The paper presents one aspect of the analysis of energy consumption and productivity of the manufacturing operation. As an example of the operation, the operation of turning with a single-blade tool was taken. Sustainable development in its general concept implies sustainable materials, sustainable design, and sustainable manufacturing. This paper presents an analysis of one important part of sustainable manufacturing, and that is energy saving. The experimental study was conducted as follows. In laboratory conditions, an experimental-mathematical regression model of the relationship between cutting force and processing conditions was defined. Machining experiments were performed under ECO-friendly conditions with technology known as MQCL (Minimum Quantity Cooling Lubrication) machining. The obtained mathematical model was used to calculate the energy consumption and the workpiece material removal rate (MRR, productivity). The results of the analysis showed that there is a lot of space for optimization of machining conditions from the aspect of power consumption, with mandatory calculation and other machining costs, above all, the cost of tools and machine tools. In this regard, recommendations for analysis with the aim of power saving are given.

In the recent years, 3D printing has become a topic of great interest from both academic and the industrial sector through the increasing importance of Industry 4.0. This technology is based on layer-by-layer melting of materials to create a three-dimensional object. It is also known as additive production, and it is feasible through several different methods such as stereolithography, selective laser melting and sintering (SLM, SLS), these are just some of the examples, but fused decomposition modeling (FDM) has become the most interesting technique.This paper seeks to analyze the fracture strength (torque) of coupled gears made out of PLA plastic produced by the 3D printing process. To reduce the number of experimental measurements, the Taguchi L8(27) orthogonal array was used to analyze the influence of factors on two level. Investigated factors were: wall thickness, infill and number of infill lines, layer height, temperature, cooling and speed. Finally, optimization of most influential factors according to maximum torque was preformed, using Taguchi method too.

White Layer (WL) has been known in literature for a couple of decades. In general, the term has been used to describe non-etching, hardened surface layer of machine parts which is seen under an optical microscope as white “featureless” phase on the surface of the base material. The reason for such “metallographic” occurrence of white layer is in the fact that the same is resistant to chemical etching which is carried out in order to prepare the samples for metallographic examination. Metallographic examinations on the optical microscope are limited by wavelength of the visible light and it allowed magnifications about 1000x. In Scanning Electron Microscopy, using the electron beam instead of the visible light this magnification has been increased significantly. In this paper has been shown how the White Layer is seen under SEM microscope in comparing to optical microscopy. The feasibility of the SEM/EDS (Energy Dispersive Spectroscopy) instrumentation has been shown on example of investigating influence of the alloying elements (C, Mn, V and Cr) on WL formation in process of hard turning. It has been revealed that what has been known as a white “featureless” layer under the optical microscopy in SEM analysis has its specific microstructural form that depend on material and conditions in which the WL is formed.

Cold forming is characterized by a number of advantages which are mainly result of material strengthening during the final workpiece formation. Effects of material strengthening are reflected in shaping accuracy and in improving mechanical characteristics of workpieces. Flow forming is one of the specific forming methods used to form different parts of rotationally symmetrical parts in military, aeronautical, nuclear and other industries, which uses positive effects of the material strengthening. Design of products for extremely demanding industries, in addition to dimensional control, requires checking the accuracy of their circular shape. This paper, through the example of making tubular workpieces from Al 99.5% using flow forming technology, presents a method for determining the workpiece roundness using a 3D Coordinate Measuring Machine and analyzes the influence of number of revolutions, shift and the deformation rate to the deviation of roundness.

ABSTRACT The process of forward cold flow forming is a specific procedure of material processing which is used for forming of different rotationally symmetric parts from cylindrical workpieces placed between the pin and roll in the military, aeronautical, nuclear and other industries. Under the pressure of the rolls (two or three rolls) material is brought to the state of plastic flow and extruded in the axial direction, what results in the reduction of the diameter and increase of the length of workpiece. The deformation of workpiece causes the increase of the heat during the processing. In this paper, the temperature analysis of tubular workpieces Al 99.5 during the processing by cold flow forming is shown. The numerical simulation of the process was carried out using simufact.forming GP 11.0 software. In the next step the results of numerical simulations were experimentally verified by measuring the temperature of heated workpieces during the forming with the help of contactless thermal imaging methods (Thermo-camera Fluke Thermography Series These 32).

Machinabilty is a very important feature of materials subjected to machining process and can be analyzed from various aspects. The main question of many machinability studies is, “What are the influencing factors on the machinability?” This work describes experimental investigation on influence of cold flow forming process onto cutting force changes in machining of a 99.5% Al workpiece. the aim of the work is to find if and to what extend the cutting force is changed after plastic deformation in the process of cold flow forming. Full factorial plan has been applied in experimental works on three specimens, one before and two after plastic deformation. Cutting forces were measured by means of a three-component Kistler dynamometer Type 9265B. Regression analysis is performed in Microsoft Excel Data Analysis Package for both specimens. Obtained results have been compared and confirmed the fact that there are significant differences in character of the cutting force changes between undeformed and plastically deformed workpieces.