ABSTRACT
This article describes the application of the A-priori algorithm for defining the rule-based relationships between individual defects caused during the lamination process, affecting the deformation defect of the yacht shell. The data from 542 yachts were collected and evaluated. For the proper development of the algorithm, a technological process of the yacht lamination supported by expert decisions was described. The laminating technology is a complex process of a sequential application of individual laminates according to a special strategy. The A-priori algorithm allowed for obtaining the set of association rules defining the relationships between the defects resulting from the lamination process and influencing the deformation defect of the yacht shell, which is one of the most common errors in yacht production. The obtained aggregated rules were compared with the expert knowledge of the employees of the production, quality control, mould regeneration, and technology departments of the yacht yard. The use of the proposed A-priori algorithm allowed for the generation of relationship rules consistent with the general opinion of experts. Associative rules additionally took into account detailed causes of a specific error, which were not always noticed by employees of specific departments. The assessment of the lamination process using an artificial intelligence algorithm turned out to be more objective, which made it possible to gradually reduce the total number of errors occurring in the yacht shell lamination process, and thus shorten the time needed to repair errors and the total time of producing the yacht.
ABSTRACT
The growing use of contemporary materials in various industrial sectors, such as aerospace, automotive, as well as the oil and gas industry, requires appropriate machining methods and tools. Currently, apart from the necessity to obtain high-dimensional and shape accuracy, the efficiency and economic aspects of the selected manufacturing process are equally important, especially when difficult-to-cut materials, such as hard and brittle ceramics, have to be machined. In the research presented in this paper, a prototype tool fabricated from polyamide powder by the SLS method was used in flat-lapping of Al2O3 ceramics, showing the promising potential and efficacy of rapid tooling and manufacturing in the area of abrasive machining. The influence of the selected input process factors, such as machining time, the type of abrasive suspension, kinematic parameters, and unit pressure, on technological effects, was analyzed. The microscopic observations of the active surface of the prototype tool showed its reinforcement with loose diamond abrasive particles (size D107), resulting in the effective material removal and improved surface finish of Al2O3 ceramic samples. The directions for further development of tools fabricated by the SLS method for applications in abrasive machining were also envisaged by the authors.
ABSTRACT
High requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used to produce fully functional machine parts, which is known as Rapid Manufacturing and also Rapid Tooling. Rapid Manufacturing refers to the ability of the software automation to rapidly accelerate the manufacturing process, while Rapid Tooling means that a tool is involved in order to accelerate the process. Abrasive processes are widely used in many industries, especially for machining hard and brittle materials such as advanced ceramics. This paper presents a review on advances and trends in contemporary abrasive machining related to the application of innovative 3D printed abrasive tools. Examples of abrasive tools made with the use of currently leading AM methods and their impact on the obtained machining results were indicated. The analyzed research works indicate the great potential and usefulness of the new constructions of the abrasive tools made by incremental technologies. Furthermore, the potential and limitations of currently used 3D printed abrasive tools, as well as the directions of their further development are indicated.
ABSTRACT
The paper contains the results of a metallographic examination and nanoindentation test conducted for the medium carbon structural steel with low content of Mn, Si, Cu, Cr, and Ni after its grinding to a depth ranging from 2 µm to 20 µm, at constant cutting speed (peripheral speed) of vs = 25 ms-1 and constant feed rate of vft = 1 m/min. Applied grinding parameters did not cause the surface layer hardening, which could generate an unfavorable stress distribution. The increase in the surface hardness was obtained due to the work hardening effect. Microstructure, phase composition, and chemical composition of the grinded surface layer were examined using an X-ray diffractometer, light microscope, and scanning microscope equipped with X-ray energy-dispersive spectroscopy, respectively. Hardness on the grinded surface and on the cross-section was also determined. It was shown that the grinding of C45 steel causes work hardening of its surface layer without phase transformation. What is more, only grinding to a depth of 20 µm caused the formation of an oxide scale on the work-hardened surface layer. Nanoindentation test on the cross-section, at a short distance from the grinded surface, has shown that ferrite grains were more susceptible to work hardening than pearlite grains due to the creation of an equiaxed cellular microstructure, and that different dislocation substructure was created in the work-hardened surface layer after grinding to different depths.
