of biogas is approximately 300 000 m3. too. Different risk cannot be detected with these index methods. The biogas production facility exploded in the municipality Oggenried on the November 2007 and the building was damaged. 613 00 Brno. This method are used for detect of points with the greatest of potential losses and enable to predict the extent of the damage. It is above all chemical industry. Biogas probably contained mainly CO2. The next explosion of equipment was on December 2007 in the municipality Daugendorf. Food and Environmental Engineering. Unfortunately accidents were more serious in the Germany. Identify equipment that would be likely to contribute to the creation or escalation of an incident. There the biogas reactor was damaged [5]. The method primary serves as lead for a selection of successful way of fire protection.tk Manufacturing Engineering & Management The Proceedings Calculation Fire and Explosion Index Value for the Biogas Station Petr Trávníček1 ‐ Petr Junga1 ‐ Tomáš Vítěz1 1 Mendel University in Brno. The first edition of Dow’s Fire & Explosion Index (F&EI) arises in the year 1964. which is located in the Czech Republic (biogas station on Fig.17 MW. 2. Biogas is composed mainly from two majority gases. huge financial losses due to equipment damage and production interruption. Quantify the expected damage of potential fire. district Znojmo) is in the Czech Republic to the date 15. One of the methods is Dow’s Fire and Explosion Index. The result was burned worker. When is calculated that power 0. ISBN 978‐80‐553‐1216‐3 INTRODUCTION the landfill were not calculated). district Rakovník) to 2000 kW (Velký Karlov. p. The rate of gases fluctuates in the dependency on kind of processing material and technology which is used. who’s executed the adjustment. There is relatively big amount of risk in the Czech Republic. The next case is leakage of biogas in biogas station in Žďár nad Sázavou on the May 2011. Content of CH4 is approximately 50 % and content of CO2 is also 50 %. These methods help to detect specific risks. When it comes fulfilling of this potential so it leads to loss of life. Communicate the F&EI risk potential to management. But experience with F&E Index is minimal in the field of agricultural and waste management.czba.10 0. F. Pressure 0. Tab.cz [on‐line]. Calculation of Fire and Explosion Index (F&EI) value for the Dow Guide taking credit for the loss control measures.10 Special Process Hazards Factor (F2) 1.htm> [6] GUPTA.31 15.10 0. VUT Brno. 79–90.65 0.51 1.44 R2 = 0.82 720 680 Evaluation of F&E Index is showed on the Tab. The area of exposure is ranged from approximately 690 to 766 m2. 2 Evaluation of F&EI Degree of Hazard 730 690 24 C. Coefficient of 177 710 0 689. 15.65 1. P. American Institute of Chemical Engineers.).699Ln(x) + 364.97 751.4. The dependency is given by function y = 46. Leakage ‐ Joints and Packing 0. M. were excluded (for example items such as Toxic Material.65 735.00 1. All tanks with volume to 5000 m3 have light degree oh hazard.93 715.90 58. But how is from the paper evident. 3000 m3 (gasholder No.10 0.31 15.65 2. 235–241. IV) and 5000 m3 (gasholder No.989.61 2 Area of Exposure [m ] Height of Cylindrical Volume [m] 15. placed on these biogas stations.52 2.00 1. 2 Dependency volume of a storage tank on area of exposure 770 Area of Exposure [m 2] 750 Number of Storage I II III IV V 1. [2] COCO. Special Process Hazards Base factor 1. 7th edn.47 15. However the boarder value of F&E Index is 61..65 1.00 1. S. This is demonstrable value from the statistical view of point. Czba...11 0. F&E Index has also a place in this field. determination is R2 = 0.00 1.54 Process Unit Hazards Factor 2. From the results is evident that degree of hazard for tanks to size 5000 m3 is only “Light”.13 0. The integration of Dow’s fire and explosion index (F&EI) into process design and optimization to achieve inherently safer design. New York (1994). [3] ČESKÁ BIOPLYNOVÁ ASOCIACE: Mapa bioplynových stanic. [7] SUARDIN J. 20 (2007).18 0.00 E. The chemical industry uses the F&E Index almost 50 years.65 General Process Hazard Factor (F1) 1.00 1. Material Handling and Transfer 740 700 Calculation of F&EI is given by the Tab.65 0. where biogas technologies are the most often used.00 1. MANNAN M. 16 (2003).7).65 1. This is not insignificant amount.Calculation Fire and Explosion Index Value for the Biogas Station P. Only adequate items were included in the calculation.65 765. New York: J&H Marsh & McLennan (1998). Trávníček et al. However some biogas stations have power up to 20 MW (Penkun. Schwere Verpuffung zerstört Biogasanlage in Daugendorf.47 1000 2000 3000 4000 5000 6000 Volume of a Storage Tank [m3] CONCLUSION In the paper was determined F&E Index for four sizes of biogas storage tanks in the biogas station.10 I.65 0. 39– 40..54 Fire and Explosion Index 57. In the model biogas station was produced biogas. III).53 1.de/einsatz /2007/e_07_91/e_07_91. 4000 m3 (gasholder No. 2000 m3 (gasholder No. MANNAN. Tab.46 2.61 This fact is presented on the Fig.00 0. Germany) in the Europe. which were not adequate.1 % ‐ Calorific value = 22 MJ•m‐3 For evaluating of F&EI was used method which is showed in the documentation Dow’s Fire & Explosion Index Hazard Classification Guide. Dostupné z WWW: <http://www. [on‐line]. II).cz/index. Faculty of Mechanical Engineering (2006). 2. Loss Prevention & Safety Promotion.43 60. The all biogas station in the Czech Republic have biogas storage tank to size 5000 m3.10 15.18 G2 Liquids or Gases in Storage 0. Buffer volume of these gasholders was 1000 m3 (gasholder No. RESULTS AND DISCUSSION Fig. EL‐HALWAGI. For example when this F&E Index is compared with F&E Index of ammonia synthesis reactor [6] so F&E Index is three times lower than F&E Index of an ammonia synthesis reactor (161. 7th Edition.08 0.php?art=stanice&parent= provozovatele‐a‐ investori&nid=bioplynove‐stanice> [4] Dow’s Fire & Explosion Index Hazard Classification Guide.18 0.00 1. Dostupné z WWW: <http://www. Large property damage losses in the hydrocarbon‐chemical industries: A thirty‐year review. General Process Hazard Base factor 1.49 2. I).65 0. C.18 0.989 760 . Rotating Equipment etc. which has had following parameters: ‐ CH4 content = 62 % = 37.10 0. With use of mathematical function can be determined how large will be area of exposure in the case of various size storage tanks accident. This implies that storage tanks of biogas. M. January 1994. Corrosion and Erosion 0.15 0. And the maximal exposure area is 2 approximately 766 m .10 0.10 15. From this table is evident that final Fire and Explosion Index is relatively low. [5] FUERWEHR RIEDLINGEN.00 1. KHEMANI. which are bigger as 5000 m3 have “Moderate” degree of hazard and higher.7•Ln(x) + 364.9 % ‐ CO2 content ‐ N2 content = 0. 1 Calculation of F&EI Material Factor y = 46.82 15.16 H. This central pole was simultaneously used as guiding during the movement gasholder membrane. J. Journal of Loss Prevention in the Process Industries.46 1. REFERENCES [1] BABINEC. The rooftop of a reactor was made from textile with a light support structure on the central pole. Journal of Loss Prevention in the Process Industries.80 60.49 1.10 0.41 2.98 Light Light Light Light Light Radius of Exposure [m] 14.96 59. G. IV). II.51 14. Items. Here the storage volume of a biogas can be up to 30 000 m3.18 0. S. The reactor was designed as a cylindrical above‐ground tank.65 1. The dependency of radius of exposure on the size of the tank is logarithmic.10 0.feuerwehr‐riedlingen. I.10 0. J. They have emphasazed that coating materials has a positive effect on scoring strenght for the load capacity and has a good thermal effect. Wear as a The aim of this study is to investigate the ability of load capacity of gears which is coated with different coating materials experimentally and to observe the advantages and disadvantages of using coating materials on gears.icmem. Gears which used in the experiments are plated chrome. in terms of scoring is determined taking into account the surface roughness of load‐carrying capabilities. It is having more advantages from the point of Conclusions: increasing their scoring strength. the experiment is continued by increasing the load. nickel. Fig. zinc. scoring is increasing rapidly. blacklead and copper. motor 9. Turkey. Reductor 3. Test Procedure RESEARCH SIGNIFICIANCE If there is no rapid change in weight as a result of wear values.
[email protected]. motor 4.C. Subscript 1 for pinion. depends on the increase of mass tempature. In the result of their studies. Power transmission gearbox 10.tr 2 3 ARTICLE INFO: Category : Original Scientific Paper Received: 1 November 2012 / Revised: 12 November 2012 / Accepted: 14 November 2012 Keywords:(in causal order) Abstract: In parallel with the developments in technology gears for machines with an increase in speed and Background: torque. nickel and mangenese. The experiments of the same type of steel gears. Heating‐cooling system control unit 7. Coupling 6. Plain bearings 12. ISBN 978‐80‐553‐1216‐3 INTRODUCTION gears as result of rapid wear. Test gears 16. the system operation time is 20 minutes at a time. In their studies.edu. the system's operating speed 3000 r / min. Loading bar 14. Tunalıoğlu and others [4] have tried to find out critic scoring temperature of gears by using kinds of coating materials. MoS2. scoring strength and wear strenght are increased while the roughness is discreased. manganese coated gears has more advantages than uncoated gears.Terauchi and others [2] has done experimental studies on coated gears by copper. subscript 2 for gears are identified in Table 1. Power control unit 5.tr Mechanical Engineering Department. Gazi University. MoS2.Contents lists available at www. blacklead. et al.S. Coating materials is used for improving of chorosion strenght of coated material. Test gearbox Test Gears Gears that are used in experimental studies are 20MnCr5 Steel and their hardnesses are between 170‐220 HB. Çorum. Citation: Tunalioğlu M.2 N in accordance with the starting scoring formation was continued until an indication increased in increments of 20%. Ankara. Çorum.
[email protected]. Hitit University. As a result. Torque coupling 13. The features of gears are shown with details in table 1. Water can11. Power transmission gears 8. They have found out on reaching temperature of scoring of coated gears by zinc.1 The power circulating gear wear test rig 1. nikel. EXPERIMENTAL METHOD Test Equipment Closed circuit power circulating gear wear test mechanism (FZG system) is used to investigate scoring strength of 178 . Experiments in the literature [1‐5] 15. as well as scoring the formation of teeth in the bottom of the fracture and pitting has shown itself.tr Mechanical Engineering Department. When coating material is used at gears. Results: Chrome. manganese. p. Plain bearing 15. nihatgem@gazi. Facing of gears by coating materails is a usual improvement of strength method. gears are coated with Methods: various coating materials. 2ndInternational Conference Manufacturing Engineering & Management 2012. also they emphasized that time of scoring formation goes lower range for coated gears as in a row. MoS2.tk Manufacturing Engineering & Management The Proceedings The Investigation of Scoring Resistance on Spur Gears Mert Şafak Tunalioğlu1‐ Nihat Gemalmayan2 ‐ Emre Ozyilmaz3 1 Mechanical Engineering Department. D. Scoring is a case of rapid seperation of little particles which are adhered each other by metalic contact from gear surface in gear systems that work simultaneously [1]. Terauchi and others [3] have tried to find out the scoring strenght of coated gears by copper.: The Investigation of Scoring Resistance on Spur Gears . uncoated. Turkey.edu. Counter 2. zinc and phosphate to find out the scoring strenght. 178‐ 181. This system is convenient for changing the experiment parameters. Oil temperature 50 °C through the system in the heating‐ cooling device is fixed for all the experiments.. preventing of discountiny that exist on metals and gaining functional feature. Water transmission D. Hitit University. In the experiments. blacklead. Turkey. to determine and investigate the factors which is affecting the event. Scoring Pitting Spur gear Surface roughness Coating material Scoring strength calculations during its formation due to the effect of several parameters clearly identified. By facing of gears. (2012). zinc and phosphate in dry friction condition. they have tried to find out formation of scoring with rapid surface temperature method by putting a termocouple to active gear profile of gear. 1.9 21900 4 26. The gears that enters to clutch.712 7. were identified as critical scoring load for the gear that join the while the system is running. N.S. result of the tests carried out to determine load of scoring at a critical load and the transmitted torque values are given in Table 2. In order to determine the scoring load which occurs depending on the rapid weight loss on active gear profile of gear couple which join clutch.6 54600 9 65.8]. In the figure “s“ indicates the starting point of scoring. the surface roughness is measured after coating of gears until critical scoring load occur. After every load stage.612 1.3 26300 5 31.3 94300 12 113.1 The properties of test gears Tooth form no Number of teeth Module (mm) Tooth width (mm) Pressure angle (º) Pitch diameter (mm) Addendum diameter (mm) Dedendum diameter (mm) The distance between the axis (mm) Input coupling length (mm) Clutch output length (mm) Coupling ratio Tooth height (mm) Symbol z1 z2 m b o do1 do2 Value 17 41 3 20 20 51 123 db1 57 db2 129 dt1 43.616 6 Fig. that the rapid incresement of wear is firstly seen on uncoated pinion gear (K‐pin).8 135800 14 162.8 a 87 e1 e2 h 6.9 337900 In order to define critical scoring load which is inside active pair of gear tooth profiles. methods were used.8 dt2 115. E.[9‐ 12] measurements are taken from four different point of that area to determine the surface roughness and shown as graphics (Figure 2). the active change of tooth surface roughness profiles [7.5 195500 16 234. EXPERIMENTAL RESULTS To Determine The Critical Scoring Load With Rapid Weight Loss According to DIN 51354.6 281600 18 337. Tab. in which the rapid increase of wear at gear pinion as a result of clutching evaluated. pinion gear removed and cleaned from the dirt and oil. gears were loaded gradually.3 The changing of weight in the pinion to determine the critical scoring load It can be seen from Figure 3. Top‐end height values at active profile was tried to determinein the measurements.The Investigation of Scoring Resistance on Spur Gears M.9 162900 15 195. Tunalioglu. During the clutch gear pairs in accordance with DIN 51354 rapid loss of weight as a result of wear [6].8 18800 3 21. According 179 . At the load stage in which wear increased rapidly and the rapid weight loss were investigated depending on the wear.5 65500 10 78. Weights of pinion and gear are measured in every load level.6 78600 11 94.2 Critical load and the transmitted torque values Experiment Load Transmitted Torque (Nmm) No (N) 1 15. Gemalmayan. Because of. the first scoring occuring is investigated between top of gear and bottom of gear.6 234600 17 281. Fig. The graphic of rapid increase of wear as a result of coupling is given in Figure 3. The results of experiments for defining critical scoring load is observed both for coated and uncoated each pinions. (Ra) average surface roughness of active gear profile in the clutch and max. Taylor Hubson 3+ Surface Roughness Measurement machine was used for the measuremnt of surface roughness.2 15200 2 18.2 Areas that are measured the surface roughness on tooth profile In order to findcritical scoring load with surface roughness. then measured with sensitive basvular. it is enough to do measurements on the pinion gear in order to define critical scoring load. secondly on manganese coated pinion gear (M‐pin). Tab.6 31600 6 37. 2. gears were loaded with loadings gradually from the Table 2 and the system was worked for 20 minutes. Ozyilmaz In the method for determination of critical scoring load by rapid change of surface roughness at gear profile of gear couple that join clucth. thirdly on nikel coated pinion gear (N‐pin) and finally on chrome coated pinion gear (C‐pin).7 37700 7 45.1 113100 13 135.5 45500 8 54. Bulletion Of JSME... According to result of experiments usage of coating material on gears is advantaged for the formation of scoring. The Effect Of Surface Roughness to The Critical Scoring Load In the method for Determining Critical Scoring Load with rapid difference of surface roughness at active gear profile of gear that join clutch. average roughness values were discreased until 5th load stage at mangan coated pinion gear. Gazi Üniversitesi. then it increased gradually. at 18th load stage at chrome coated pinion. gear’s scoring resistance is increased. H. on conicial gear[4. after coating of surfaces were done. and Nakamoto.7 The average of surface roughness on crom coating pinion gear When figure 4. Volume:29.. Y. This particules need to filter very well for not cause abrasive wear.6].6 The average of surface roughness on nickel coating pinion gear 180 [1] Tunalıoğlu. Ozyilmaz The Investigation of Scoring Resistance on Spur Gears to figure 3. scoring is seen because of rapid wear at uncoated pinion in 7th load stage. occuring of scoring is increasing gradually and while the period of scoring occuring. was tried to determine by considering on surface roughness. at 15th load stage at nickel coated pinion. [2] Terauchi. [3] Terauchi. coating materials are mixed into oil breaking on gears. Besides both gear corrosion‐resistant also beauty of the view is gained. Scoring resistance of spur gear with various coathing (1st report.. M.(1986). scoring tests under forced lubrication). Number:249. M. pp:999‐1004. H. scoring load that occur as a result of rapid wear in differently coated gear. Volume:29. ACKNOWLEDGEMENTS The authors would like to thank Prof. then it increased gradually and occuring of scoring is investigated at 10th load stage at mangan coated pinion . As a result of a rapid wear. chrome‐plated pinion gear is worked in 11 different load stage in 220 minutes more than uncoated pinion gear.5 The average of surface roughness on manganese coating pinion gear In this study. REFERENCES Fig. at manganese coated pinion in 10th load stage. Chrome‐plated pinion gear reached the scoring point of uncoated gear under 10 times larger load than uncoated gear’s load. Bulletion Of JSME. is investigated . scoring tests under dry friction). when the coating process on gears. and it increased rapidly where scoring occur is investigated. . Nadano.average surface roughness of active gear profile (Ra) and max. When figure 4‐7 investigated. Kohno. Because of pinion gear join to clutch more than opposite gear . Y. Scoring resistance of spur gear with various coathing ( 2nd report. Bedri TUÇ for his help during the work. surface roughnesses are measured until critical scoring load was occured.Depends on the figure 4 average of roughness of four area is between the surface roughness values.. (1986). Tunalioglu. Fen Bilimleri Enstitüsü. it is enough to do surface roughness measures for determining scoring load . at nikel coated pinion in 15th load stage and at chrome coated pinion in 18th load stage.5. Düz dişli çarklarda scoring oluşumunun deneysel incelenmesi. If figures 4 and 7 (scoring at coated and uncoated materials) are investigated. (2004). experiment of critical scoring load show us. Fig.. When we compare all test results It can be seen clearly that the usage of chrome coated gear has more advantages than other coated gears and uncoated gear. Dr. M. while the roughnesses that results of production period and coating of material are discreased until a spesific load value while the period of gear couple working. Cap‐end height values (Ry) on active profile were tried to determine. Ş. average roughness values discreased until 3rd load stage . RESULTS AND RECOMMENDATIONS Fig. Yüksek Lisans Tezi. until 10th load stage at chrome coated pinion gear.. surface roughness is increasing rapidly. N. until 8th load stage at nickel coated pinion gear.4 The average of surface roughness on no coating pinion gear Fig. It showed that gear has more scoring strength than uncoated gear.M.S. Number:247 pp:235‐241. Y.In surface roughness measurements that were done to determine critical scoring load. For example. Nadano.. Gemalmayan. E. During wear tests with gears used in coating. and Kohno. (2009). Wear. M. Ishikawa. Effect of tooth profile modification on the scoring 181 [9] [10] [11] [12] resistance of heavy duty spur gears. M. pp:938‐948.. (1997).S. Gemalmayan.v [6] Tevruz.(1997). Gemalmayan. H.. Wear. S. UMES’07. Volume:217. (2007).. [8] Yokoyoma. Volume:208. pp:204‐213. and Hayashi.The Investigation of Scoring Resistance on Spur Gears M.. E. N. Shipley. and Tuç.Kaplamalı düz dişlilerde scoring sıcaklığının deneysel yolla incelenmesi. pp:703‐706. Dişli çarklarda yenme olayının deneysel incelenmesi. H. Ş. Wear... Ulusal İmalat Kongresi. Tunalioglu. M.. P.. A fracture mechanics model for the wear of gear flanks by pitting.. 3.. [7] Goledez. H. Volume:19. T.(1972). and Stüwe. pp:77‐82... 12 ways to load test gears. TH‐München.. Experimental investigations on scoring of gears and calculation by temperature method. Die fress‐grenzlast bei stirnradern aus stahl. [5] Tevruz. Volume:206. pp:177‐183. pp:131‐141.. pp:81‐94. Imrek. . and Unuvar A. Wear. Experiments of scoring and the calculation of scoring on gears by heat method. Mechanism and Machine Theory. (1998). J. B. Lechner. (1966). N. T. (1958). (1998). dissertation.. Product Engineering. Investigation of influence of load and velocity on scoring of addendum modified gear tooth profiles. T. Winter. Ozyilmaz [4] Tunalıoğlu. G. K. Volume:44.. Tevruz. The experiment described in this article aims on verification of a hypothesis.czu. and that nanoparticles are more efficient than microparticles. Email: valasekp@tf. p.Contents lists available at www. Lee et al. Different physical and mechanical properties of composite phases define the resultant tribology properties.g. Test pieces were prepared with 25 volume percentage of filler in matrix. (2012). and Ni. Only such waste that is not classified as dangerous waste can be used as a filler for polymer matrix. In case of lower concentration there would be undesirable sedimentation and in case of higher saturation by splinters the desired cohesion of the system could be breached. al [9] describes the usefulness of microparticles in renovation processes of functional areas of device parts by epoxy resin. Czech Republic. These composites provide up to 26 times better wear resistance than the polymer without fillers. The compound of resin and filler was created by mechanical mixing in ultrasonic tank and hardened according to technological requirements of the producer. in which microparticles of Al2O3 are dispersed. Splinters after machining of various hardfacing alloys were used as filler. The article leads to the description of polymer‐particle composites that enables material recycling of waste and is usable in some areas of renovation of functional areas and parts of devices. anorganical materials inside. Cieslar J. In technical practice these metals are mainly used in areas where the resistance of functional areas against different types of wear is required [1]. The article describes filler on basis of waste from ferrous metal splinters – hardfacing alloys from machining process. Email: muller@tf. ISBN 978‐80‐553‐1216‐3 INTRODUCTION against three body abrasion. Olea‐Mejia [8]. Prague. Wear mechanism is examined in relation to morphology and chemical and physical properties of each dispersion particle type. 4]. Preparation of the compound without vacuum was chosen on purpose and in relation to the area of applicability (the applications with no availability of vacuum in order to reduce expenses are expected).icmem. The concentration of 25% was chosen on purpose. Prague. Email: cieslar@tf. qualitative material resistant to abrasive environment can be created by inclusion of secondary material into the polymer matrix that uses properties of sub‐components. Influence of some specific anorganical particles based on primary materials on increase of polymers’ abrasion resistance is proven. Citation: Valášek P. by presence of 10 volume percentage of micro‐ and nanofillers (microsized Al.cz 2 3 ARTICLE INFO: Category : Original Scientific Paper Received : 15 October 2012 / Revised: 13 November 2012 / Accepted: 15 November 2012 Keywords: (in causal order) Abstract: Abrasion wear Polymer particle composite Waste The effect of two body and three body abrasion on polymer‐particle composites composed of 25 volume percentage of splinters from ferrous metals ‐ hardfacing alloys ‐ is discussed in this article. Up till now the anorganical microparticles are distributed only by primary materials [10]. Use of polymer with anorganical fillers are often in area of renovation. and they also revealed a correlation between hardness and wear resistance of material.cz Faculty of Engineering. Müller et. Müller M. Czech University of Life Sciences. For the structure netting of these resins connected with curing the polyamines are used. Prague. A polymer matrix of such materials is the source of material recycling. These materials are most often produced by the reaction of epichlorhydrine with bisphenol A. The common attribute of these materials is high level of hardness. Prior machining the hardness of monolithic material had 182 .cz Faculty of Engineering.tk Manufacturing Engineering & Management The Proceedings Two and Three Body Abrasion of Polymer-Particle Composites with Fillers on Basis of Machining Splinters from Hardfacing Alloys Petr Valášek1 ‐ Jiří Cieslar2 ‐ Miroslav Müller3 1 Faculty of Engineering. Increased hardness of polymer matrix induced by inclusion of reinforcement affects the depth of penetration of abrasive particles into the polymer matrix and decreases the amount of removed material [3.czu. Basavarajappa [6] also describes a significant influence of SiC particles on resultant resistance of polymer matrix METHODOLOGY Materials Sample Preparation The polymeric matrix of particle composites was from the epoxy resin (Eco‐Epoxy 1200/300). [5] experimentally discovered on fenolic resins filled by corundum particles with size between 40‐100 μm that blending of corundum increased the two body abrasion resistance and tensile strength. Splinters from ferrous metals are specific type of waste that is characterized by given legislation of the given country. Splinters created that way excel with similar properties as monolithic material from which they are taken and they usually do not have any further use. Mohan [6] speaks about perfect tribological properties of polymer matrix with primary. Ag. [2] include among the critical factors affecting abrasion resistance of hard filler systems interface properties and geometrical and mechanical properties of the reinforcement. Czech University of Life Sciences. The methodical process of preparation in the ultrasonic tank and hardening of test pieces in a form from two‐part silicate resin partly eliminates the porosity of composites after hardening.czu. that a new. e. Concentration of the filler affects the resultant mechanical properties of the system. 2nd International Conference Manufacturing Engineering & Management 2012. graphite and silicon carbide that were determined on rubber wheel. Czech Republic. Czech University of Life Sciences. nanosized Al and Ag) in polymer (branched LDPE) concluded. because due to the mutual contact of splinters from filler the sedimentation by gravity is minimized on this concentration. that the presence of Ag particles in comparison with LDPE significantly increase the abrasion speed. Satapathy et al. Czech Republic.: Two and Three Body Abrasion of Polymer‐Particle Composites with Fillers on Basis of Machining Splinters from Hardfacing Alloys . 182‐186. that should be preferred among other methods of dealing with waste. 1 ‐ ρ) and resin (1.1 mm. The testing specimen is in the contact with the abrasive cloth and it covers the distance of 60 m. The pressures force is 10 N. the diameter of the disc was 130 mm and the frictional distance 350 m. The process of machining itself together with chemical and physical properties of the workpiece affect the creation and movement of taken material in form of splinters [12]. 183 P. created by two body abrasion in relation to the hardness of composites or epoxy respectively are shown in Fig. to Vickers (HV) by 4‐point pyramid with apex angle of 136°. despite the process of machining.9 °C. 2 also describes distribution of hard facing alloy splinters on the area. It was necessary to define porosity (P) as an index of polymer composites’ quality [4] (see equation 1).0277 ± 0. The trial burdening corresponded to 2. Abrasion wear resistance of alloys is dependent on their chemical composition and microstructure. High variation coefficients in case of the three . Andrex CMA 357 – 3x3 mm was used as a source of radiation. 1. The trial specimen with the size 39. The two body abrasion was tested on a rotating cylindrical drum device with the abrasive cloth of the grain size P120 (dimensions of bound Al2O3 grains 125‐106 µm) according to the standard ČSN 62 1466 [14].2 °C. It is obvious from the results that inclusion of all hardfacing alloy splinters into epoxy matrix significantly increased resistance of the composite systems against two body and three body abrasion. Average temperature measured on two body abrasion reached value of 35. 1[15].1 mm. High variation coefficient has been caused by material cracking as a result of high brittleness.5 ± 0. Volume reduction of epoxy resin on two body abrasion was equal to 0. Representation of phases was evaluated on stereoscopic microscope.6 ± 3.0 ± 0.15 g∙cm‐3) was computed.1 mm and their height was 20. Temperature of the interface of worn areas of test piece was measured during abrasion wear by noncontact laser thermometer.5 ± 0. had been tested for hardness and chemical analysis (processed by Škoda a. Porosity (P). Variation coefficient of average values (in form of variation coefficient on x and y axes) is shown on the pictures. In case of splinters from those alloys similar properties might be expected. Cieslar. Valášek. M.cm‐3). Alloy splinters were taken during machining on C11 A /1000 lathe. Described data reflects the progressive technologies where higher cutting speed and minimization of cutting liquids are preferred.3 mm (the sand for this fraction was suctioned there through mesh screens). Experimental tests The test of hardness was based on the standard ČSN EN ISO 2039‐1 [13]. Measured temperatures in relation to technological characteristics of the used resin did not affect the process of wear significantly. Splinters’ morphology in interaction with polymer material defines the resultant composite properties.1 and 0. J. exposure 20 s. see Tab. I = 3 mA. thus created heat and deformation. load 294 N [11]. Test pieces were also analyzed by X‐ray. The particles used for the experiment were the particles of fire sand with grain size between 0.s. up to 32 USD•kg‐1. During one drum turn of 360° it is provoked the testing specimen left above the abrasive cloth surface. the standard deviation is given by symbol (s). The testing machine with the abrasive cloth consists of the rotating drum on which the abrasive cloth is affixed by means of a bilateral adhesive tape.5 ± 0. The mean of the testing specimens was 15. From the point of interaction between filler and polymer matrix perfect wetting ability of particles’ surface was expected.0 ± 0. no cutting liquid used during machining (Dry Machining). partially affects mechanical properties. The mass decreases were measured on analytic scales weighing on 0.1 mm and 8. Müller The approach described is modifying the regulation ASTM G65 see Fig. In case of three body abrasion as a result of higher velocity of abrasion particles against the surface under wear the temperature influence increased to 60.Two and three body abrasion of polymer-particle composites with fillers on basis of machining splinters from hardfacing alloys been measured acc. where the polymer composite had been exposed to two body (Ph1) and three body (Ph2) abrasion. 2. Cutting plates from sintered carbide were used.1 mm was pressed to the rubber disc by a pressing force of 36. Variation coefficient of hardness testing was from 3. U = 75 kV. Consequent impact of the testing specimen simulates the concussion. ρRea – real composite density (g. the speed of spindle 910 turns•min‐1.185 mm•turn‐1.0024 cm . Volume reductions of the composite systems and epoxy resin that created the matrix. Removed splinters were analyzed by image analysis on stereoscopic microscope in 2D plane (A). ρ ρ P The Rea 100 ρThe (1) Where: P – porosity (%). in case of three 3 body abrasion 0. ρThe – theoretical composite density (g. Volume reductions of the composite systems and polymer matrix caused by three body abrasion in relation to their hardness are shown in Fig. see Tab 2.3 to 7. 5 ‐ weight RESULTS Prior machining the monolithic material.043 cm3. a ball of hard metal with the diameter D = 10 mm was used.9 %. 3. 3‐ test specimen. theoretical density of the composite systems (ρThe) based on density of monolithic material (see Tab.cm‐3). For the experimental definition of three body abrasion we used a machine with a rubber disc which simulates the process of abrasive wear by free particles.4 N. For description of the hardfacing splinters’ morphology had been used optical analysis on stereoscopic microscope. from which the splinters were taken. where the position of splinters in 2D plane was observed. 24. Tab. Price of these hardfacing alloys is comparatively high.603 ± 0. 2‐ rubber disc. parameters – focal length 700 mm.452 kN.). The testing specimen is secured in the pulling head and during the test it is shifted by means of a mowing screw along the abrasive cloth from the left edge of the drum to the right one. 4 ‐ handle. longitudinal displacement 0.0 ± 0. the burdening time was 30 s. Fig. The volume decreases were calculated on the basis of the found out volume and the density of the composite systems.1 The machine with the rubber disc 1 ‐ funnel. Because of the size of the filler.1 mg. 67 3.67 1.3037 0.75 2.01 0.8868 0.01 0.01 0.96 1.4 Three body abrasion – Volume loss of composite systems in relation to hardness 184 .8 27.6399 1.16 3.8 28.38 3.1 30.38 0.29 2.1 29.0070 ± 0.0 7.63 7.028 0.38 2.027 0.027 0.4 31.43 3.02 4.72 7.003 0. M.01 0.00 0. Res.30 3. A 2 mm s 2 mm ρThe ‐ g∙cm 3 P % Ph1 % Ph1 % 1 2 3 4 5 6 7 8 9 10 11 12 0.7 2.66 3. dark part is the matrix).P.28 1.6439 1.0 27.8 2. Res.8 41.5 29. Res.5 7.14 0.67 7.14 0. that was directed by wear velocity of the filler.3667 0.8 2.14 0.8 6.7 7.8 8.4 25.8 30.3717 0.8 2.37 3.9 28.14 0.4 5.0 30.8 2. 4 (light part of the picture are splinters with obvious grooves due to abrasive material.38 3.12 0.2 Size of splinters.82 0.01 0. Res.6 Fig.010 0.57 7.26 2. Res.7392 0.07 2.71 2.61 7.2 30.2 Two body abrasion – Volume loss of composite systems in relation to hardness Fig.004 0.32 3. J. when the polymer matrix and the filler were worn by the same speed.026 0.0008 cm3).15 0.00 3.027 0.5546 0.75 2.14 0.4897 0.31 2.29 2.01 0.8 2.7772 1.8 29.13 0.8 10. Res.02 0.026 0.8 2.1 Hardness.24 3.02 2.77 0.65 7.26 Tab.12 0.07 2. see Fig.8 2. Res.2051 0.0009 cm3). 3 (volume reduction of 0.20 3.88 1.2683 0.12 0.3318 0.14 0.19 1. porosity of composites and phases ratio Nr.0932 0.67 0. Res.4781 0. Res.7 2.05 0.5321 1.4583 0.31 3.20 3.13 0. In case of the two body abrasion on abrasive cloth with graininess of P120 the highest resistance had composite no.026 0.7 28.01 0.9 1. 3.30 7.5 0.79 2.67 7.86 7. Valášek. Res. 5 (0.9 31. body abrasion might be caused by mechanism of wear.35 3.9 27. Structure of worn surface after two body abrasion is shown in Fig.96 1.3776 0.67 7.008 0. 1 2 3 4 5 6 7 8 9 10 11 12 HV ρ ‐3 g∙cm Fe % C % Si % Mn % P % Cu % Cr % Mo % Ni % 609 755 546 376 803 825 745 740 589 794 826 750 7. density.06 4.78 0.92 1.12 4.0230 ± 0.86 0.6 29.72 0. 5 and 6.4292 1. therefore by chipping of splinters from the matrix.01 0.5 7.5399 0.1290 1.2387 0.49 3.40 1.6162 0.93 3.68 0.8 2. Cieslar.28 3.00 0.91 1.026 0. Müller Two and three body abrasion of polymer-particle composites with fillers on basis of machining splinters from hardfacing alloys significantly different between mentioned methods of abrasion.5 30.8 2.69 Res.6 23.02 0.26 4. density and chemical analysis of monolithic material Nr.5 29. in case of the three body abrasion the smallest volume reduction has been measured on composite no.5918 2.8 30. Structure of worn areas on the composite systems was Tab.14 0.3 Surface structure after two body abrasion – grooves Fig.8 25. Res. In case of the two body abrasion grooves were produced.55 2.0 35.7 5.8 2.43 7.13 2.63 0.60 1.22 2.23 3. [17]. This interval corresponds to dimensions of some hardfacing alloy splinters. [17]. who determined the interval in primary corundum. resulted in concordance with claim of Kim et al. This recycling uses the properties of polymers (e. Fig. 10 X‐ray image – Nr. who discovered that inclusion of anorganic particles increased the resistance against two body abrasion. Experiment has proved the results of work by Stewart et al.7 Surface after wear by three body abrasion‐ Nr. that had influence on high resistance against two body abrasion. Two body abrasion of polymer composites with Al2O3 particles have been also described by Xian Jia et al.g.Two and three body abrasion of polymer-particle composites with fillers on basis of machining splinters from hardfacing alloys Fig. 1 Fig. 3 P. It is also low‐cost and environment‐friendly. 9 and 10 there are X‐ray images of the test pieces for the three body abrasion.6 Surface after wear by two body abrasion ‐ Nr. Müller Fig. similar as nanoparticles dispersed in epoxy resin. 3 Results have proved that the presence of splinters from hardfacing alloys in polymer matrix increased the ability of material to resist described methods of abrasion wear. to qualitatively new materials. 1 Fig. 7 and 8. M. who described the fact epoxy resin is easy to be filled by various kinds of anorganic particles. 9 X‐ray image Nr. which was chipped out of the matrix by free abrasive particles.5 to 161 μm. however it is necessary to take into account the side of abrasive particles. In Fig. 185 . 1 In case of the three body abrasion the speed of the polymer matrix and splinters were not the same.5 Surface after wear by two body abrasion ‐ Nr. Polymer matrix got worn faster than the filler. see Fig. [5]. the performed experiment refutes results of Kumara et al. Valášek.8 Surface after wear by two body abrasion ‐ Nr. [19] and DISCUSSION Application of splinters from machining process of hardfacing alloys into a polymer matrix is one of the possible alternatives for material use of this sort of waste. from 40. [16] and Kim et al. J. [18]. Mutual interaction of particles in form of hardfacing alloy splinters and polymer matrix than. Nevertheless. epoxy resin) and especially the ability to be filled by anorganical fillers.3 Fig. Cieslar. Similar results as those in this experiment but with use of primary material (artificial corundum) have been reached by Satapathy et al. 3852 ‐ 3858. [10] MÜLLER M. [8] OLEA‐MEJIA O. that different morphology and chemical and physical properties of splinters used from machining process of hardfacing alloys have insignificant influence on resultant resistance against described two body and three body abrasion.. BIJWE. KUMAR M. Technic‐economical evaluation of the overlays application on the plough shares.. 119 (2009).. Wear. 2011:11 55‐59. A physically‐ based abrasive wear model for composite materials.. 30 (2009). [3] SUCHÁNEK J. Wear. G. 2000. Aplikace návarů a kompozitů v oblasti technologie pěstování a sklizně cukrové řepy. CHAMBERS A. 484‐494 . [9] MÜLLER. 2010.H. International Journal of Adhesion and Adhesives. Rubber.K.... Standard Test Method for Measuring Abrasion Using the Dry Sand/Rubber Wheel ApparatusASTM G65. . Acta univ. Prague. 55‐59. It can be claimed. [13] ČSN EN ISO 2039‐1.. 277‐ 287. M. milling. Resistance against two body abrasion increased up to 26.) in form of fillers of polymer composites. J. [17] BYUNG CHUL KIM. E. NATARAJAN S. Composite Materials ‐ Mechanical Behavior and Structural Analysis. [20] SURESHA B..). (nr. VALÁŠEK P. KUKLÍK. [18] XIA JIA. P. that was focused on the two body and three body abrasion of polymer composites with filler on basis of hardfacing alloy splinters. Suresha et al. Journal of applied polymer science... Abrasive wear effect on Polyethylene.. Composite systems with filler on basis of ferrous metal splinters from machining process shall find application when solving problems with maintenance of devices. no correlation has been found between the hardness of composites with hardfacing alloy filler itself and resistance against two body and three body abrasion. Analysis of simultaneous influence of operating variables on abrasive wear of phenolic composites. RITCHIE. The role of synthetic and natural fillers on three‐body abrasive wear behaviour of glass fabric‐epoxy hybrid composites. I. fast repairs of functional areas and worn device parts. Effect of particulate fillers on mechanical and abrasive wear behaviour of polyamide 66/polypropylene nanocomposites. 1 was far from the resistance against described methods of abrasion. M. Brno.K.P. Polymer‐Plastics Technology and Engineering. JOSHI A. Wear. VENKATARAMAREDDY M. Surface duality hardened steels after grinding. [12] NOVÁK. 1342‐1347... polyuretan resin etc. [19] RAVI KUMAR B. 8‐12.. R. Et silvic. Journal of nanoscience and nanotechnology. XIAOMEI LING. VALÁŠEK P. Only composite no. 186 .. It is necessary to respect the complex mechanical properties of systems. Composite Structures.. Abrazivní opotřebení materiálů. Influence of Al2O3 reinforcement on the abrasive wear characteristic of Al2O3/PA1010 composite coatings. 12 (2012). 1985..O. KUMARESHBABU S... Manufacturing technology. 10 (2010). 27 (2006). Determination of abrasion resistance using a rotating cylindrical drum device. (2008). This fact has not been proved by this experiment. Listy cukrovarnické a řepařské. Polyamide 6 and polymeric particle composites. 2006. [20]. 258 (2005). M. especially reactoplastics (epoxy. 252 (2002).. Material and Design. 2007... 9 (2011). [7] BASAVARAJAPPA S.. [16] STEWART.. Müller Two and three body abrasion of polymer-particle composites with fillers on basis of machining splinters from hardfacing alloys [5] SATAPATHY B. In addition.N. etc. Valášek. 787‐794.. 253 (2002).. Manufacturing technology.. BUCHMAN E. can be summarized in the following points: The addition of 25 volume percentage of hardfacing alloy splinters leaded to sharp increase of abrasion wear resistance. SANG WOOK PARK. [6] MOHAN N. HRABĚ P. KUMAR R. Berlin..0 times of the value of epoxy resin.. ARUN K.. DAI GIL LEE. 2292 ‐ 2301. G. The performed experiment gives a basis for possibility of use some sort of waste from machining process (turning.. Mechanical engineering series. ZDRAVECKÁ. 1998. C. resistance against three body abrasion increased up to 4. [14] ISO 62 1466. [2] LEE. Two‐Body Abrasive Wear Behavior of Particulate Filled Polyamide66/Polypropylene Nanocomposites. KUMAR A. Wear Resistance and Wear Mechanisms in Polymer plus Metal Composites... 124 (2012). Cieslar.. ACKNOWLEDGEMENT This paper has been done when solving the IGA TF grant. SURESHA B. [4] BERTHELOT J. 322‐331. The cohesive mechanical properties of a toughened epoxy adhesive as a function of cure level. DHARAN. PAŠKO J. Metallic materials ‐ Vickers hardness test ‐ Part 1: Test method. NOVÁK P.2 times of the original value. 304 ‐ 307. Journal of Applied Polymer Science. (2007). 31140/1312/3104) REFERENCES [1] BROŽEK. M.P. Plastics ‐ Determination of hardness ‐ Part 1: Ball indentation Metod. J. V. [11] ČSN EN ISO 6507‐19‐1. DISCUSSION Results of the performed experiment. 129‐136. M. agric. who found a relation between abrasion resistance against two body abrasion and three body abrasion of polymer composite systems. 69 ‐ 77. 49 (2010). GORDON T. [15] ASTM G65.. Three‐Body Abrasive Wear Behaviour of Polymer Matrix Composites Filled with SiC Particles.P. However morphology and physical and chemical properties caused different measured values of composites’ hardness.. BROSTOW W. 8254‐8259. Fracture toughness of the nano‐particle reinforces epoxy composite.Y. Dt is averaged with the previous estimation of current value. FUZZY TIME SERIES Fuzzy time series analyses are frequently used in literature. This method utilizes α and β smoothing coefficients in two smoothing equations [1]: St= α. Due to uncertainty about the object and environment whose trajectory will be estimated. This study takes α=0. and allocates a higher weighting to more recent observations [3. due to easy applicability to data with linear or curvilinear characteristics.Gt‐1 (3) Fig.t+ τ = St + τ. hloch. Tuzla. In case of possible circular and curvilinear movement of the object. estimations are made by calculating next steps. In the second stage. of Manufacturing Management Faculty of Manufacturing Technologies TU of Košice with the seat in Prešov. Turkey.9. Tozan H. ESTIMATION TECHNIQUES OF DOUBLE EXPONENTIAL SMOOTHING AND FUZZY TIME SERIES Estimation can simply be defined as the prediction of future events [7]. Lastly. real time images containing tracked object from the camera are transferred to a C# based software.(St ‐St‐1) + (1‐ β). 34940.Contents lists available at www. it is difficult to determine which data should be used in trajectory estimation. as can easly be seen from the Figure 1. the trajectory the moving object is estimated with double exponential smoothing and fuzzy time series. Here. which was developed for linear inclination time series. and depending on exponential smoothing. and the destination from reference point was found using the following equation [6]: E (x1 x2 )2 (y1 y2 )2 (1) The software determined the location values of the object on horizontal and vertical axes. is obtained. trajectory estimation is proposed with two different estimation techniques.tk Manufacturing Engineering & Management The Proceedings A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series Mustafa Yağimli1 ‐ Hakan Tozan2 ‐ Sergej Hloch3 1 Turkish Naval Academy. (2012). Double exponential smoothing is used for time series that show linear trend. (St‐ St‐1) value found in the first equation is revised. the estimation value after τ steps is calculated through the following equation: Ft. After determination of centre point coordinates of the object. Electrical and Electronics Engineering Department.’s Fuzzy Time Series (FTS) model can be summarized as follow [8‐17]: . a value of β<α is preferred in most applications. Istanbul. in order to provide stronger determination. The steps of Hwang et al.icmem. p. 2nd International Conference Manufacturing Engineering & Management 2012. Dt. while providing greater flexibility [2].Gt (4) In this study. Istanbul.sergej@gmail. Citation: Yağimli M. The literature includes algorithms to estimate trajectory [1]. Smoothing coefficients may be the same. htozan@dho. β=0. 187‐191.edu.1 Camera image The midpoint of a moving object was determined from a camera image using C# software according to color values. and Gt is inclination at t time. however. St is the value of the intersection at t time. The average of previous inclination value and (Gt‐1) is calculated and then the inclination (Gt) in t time is found. Yan‐Hua and Li‐Xiaused a fuzzy time series method in a similar way. Industrial Engineering Department. DOUBLE EXPONENTIAL SMOOTHING This study uses Holt's double exponential smoothing method. Turkey. and the ability to include few or many observations without assuming observation number as restriction. the inclination and St.: A target trajectory estimation with double exponential smoothing and fuzzy time series. the image zone received from the camera is scaled as 4800 horizontally and 3600 vertically [5]. Exponential smoothing uses a weighted average between the estimation of the previous step and observed values.Dt + (1 ‐ α)(St‐1 + Gt‐1) (2) Gt= β.1.edu. By use of image processing techniques. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Determination of collision between targets and estimation of the movement of a target in an environment where bullet gets to target and which has more than one target like weapon systems are important performance factors of a defense system. its next location value was found through two different estimation algorithms.tr Turkish Naval Academy. Hloch S. 4]. The most current actual value.com 2 3 ARTICLE INFO: Category : Short communication Received : 21 July 2012 / Revised: 26 October 2012 / Accepted: 3 October 2012 Keywords: (in causal order) Abstract: Trajectory Estimation Double Exponential Smoothing Fuzzy Time Series In this study.tr Turkish Dept. myagimli@dho. 187 Where. Tuzla. 34940. . Z3 . . A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series Then the estimated variation will be determined with the following equality. O wm w1 w 2 O11 x Z1 O12 x Z1 . O2mxZ m R(t ) . Dmin /Dmax) are to be determined... .. the object was moved circularly. O1m FTs t ( 3 ) O21 O22 . 188 . O2m w . A total of 32 location values were obtained at equal time intervals. (12) Fv(t ) r1 .2b Real and estimated values for the curvilinear motion. .. . n ).. 3.rm First. Then... fuzzy sets on Ud are to be defined and variation data is to be fuzzified... R wm w1 w2 Fig. . .. circular movement of a moving p z 1 pz 2 pzm object. Next step is to define the universe discourse (Ud) with following equation using Dmin ve Dmax. For period t.. . .M. .. . have to be determined which shows the number of periods of variations that will be used for forecasting. Ft is computed as. The real location values used were obtained through target tracking where the memberships pzi are 0≤pzi≤1.. When the object make a curvilinear like motion as illustrated in Figure 2. (8) FTs(t 2) O11 O12 . O1m x Z m O21 x Z2 O22 x Z2 . Z2 . Z (t) and R(t ) is defined respectively as follow: Z (t ) FTs(t 1) Z1 . et al... O x Z O x Z .Z n SMOOTHING In the double exponential smoothing application.. Defining fuzzy time series FTs(t) as where At 1 is the one‐step back actual observation value of the time series. Zm u 1 2 m (7) Next step includes composing the relation matrix... as in Figure 3. . FTs(t ) . the next location of the target was estimated u2 um u1 through the developed target tracking system. . which is governed by operation ( Ow (t) ) and criterion matrixes ( Z (t ) ). In this step the windows basis. R11 R12 . the variation between two historical data is to be calculated and minimum/maximum variation values (i. equation 9 can be rewritten as. R1m R21 R22 . . . . and the following values were estimated as the next step values.. FTs(t w 1) O O . the first 10 location values for two types of movement made by a target were coded as standard. In the second stage. . .... rj = Max (Rik) (13) • And finally.. . The real and estimated values for the curvilinear motion are given Table 1... (10) Let Oik x Z k Rik (for 1 i w and 1 k m ) then. (14) Ft = Fv(t) + At−1 Ud= [Dmin ‐ D1 . w ( w 2. O (t ) .. Table 2 shows the results obtained using real values in combination with the double exponential smoothing technique.. of which the last 22 values were estimated. and defuzzifying the calculated variation which will be used for estimating the forthcoming value using the relation of the chance value gathered from relation matrix .. 2a Curvilinear motion. . R2m (11) R(t ) . APPLICATION (6) In case of a curvilinear. . Yağimli. 2a illustrates both the real and the estimated values for the curvilinear motion. the forecast value for the period t . .... R R . . r2 . of Ud then can be represented as APPLICATION OF DOUBLE EXPONENTIAL p p p S~i Z 1 u Z 2 u . R(t ) . (9) Fig.. Dmax+D2 ] (5) where D1 and D2 are positive appropriate values that fits for separating Ud into equally length intervals. . The fuzzy sets S~i software developed in the C# programming language.. .. . Ow (t).. O x Z wm m w1 1 w2 2 Fig. ..e.. the first 10 location values for a target in two types of movement were coded as standard. In the first stage. Fig. 2100 2400 2600 2800 2970 3100 3170 3200 3200 3200 3080 2900 2667 2450 2240 2033 1828 1625 1422 1220 1018 816 562 297 286 730 964 1176 1382 1585 1788 Tab. 24 location values were obtained at equal time intervals. et al. Table 3 shows the results obtained through real and fuzzy time series techniques. and the next location values were estimated. Yağimli. of which the last 14 values were estimated. .4 Real and estimated values for the circular motion.2 Real and estimated values of circular motion. APPLICATION OF FUZZY TIME SERIES In the fuzzy time series application. 1200 1300 1400 1540 1700 1900 2100 2300 2500 2649 2963 3222 3424 3573 3668 3721 3754 3600 3560 3525 3427 3288 3061 2645 2071 1689 1378 1212 1111 1052 1014 I(y+1) 1800 . Ix 1150 . Fig. In this stage.A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series Tab. I x 200 5 300 400 500 600 750 850 1000 1100 1200 1300 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3500 3600 Iy 2100 5 1950 1800 1650 1500 1300 1150 1000 900 800 700 600 500 400 300 250 200 250 300 400 500 600 700 800 I(x+1) 200 5 300 400 500 600 750 850 1000 1100 1200 1313 1412 1511 1695 1903 2110 2316 2521 2726 2930 3134 3337 3540 3662 M. 189 Figure 5 illustrates both the real position and the estimated values for the curvilinear motion.1 Coordinates and estimated values of curvilinear motion. inclined shot movement was applied. 3 Circular motion.3 Real and estimated values of curvilinear motion. Figure 4 illustrates both the real position and the estimated values for the circular motion.. Tab. 1200 1300 1400 1540 1700 1900 2100 2300 2500 2800 3050 3250 3400 3500 3560 3600 3600 3580 3550 3470 3350 3150 2780 2260 1900 1600 1430 1320 1250 1200 1160 I(y+1) 2100 5 1950 1800 1650 1500 1300 1150 1000 900 800 644 550 454 358 261 164 108 64 300 350 458 568 675 779 Iy 1800 . 2100 2400 2600 2800 2970 3100 3170 3200 3200 3140 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 750 490 470 600 800 1000 1200 1400 1600 1800 I(x+1) 1150 . Table 5 shows the results obtained through real and fuzzy time series techniques. REFERENCES [1] Nahmias. When the object made a circular movement.D. Figure 8 shows that double exponential smoothing produces smaller deviation than fuzzy time series and shows better performance. A Target Trajectory Estimation with Double Exponential Smoothing and Fuzzy Time Series inclination. Figure 6 illustrates both the real position and the estimated values for the circular motion.4 Real and estimated values of circular motion. 32 location values were obtained. and generally shows better performance. A. Figure 7 shows that the double exponential smoothing technique produces smaller errors in upwards 190 . Fig. McGraw‐Hill International Editions. Fig.8 Circular motion.. et al. despite making more errors than the fuzzy time series. Fig. 1997..5 Real and estimated values for the curvilinear motion. Fig. of which the last 22 values were estimated. Yağimli. S. Tab.M.7 Curvilinear motion.6 Real and estimated values for the circular motion.B. RESULTS AND DISCUSSION Figures 7 and 8 compare inclined movement and circular movement for evaluations. Production and Operations Analysis. C. 5. 100. WSEAS Transactions on System. Q. International Conference on Risk Management and Engineering Management. 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Q. 298‐300. Palit. D. 62. 2006.. Gustafsson. 8. H. 1993. M. J. 1‐8.. Tourism Management. “Ground Target recognition Using Rectangle Estimation”... Recent Advances in Neural Networks. Popovic. S. Q. 2004... “Fuzzy Forecasting Applications on Supply Chains”. [3] Risteski. "A Study For Second Order Modelling of Fuzzy Time Series".. S. 2009.. D. “Predicting Tourism Demand Using Fuzzy Time Series and Hybrid Grey Theory”. IEEE Transaction on Image Processing. D. T. 1919‐1925. B. Y.. education. Step 5: Develop evaluation criteria. an Analytic Hierarch Process (AHP). criteria and the weighting for the criteria that are used in the application are determined via questionnaire technique applied to specialists and profound discussions with experts working in the field in Presov/Slovakia. Citation: Yanar L. 34942. a decision support model for determining the appropriate operation method in soft tissue cutting process of surgical operation is proposed and performed. On the other hand MADM is used to represent the decision making problems in which the aim is to select one of the determined alternatives considering the criteria. Step 7: Apply the tool to select a preferred alternative . Step 6: Select a decision making tool.hloch@tuke. MODM is used to define the problems which have a continuous decision space and infinite criteria.. This study focuses on ‘Multi‐criteria Decision Making Methods’ in which more than one objective is to be maximized. Turkey. This method uses eigenvalue technique to derive a priority vector from pair‐wise matrices which consists comparisons of elements in a hierarchy of criteria and alternatives. Finally. In the following sections first the metrology used in study is briefly explained. Analytic Network Process (ANP). The alternatives. and the criteria are determined via profound discussions with experts and questionnaire technique applied to specialists working in that field. Decision Support Systems (DSS) are model based procedures or computer based tools or systems those take out and display the information to help decision maker in order to get more strong and of good quality decisions[ 6.0) developed using C Sharp programming language.11] for solutions. the decision space is discrete [3] and usually the criteria are conflict [4]. p. In this paper. an Analytic Hierarchy Process/Analytic Network Process decision support system (DSS) for determination of the appropriate method in medical soft tissue cutting operations is proposed together with decision support software (DESTEC 1.tk Manufacturing Engineering & Management The Proceedings Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software Latif YANAR1 ‐ Hakan Tozan1 ‐ Sergej Hloch2 1 Turkish Naval Academy.+90 216 3952658 Faculty of Manufacturing Technologies.1 Steps of decision making (2). et al. In the literature of decision making there exist various types of software which generally uses non‐fuzzy methods for the solutions (see [8]) but also. Naval Science and Engineering Institute. In the literature MCDM is also used sometimes instead of MADM just like in following sections of this paper. 7]. MODM designs the best alternative for the decision maker such as goal programming. 192‐197. an application to the problem of “selection of the appropriate method in soft tissue cutting process in surgeries” is performed and results and conclusions are illustrated. industry and government for the aims of 192 . This topic can be divided into two groups as Multi‐attribute Decision Making (MADM) and Multi‐ Objective Decision Making (MODM). Step 8: Check the robustness of the evaluation . Step 3: Establish goals that solve the problem . There exist various types of DM problems and also many methods for solution of those problems in literature (Figure 2). Fig. 080 01 Prešov.Contents lists available at www. Technical University of Košice with a seat in Prešov. and then the proposed DSSS (DESTEC 1. Table 1 illustrates some of those software’s used for MCDM problems and their solutions. The proposed software also has the ability of performing the fuzzy models of the proposed DSS to cope with the ambiguous and linguistic nature of the model. which is developed by Saaty in 1970’s. Step 1: Define problem Step 2: Determine the requirements of the solution to the problem .sk 2 ARTICLE INFO: Category : Original Scientific Paper Received : 15 August 2012 / Revised: 24 September 2012 / Accepted: 31 October 2012 Keywords: (in causal order) Abstract: In this study. engineering. Here. ISBN 978‐80‐553‐1216‐3 Decision making Fuzzy AHP Fuzzy ANP Waterjet Decision support systems INTRODUCTION Decision making (DM) is a reality of every part of human life for thousands of years and can simply be defined as choosing one of the alternative ways of actions considering the needs of decision maker [1]. Abrasive Water Jet (AWJ) ‐ classical scalpel. is developed for improving the quality of decisions [5] of any MCSM and an application is performed for the selection of appropriate method in soft tissue cutting process in surgeries.icmem.0) is introduced. Tuzla ‐ Istanbul. The steps of DM are illustrated in Figure 1 [2]. which is named as “Decision Support Tool for Enhanced Choose” (DESTEC 1. 5. (2012). Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software .10. Fig. manufacturing. Step 4: Indentify alternatives to be evaluated . Up to now this method is used in many fields like social. +90 216 3952630. fuzzy AHP and fuzzy ANP based ‘Decision Support System Software’ (DSSS). politics.0). Email: sergej. METHODOLOGY Analytic Hierarchy Process (AHP) Analytic Hierarchy Process (AHP) is one of the most used MCDM methods. 2nd International Conference Manufacturing Engineering & Management 2012. The alternatives. As an application.2 Classification of decision analysis methods (23). there exist a limited amount which uses fuzzy systems and fuzzy mathematics [9. Establish un‐weighted super‐matrix using priority vectors of the pair‐wise matrices established for each criterion. Fill the comparison matrix for criteria (pair‐wise matrix). MAUT ELECT R E I I ELECT RE III AND IV ELECT R E I ELECT R E T R I MAUT AHP SMAR T MACBE TH ELECT R E T R I 2 0 I R IS † 21 Logical Decisions AHP NO YES NO MACBETH MACB ETH N O YES N O 2 2 24 MakeItRation al MindDecider 2 5 N A IA D E 23 2 6 2 7 28 29 3 0 3 1 Open D e ci s i o n Maker P r i me O p t i o n RightChoiceD SS SelectPro T r i bi um D e ci s i o ns W e b‐ H I PR E AHP NO YES YES AHP N A IA D E NO YES YES YES N O N O A H P N O YES N O M F E P‡ N O YES N O AHP NO YES YES AHP Utility Theor y A H P NO YES YES N O YES YES N O YES YES Fig. The method can be explained briefly with the following steps: i.3 A Hierarchical Model for AHP. and the priority vectors are calculated in the same way. Then in this super‐matrix.Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software ii. With these arrows. the priority of each sub‐criterion is multiplied with the priority of its parent criterion so the global priorities of each criterion which will be used to compare alternatives are obtained. multiply every cluster block with the element corresponding that block in the cluster matrix and obtain the weighted super‐matrix. resource allocation. selection. AHP. *Decision Support Tool for Enhanced Choose.). the method uses feedback and inner dependencies in problem. Define the problem and goal.1. and then compare sub‐criteria for each main criterion and get priority vectors. forecasting [12]. which is a generalization of priorly explained method.1 Some of the Software used for MCDM (Utilized from Wikipedia and (8)) No. In an ANP network. iv. The cluster at the end of the arrow influences the one at the start (Fig. Establish the network structure of the problem. Determine the criteria. iv. priority. SMART PROME THEE AHP Utilily Theory AHP AHP. evaluation. Analytic Network Process (ANP) Analytic Network Process (ANP) is another MCDM method developed by Saaty in 1996. alternatives are treated as other criteria in the problem. Priority vector is obtained by (the eigenvalue formulation). benefit‐cost evaluation. Check the consistency index of the pair‐wise matrices. There exist several methods to derive the priority vector. Here. FANP AHP MAUT PROME THEE. (This is the so ware is developed by writers of this paper) †Interac ve Robustness analysis and parameters’ Inference for multiple criteria Sorting problems. FAHP. ‡Mul ple Func on Evalua on Process To elucidate the method the steps are explained below: i. so the result becomes more reasonable and accurate. Tab. ANP. Following this calculation. the criteria are collected in clusters and the influences between clusters are displayed by arrows.0 * 10 DecisionPad 11 D‐Sight 1 2 E L E C CA L C 1 3 ELECTRE I I I ‐ IV 1 4 E L E C T R E IS 16 17 ELECTRE T R I ERGO Expert Choice 1 8 HiPriority 19 Hiview3 1 5 AHP AHP. . Then the cluster matrix is established which includes information about how each cluster influences the others. Derive priority vectors for alternatives by comparing them for each sub‐criterion as in step 3. ANP also supports problems which are modeled as a network instead of a hierarchy. is the maximum eigenvalue for pair‐ wise matrix and w is the priority vector [13]. In this formulation A is the pair‐wise matrix. 193 L. In addition to hierarchical problems. rebuild the pair‐wise matrices because the comparisons made in the matrix are not enough consistent to make a reasonable decision [13]. iii. development. v. Saaty uses normalize columns and then average the rows. if there are). Yanar et al. Synthesize the priority vectors and derive the global priority of each alternative. iii. In pair‐wise matrices the same comparison table in AHP is used. ii. If consistency is greater than 0. alternatives and make clusters and indicate influences. Make pair‐wise matrices for each criterion (node) containing the effecting criteria for each cluster. and determine your criteria (and sub‐criteria. Compare main criteria among themselves. Software 1 1000Minds 2 AliahThink Choice Reaults Criterium DecisionPlus Decision Lab 2000 Decision Lens Decision Manager Decision Oven Supporte d MCDM Method (s) PAPRIK A AHP Fuzzy Methods Supporte d Sensit ivity analys is Group Decision Making NO YES YES NO YES YES NO YES YES NO YES NO NO YES NO NO YES YES NO YES NO NO NO NO YES NO NO NO YES NO YES YES N O N O N O N O N O N O N O N O N O N O N O N O NO NO YES YES NO YES N O N O N O NO YES YES N O N O N O 3 4 5 6 7 8 9 DESTEC 1. … . values as .3.. … .2. where d is the ordinate of the highest intersection point D (Fig. 19. . 0 . In this method for each goal i extent analysis is performed for each object j. … . that are generally named due to their shapes. perform a fuzzy addition operation To obtain ∑ of m extent analysis values for a particular matrix as. Here we can have the local priorities of alternatives (as any other criterion) by normalizing the priorities of alternatives in alternatives cluster. 2 Fig. Zadeh in 1965 (16).5 Triangular Fuzzy Number .….….2. In fuzzy calculation fuzzy numbers are used which are basically fuzzy sets that typically in types like triangular. 2. et al. 1. 2. Chang’s extent analysis can be briefly summarized as follow [17. . 1. perform the fuzzy 1. .6 Intersection of Fuzzy Numbers M1 and M2. … . The triangular membership function is illustrated in And can be expressed as: . Step 2: For two fuzzy numbers . … min .. is the goal set. 3. . is the object set and .4 ANP Network 1 ∑ . Finally. and is ∩ 1 .L. Yanar. where 194 1 ∑ . … . Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software v. can be defined by There are several approaches to fuzzy AHP and Fuzzy ANP methods but in this study Chang’s Extent Analysis selected and used due to its common usage and simplicity [17. are elements. 15]).…. . . 19]. . 20]: Let . . … . Zadeh defined the fuzzy set as ‘a class of objects with a continuum of grades of membership’.. . In fuzzy sets. .2. . This membership degree is derived from a membership function defined for every fuzzy set. trapezoidal and etc. 18.6) between 2 1 1) 2 2 1 2 1 1 Fig. . and to obtain ∑ ∑ addition operation of follow. use “Cesaro Sum” method [14. 1. .A. 18. the weight vector than can be given as T . compute the inverse of the vector in the proceeding equation. 1. the degree of possibility defined as Fig.2. min for . 1 . ⊗ . … . . the membership degree of an element differs in the interval from 0 to 1 while in a crisp set it is basically 0 or 1. and m extent analysis values are obtained: . Source: (19) Step 3: The degree possibility for a convex fuzzy number than k convex fuzzy numbers . vi. ∑ Fuzzy AHP and Fuzzy ANP Fuzzy set theory is introduced to the literature by L. Step 1: Fuzzy synthetic extent value Si is obtained for each object i by the equation below: Assuming 1. . . Following this find the limiting matrix by getting powers of weighted super‐matrix (If limiting matrix cannot be achieved by getting the powers of the matrix. In limit matrix all columns are the same and the values in the lines shows the global priority of each criterion for the network. where ’s are triangular fuzzy numbers. . the normalized weight vectors can be given as T . Yanar et al. the results are displayed on the user interface of the DESTEC in details or in short form according to the choice of the user so that the Weighted crisp and fuzzy supermatrices along with the limit matrices can be displayed. The data entry by the user only involves the necessary data needed for AHP or ANP to the sheet provided by DESTEC.….7 Flow diagram for limit matrix calculation The steps for using the software are shown in Fig. ANP and Fuzzy ANP both in L. Fig. This allows the user to see the influences of each element in problem for ANP models. DESTEC uses the algorithm of Williams Adams. Fig. 13. The most important features of DESTEC is to allow to the decision maker to use different methods at the same time including two fuzzy MCDM methods.9 The user interface of DESTEC 1. 7. Developed Decision Support System Software. Following the calculation.1. 195 . and the user interface and Excel sheets are displayed in Fig. Fig. the developer of the Super Decisions software. where is a non‐fuzzy number. Fuzzy AHP.Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software Step 4: Via normalization. for limit matrix calculations [21].8.8 Steps for using DESTEC 1. The flow diagram for limit matrix calculations is illustrated in Fig. DESTEC 1. . the same time or separately.0 Fig. The software enables the decision maker to use AHP.0 is a C Sharp base DSSS developed to handle the sophisticated MCDM problems. 9.0.0 DESTEC . 0. For AWJ. 14 and Fig.L. The main criteria ‘economic impact’ holds the sub criteria about the costs of the equipment.12 Excel sheet of DESTEC 1. 15 respectively. the main criteria ‘cut characteristics’ holds the sub criteria representing the features of the cut of which differs according to the used device. Here the ‘material selection’ sub criterion represents the ability of the equipment about selecting the material (tissue) to be cut or uncut.10 Excel sheet of DESTEC 1.14 AWJ Equipment used in surgeries and its applicator nipples (25) In the study. Fig. The other main criteria ‘control’ holds ‘manual’ and ‘automatic’ which represents the usage of the equipment. This affects the selection of the equipment because if the surgeon has more information about the surgery field it is more easy to use AWJ due to the ability of AWJ provides adjusting up to layer of the tissue changing the cutting pressure of the AWJ.0 after calculation showing results and supermatrices and limit matrices Proposed Model and Application In this study AHP. The AHP model and ANP models for the problem are illustrated in Fig. The alternatives for the solution of the problem are determined as “classical scalpel method” and “Abrasive Water Jet (AWJ) technology”. Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software Fig. Fig. rock [22‐24].0 for problem definition Fig. plastic.13 The user interface of DESTEC 1. Yanar. it is adjusted 196 . metal.0 for pairwise matrices Fig. ANP. Fuzzy AHP and Fuzzy ANP models for surgery equipment selection for soft tissue cutting process are proposed and solved using DESTEC 1. alternatives and criteria are determined via profound discussions [25] with experts and questionnaire technique applied to specialists working in that field in Presov/Slovakia.11 Excel sheet of DESTEC 1.. In this model the main criteria holds the methods used for detecting the disease.0 for influence entrance for ANP and FANP. An example for AWJ used in medical operations is shown in Fig. abrasive particles including water [22‐24]. And finally. et al. AWJ is a technology that cuts material with pressured. This technology is widely used in many areas in industry for cutting materials like wood. Recently it is stated to be used in medical. 5(1). Int. Production Economics. 2005. Liang G. difference between the results of fuzzy methods are bigger that crisp ones. A Fuzzy AHP Based Decision Support System for Disaster Center Location Selection and a Case Study for Istanbul.16 ANP Model of the Problem The influences which are determined by the expert for the ANP model are also shown in details with fig. 1996. Application and Development of a Fuzzy Analytic Hierarchy Process within a Capital Investment Study. 169(1). European journal of Operational Research. Poh BW. USA: Prentice Hall .0. 2006. Ding JF. 1965. Multi‐Criteria Decision Making Methods and Fuzzy Sets. Arslan G. Fuzzy Sets. Piantanakulchai M. 2003 March. is presented that enables the decision maker to use AHP. Saaty TL. 2005 June . Miloslav L. [Online]. [5] [6] [7] [8] [9] [10] Fig. Tozan H.isy. [20] [21] [22] [23] [24] [25] 197 L. Journal of Economics and Management. 26(7). [16] [17] [18] [19] CONCLUSION In this study a generic DSSS. Marketing Applications of the Analytic Hierarchy Process. Scott‐Morton MS. Honolulu. [Online]. Yanar et al. Zadeh LA. 2005. Herekoglu A. J. Hloch S. 1996 December. Analytic Network Process Model for Highway Corridor Planning. Available from: http://www. Wind Y. 19 Turgut B. Multi‐attribute Comparison of Catering Service Companies Using Fuzzy AHP: The Case of Turkey. the decision maker can gain the ability of evaluating the alternatives from a wider view that may provide a better decision. In C. Continuous Optimization and Knowledge‐Based Technologies. İstanbul: Springer. Murphy J. Saaty TL. 2007. Using fuzzy MCDM to select partners of strategic alliances for liner shipping. Chang DY. Communications of the IIMA. 16.edu/~hweistro/mcdmchapter. Aouam T. Keen PG. Aydın Ö. With the use of the proposed DSSS. Information Systems Management in Practice Upper Saddle River. editor. 2004. Krupa J. Ruan D. 173(1‐3). 2001. 2009. Ohlidal M. named as DESTEC 1. Applications of the Extent Analysis Method on Fuzzy AHP.pdf. 1980 July. McNurlin BC. Gombar M. 31.vcu. Hunter R. Simkulet V. Models and Managers: The Concept of a Decision Calculus. 87(2). Experimental analysis of irregularities of metallic surfaces generated by abrasive waterjet. Weistroffer R. Co. Kumar S. 1993. Fuzzy MADM: An outranking method. Introduction to Decision Making Methods.15 The AHP model of the problem [11] [12] [13] [14] [15] Fig. Bernroider EWN. 3(4). Zhou PA. RESULTS The results from the whole the outputs of all four techniques illustrated AWJ is the appropriate alternatives according to the given weights to the criteria and alternatives (see Fig. REFERENCES [1] [2] [3] [4] Fülöp J. Little JDC. 20 (5). 16. Operačná resekcia nádorov a metastáz v obličkách vodným prúdom. Neringa. 47. Lithuania.ht m. Vaidya OS. As it can easily be seen from the Table 2. J. Bridges D. NJ. ANP and their fuzzy models together which makes the DSSS special. 1970.Selection of Equipment for Soft Tissue Cuttings Using Fuzzy AHP and Fuzzy ANP with a Proposed Decision Support Software by changing the pressure of the water while with scalpel it is totally the experience of the surgeon.. Energy. Decision Making With Dependence and Feedback: The Analytic Network Process Pittsburg: RWS Publications. Tang YC. 8(3). Blichova M. 2001 [cited 2011 March 03. Management Science. Int. Characteristics of the Multiple Attribute Decision Making Methodology in Enterprise Resource Planning Software Decisions. Information and Control. In 20th EURO Mini Conference 2008. . Kahraman C. vcubusiness. et al. Cebeci U. As to our knowledge no other DSSS is both able to solve all four models and not being problem specific. K. Johnson G. 2005. [cited 2011 Mayıs 04. Disaster Prevention and Management. European Journal of Operatioan Research. 2005. Kahraman C. Available from: http://www. 95(3). Information Sciences. Valicek J. WSRC‐IM‐2002‐ 00002. Adams W.creativedecisions. Presov: TUKE. 15). 2006 February . Decision support systems: An organizational perspective: Addison‐Wesley Pub. Valicek J. 2011. Drzik M. 145(2). Sprague RH. On a Software for Fuzzy MCDM. Baker D. Fuzzy Multi‐Criteria Decision Making. et al. Hungarian Academy of Sciences. International Journal of Machine Tools & Manufacture. Tas T. 1(2). In ISHAP. Guidebook to Decision‐making Methods USA: Departmant of Energy. 2008. 2008. Mitlöhner J. Computer and Automation Institute. Surface Science and Engineering. Hloch S. Europian Journal of Operations Research. Analytic Hierarchy Process: An overview of Applications. Super Decisions Limit Matrix Calculations. Decision analysis in energy and environmental. Vayvay O. Estimation of the smooth zone maximal depth at surfaces created by Abrasive Waterjet. Master's Thesis.net/papers/papers_etc /calc‐white‐paper. Beynon MJ.. 1978. 198‐203. In this paper. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Quick management or quick project management is a repetitive method of determining requirements for engineering and information technology development projects in a highly flexible and interactive manner. people. However. especially concerning product development[6]. yea it can be applied in practice that can be use it in types of projects for implement a system of planning and project control based on quick project management principles. Kolltveit. such as standardization. p. Citation: Zohrevandi S. ocular. It is common to talk about quick systems for modern project management processes in the context of a set of lightweight activities used to manage the development or acquisition of software. design. a set of principles and concepts for innovative product development projects has recently emerged from the software development area[8] . LITERATURE REWIEW How do companies plan and control projects of new products in a project environment laden with uncertainties? In an attempt to answer this question. Although the literature on quick project management proposes a set of values and principles to be applied in the context of innovative products. and testing processes based on a minimal set of activities needed to reach the end goal a working software system Although some of these quick development systems address the management aspects of software projects. encourage exploration. processes. This paper shows that the application of this system at the companies under investigation evidenced the benefits of using simple. deliver customer value. including (Crawford 2006[1]. The way is to deal with the growing demand for projects that aim is to develop new products is suitable. After the system implementation. Söderlund 2004[5]). Quick project management is “a set of values. and technology they are primarily focused on coding. self management and self‐discipline.Contents lists available at www. applying quick project management principles was developed. entitled hereafter repetitive and ocular project management system.com ARTICLE INFO: Category : Original Scientific Paper Received : 11 September 2012 / Revised: 25 September 2012 / Accepted: 2 October 2012 Keywords: (in causal order) Abstract: Management System Project Control Project Management Project Planning Quick Project Variety of ways to planning and project management so far has been studied and has been used by managers and related professionals. Core quick project management values are [12]: Employ repetitive feature delivery. This paper is based on a case study and literature review.icmem. are based on flexibility and simplicity. Quick techniques are best used in small‐scale projects or on elements of a wider program of work. Project managers are used to dealing with an ever growing demand for projects that aim at developing innovative and complex products. Therefore. (2012). Quick project management focuses on people development. 2nd International Conference Manufacturing Engineering & Management 2012. we try to project management best practices is not only in literature. 198 . there are not many empirical studies evaluating the effectiveness when applied to the development of project management tools and systems. Time is an important factor in the implementation of these methods and for doing rapid and timely for project managers. plays a vital role. champion technical excellence. The best practices in project management from 1960 onwards have been published widely. Email: shakibzohrevandi@gmail. Karlsen. and practices that assist project teams in coming to grips with this challenging environment”. and less bureaucracy. Quick Systems in Planning and Project Management: A Structured Approach for developing a new project. One of the challenges that companies must face is the development of new tools and systems to suit specific project management environments. and software artifact delivery. a System. and quick techniques to planning and control innovative product projects combined with traditional project management best practices. similar to Lean Thinking principles [10]. Payam Noor University. Iran. Kloppenborg & Opfer 2002[2]. [7] Quick project management approaches have emerged to assist the adaptation of consolidated project management practices to improve these projects. few authors have proposed well‐defined and pragmatic methods to apply these approaches or provided systematic evaluations of their results. testing. the research is for implementation of repetitive and ocular project management system. there are some barriers when these practices are applied to innovative and complex projects. A project complexity definition is necessary in order to cope with project management challenges. coding. for example quick software development. Shenhar & Dvir 2007[4]. repetitive. simplify. They are developed by iterations and add value to customers by means of short time deliverables [11]. & Gronhaug 2007[3]. known in the literature as quick project management. These activities include requirements. or on projects that are too complex for the customer to understand and specify before testing prototypes.tk Manufacturing Engineering & Management The Proceedings Quick Systems in Planning and Project Management: A Structured Approach for developing a new project Shakib Zohrevandi1 1 TSTA Company. build adaptive teams. a qualitative evaluation was carried out by a document analysis and questionnaire application. followed by a procedure to use it. Quick project management principles. customer focus. Core quick project management values address both the need to build quick and adaptable products and the need to create quick and adaptable development teams [9]. participatory decision making. and the results of two implementation cases. This article proposes a method for planning and controlling innovative product projects using quick project management principles. principles. Despite the extensive literature available on project management[24]. followed by the definition of the project scope (project data sheet). a project plan should start with the product vision (vision box and elevator test statement). It also includes managing the implementation of the project plan. but with limited results. each one for a specific project management process [19]. such as prescriptive. a set of underlying values are useful: Communication of information within and outside a quick project is constant. These need cross functional expertise in a given organization [14] . Project Management’ is an important topic because all organizations. In addition. and with designated resources. and critical path method. changes are negative aspects. For example. Humility. Courage. there are two aspects to be considered. there are few studies that present advances on how to plan and control innovative product projects. Figures 1 describe how these attributes could be related in quick project management systems[16].Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project processes for project management [20]. To keep ahead of their competitors. The successful performance of a project depends on appropriate planning. 2004). of which project management software and Gantt charts are the most relevant. characterized by project complexity. Chin suggests most innovative products are developed under uncertainties in turbulent environments. The quick project management approach is indicated for innovative product development projects. Simplicity. the majority of the quick project management proposals cannot be properly considered as techniques. Quick project management can be built on this framework. Project management includes developing a project plan. the best project managers acknowledge they don’t know everything. and the mechanisms to implement recovery actions where necessary[13]. They must be appropriately evaluated because not many studies have evaluated these applications. all important decisions and changes in the direction of the project need to be made with the courage. Highsmith suggests some directions for project planning and control. The second aspect refers to the guidelines. Another study[23] with transnational companies also evidenced the wide use of Gantt charts by project managers to plan and control projects. and end with the project plan (repetitive feature plan). to control the execution of the project (PMI. product development projects rarely end according to the original plan [25]. This approach focuses on the communication and people centric aspects of project management. which includes defining and confirming the project goals and objectives. There are many techniques and methods to manage projects. However. identifying tasks and how goals will be achieved. Creating a project plan is the first thing you should do when undertaking any kind of project [18]. large and small. the control process includes many tools and techniques. and determining budgets and timelines for completion. Steffens et al. According to the Software Engineering Institute. usually with defined stages. are involved in implementing new undertakings as diverse as the development of a new product or service. or a public relations campaign. First. Fig. In turbulent environments. quantifying the resources needed. such as White and Fortune (2002). In the perspective of traditional project management best practices. Before the principles of quick Project Management can be defined. research on project management has taken into account common assumptions. Iterations and other quick project management recommendations do not address this wide spectrum and have been treated as guidelines and principles that are not supported by the literature.Zohrevandi . processes and tools used to plan.1 Interrelation between Project Management Activities PROJECT CONTROL PROJECT PLANNING Put simply. grounded on ideal project planning and control models [21]. theoretically. every organization is faced with development of complex services and processes. program evaluation and review technique. PROJECT MANAGEMENT Project management is a carefully planned and organized effort to accomplish a successful project. along with operating regular 'controls' to ensure that there is accurate and objective information on 'performance' relative to the plan. manage and mitigate cost and schedule issues and any risk events that may impact a project [26]. and changes where the traditional approaches have presented limitations. have identified that a restricted set of systems and tools are used in practice. whereas in turbulent environments they are prerequisites to successful projects. Similarly to project planning. This structure is a process pattern view of project activities[17]. The key to a successful project is in the planning. whenever necessary. Project control implies observing project execution so that potential problems may be identified in a timely manner and corrective action may be addressed. a methodology must possess certain attributes in order to meet the requirements of being called a methodology[15]. unpredictable activities. Project planning is a discipline for stating how to complete a project within a certain timeframe. normative theory. Project Controls encompass the people. The PMBOK Guide defines the use of 21 processes that relate to planning out of the 39 199 S.However. defines the approach to identifying the critical success factors of the project in terms of the simplest possible solution. also emphasize that in the traditional project management approach. some authors. such as a Gantt chart. One view of project planning divides the activity into [22]: Setting objectives (these should be measurable) Identifying deliverables Planning the schedule Making supporting plans This evidence leads to the question of how properly project managers have been using project management tools and which actions have been taken to adapt these tools to meet project requirements. a technique is based on a well‐established theory with well‐specified procedures for its use and implementation. and the deliverables are organized on the board according to a top down priority sequence (highest priority at the top). Highsmith emphasizes the definition of what control. and deliverables control. Data collection was carried out through interviews. Performance Indicator procedure: A simple set of performance indicators was adapted to measure the lead time of deliverables by means of EVA. Each activity is connected to one or more Planning and controlling board deliverable. and Spraggett (2006) provided an extensive review of the literature on project control. activities. Project Deliverables Model also includes a simplified set of templates used to collect. It was based on quick project management principles as described in the literature 200 .Could it be considered quickly? The data collected were analyzed in a qualitative manner. Adapting the plan and project scope depends on apprehending a wide range of information. and focus on leadership and development of team competences. then frequent and effective feedback is required to test them. He discusses the necessity of simplicity.Did the system benefit the company’ project management? 2. evolution of requirements. where some problems and difficulties in project management were identified. The success of projects that adopt the exploration approach depends on reality‐based feedback.S. and design. Based on the project baseline. Vitner. time. c) A method to plan and control projects was developed by means of action research [28]. All five components of the repetitive and ocular project management system were integrated into planning and control projects in a simple. The deliverables are inserted in the whiteboard using colored sticky notes. The Weekly Planning board uses an iteration concept. He also argues that if plans are speculations or hypotheses about the future. The role of quick project management control and planning surpasses merely taking corrective actions and following plans (Highsmith. which includes the assessment of the project progress. divided into two periods on each day (morning and afternoon). by having fast short time results. b) A diagnosis of project management practices was carried out at a small company. Planning and controlling board: The Planning and Controlling board was designed to integrate the project phases with the deliverables in a simple timescale. The project planning focuses on defining deliverables instead of activities. and organize all project information produced. A questionnaire was applied to address two research questions: 1.2 Repetitive and ocular project management system‐ based on quick project management Project Deliverables Model: The phase and project deliverables model combined the principles of stage‐gates [29] and project life‐cycle management. Fig. which does not imply that the control process or standardization and procedures should be given up. Weekly Planning board also uses sticky notes to show the input of tasks. the project team does not define the exact work that must be done. Each project uses a different color. d) After the implementation. They concluded that in the project management literature authors use a one‐dimensional control system in spite of not integrating project objectives at all. The disadvantage of EV analysis is its lack of integration with other project dimensions such as technology. but only the project scope. and a seven stage procedure to use the system. document. Some standard phases and deliverables were defined to guide the project planning and execution. 1989). 2004). argued Highsmith (2004). followed by their description. but only what is going to be delivered. 2004). because they do not yet have a clear view of the tasks and activities. the project is measured in RESEARCH METHOD The research method was divided into four phases: a) A systematic literature review was carried out to identify empirical studies of implementations of quick systems in innovative product development projects. Highsmith noted a self disciplined and self managed team development. The templates have two objectives: to organize the project information and to guide the documentation and standardization of project process. Rozenes. The development of a suitable Project Control system is an important part of the project management effort [27]. and ongoing competitive market analysis. The deliverables can be defined according to their execution phase. The literature on project control presents many dimensions and approaches to apply control techniques and tools. weekly observations. and deliverables were evaluated in this study. PRESENT PROJECT MANAGEMENT SYSTEM The system developed is entitled repetitive and ocular project management system. Also found evidence that the most utilized multidimensional control system is the earned value. according to Highsmith. Figure2 presents the repetitive and ocular project management system. Weekly Planning board: This whiteboard is used to define some activities and work packages. they are only certain of the project goals and mission. This study focuses only on scope. Considering the context and values derived from the application of quick project management principles to project management practices. and subsequently implemented. and document analysis. added value to the customer. Rozenes etal. It is important to emphasize that there are many outputs and activities in the planning and control phases (PMI. time. and work packages. technical risks. The whiteboard has the weekdays printed at the top. Zohrevandi Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project review. its components. At this stage. quality. Quick project management control plays an important role in learning‐ in‐progress and not following a rigid plan. which indicated issues to be investigated in this field. the system was evaluated using a case study method (Yin. ocular. and interactive way. value added. and encourages rapid and flexible response to change[30] . A customized module was developed to generate project performance reports based on the Performance Indicator procedure. their learning about the project uncertainty. The reports are used to control the project progress. Fig. task name. at weekly short meetings (average 40minutes). and time spent. The role of the software is quite different from traditional project management. they must be uploaded onto the software (step 3). The project manager and the team insert the deliverables on the Planning and controlling board (step 2) according to descriptions of the project phases. the Company is a small company that develops highly technological products involving hardware and software. estimated delivery date. Once a WP is completed. were able to define. The team uses the Planning and controlling board and Weekly Planning board to plan and control projects. It is not used for planning and controlling project tasks. and 100% agreed that self discipline had a positive impact on and improved project results and team development (3). phase. At step 6. The software was customized to fulfill the Planning and controlling board and Project Deliverables Model standards. Each sticky note is organized on the Planning and controlling board according to its priority. CASE APPLICATION Founded in 2003 in Brazil Country.Zohrevandi . The need for self discipline and its impact on the companies and their projects were evaluated. teams. and person in charge. The project team defines the deliverables and the phases of the Project Deliverables Model‐based project. value added. the risk analyses and most of the product requirements are defined. current progress. and the project progress to be able to take adaptive actions and anticipate changes. 201 S. SYSTEM EVALUATION A questionnaire was presented to 19 participants that had applied the method. where requirements and solutions evolve through collaboration between self‐ organizing. the person in charge of it logs in on the software and inserts a brief comment with respect to the task. inputting them into the software. The information on these sticky notes comprises the deliverable name. Described next are seven stages that represent a procedure to use the repetitive and ocular project management system. deviation. 2‐ repetitive and ocular project management system required team self discipline and self management. and the percentile of each task represented by the deliverable defined on the Planning and controlling board (step 5). But 32% were indifferent or disagreed. The project managers. Once the deliverables are placed on the Planning and controlling board. executing. Figure 3 shows the percentile frequency of the answers regarding the system analyses considering the following criteria: 1‐ encourages project innovation and creativity. and goals. The software is DotProject and consists of an online Internet based and open‐source software for project management. 7‐ flexibility suits the project changes requirement. By means of a project plan template. The quantity of iterations will depend on the type of the project. 5‐ repetitive and ocular project management system provided to ocular communication and team view. All stages of this method have been designed to be repetitive. as shown in Figure 2. its complexity and uncertainty level must be considered. the work packages by decomposing the deliverables into measurable tasks (step 4). and estimated end date. but it is important to have a general view of the project goals and constraints. person in charge. and informing the project team. This aspect is critical and relevant to their work due to the innovative nature of product development.Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project terms of time spent. constraints. 7. taking into account its deadlines. defining. the software generates the reports with project performance indicators. The sticky note is inserted on the day of the week that the work starts. The team member can break the tasks and even reorganize his or her schedule to better respond to project changes. Each criterion is discussed in the paragraphs that follow. and deviation plan. 8‐ simplicity. the project team analyzes the information from the software reports and uses it to check the value added to customers. The system provided accurate data and organization without adding much bureaucracy to their process. but some changes were made in Project Deliverables Model and Planning and controlling board components. 4‐ added value to the team and customer.5. Has the system encouraged innovation and creativity (1)? According to 68% of the respondents. especially concerning time‐scale positioning. 3‐ self discipline and self management contributed to better project team performance and development. It has “templates” of each phase and deliverable to guide users in their work. They were able to adapt in face of changes. That is specialized in computer programming and integrative hardware systems for education and entertainment. The system was applied to one of its projects in which the goal was to develop a robot for education and research computer laboratories. Project management software for portfolio control: Quick software development is a group of software development methods based on repetitive and incremental development. as defined in the Performance Indicator procedure. the method enabled process creativity and innovation. A repetitive project life‐cycle management implies defining deliverables. but for registering project data to enable the team to make decisions and manage the project portfolio. a time‐boxed iterative approach. integrated. The Planning and controlling board deliverables are inserted by means of different‐ colored sticky notes (one color for each project in case the company has more than one). The robot includes features that can be reprogrammed using modular programming. At step 7. and delivery date. 6‐ the ocular communication contributed to better project results. The software deliverables must have the estimated starting and ending dates to enable the baseline creation. Ninety four percent agreed that repetitive and ocular project management system required self discipline (2). It starts with the demand for a new project (step 1). Team members input the tasks in to the Weekly Planning board by means of sticky notes. It promotes adaptive planning. Each phase has standard activities. evolutionary development and delivery.3 Results of the answers from the data interview reports. Each sticky note represents a deliverable and contains the deliverable name and short description. Changes may occur. controlling work packages. with all team members. and repeatable during the project life cycle. The Performance Indicator procedure is not applied to resources control. deliverables. to fulfill the project goals and add 202 value to customers. as discussed next. The ocular and simplicity related aspects of the system have contributed to project flexibility. Concerning the ocular communication aspect. team members highlighted the repetitive development of all project phases and deliverables during the system application. evaluate. regular iterations with their customers contribute to add value and to better project deliverables by anticipating project changes. but . 73% of the participants agreed the method is flexible and enabled project changes. the team developed a common view that provided a better understanding of the project deliverables and phases for the Company. and a simple set of templates contributes more to customers and project teams than does using concepts based on traditional planning and control tools. that impact the way they manage their projects. in turn.S. it’s easy to check whether or not the project is running smoothly. The team got used to discussing project deliverables through project progress on a weekly basis. On the subject of some specific characteristics of the method. The participation of senior management and project sponsors contributed to the final results. not only the project manager. In this context. Iterations with customers. the project manager became more confident about the results: It’s ocular.. For these companies. what we have to do. the Planning and controlling board and Weekly Planning board. and discuss the role of project management in the quick project management approach. most agreed that it improved their project management skills. CONCLUSION Due to the characteristics of the chosen investigation design. user friendliness. every day. provided the team with a holistic view of the major project deliverables. This study has also identified that it is possible to have benefits through the combination of advanced techniques to manage a group of projects (such as software and metrics based in time) and simple and ocular techniques. In addition. and taking adaptive actions. Zohrevandi Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project With respect to the value added to customers and the project team (4). the necessity of self managing and self disciplined capabilities to use the method). by analyzing the organizational benefits. The software assisted in the registration of project data by creating a single file of the project history. The regular customer iteration inherent to this method promotes the identification of changes during the review of the phase gates. the software provided a chronological account of the project data covering its entire life cycle. Their focus clearly moved from project planning to project exploration (execution) (Chin.e. The templates provided a historical file of the entire project. Highsmith. A critical and controversial point must be addressed here. project management activities were reliable and organized in the company.g. the project management role in the company became faster than it had been (i. can add value. this study presents some limitations. such as resources and knowledge about project management concepts. the results evidence the feasibility of adopting a quick method with simple and flexible techniques to plan and control projects despite their perception. which may be useful in the management of the project team schedule. and tasks execution. helped the team deliver exactly what the customer expected. whenever they judged necessary. Leadership and participant decision making are mainstream and are rooted in the lean thinking approach. Despite the research limitations. A parallel evaluation was carried out and included a qualitative analysis based on the data collected during the implementation process. 2004). and flexibility. In addition. without much effort. nor does it intend to advance generalizations to all types of project and companies. It does not mean to neglect the best project management practices available in the literature. Regarding research question 1. 68% agreed that repetitive and ocular project management system contributed to the project team view (5) and 78% agreed that the ocular communication provided by the method contributed to better project results (6). such as visibility. thus enabling preventive actions. the graph shows that 100% of the respondents agreed that repetitive and ocular project management system added value to customers. enabling a fast retrieval of any project information. With respect to project flexibility (7). when they had to define all tasks and to develop an entire project plan by means of traditional project management systems). the system has contributed to improve their project results. The results also show that commitment to the role of project management is very important to achieve successful results. the project manager expressed that their customers enjoyed the results and the project organization and procedures adapted. there is ample evidence that a simple way of planning and controlling projects by means of sticky notes and a whiteboard. This is a ocular and repetitive way for project planning and controlling by means of sticky notes and whiteboards. As regards simplicity (8). both Questions were addressed. 2004. Regarding research question 2. The use of this system with project management software helped to reduce planning time and improve communication: Now we can see. which involves uncertainties and dynamic work requiring creativity. but in the cases in question. although the implementation in the Company was fast due to leadership commitment and project team motivation. Some disadvantages arose during the implementation (e. a sine qua non in their project environment. Each team member needed to contribute. which refers to question 1. Reports were automatically generated. innovation. The implementation provided a holistic view of the challenges found in the management of projects at small companies that have specific constraints. By controlling tasks and reports through the software and a simple set of KPIs faster and accurate performance can be easily checked. such as the standardization and the use of templates and procedures in order to meet project requirements. traditional and quick. For the specific companies under consideration. the team members agreed that it saves time in planning and focuses on the execution phase. They usually had to reinvent the project process and documentation templates to register project information. Before the system was implemented. which develop innovative products. It became easier to discuss project deliverables in view of Planning and controlling board. Analyzing project scope.. by means of regular phase review meetings. Regarding process and standardization by means of Project Deliverables Model. Although only 26% agreed that the system entailed some simplicity. Project Deliverables Model worked as a standard by providing the company with an overview of the project management life cycle. This research also provides some guidance on how to apply both approaches together (traditional and quick). but all the project team members. and agility. In the company. 74% were indifferent or disagreed that repetitive and ocular project management system is simple to use. In the company. with the support of project management software. they were not able to meet project changes requested by customer and market changes. Both the approaches. Their projects are developed locally. They had to follow a rigid plan. 111‐122.uni‐karlsruhe. (2004). & Coghlan. ( Developing organizational project management capability: Theory and practice. (2001). M. Cambridge. [24] Kloppenborg. (1999. November). Book review: Agile project management: Creating innovative products. J. . L. http://agilemanifesto. Project Management Journal.. [18] By Duncan Haughey. & Hodgson. 220‐240 [29] Cooper. J.org/. 702‐713. Agile project management: Creating innovative products. Globerson (2005).. (2004). G. (2007. & Dvir. Tichapondwa Modesto and Stephen P. October 1999. W. August. J.info. 92‐100 [7] Williams. 376–369. vol. how should resource planning and cost planning is dealt with? b) How can plan and managing risk in innovative and complex projects be kept simple and practical? REFERENCES [1] Crawford. & Kleinschmidt. Journal of Product Innovation Management. K. TR 99. 25(1).. International Journal of Operations &Production Management.aspx [27] A. (2006. [11] Chin.org/projectmanagement/ind ex. S & Zwikael.. A. J. [9] Highsmith. 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[30] Beck. Change decisions in product development projects. 93‐ 99 [5] Söderlund. Winning at new products. (2007. Karlsen. (2004). T. p 28.F. Agile project management: How to succeed in the face of changing project requirements. (2001). 19(1).Quick Systems in Planning and Project Management: A Structured Approach for Developing a New Project also need further empirical research. PA: Author. June). Shtub. "Manifesto for Agile Software Development". 2002). So some questions for future research would be as follows: a) Because resource and cost planning are not dealt with by this system. T. S..com/Home/Definit ionandImportanceofProjectControls. Perspectives on project management. 74‐86 [2] Kloppenburg. June). European Management Journal. 17(5). New York: Amacon. E. Newtown Square. SUCCESSFUL PROJECT MANAGEMENT: Insights from Distance Education practices. October). S. [20] Globerson. M. and Economics [28] Coughlan. & Opfer. 25... 22. August). Humans and Technology Technical Report. 92‐100.. J.com/definition/project‐ planning [23] Maylor. 2007). Kent. Project Management Journal. J. New possibilities for project management theory: A critical engagement. [17] One source of process patterns is http://i44pc48. W. February). Project Management Journal. (2004). J. July).. Edgett. G. P.edu/legacy/kit/taxonomy.html [16] “A Methodology per Project. &Grønhaug. [22] http://searchcrm. Agile Alliance. G. J. 33(2). 38(2). Project Management: Processes. and predictions. 33.techtarget. 22. Project management research‐The challenge and opportunity. H.htm 203 S. A. (2004. Methodologies. [10] Smith. Agile project management: How to succeed in the face of changing project requirements. B. European Management Journal. A. MA: Perseus. 37(3).sei.projectcontrolsonline. interpretations. 33(2). no. 2002). June (. interpretations. 5‐18 [3] Kolltveit.Zohrevandi [14] S. & Artto. January (. R..04. T. Boston: Addison‐ Wesley. p 15 [15] „Software Development Taxonomy. (2002. H.. 269‐273 [8] Chin.” www. October). The current state of project management research: Trends. O 2002. Bard and S. [12] Highsmith. et al. Beyond the Gantt chart: Project management moving on. 3. International Journal of Project Management. International Journal of Project Management. 37(3). (2005. Martinsuo. New York: Amacon. International Journal of Project Management. K. The current state of project management research: Trends. It is a product of mutual exothermic reaction – polyaddition of diphenyldiisocyanate and mixtures of polyhydric polyether and polyester alcohols. sometimes even as an additive to asphalt [5]. Czech Republic 3 Porobeton Ostrava a. Due to the resulting transverse forces. The paper presents the guideline prescriptions. et al. p.2 ‐ Tomáš Dvorský1. strength characteristics. in which we were looking for an optimal ratio of binding components depending on the achieved volume weight. water. Waste from plastic industry materials.2 – 0. this trend may lead to the depletion of the natural stocks. Further research in this area is devoted to the problems of the utilisation of rigid crushed polyurethane foam as the dominant filler in thermal insulating mortars and light concretes [8.35 – 0. finally. A pellet mill consists of two or more metal rollers that push the polyurethane foam through small holes in a MATERIALS Rigid Polyurethane Foam Polyurethane foam is a macromolecular construction material (thermoset). are used as fillers in concrete mixtures [3.25 mm. stabilizers. 204‐208. we are experiencing problems with their availability and. thermal conductivity coefficient and capillary water absorption.2 ‐ Vojtech Dirner2 ‐ Jaromír Daxner3 ‐ Jan Valíček4 ‐ Milena Kušnerová4 1 Institute of Environmental Engineering. mining.Contents lists available at www. From the viewpoint of the mass.7 0. plastic industry materials.3 – 0. and auxiliary expanding agents [6]. This trend is caused by the need of the people in the society to continuously expand their territory and the building production must respond to this pressure. 11]. 4]. electricity industry and.85 0. 2nd International Conference Manufacturing Engineering & Management 2012. and it is able to provide a particle size smaller than 0. 9]. Crushed polyurethane foam is also used in the USA as a component of thermally insulating shutter during the construction of concrete structures. such as crushed PET bottles or thermoplastic materials. we can observe an increasing utilisation of the secondary raw materials suitable for building production. Crushing using an impact crusher. Cryogenic grinding. Due to the increasing consumption of raw materials.3 5.. Recycled Polyurethane Foam as New Filler in Restoration Mortars. Czech Republic 2 ARTICLE INFO: Category : Technical Note Received : 29 October 2012 / Revised: 5 November 2012 / Accepted: 15 November 2012 Keywords: (in causal order) Abstract: Recycling Polyurethane Foam Filler Restoration Mortars The article describes the basic results of an experimental research dealing with the utilization of rigid polyurethane foams. Czech Republic 4 Institute of Physics. The crumbling of polyurethane foams can be performed using conventional crushing and grinding methods in various crushers and mills.4 0. 1 Properties of rigid polyurethane foam with volume weight of 30‐60 kg/m3 Civil engineering has currently been experiencing a substantial increase in the consumption of construction materials. A knife grinder is characterized by its large number of static and rotating knives that cut the crushed material and further crumble it through special sieves [10].15 – 0. ISBN 978‐80‐553‐1216‐3 INTRODUCTION flame retardants.12 CRUMBLING OF RIGID POLYURETHANE FOAM The crumbling technology opens new ways for the recycling of rigid polyurethane foams and composites. it is hard or semi‐hard macromolecular foam with a high proportion of closed cells. Faculty of Mining and Geology. The crumbling process using this type of mill is more suitable for flexible polyurethane foam [10.tk Manufacturing Engineering & Management The Proceedings Recycled Polyurethane Foam as New Filler in Restoration Mortars Vojtěch Václavík1. The properties of rigid polyurethane foam change with its volume weight. VSB‐Technical University of Ostrava.s. ultimately. VSB‐Technical University of Ostrava. Crushing using a knife grinder. VSB‐Technical University of Ostrava. Experimental researches of the utilization of waste products from the mining and metallurgical industries as secondary raw materials are devoted to replacing Portland cement with finely ground blast furnace slag in the production of plain concrete [1] or the potential use of fly ash with a high content of unburned coal in geopolymers with mechanical strength of up to 55MPa [2]. their crumbling using knife mills and subsequent use in restoration mortars with thermal insulating effect. A twin‐roll mill consists of at least one pair of contra rotating rolls of different speeds. Faculty of Mining and Geology. Fortunately. Grinding using a pellet mill. Czech Republic Institute of Clean Technologies for Mining and Utilization of Raw Materials for Energy Use. activators. this mill is capable of crumbling rigid polyurethane foam to a size smaller than 0. There is an ongoing verification of the possible utilisation of rigid polyurethane foam in building materials. such as experimental studies dealing with partial replacement of light filler with crushed rigid polyurethane foam for lightweight concrete [6]. predominantly organic based. [7] Property Specific weight Strength in compression Strength in tension Strength in bending Shearing strength E‐module Value 30 – 60 0. Citation: Václavík V.icmem. The most commonly used processes of crumbling are: Grinding using a twin‐roll mill. (2012). See Table 1.1 mm. A knife grinder is used both for flexible and rigid polyurethane foam grinding. 204 Unit kg/m3 N/mm2 N/mm2 N/mm2 N/mm2 N/mm2 . It is mainly the use of waste products from metallurgical. Tab. catalysts. the resulting product is either a polyurethane powder or compact polyurethane pellets. traffic loads.o.6 mm represent 50% of the sample weight in case of this polyurethane sample. 3 Restoration mortar prescriptions A grain size analysis of the sample of rigid polyurethane foam was performed for the purpose of the experimental research. in order to determine the thermal conductivity coefficient.5 R (Cement Hranice. 3 test specimens were manufactured from each experimental mixture. 100 Total siftings (% of weight) 80 EXPERIMENTAL PART Binders and Additives 70 60 50 PUR dust 40 30 0. The frames were kept in a room at 22° C for 28 days and then placed in a dryer at a temperature of (60 ± 5)° C. the conversion of work into grinding energy is larger. amounting to one test set. Hostapur OSB SE Tylose GmbH was used as an additive. They are used both for indoor and outdoor plasters.125 0. The resulting product contains about 40% of particles smaller than 0.063. The graphic presentation of the grain size curve (see Figure 1) clearly shows that the siftings of grain size of 0. 0. overcooled air (max ‐ 130° C) or a combination of both can be used as the cooling medium [10. They were frames with the dimensions of 40x40x160 mm. the material is exposed to heat that depends on the roller speed. etc.5 1 2 4 6. The results of the particle‐size analysis are presented in Table 2 and Figure 1.9 8.s. basement rooms used for commercial purposes.8 100 100 0. Hydrate CL 90‐S (Kotouč Štramberk. Václavík.3 1915 P2 736 1702 216 ‐ 19. Depending on the type of crumbled foam and the performance of the mill. especially in old and historically valuable objects that do not have functional hydro insulation or in which the utilisation of the building changed or in which the external effects The value was determined according to ČSN EN 1015‐10 standard. 4 sets of test specimens with the dimensions of 40x40x160 mm were produced from these experimental mixtures in order to determine the volume weight of hardened mortar. s r.3 2555 P4 736 810 ‐ 1621 24. plate.9 6. Firstly. 2 Grain size analysis of sample Sieve hole [mm] 0.1250. the material is crumbled in a knife grinder to a particle size of about 3 mm. see tab 3.5.2 mm and 60% of particles larger than 0.1 99. thus increasing the crusher efficiency.Recycled Polyurethane Foam as New Filler in Restoration Mortars V.063 0.063 0. a. affecting the construction changed ‐ utilities.05 Ground Rigid Polyurethane Foam Components PUR fr. additives and water were gradually added to the mixtures. A precisely specified amount of polyurethane chippings was measured for each mixture. Test specimens with dimensions of 140x40x160 mm were manufactured as well. Due to overcooling. 11]. The product is further separated and used for various other applications [11].25 0. Tab. The grain size analyzes were conducted using laboratory sieving machine with standard sieves according to ČSN EN 933‐1. the coefficient of capillary absorption of water in hardened mortar. spol. pavement. the material thickness and the hole diameter [10]. Cryogenic grinding is suitable both for rigid and elastic polyurethane foams. 2. Crushed polyurethane foam with a grain size of 0‐1 mm was used as the filler. During the crumbling process. and then it goes to the impact crusher. 10 0 Siftings percentage summary [%] 0.5 20 Portland cement CEM I 42. The frames were subsequently weighed on scales and dry volume weight of hardened mortar was calculated for each experimental mixture 205 1 2 90 . et al.5 ‐ 1 mm. 0. Crushing using an impact crusher is widely used for crushing polyurethane products manufactures by the RIM technology ‐ Reaction Injection Moulding. Their main purpose is moisture diversion.) and Metakaolín Mefisto K05 (České lupkové závody a.0/1mm Cement CEM I 42. the strength of hardened mortar in compression. The analysis of the particle‐size took advantage of this range of sieves: 0.18 1604 P3 736 1621 810 ‐ 24. 4 prescriptions with different ratios of bonding components have been designed for experimental mortar. until the weight of the testing specimen was stabilized.s.) was used as the main binder in restoration mortar mixtures with thermal insulating effect.5 5 Square screen hole size (mm) Fig. 4 mm. Crushing takes place in two steps. A sample of polyurethane foam has a balanced share of particles in the grain size range of 0. in order to increase the porosity of restoration mortar with thermal insulating effect.2 mm.) were used as well. 1. salt retention and protection of masonry against the effects of water contained in the masonry or external water that was brought in. 1 Graphic expression of curves illustrating sample grain fineness Tab.3 2715 RESTORATION MORTAR TESTS The individual mixtures were prepared in a laboratory mixer BS‐MI CM5AX from Betonsystem company. Determination of volume weight of dry hardener mortar DESIGNED RESTORATION MORTAR PRESCRIPTIONS Restoration mortars are designed for surface treatment of damp and salinised masonry. Liquid nitrogen.25 0. 0. the tensile strength in bending.25.125. and the individual components of binders.4 27.5R Metakaolín Mefisto K05 Hydrate CL90‐S Hostapur OSB Water Unit (g) (g) (g) (g) (g) (g) P1 736 2431 ‐ ‐ 24. After this time.906 0.00026 0. 4 Results of determination of volume weight of dried hardened mortar Sample marking ms.1185 0.1251 0.79 1.00026 0. 5 The results determining the strength of hardened mortar in tension in bending ms.884 0.56 3 Volume weight of hardened mortar [kg/m3] 603 474 585 Sample marking Weight [g] Partial strength in tension in bending [N/mm2] REC1_1 REC1_2 REC1_3 REC2_1 REC2_2 REC2_3 REC3_1 REC3_2 REC3_3 REC4_1 REC4_2 REC4_3 154.9 150.539 1.3 154 154.688 0.6 119.36 0.270 0.56 603. The strength of hardened mortar in compression was determined using Formtest prüfsysteme 2201 Mega 10‐200‐10 device.565 0. until the frames broke. the forms were dismantled.352 0.691 0. The results are presented in Table 4 and Figure 2.67 563.539 0.64 588.675 0.750 0.542 0. They were frames with the dimensions of 40x40x160 mm. the frames were stored in a laboratory environment at 22 ° C for 21 days.00026 0.00026 0.4 141.688 0.375 0. The preparation of the specimens was carried out in the same manner as the preparation of test specimens used to determine the strength of hardened mortar in tension in Determination of strength weight of hardened mortar in compression Two test specimens with the dimensions of 40x40x160 mm were used to determine the coefficient of capillary 206 Strength in tension in bending [N/mm2] .78 0.678 0.656 0.359 Strength in compressio n [N/mm2] 0.352 0.89 488.234 0.1540 0.5 125.73 601.2 144.356 0. et al.601 1.97 462. Václavík.863 0.00026 0.768 0.00026 0.725 0.00026 0.48 0. 3 Graphic expression of the results determining the strength of hardened mortar in tension in bending and in compression Determination of strength weight of hardened mortar in compression It was determined according to ČSN EN 1015‐11 standard.69 0.7 144. The measurement results are presented in graphic and tabular form (see Fig.258 0. The frames were placed in the testing machine Formtest prüfsysteme 2201 Mega 10‐200‐10 on supporting rolls. after that.445 0.381 0.V.1489 0. The measurement results are presented in tabular form in Table 5 as well as graphically (see Figure 3).785 0.1543 0. The frames in the form were packed in polyethylene bags and stored in a room at temperature of 22 ° C for 2 days.719 1.67 583.560 1.36 3 test specimens were produced from each mixture.4 148. returned back to the bags and stored for the following 5 days.1444 0. Recycled Polyurethane Foam as New Filler in Restoration Mortars according to formula (1).1 149.844 1.00026 0.00026 0.2 0. .706 0.59 581. The machine applied balanced load.25 Tab.91 467.369 0.00026 0. free of shocks.28 564.793 0.703 0.518 1.706 0.8 118.1546 0. 2 Graphic expression of the results determining the volume weight of hardened mortar Determination of volume weight of dry hardener mortar Sample marking Strength in compressi on 1 [N/mm2] Strength in compressi on 2 [N/mm2] Partial strength in compressio n [N/mm2] REC1_1 REC1_2 REC1_3 REC2_1 REC2_2 REC2_3 REC3_1 REC3_2 REC3_3 REC4_1 REC4_2 REC4_3 0.00026 0.375 0.1494 0.553 0.dry [kg] Vs [m ] Volume weight of hardened mortar ‐ partial [kg/m3] REC1_1 REC1_2 REC1_3 REC2_1 REC2_2 REC2_3 REC3_1 REC3_2 REC3_3 REC4_1 REC4_2 REC4_3 0.1442 0.06 551. 6 The results determining the strength of hardened mortar in compression 560 Fig.00026 602.1507 0.378 0. [kg/m3] (1) bending.612 1.344 0.781 1.1412 0.56 0.1198 0.356 0. always in such a way so that the compression force is perpendicular to the direction of the frame compaction. Tab.dry ‐ weight of the frame dried in a dryer [kg] Vs ‐ frame volume [m3] Tab.363 0.590 1.469 0.669 0. 5 and Fig 3) Fig. 2 139. The surface of the specimens was subsequently coated with a layer of sealing compound of beeswax along their long sides.1 126. Both parts were weighted together and the weight was recorded in table.1105 0.6 31.0937 0.0 41.9 29.1071 0.475 0. The test specimens were broken in two halves and placed with the fracture edge down into a bowl of water.5 14.461 0. The capillary absorption coefficient was calculated using the relation: C = 0.0936 0.242 0.3 129.4 76. M3 – weight of soaked test specimens after 24 h [g]. The evaluation of the thermal conductivity and the volumetric heat capacity is based on regularly collected temperature records as a function of time. The test specimens were placed in a dryer at a temperature of (60 ± 5) ° C. 8 Results determining the thermal conductivity coefficient of restoration mortar absorption of water.0 129. The production of the test specimens. when there was an apparent display of wet spots on the free surface of the test specimens. such as vermiculite.5 41. The thermal conductivity coefficient λ was always determined on one set of test specimens from each experimental prescription. 5 Graphic expression of the results determining the strength of hardened mortar in tension in bending and in compression CONCLUSIONS Fig.3 78. The comparison of the developed restoration mortar with the thermal insulating effects based on polyurethane (Prescription 3) with competing restoration mortars and restoration thermal insulating mortars are presented in Table.6 89.1 31.7 15. Tab.4 112. Václavík.0937 0.8 134.7 30.1074 0. The values of the strength in compression and the capillary .253 Weight M0 [g] Weight M3 [g] Capillary absorption coefficient C [kg/m2] 77. 7 Results determining the capillary absorption coefficient of water in hardened mortar Sample marking REC1_1 REC1_1 REC1_2 REC1_2 REC2_1 REC2_1 REC2_2 REC2_2 REC3_1 REC3_1 REC3_2 REC3_2 REC4_1 REC4_1 REC4_2 REC4_2 Tension in bending [N/mm2] 0.6 31.9 64.3 29. M0 – weight of dried test specimens [g].0998 41. The measurement results are presented in Table. 9. including their conditioning. The measurement is based on the analysis of the thermal response of the analysed material to heat flow impulses. perlite.0998 Thermal conductivity coefficient [W/m∙K] 0. Based on the properties presented in Table 9.0 79. was identical to the test specimens used for test s of the strength of hardened mortar in compression and in tension in bending. and obsidian in restoration mortars with thermal insulating effect.4 100. prior to the test.9 82.6 31.1 42.(M3 – M0) [kg.9 84.1074 0.5 103. 8 and Figure 5.7 Average capillary absorption coefficient Cm [kg/m2] 31.368 0.1109 0. The test specimens were later broken longitudinally.2 128.3 104.4 60. assuming that the heat is spreading in an unrestricted environment. The actual measurement was carried out using ISOMET2104 device.3 41.9 129. 7 (value M3). 4 Graphic expression of the results determining the strength of hardened mortar in tension in bending and in compression 207 The presented results of the experimental research has shown that crumbled rigid polyurethane foam with a grain size of 0‐1 mm can be used to replace the currently used light fillers based on expanded volcanic glasses.8 130. in order to stabilize the weight.4 Fig.791 0.5 16.780 0.9 101. Tab. The test was terminated after 90 min.0939 0.356 0.3 Sample marking Thermal conductivity coefficient ‐ partial [W/m∙K] REC1_1 REC1_2 REC1_3 REC2_1 REC2_2 REC2_3 REC3_1 REC3_2 REC3_3 REC4_1 REC4_2 REC4_3 0.2 63.1106 0.6 126.1000 0. and it was stated that they had been fully saturated with water. Heat flow is excited by an electric heating of resistance heating element embedded in a probe that is in direct thermal contact with the test sample.6 77.3 68.625.2 80.0996 0.1104 0.Recycled Polyurethane Foam as New Filler in Restoration Mortars V. et al.1 30.2 114. it is obvious that the values of restoration mortars with thermal insulating effect based on polyurethane (Prescription 3) are comparable to those of the competing plasters.1073 0.4 63.9 30.1 66.8 75.m‐2] where: C – coefficient of the capillary absorption of water for the individual test specimens [kg/m2].4 14.3 134. with the water level of 10 mm.3 13. D.. 6. ISSN 0543‐5846. no.. vol. 1581– 1588. V. K. no. AKCAOZOGLU. no. [6] [7] [8] REFERENCES [1] VÁCLAVÍK. et al. DVORSKÝ. 0. E. M. 2004. pp. p. 67.0082 supported by the Operational Program Research and Development for Innovations financed by EU structural funds EU and from the state budget of the Czech Republic.390 > 1. 2007. 2011. ZARGAR. adhering to the Tab. 2008.. DAXNER.. The potential use of fly ash with a high content of unburned carbon in geopolymers. vol. which would otherwise be disposed of by The new feature of restoration mortar with thermal incineration or landfilling. 9.V. [3] AKCAOZOGLU. cycle. Treatment and disposal of polyurethane wastes: options for recovery and recycling. DVORSKÝ. 285–290.9 0‐1.. I. Cement and Concrete Composites.. 19. BOTULA J. R.56 Thermal conductivity coefficient λ [W/m∙K] 0. J. T. Helsinki University of Technology Energy Engineering and Environmental Protection: Espoo. p. Journal of Industrial Technology.420 min. ISSN 1330‐3651 FRAJ.. 10.. p... p. An investigation on the use of shredded waste PET bottles as aggregate in lightweight concrete. p. Grants from the budget of Moravian‐Silesian region No. Acta geodynamica et geomaterialia.5 to 5 ≤ 0. R. no. P..5 1.. 2010. XXIV. N... 2. M. W.410 min. 28. B. no 2. KARIM. Proportioning and characterization of lightweight concrete mixtures made with rigid polyurethane foam wastes. A.2 1. vol. V. 2008. GBONGBON. 2004th ed. R. no.0 1200‐1400 0‐3 1. A. Recycled Foam and Cement Composites in Insulating Concrete Forms. KRINICKA I. 3 VÁCLAVÍK. 9. ŠŤASTNÝ. RAGSDALE.0 Volume weight of hardened mortar 3 [kg/m ] Grain fineness [mm] Strength in compression [N/mm2] 585 0‐1 1100‐1400 Acknowledgement The article was elaborated in the framework: Project of Institute of Clean Technologies for Mining and Utilization of Raw Materials for Energy Use. 1. BOSER. ED2. 4844–4849.. KOLESAROVA M. 7. Tehnicki Vjesnik. vol. DIRNER. ‐ Use of blast furnace slag. 665‐672. SISOL M. 1. SHAFIGH. p. Reactive & Functional Polymers.5 to 5 max. POULLAIN. is the only used filler. Waste Management. 2012. Nr. ZEVENHOVEN. 3. 123‐132. registration no. Václavík... TURCRY. Methods for polyurethane and polyurethane composites. KISMI.. [2] SVARLA.5 to 5 max. no. P. 1069‐1077. p. K. lies in the fact that 998‐1 Specifications of masonry mortars ‐ Part 1: Mortars crumbled rigid polyurethane foam after the end of its life for internal and external plasters.1. Polyurethane foam as aggregate for thermal insulating mortars and lightweight concrete. DUVEL.. C.0 1250 0‐2. Materials & Design. ATIS. 3. M. Metalurgija. Reuse of thermosetting plastic waste for lightweight concrete. 675–692. 32. Ch. DIRNER. 30. T. insulating effect based on polyurethane... Using waste plastic [9] [10] [11] 208 bottles as additive for stone mastic asphalt. BHATTI. P. M. 2010. vol. 4. ZIA. ABDELAZIZ. T. 30. 9 Results determining the thermal conductivity coefficient of restoration mortar Name PRESCRIPTION 3 Restoration mortar ‐ brown coat WTA CEMIX KVK Restoration mortar ‐ brown coat 0230 K SANIER‐ Porenausgleichsputz 208 HASIT 1. 0014/2012/RRC. 2002. recycling and recovery: A review. J. M. P. ISSN 0950‐0618.. S. 806–814. 2011. Research Institute on Civil Engineering and Mechanics. M. H. 0. no...110 Capillary absorption coefficient 2 [kg/m ] 14. MOUNANGA.. V. [4] PANYAKAPO. BHATTI. Valorization of coarse rigid polyuretane foam waste in lightewight aggregate concrete. V. P. p. 2012. PANYAKAPO.00/03. Recycled Polyurethane Foam as New Filler in Restoration Mortars absorption coefficient meet the requirements of ČSN EN requirements of restoration mortars. vol.. no. vol. ISSN 1214‐9705. M. P.. [5] AHMADINIA. vol.. 461–464. .. 18. J. Waste Management. DAXNER. 51.. vol. MOUNANGA. Keynote Lecture | Requested invited| "Anyone who has never made a mistake has never tried anything new." Albert Einstein . The modern methods of QM.ift. Citation: Durakbasa N. a high quality level of the prepared products together with effectiveness and productivity must be guaranteed. 2nd International Conference Manufacturing Engineering & Management 2012. Metrology is also devoted to the practice of measurement tasks. In operational and industrial environment production metrology delivers essential information for the completion of products and about working condition and status of processes to increase the efficiency. During the last few decades there have been many attempts to improve the quality of components and products by industry and as a consequence to reduce the manufacturing defects that disrupt the manufacturing process and become a severe cost burden to industry in general. ISBN 978‐80‐553‐1216‐3 INTRODUCTION Adequate knowledge in the areas of intelligent metrology is important presuppositions to achieve waste free production and low costs of manufacturing and accuracy at the same time within the sophisticated production systems. Metrology is also devoted to the practice of measurement tasks. 1040 Wien – Austria 2 UTN ‐ FRBA/ Argentina & AuM‐TU‐Wien. TU Wien. This cost burden is inevitably passed on the consumers. the interaction and correlation between the dimensional tolerances and surface finish becomes continuously more important [6. burning or steel production a high potential of recycling is necessary. Measurement technique can be named as an "enabling science" meaning that it is a science which makes other developments first of all possible and it forms the basis for inventions.bas@mail. Technical surfaces are created by a large variety of manufacturing processes.tuwien. Bas G. environmental management [3] and energy management [4] have been developed and refined in manufacturing organisations and therefore there exists close interaction to sophisticated intelligent metrology and industrial and technological developments. On the other hand important charge of the environment. This is of extreme importance in present time of worldwide international competition in industry and production engineering and at the same time increasingly higher costs of energy and raw material. 1) [8]. To survive economically also at the today thoroughly usual short‐term changes of the state of the market under world wide competition. p.ac.Contents lists available at www. Bauer J. EM and EnM have been developed and refined in advanced manufacturing systems and therefore there exists close interaction to intelligent metrology and industrial and technological developments. The problematic of the high accuracy of the work pieces in modern industrial production gained in the last years more and more importance through constantly increasing demands on the quality of the produced parts and quality of the production processes with higher efficiency and effectiveness. Karlsplatz 13/3113. A sophisticated high‐accuracy measurement technique can be considered as most crucial requirement for the production of industrial goods and for the production processes of high quality. Austria. and final are aspects with regard to protection and conservation of the environment of essential meaning.tk Manufacturing Engineering & Management The Proceedings Developments in High Precision Metrology for Advanced Manufacturing Numan Durakbasa1 ‐ Jorge Bauer2 ‐ Gökcen Bas3 1 Department for Interchangeable Manufacturing and Industrial Metrology and Nanometrology Laboratory – AuM at the Institute for Production Engineering and Laser Technology. for an avoidance of energy losses must be carried likewise as for thrifty consumption of raw materials care. The modern methods of quality management [1]. High accuracy workpieces are created nowadays by a large variety of advanced manufacturing system and techniques. As the tolerances of workpieces and their features decrease. To evaluate of surface finishes in the sub‐micrometer and nanometer level. Fig. Developments in High Precision Metrology for Advanced Manufacturing. furthermore must be secured the reliability at application and employment. Email: goekcen. (2012). [2].1 3D investigation of a nanometer scaled surface using an AFM 210 .at ARTICLE INFO: Category : Original Scientific Paper Received : 13 October 2012 / Revised: 21 October 2012 / Accepted: 29 November 2012 Keywords: (in causal order) Abstract: Precision metrology Nanotechnology Workpiece accuracy Industrial environment Advanced Multi‐Functions Integrated Industry Integrated Management The application of intelligent technologies also puts appropriate demands on production engineering in modern industrial environment. On the basis of metrology essential measurement know‐how is developed and organisations are supplied with this know‐how. 210‐215.icmem. consumer electronics and passenger cars ‐ instead of land filling. Email: 3 AuM‐TU Wien. On the basis of metrology essential measurement know‐how is developed and organisations are supplied with this know‐how [5]. reduced availability of natural resources and the increasing growth of waste as well as energy use require new concepts and strategies to recycle technical consumer goods as there are household instruments. Vienna. very sophisticated instruments have been developed (see Fig. 7]. G. 3) [10]. position or their derivatives such as strain. production. photolithographic techniques.Developments in High Precision Metrology for Advanced Manufacturing N. 2. In the same period the needs of the industry for ultra‐high precision engineering and workpieces with a surface roughness less than few nanometers call for measurement instrumentation that can be applied reliably in modern production engineering. Also a special demand for quality management is in the point of view in this field. standards have been developed in the area of GPS. The problematic of the high accuracy of the work pieces in modern industrial production technique gained in the last years more and more importance through constantly increasing demands on the quality of the produced parts. But also within the surface of every single feature there exist interactions between geometrical deviations of different kind and different order. form and position collectively the existing interactions are significant for the accuracy. Together with these applications the need came to make smaller sensors and actuators to enable the non‐intrusive control of instruments and machines.2 Features forming the periphery of the part on ideal model and "Skin‐Model" of a workpiece [9] INTELLIGENT DESIGN IN THE FRAME OF: GEOMETRICAL PRODUCT SPECIFICATIONS AND VERIFICATION ‐GPS ADVANCED PRECISION MANUFACTURING Developing from the need for more accurate machines as demands grew for example in the fields of IT. Duality principle. production and measurement and to clarify the mutual importance. These include micro and nanofabrication of surface patterns and topographies by the use of laser machining. Durakbasa. which do not fulfill these requirements. Responsibility principle etc. In order to establish this relationship between design. Functional control principle. including miniature motors of submicrometer dimensions. It defines on a technical drawing the shape (geometry). fine mechanics and biotechnology. surfaces with thin film deposition and ultra precision surface treatment with the utilization of new manufacturing and measurement instrumentation and techniques. functionality. 4. If we take these deviations of dimensions. contact problems and functional behavior of surfaces (see Fig. EM and EnM. 211 . Therefore workpieces are measured in order to compare them with the specifications. the above‐mentioned international standards have been adopted also on a national level. Micromotors and articulations are more ambitious but are developed in many parts of the world.. the workpiece as manufactured. high quality and the functions of the parts that should be accomplished during practical application. which applies to the interpretation of GPS indications on all types of drawings. Fig. Focal points of interest included. metrology. 5). environmental management and energy management [1. quality management. 3. friction and miniaturization demands creation of nanometer scaled surface structures. the knowledge about the workpiece as measured. to produce due to the worldwide competition fight's and it price pressure's resultant from that maximally economical and to strive for cost savings and efficiency increasing in production. dimensions and surface characteristics of the workpiece under discussion. QM. indentation. In engineering applications. 2) [9]. There is a need to relate between actual workpieces and: the workpiece imagined by the designer. Already many small mechanisms are being made. Nevertheless workpieces will be produced. The most important parameters in determining the suitability of a technical part are its compatibility. as well as tolerancing principles such as. which has emerged from the technology developed for integrated circuits.3 Geometrical tolerances and tolerances of dimension and geometrical properties of the surface The standards governing product design and manufacturing have undergone basic international harmonisation. J. Highly reliable accelerometers are already in use. Independency principle. construction. topography. roughness. These devices are fabricated on silicon substrates using extensions of such integrated circuit manufacturing processes as photolithography. Feature principle. pressure and acceleration. 90 % of transducers are concerned with the measurement of displacement. thin film deposition and the like. according to the international standard [13]. The necessity faces to the additional outlay caused through that in the entire manufacturing process. Bas If the workpiece geometry of machined parts is considered as a whole there exist interactions between the different features forming the periphery of the part (Fig. together with international standards defining parameters and tolerances in the nanometer scale in the frame of: Geometrical Product Specifications and Verification – GPS (Fig. Bauer. similar as the new international standards about quality assurance. At the time being 3D surface measurement is already proved to be an important tool in several areas of surface analysis including wear. In many countries. In this way the optimal function of the respective part is supposed to be guaranteed considering certain manufacturing tolerances. 4]. and electron beam and colloidal lithography to produce controlled structures on technical surfaces in size ranging from 10 nm to 100 µm. performance and corrosion resistance. In this respect the general term "Geometrical Product Specifications and Verification ‐ GPS" has become recently well‐known for the area of mechanical engineering. General specification principle. Fig. This has resulted in a mechanical micro world. Comprehensive knowledge in this area is an important presupposition to achieve economic design. workpiece microgeometry [11] and geometrical deviations [12]. The precise assessment of wear. electronics. new methods of fabrication came with different materials. N. Durakbasa, J. Bauer, G. Bas Developments in High Precision Metrology for Advanced Manufacturing of high priority for mechanical engineering. This fundamental is based on the development and application of high precision manufacturing processes. Generally dimensional surface measurement technique has the task to recognize at explored surfaces corresponding details and magnifies greatly in most cases especially perpendicularly to the tested surface to make possible distinctions between individual lateral details. In nanotechnology and precision machining however very often smallest or even crystalline structures and molecular assignments are of special interest. The production of very precise components goes hand in hand with the development of the necessary metrology, and a wide range of measuring instruments has been devised to cater for the evaluation of surfaces and structures down to the 0.1 nm level (Table 1). This powerful array of instruments provides a measuring capability in nanometrology (Fig. 6). Tab.1 Measurement techniques related to measuring capability Fig.4 Analysis of topographic structure on micro/nano scale machined surface [14] In the first place the extraction of high‐quality information is a task of the measurement technology. High product quality can be achieved only there, where the measurement technology is integrated into the production event as far as possible strongly. On the other hand, however, continuously new orders are made through increasing quality onto the capability of the measurement technology. Quality protection and measurement technology form an inseparable unit from that in the process of manufacture. The trend in instrumentation and metrology was already developing in the electronics industry where the drive was towards miniaturization for higher packing densities and faster switching. As a result, highly controllable and stable processes such as lithography were introduced. This meant a need arose for the very accurate positioning of specimens. In turn this resulted in an interest in miniature actuators, motors and accurate slideways for which new technologies have required development. In particular new materials and thin film research were pre‐eminent. The appropriate laboratory research provides the measurement bedrock upon which modern society stands. Advanced products require length measurements many times smaller than human eyes can see, as well as precision measurements of voltage, frequency, velocity, pressure, radiation, and temperature. Limit size >10 µm 10µm‐1µm 1 µm–100 nm 100nm‐10nm 10nm‐1nm 1nm‐0,1nm Fig.5 Measurement and analysis of surface texture in 2D and surface topography in 3D [14] Fig.6 Measuring resolution and measuring range for different methods [15], AFM Atomic Force Microscopy, STM Scanning Tunneling Microscopy, SEM Scanning Electron Microscopy, OIM Optical Interference Microscopy, SCM Scanning Confocal Microscopy, SSM Scanning Stylus Microscopy NANOMETROLOGY IN ADVANCED PRODUCTION ENGINEERING To achieve surface finishes and part tolerances in the sub micrometer and nanometer level it is necessary to incorporate very sophisticated instrumentation and metrology into the design. This development started in the electronics industry but micro miniaturisation is also now The dramatic improvement of ultraprecise manufacturing machines and the invention of new production techniques like Focused Ion Beam Technology have made the production of features and functional elements with 212 Measuring techniques CMM, mechanical and pneumatic comparators, optical systems CMM, fine mechanical comparators, optical and electric comparators spin resonance CMM, Electromagnetic and electrostatic comparator, optical interferometer, phase microscopes, dark field microscopes CMM, Laser interferometers, roughness measuring devices, fluorescence microscope Laser confocal microscope, X‐ray microanalyzer, SEM, SPM (STM, AFM), electron and X‐ray diffraction system Developments in High Precision Metrology for Advanced Manufacturing N. Durakbasa, J. Bauer, G. Bas micro‐ and nanometer size possible and economically reasonable. In metrology, the further development of the above mentioned microscope techniques and especially special variants and related techniques has helped to establish nanometrology in research institutes and meanwhile industrial application has been taken into consideration too. Although both manufacturing technology and measurement instrumentation fulfill in principal several of present demands in nanotechnology, international measurement standards in nanometrology are still in preparation. These standards, including the calibration of instruments, the toleration of form and functional elements in the nanometer scale, new parameters and measurands for nanometrology and guidelines for reproduceable and comparable measurement results are vital for the acceptance of an industrial nanometrology in industry. Scanning tunnelling and atomic force microscopes achieve a ratio of resolution in lateral and in vertical direction of nearly 1 showing an important advance over the conventional methods. The needs of the industry for ultra‐high precision engineering and workpieces with a surface roughness less than few nanometers call for measurement instrumentation that can be applied reliably in modern production processes, together with international standards defining parameters and tolerances in the nanometer scale. The requirements on the measurement systems and the measurement strategy to determine suitable parameters, time, costing and the guarantee of a predetermined process stability by means of measurable and correlated parameters come into focus. On basis of industry needs, the demands on industrial nanometrology can be subdivided into three major scientific attributes (Fig. 7): Reliability: Measurement results have to mirror the real surface structure and statistic and systematic errors may be reduced to an absolute minimum. Comparability: Measurement results must be comparable when they are measured with different measurement systems of the same kind. Ideally measurement results taken with different systems should be comparable too. Reproduceability: Several measurements of the same sample under the same conditions must result in the same results. Changes in measurement conditions must result in comprehensible changes in the measured parameters. Fig.7 Demands on Industrial Metrology measurement technique is to be found in the real sense hardly, but productive power joined with reliability stands thoroughly in the foreground. Criterion is the establishing of arbitrarily modelled products together with a supplier‐ customer‐relationship. Completely actual transformations can at first of all very abstractly appearing applications as necessarily prove [16]. The various efficient tools, methods and techniques of modern quality management can be utilised however also in connection with management systems as environmental management, energy management etc. Quality management systems according to International Standards of the EN ISO 9000 series are a good basis for building environmental management practice (ISO 14001, ISO 14004) as well as energy management systems (ISO 50001). This offers the opportunity to apply well known systems and well known tools in a modified form to solve a company's environmental and energy efficiency problems [17]. To meet high‐level demands both from industrial and from private customers in the future, manufacturing enterprises must be flexible and agile enough to respond quickly to product demand changes. New models for alternative configurations of future industrial organisations in general which are usually applied and especially for small and medium sized enterprises (SMEs) need to be investigated. Those new models can be developed on the basis of intelligent production technologies and extensive use of the internet, of distributed computing environment (DCE) technology, parallel‐processing computing and advanced engineering data exchange techniques [18]. By these means global competitive associations of factories as well as of collaborating SMEs with intelligent, associative, concurrent, interactive, modular, integrative, learning, autonomous, self optimising and self organising functions are already under development and the world wide application of such associations and co‐operations will be possible in the near future. Intelligent measurement technique closes quality control loops in production, in that an early recognising possible reasons for rejections together with an analysis results the improvement of manufacturing processes and preventive corrections can be introduced (Fig. 8). For the draft and the completion of workpieces experimental values and expert knowledge of geometric deviations facilitate the discovering of meaningful strategies [19, 20] therefore the demanded workpiece accuracy can be achieved under an economic point of view. INTEGRATED MANAGEMENT FOR ADVANCED MANUFACTURING Fig.8 Control Loops in Intelligent Manufacturing Systems Today the general principles of Integrating Quality, Environmental and Energy Management Systems , are introduced in very different organisations in which partly The way to scrap free and zero defect production will be made possible by learning with self improving ability, a 213 N. Durakbasa, J. Bauer, G. Bas Developments in High Precision Metrology for Advanced Manufacturing essential meaning whereas flexibility must be considered as an important boundary condition. In an industrial environment of computer integrated and intelligent manufacturing it is necessary that measurement technique can be adjusted flexibly to changing task designations. Appropriate solutions can be found with the help of flexible intelligent measuring cells and their components [19]. To meet high‐level demands for comfortable daily life in the future, manufacturing enterprises must be flexible and agile enough to quickly respond to product demand changes, and new models and configurations for future manufacturing systems and enterprises need to be investigated. "Multi‐Functions Integrated Factory ‐ MFIF" [22] is an innovative concept and model for future enterprises. It is initiated with the aim to provide cost‐ effective, agile and optimum ways to produce customer‐ driven "Multi‐Functional Products ‐ MFPs" in the near future, based on intelligent production technology and especially the information highway making possible the application of intelligent metrology at world wide distributed factories on the basis of advanced engineering data exchange techniques (Figure 9). Fu, S., and Raja, J., gave an example for an appropriate application for engineering metrology and ICAQ [23]. Automated measurement technique closes quality control loops in production, in that an early recognising possible reasons for rejections together with an analysis results the improvement of manufacturing processes and preventive corrections can be introduced. For the draft and the completion of workpieces experimental values and expert knowledge of geometric deviations facilitate the discovering of meaningful strategies [19] therefore the demanded workpiece accuracy can be achieved under an economic point of view. Under this organizational production philosophy (MFIF) described, we work on the research and development of an autonomous mobile robot for particular tasks of quality control and data collection for SPC (Statistical Process Control). MFI‐MR Multifunction Intelligent Measure Robot (Fig. 9) is an autonomous unit to be able to move by itself from machine to machine, take a production piece, check the main variables and transfer the measure results to the QA system. This unit is composed by a robotic arm with six freedom degrees, automatic change for Grippers to take production parts or different metrological instruments. The arm is placed on a platform that allows the transfer from one machine to another, adjust its height to match the production machine, fixing temporarily its relative position and do the QA planned tasks. The MFI‐MR Robot is equipped with its own intelligence that gives it work autonomy, link with WI‐FI and Internet, to enable the telepresence and teleoperation from a local or global position. goal which at least can be realised partly. Improvement and optimization of production processes is possible based on the supervision of quality in the process chain as well as by means of knowledge and learning management systems and self‐learning systems. This method permits to learn stepwise from deviations and to improve the used processes continuously. In the ICAQ system Fuzzy Logic will be applied for Quality Function Deployment (QFD) and for monitoring and forecasting of maintenance of measuring instruments [20], further on for CAD and for an expert system for tolerancing and quality planning. Through the application of fuzzy logic at the interface between manufacturing and metrology can be performed on the one hand evaluation and trend analysis of measuring data help to achieve waste free production, on the other hand failure analysis, which is the basis for decisions to monitor production equipment. Intelligent coordinate metrology is a very important tool to solve various problems of production metrology and to improve the process and product quality within the integrated management systems according continuous improvement quality management and environmental management in advanced production engineering especially when high accuracy and high flexibility are demanded simultaneously [1‐4]. This way of metrology is the up‐to‐date measuring method for complex dimensional and geometrical measuring problems. In the advanced manufacturing environment, the integrated ICAQ system with intelligent coordinate metrology ICM is utilised to test the product or to scan and digitise complex product models with freeform surfaces. This is in order to obtain the digital model of the product and to modify it in ICAD system and then to create a new modified surface model and CNC programs for manufacturing of the final product by machine center in the workshop. An important development as far as workpiece metrology is concerned is the big general advance of coordinate metrology which also happened in the same period of time as computer‐aided metrology and “GPS” in general. In a system or compound of SMEs as described above, CNC‐controlled intelligent CMMs are connected by using networks with design and manufacturing. The goal is to mutually use the data stored in ICAD, ICAM and ICAQ systems, and to realise data parallel‐processing. New breakthroughs by the instrumentations have been made in recent years, to establish high‐tech instruments which can acquire a 3D surface structure of the precisely machined surfaces to fulfill the requirements for the application in industrial environment [21]. These measuring techniques are typically used for surface characterization. For 3D measurements it is often more advantageous to use a CMM. Such Nano‐CMMs have been recently introduced achieving an uncertainty of 100 nm or better and enabling three‐dimensional measurements as well as scanning of high precision parts. The concept of the ultra high accuracy coordinate measuring machines is based on the linear scales to measure the position of the probe tip and measuring heads for the scales in the horizontal plane. The design also features air bearings for high repeatability and small power dissipation in the slides. Measurements with resolutions less than 50 nm in industry and less than 1 nm in national metrology institutes are desired today. INTEGRATED MANAGEMENT FOR ADVANCED MANUFACTURING The automation of measurement technique is particularly under the point of view of the productive power of Fig.9 Multifunction Intelligent Measurement Robot. 214 Developments in High Precision Metrology for Advanced Manufacturing N. Durakbasa, J. Bauer, G. Bas CONCLUSION AND FINAL REMARKS In modern manufacturing systems there exist close interactions between intelligent design, intelligent metrology and industrial and technological developments. Special points of interest are quality and environmental management, automation, high accuracy, high efficiency, precision manufacturing and metrology. In modern metrology it is possible to use instruments capable of creating atomic resolution images of the surfaces of different specimens and 3D measurements as well as scanning of high precision parts. SCM, AFM, STM, Scanning Probe Microscopy (SPM) and Nano‐CMM are such advanced measurement technologies. At the atomic level metrology and fabrication are closely related. STM has made possible the first steps of atom manipulation which may lead in the future to fabrication at the atomic level.The integrated management system processes will be used based on intelligent metrology in all product production processes in such a system – from the design stage to the final assembly and from the after use to recycling ‐. Such integrated management systems in individual activities of different function enterprises can play a basic role to ensure the realisation of the concept, through the advanced manufacturing systems based on intelligent production metrology in the system to create, to realize and to present the features, such as concurrent, interactive, modular, integrative, learning, autonomous, self optimising and self organising functions. It is correct that integrated management is much more than practical application of measurement technique but it is not possible to achieve high quality, environmental compatibility of technical products and high efficiency of the production processes without appropriate and intelligent measurements. [12] [13] [14] [15] [16] [17] [18] REFERENCES [1] EN/ISO 9001: 2008; Quality Management Systems ‐ Requirements. [2] EN/ISO 9004: 2009; Managing for the sustained success of an organization ‐ A quality management approach. [3] ISO 14001: 2009; Environmental management systems ‐ Requirements with guidance for use (ISO 14001: 2004 + Cor. 1: 2009) [4] ISO 50001: 2011; Energy management systems ‐ Requirements with guidance for use [5] Osanna, P.H.: Intelligent production metrology ‐ A powerfull tool for intelligent manufacturing e & i 112 (1997), H. 4, pp. 162‐168. [6] Tabenkin, A. Effects of Form and Finish on Tolerances ‐ Quality Vol.9, 1993 [7] Osanna P. H., Durakbasa M.N., Kräuter L., "IndustrialMetrology and Interchangeable Manufacturing under the Viewpoint of Nanotechnology and Nanometrology, Bulgarian Academy of Sciences, Problems of Engineering Cybernetics and Robotics, vol. 59, 2008, pp.60‐73. [8] D. Whitehouse, "Comparison between stylus and optical methods for measuring surfaces", Annals CIRP , vol. 37, no. 2 , 1988, pp. 649‐653. [9] M.N. Durakbasa, A. Afjehi‐Sadat, N. Nomak Akdogan: ?"Dimensional and Geometrical Measurements and Interpretation of Measuring Results on the Basis of the Skin‐Model"; ?Measurement Science Review, 1 (2001), 1; S. 89 ‐ 92. [10] ISO TR 14638: Geometrical product specification (GPS) ‐ Masterplan [11] EN ISO 4287:2009, Geometrical Product Specifications (GPS) ‐ Surface texture: Profile method [19] [20] [21] [22] [23] 215 ‐ Terms, definitions and surface texture parameters (ISO 4287:1997 + Cor 1:1998 + Cor 2:2005 + Amd 1:2009). EN ISO 1101 ‐ 2006: Geometrical Product Specifications (GPS) ‐ Geometrical Tolerancing ‐ Tolerances of Form, Orientation, Location and Run‐ out; EN ISO 1101/A1: 2010 Geometrical Product Specifications (GPS) ‐ Geometrical tolerancing‐ Tolerances of form, orientation, location and run‐out‐ Amendment 1: Representation of specifications in the form of a 3D model. EN ISO 8015 ‐ 2011: Geometrical product specifications (GPS) ‐ Fundamentals ‐ Concepts, principles and rules. Keyence: Laser Scanning Microscope Guide (Complete Edition). www.keyence.com Whitehouse D.J., 2003, "Handbook of Surface and Nanometrology", London, Institute of Physics. Osanna, P.H., M.N. Durakbasa, J.M. Bauer, L. Kräuter: "Global International Cooperation of Collaborating Small and Medium Sized Enterprises to Achieve Total Quality Management"; Vortrag: Proceedings Fourth International Working Conference, Belgrad; 27.05.2007 ‐ 30.05.2007; in: "Total Quality Management ‐ Advanced and Intelligent Approaches", V. Majstorovic (Hrg.); (2007), ISBN: 978‐ 86‐7083‐594‐8; S. 1 ‐ 6 Osanna, P.H., Durakbasa, N.M., Afjehi‐Sadat, A.: Life Cycle Assessment and Modern Metrology for Quality Management Systems in Industry. International Journal for Production Engineering and Computers, Production Engineering Department, Belgrade, SCG, Vol. 6, No. 7, 2004, YU ISSN 1450‐5096, pp.29/38. Osanna, P.H., Durakbasa, N.M., Tahirova, H.S.: Intelligent Flexible Disassembly and Recycling of Used Products to Support Total Quality Management and Sustainability in European Industry. Proceedings of 3rd International Working Conference "Total Quality Management ‐ Advanced and Intelligent Approaches" (Editor: V.D. Majstorovic), Belgrade, SCG, May‐June 2005, ISBN 86‐7083‐514‐2, pp.1/4. Osanna, P.H., Durakbasa, N.M., Oberlaender, R.: Low Cost Solutions for Quality Management in Flexible Automated Production Systems. Durakbasa, N. M., Osanna, P. H.: Lageabweichungen bestimmen die Werkstückgenauigkeit. wt‐ Werkstattstechnik 79 (1989), N.3, 141/145. Durakbasa M.N., Osanna P.H., Demircioglu P., The Factors Affecting Surface Roughness Measurements of the Machined Flat and Spherical Surface Structures ‐ The Geometry and the Precision of the Surface, Measurement 44, 10, pp.1986‐1999, 2011 . P.H. Osanna, M.N. Durakbasa, M.E. Yurci, J.M. Bauer: ?"Enterprise Information Systems for Business Integration in Global International Cooperations of Collaborating Small and Medium Sized Organisations"; ?in: "Enterprise Information Systems for Business Integration in SMEs Technological, Organizational and Social Dimensions", M. Cruz‐ Cunha (Hrg.); herausgegeben von: Business Science Reference; Business Science Reference ‐ IGI Global, Hershey PA ‐ USA, 2009, ISBN: 978‐1‐60566‐892‐5, S. 175 ‐ 186. Fu, S., Raja, J., Slawi?ski, E., Mut V., Control for Teleoperation of Mobile Robots, Proceeding of the 3rd International Conference on Integrated Modeling and Analysis in Applied Control and Automation, IMAACA 2007, vol. 1, pp. 17‐22, ISBN: 978‐2‐ 9520712‐7‐7, (2007). Prešov.Conference Sponsors | in alphabetical order| 1st Presov tool making company.. Slovak Republic If A is success in life. Slovak Republic SPINEA – Solution for Precision. Olcnava. Slovak Republic A.S. Slovak Republic VIA MAGNA. Bratislava. Ltd. Ltd. Prešov... Ltd. Work is x. Albert Einstein . Ltd. Prešov.E. Slovak Republic WELDEX. fair-play is y and z is keeping your mouth shut. Slovak Republic DRC.. then A = x + y + z. Prešov. Slovak Republic AVON.. Ltd. Prešov.G. . . Catalogue Katalog I/ 2009 DriveSpin DriveSpin . Specifications in this catalogue are subject to change for improvement without prior notice. z..und Transportsysteme • Navigationssysteme • Medizinische Einrichtung • Glasbearbeitungsmaschinen • Marinenindustrie.o. 2 .D D r i vre Sipv ine S p i n SPINEA. Es handelt sich um eine hochpräzise und kompakte Einheit die von einem Getriebe und einem Servomotor besteht..o. s. Ausgabe I / 2009 DriveSpin SPINEA.r. s. Our products are applied everywhere where precision positioning and compactness are needed for example: • Robotic and Automation • Machine tools • Textile machines • Manipulation and transporting • Navigation systems • Medical equipment • Glassworking machines • Naval industry … Unsere Erzeugnisse werden überall wo man eine präzise Positionierung verlangt benutzt. is rapidly growing Engineering Company. Wir würden Ihnen gerne eine neue Entwicklungslinie DriveSpin präsentieren.: • Roboter und Automatisierung • Werkzeugmaschinen • Textilmaschinen • Handhabungs. It is a high precision compact unit that consists from bearing reducer and servomotor.r. die sich an die Entwicklung und Produktion von hochpräzisen Getrieben (TwinSpin) und Aktuator (DriveSpin) orientiert.B. We would like to present you a new progress line DriveSpin. Edition I / 2009 Modifikationen der in diesem Katalog angegebenen Daten aufgrund technischen Fortschritts behalten wir uns ohne vorherige Bekanntmachung vor. which deals with development and production of high precision bearing reducers (TwinSpin) and actuators (DriveSpin). ist eine sich entwickelnde Maschinenbaugesellschaft. High dynamic performance .Radar and monitoring systems 4 kompaktes Design kein Umkehrspiel hohe dynamische Leistungen hohe Kipp.Defense industry .Aerospace applications .Machine: CNC machine.Flugzeugindustrie .Robotics: 6-axis robots.Compact design .Zero backlash .Robotertechnik: 6-Achsen Roboter.DriveSpin Main characteristics of DriveSpin: DriveSpin .und Navigationssysteme . grinding machine. lathe machine .Radar.Rüstungsindustrie .und Verdrehsteifigkeit kompakte Abmessungen einfache Installation hohe Belastbarkeit des Radial-AxialRollenlagers .CNC Werkzeugmaschinen (drehen.High torsional and tillting stiffness .wichtigste Vorteile: .Halbleiterindustrie .Flight simulators .High load capacity of radial-axial output bearing . schleifen usw.Medizinische Einrichtungen . low mass .) .Maintenance free - Applications: .Medicine equipment .Biegmaschinen .Special machine: bending machine . fräsen.Small size. Manipulatoren . Gantryroboter.wartungsfrei Anwendungsbeispiele: .Semiconductor industry . gantry robots and manipulators .Simple installation . Okrajová 33 080 05 Prešov Slovakia Tel.r.: +421 51 / 7700155 +421 51 / 7700156 +421 51 / 7756965 +421 51 / 7700162 Fax: +421 51 / 7700154 +421 51 / 7482080 E-mail:
[email protected] Web : www.spinea.SPINEA.sk . s.o. .1..o. 1. We mouldingYour ideas.. s r. prešovská nástrojáren.PN moulds & tools st 1 Presov tool making company Ltd.. spol. Using its more than 50 year tradition in the production of special tooling.750. Insert Nr. In May 1999 the company was registered in the Commercial register of District Court in Presov (Section Sro. s . Company vision: "Achievement of prominent place on the Slovak market of producers of tooling". software equipment and quality working team. In more than 50 years the production basis has been established with rich experiences and knowledge from tool making industry and these became a basis for the newly established private company called 1.o.PN moulds & tools . s. Confirming of the company qualities in its = business and character of its activities by certifying it to ISO/TS 16949.Company profile < Profile 1. Investing = < History The history of the company dates back to the year 1947. Sk (1.r. professionalism of order solving and accommodating production terms with support by modern technologies. prešovská nástrojáreò.000 EUR). the main production programme of which is represented by the production of tools injection moulds for thermoplastics and dies shear and bending tools. The tool making workshop of this company was developed as the division serving to support the production of measuring and regulation technology of the parent company. The company employs 56 employees and the estimated turnover in 2007 is 58 mil.r. when the development started in Presov of the concern company KØIŽÍK. we provide our customers with seriousness at collaboration. Priority objectives of the company: in the modernization of technologies and software equipment in order to reduce the production terms and increase the quality and effectiveness of production. Firm establishment on the demanding = markets cooperating with home appliances. 2 1. electrotechnic and automotive industries. prešovská nástrojáreò spol.o. is a private company. 11648/P) as an independent company. < Development of turnover and employment 4 year 2000 Diagram prezentation of the development of economical indicators = number of employees: 68 = turnover: 22 mil./empl. Sk = product./empl. Sk number of employees turnover productivity per employee = product./empl./empl.s.: 1.: 578 thous. Sk = product. Sk = = product. Sk = product.: 405 thous. Sk 4 year 2004 = number of employees: 59 320% 310% 300% 290% 280% 270% 260% 250% 240% 230% 220% 210% 200% 190% 180% 170% 160% 150% 140% 130% 120% 110% 100% 90% 80% 70% 60% year 2000 year 2001 year 2002 year 2003 year 2004 year 2005 year 2006 = turnover: 46 mil./empl. Sk = < Quality In the long term. Sk product. Sk 4 year 2002 = number of employees: 61 = turnover: 29 mil. was certifies by RV TUV./empl. the company has the procedures for the quality achievement implemented in the time when the tool making division. Sk 4 year 2001 = number of employees: 64 = turnover: 26 mil. The in process.018 thous./empl.: 917 thous.. The incoming inspection is realized by means of certificates of purchased materials.: 324 thous.: 475 thous. The company has proudly been ISO 9001 certified since January 2004. Sk = product. 1.5 mil. Sk 4 year 2005 year 2006 4 = number of employees: 60 number of employees: 57 = = turnover: 55 mil. Sk 4 year 2003 = number of employees: 58 = turnover: 33.: 780 thous. as the part of the company KRIZIK a. and naturally also final inspection are implemented for the validation of tools and pressings. Sk turnover: 58 mil.PN moulds & tools 3 . Within the scope of looking for the possibilities of providing the customer with wider service in the area of design and development of plastic parts.PN moulds & tools email:
[email protected] < Structure of the production .sk 4 1. including the two-composite materials moulds for direct pressing of thermosets = moulds for injection type of thermosets = moulds for pressure die casting of = 85% aluminium and its alloys Moulds for thermoplast simple cutting and bending tools = Moulds for direct pressing of thermosets processual cutting and bending tools = + combinations including those for cutting and bending tools hard metals Moulds for aluminum and its alloys assembly fixtures. production of tooling necessary for the serial production and finally its realization as such....r.lph. = Other gauges. control fixtures.sk Orientácia spoloènosti je zameraná nielen na lisovanie dielcov.".1000Ton. s. prešovská nástrojáreò and LPH Vranov n/T. entered into a common agreement on the strategic collaboration This agreement gives the customer the possibility to use the comprehensive offer not only for the production of tooling... . The limiting dimensions of tooling currently are 1100x800mm and the weight 5 T. but LPH Vranov n/T disponuje also for the subsequent vstrekovacími lismi s uzatváracou silou operating in terms of v rozsahu 25 . www. ale aj na montážne a iné dodatoèné operácie. securing the serial production of parts. Characteristics of the production Production programme: 4% pressure die casting of thermoplastic 3% 5% 3% materials.o. but also for the subsequent operation thereof in terms of securing of the serial production of parts.production programme Injection moulds for thermoplastic materials represent approximately 85 % of the production. templates and others. The common participation of these parties ended in property connection in December 2001. It is of course possible to interpret this collaboration in the opposite order production of plastic parts with securing of the production of tooling. moulds for = < Complex offer "We provide a complete offer not only for the production of tooling. the 1. PN moulds & tools 5 .< Sample of production Thermoplastic moulds for automotive industry 4 Thermoplastic moulds for home appliances 4 Thermoplastic moulds for electrotechnical industry 4 1. PN moulds & tools . iges. Other programmes are those for NC code generation for 3D or 2D machining for CNC machining centres. vda. 2D: dwg. step. CAD/CAM Four installations of Pro/Engineer are the basis of the software equipment of design department. for the definition of course of the electroerosion cutting machines and mould flow simulation. Data compatibility / supported formats: 3D: prt. dxf 6 1. exp.4 Cutting tooling for electrotechnical industry Technologies < Software equipment Control and coordination of information flow is realized by means of electronic information system from the very first phase of project recording up to the releasing approval package for either tooling or pressing with the control of timing of the individual production stages. in the assemblies and on assembly lines of several companies.5 Y 1000 mm Z 500 mm Weight of workpiece 800 kg 500 kg 600 kg 800kg 800kg 200 kg 800 kg 200 kg 100 kg 100 kg 3000 kg 900 kg References The pressings from both moulds and tools produced at 1.< Machinery equipment "The priority goal of the company is to invest into moderniza-tion. directly by our customers or indirectly.PN moulds & tools 7 . technologies and software equipment in order to shorten the delivery terms and increase the quality and effectiveness of production" Parameters of selected technologies CNC / NC Milling machines Type Working range Dimension for fixation X 1000 mm 1200 mm Deckel Maho DMC 103 V Y 600 mm 600 mm Z 600 mm 600 mm X 630 mm 800 mm Deckel Maho DMC 63 V Y 500 mm 500 mm Z 500 mm 500 mm X 710 mm 1000 mm Deckel FP5NC Y 600 mm 550 mm Z 350 mm Electroerosion sinkering machines X 500 mm 1070 mm Agietron HYPERSPARK 3 Y 350 mm 530 mm Z 500 mm 350 mm X 500 mm 880 mm Agietron IMPACT 3 Y 350 mm 680 mm Z 500 mm 350 mm X 350 mm 560 mm Agietron 100 C Y 250 mm 445 mm Z 350 mm 251 mm Electroerosion cutting machines X 500 mm 1050 mm Agiecut Classic 3S Y 350 mm 650 mm Z 426 mm 420 mm X 300 mm 560 mm Agiecut 150HSS Y 200 mm 445 mm Z 251 mm 251 mm X 150 mm 330 mm Agie 250 Y 300 mm 560 mm Z 100 mm 100 mm X 150 mm 330 mm Agie 315 Y 300 mm 560 mm Z 100 mm 100 mm Horizontal boring lathes X 1200 mm 900 mm W75 Y 600 mm 900 mm Z 700 mm 700 mm CNC Coordinate Measuring Machines X 700 mm DEA 7. i. prešovská nástrojáreò are applied.10.e.: 1. sk dzurenda@1pn. Štefan Dzurenda Vladimír Benko Ing. prešovská nástrojáreò. s r.sk benko@1pn. Email: www: +421.sk
[email protected]. R.51.sk http://www.7485054 +421.7485051 +421.7485055 +421.51. spol.51.255230
[email protected] AIRPORT: Košice Mailing address: Slovenská správa letísk Letisko Košice 041 75 Košice 1 Tel.51.51. Štefánika 823 01 Bratislava 21 Tel.sk < Contact persons: Function Name Phone email Company director Quality Production logistic Production Design Technology Economy Human resources C. Štefánika Bratislava Mailing address: Slovenská správa letísk Letisko M.51.PN moulds & tools . R.sk host@1pn. ¼ubochnianska 2407/2 080 06 PREŠOV-¼UBOTICE SLOVENSKÁ REPUBLIKA tel: Fax: Mob.sk
[email protected] 8 1. Jan Host ¼udmila Baranová Mária Kmecová Štefan Dzurenda +421.7485057 +421.7485056 +421.letiskobratislava.7485055 +421.: 055 68 32 123 E-mail:
[email protected] 1.sk http://www.7485052 +421.sk http://www.1pn.sk
[email protected] < Location map: Air connection AIRPORT: M.7485061 +421.7485052
[email protected] [email protected] +421.51.O.905. Marián Èeledinský Ing.7485053 +421.o. Vladimír Slovák Milan Leško Ing.: 02 48 57 33 53 E-mail:
[email protected] lesko@1pn. 1.PN moulds & tools 9 . uvodnf T.* kE ffii laser CNC ohybanie ./#Ef"n.rrEr UffJ-lf.. Rezanie vodnym ludom W:302*b-l PTV Praha .:fu .sl< a .:0918 654864 e-mai[: voda@drc./fax i oo42! 5t 7732929 mob.: vodnf Mi tel.:. PaLenie Laserom TruLcser 3O4a od f" TRUMPF iFf rryrfd te[.:0918 849 640 e-mai[: [
[email protected] 't ./fax : QO427 517752929 mob. lfax i oa42t 51 7732929 mob.sl< www.i. Li s OO-2 2 A tRcr g.* & G & 1. Royova 43 08O 05 Preiov Mi tel.! .:0915846777 e-mai l: mi l<ita@drc.:k e-mai[: laser@drc.:0918 849 640 e-mai[: voda@drc.:0918 654864 te[.sk e-mait: laser@drc./fax : oo42t 57 77 52929 mob.o.drc.sk vodn.OhraRovaci ERMAKS A N CN C AP 4 .:0918 849 6140 tet./fax : 00421 57 77 5a929 mob.sl< ohlbonie laser CNC tel. HUSÁR Jozef Cover Design: HUSÁR Jozef Publisher: FVT TU in Košice with a seat in Prešov Print: STEVEPRESS.. Ltd. Prešov © 2012 ISBN: 978‐80‐553‐1216‐3 . Title: Manufacturing Engineering and Management Editors: HLOCH Sergej HUSÁR Jozef KNAPČÍKOVÁ Lucia LAZÁR Ivan Layout and Design: HLOCH Sergej. wrote me in one e-mail “Democracy lies on the conscious individuals who are living for innovations in science.. But as Albert Einstein said: “It is not enough that you should understand about applied science in order that your work may increase man's blessings.Dear Participants. i.o. AGES s. by application of scientific knowledge not only do allow commercial production of goods and services.r. without the unsolved issues and issues not being solved one would possess nothing. Jointly they are included among the strongest forces helping get the ideas dressed into reality which change the way of life. Science.r.r. Specifically. DRC s. Those are exactly the words used to express degree of unawareness of causal chain of reasons and consequences that correlates with the correctness of evaluation of the particular action having occurred in time and space. technology and management surprisingly bring new inventions. breakthroughs. science. The content of the words in this proceeding is not focused solely on knowledge having been acquired through arduous and challenging research but it is a desired metamorphosis of ideas having occurred in your mind earlier to become familiar with other so far unknown “miracles”. science means studying and knowing (learning). Spinea s.o..o.. To what extent is reality accessible? The question should be raised other way. 1. Prešov. fantasy. Weldex s. research and related reshaping of natural or artificial substance-material through technologies significantly affect society development. especially in gaining new experience based on experiments. With respect to the pace of the scientific and technical progress a man often fails to understand the innovations of which they possess no adequate experience. when travelling and entertaining oneself or working – results of the work of anonymous scientists and engineers are being used. VIA MAGNA Topvar Brewery . Dražan Kozak.. Management means how to organize. Your work.Šariš Brewery ISBN 978-80-553-1216-3 . Concern for the man himself and his fate must always form the chief interest of all technical endeavours .o..o. Dear friends my great friend Prof.r. In fact.o. prešovská nástrojáreň s. Pursuant to the article published in Scientific American each person disposes of different limited field of vision exceeding the borders of imagination and fantasy of the world. technologies represent processes which through the explicit or implicit research and development stage.r.r. When examining the world around – either at home or work. Dear Colleagues. kind of “battery“(or light) in the space of unknown matters is exploration magnifying notional radius of cognition. Technologies and engineering are overcoming distances yet absence of certain closeness to the man and chiefly among people is apparent.e. Many times the reason rests in waving the advances or inventions aside or in becoming frightened of them.. habits and view over the world of every society inclusive of ours as well. On behalf of the organizing committee Conference financially supported by: AVON s.. Why? Because reality includes both objects and events occurring beyond the human cognition. Inter alia. imagination. It is the space for ideas within the frame of which the most significant moments.. For the present the only working means.” Thank you my Friend for your big words. milestones of human life commence. certain space exists between the borders of cognition and fantasy. applications and permeate in other spheres of human life. is not partial to “mess“.. Human mind.“ Yes. However. fortunately. In point of causality it is the area of undefined reasons and interactions many times vaguely described by terms of destiny or accident. Following pages deal with the issues of our ancestors and consequently with the ones is having occurred in the course of experimental work. perception. Technologies mean knowing how to do.